Functional Layered Thread Structure for Smart Textiles
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Solution Overview
Problem
Existing smart textile technologies face limitations in functionality and durability due to the integration of conductive threads and printed electronics, which often delaminate or crack due to surface roughness and friction-induced stress, leading to short lifetimes and failure to conform to 3D shapes, while also requiring large material usage and complex patterning processes.
Innovation Solution
A device comprising a single thread with a layered structure printed on its surface, allowing for miniaturization and robustness, with multiple functional units that can be arranged without inter-thread connections, enabling efficient production and integration into textiles using standard methods like stitching, and utilizing printing techniques for high-resolution deposition of functional layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If printed electronics are integrated directly onto textile surfaces, then functionality is enhanced, but the sensing layers delaminate or crack due to surface roughness and friction-induced stress
Solution Approach 1:
The invention transitions from 2D planar integration of electronics on textile surfaces to 3D tubular structures where electronic components are embedded within or integrated along the length of tubular elements. This dimensional change allows the electronic layers to be protected within the tube structure, eliminating direct exposure to surface roughness and friction-induced stress that cause delamination and cracking in conventional 2D integrated circuits on textiles.
Solution Approach 2:
The tubular structure itself acts as a flexible protective shell that encapsulates the electronic components. This shell provides mechanical protection while maintaining flexibility, allowing the integrated electronics to withstand deformation and stress without delamination or cracking, thereby enhancing reliability while preserving functionality.
2Adaptability or versatility
If conductive threads are woven or embroidered into textiles, then basic smart textile functionality is achieved, but the structural features are limited and the process becomes complex
Solution Approach 1:
The invention segments the electronic functionality into modular tubular units that can be independently manufactured and then integrated into textiles. Each tubular structure contains complete functional elements, allowing for standardized production and simplified integration compared to complex weaving or embroidery patterns. This segmentation reduces patterning complexity while maintaining versatility.
Solution Approach 2:
The tubular structure serves multiple functions simultaneously: it provides structural support, acts as a protective enclosure for electronics, serves as a conduit for signal transmission, and can be integrated through standard textile methods. This multi-functionality reduces the need for separate components and complex integration processes, simplifying overall device complexity.
3Adaptability or versatility
If printed electronics are applied on textile substrates, then functional layers can be deposited, but large material usage is required and production efficiency is reduced
Solution Approach 1:
The electronic functional layers are nested within the tubular structure, with multiple layers contained inside the protective tube. This nesting approach consolidates multiple material layers into a compact configuration, reducing the total material usage compared to applying separate layers on the textile surface. It also streamlines production by enabling integrated manufacturing of the nested structure in fewer steps.
4Productivity
If standard textile production methods are used, then large volume production is achieved, but dimensional precision and process control are insufficient for electronics integration
Solution Approach 1:
The electronic components and functional layers are pre-assembled and integrated into the tubular structures before the final textile manufacturing process. This preliminary integration of precision-critical components allows standard textile production methods to be used for high-volume manufacturing while the pre-assembled units maintain their dimensional precision. The tubular structures are manufactured with required precision upfront, then integrated into textiles using standard methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a durable and resource-efficient smart textile device with enhanced functionality, improved durability, and localized functionality, addressing the limitations of existing technologies by minimizing material usage and preventing delamination, while enabling mass production and specific feature integration.
Implementation Method 1
The layered structure is printed on a surface of the thread
Data Source
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AI summary
The invention concerns a device (1) comprising a thread (2) and a layered structure (3), wherein the layered structure (3) is arranged on a surface (4) of the thread (2). The invention further concerns a method for producing a device (1) comprising a thread (2) and a layered structure (3) arranged on a surface (4) of the thread (2), wherein the method comprises the steps of: a) providing the thread; b) positioning the thread in order to allow for a deposition of a layer; c) depositing the layer on the surface of the thread; d) optionally repeating steps b) and c) to assemble further the layered structure; e) optionally applying a coating on the thread at least in a region where the layered structure is deposited.