Dual-Layer Garment Insulation for Flexible Voltage Withstand
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Solution Overview
Problem
Existing garments with electrical elements face challenges in providing adequate insulation that balances flexibility, weight, and safety, particularly in preventing leakage currents and withstanding environmental conditions, with existing insulation solutions failing to meet performance requirements for both functional and protective insulation.
Innovation Solution
A dual-layer insulating system with a first insulating layer having a voltage withstand of at least 200 VAC and a second insulating layer with a voltage withstand of at least 100 VAC, both with high resistance and dielectric strength, encapsulating an electrically conductive layer, along with a method for testing insulation performance using a test voltage and conductive plate to ensure safety and functional integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation layers are made thicker to improve voltage withstand and prevent leakage currents, then safety and insulation performance are improved, but flexibility and weight of the garment are worsened
Solution Approach 1:
The insulation system is divided into multiple separate insulating layers (first insulating layer, second insulating layer) rather than using a single thick layer. Each layer can be optimized for specific functions, and the segmented structure provides flexibility while maintaining overall insulation performance.
Solution Approach 2:
The patent uses composite insulating structures combining multiple materials with different properties. The first insulating layer and second insulating layer may use different materials optimized for their specific roles, achieving both high voltage withstand and flexibility through material composition rather than单纯 increasing thickness.
2Ease of operation
If insulation layers are made thinner to improve flexibility and reduce weight, then ease of operation is improved, but voltage withstand capability and safety are worsened
Solution Approach 1:
By segmenting the insulation into multiple thinner layers, each layer can be made flexible and thin for comfort, while the cumulative effect of multiple layers provides adequate voltage withstand capability. The segmentation allows optimization of each layer's thickness for flexibility while maintaining overall safety.
Solution Approach 2:
The patent changes the insulation parameters by using multiple layers with different thicknesses and material properties rather than a single uniform layer. This allows tuning of the electrical parameters (voltage withstand, resistance) while maintaining mechanical flexibility through appropriate parameter selection for each layer.
3Device complexity
If single-layer insulation is used to simplify the structure, then device complexity is reduced, but adequate insulation performance for both functional and protective requirements cannot be achieved
Solution Approach 1:
The insulation function is segmented into multiple layers with potentially different functions (functional insulation, protective insulation). This segmentation allows each layer to be optimized for its specific purpose while maintaining manageable complexity through modular design.
Solution Approach 2:
The multi-layer insulating structure serves multiple functions simultaneously: functional insulation to constrain current flow, protective insulation for safety, and mechanical flexibility for garment comfort. The universal design approach allows a single insulation system to fulfill multiple requirements that would be difficult to achieve with a single layer.
4Reliability
If insulation is added to prevent leakage currents and ensure safety, then protective insulation performance is improved, but stiffness and weight of the garment are worsened
Solution Approach 1:
By dividing the protective insulation into multiple thin layers rather than one thick layer, the total weight is distributed and reduced while maintaining the necessary voltage withstand capability. Each thin layer contributes to the overall protection without adding excessive weight.
Solution Approach 2:
The patent employs composite insulating materials that provide high dielectric strength and voltage withstand per unit thickness. These materials achieve protective insulation requirements with minimal weight by using materials with superior electrical properties rather than relying on mass or thickness.
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 dual-layer insulating system effectively prevents leakage currents and ensures safety by maintaining insulation performance under various conditions, including stretching and moisture exposure, while minimizing stiffness and weight, thus enhancing the safety and functionality of garments with electrical elements.
Implementation Method 1
both insulating layers 5, 9 may have apertures 11... the conductive layer 7 retains a minimum conductivity during stretch and bending and that the insulating layers 5, 9 have sufficient resistance and dielectric strength
Implementation Method 2
the first insulating layer has a voltage withstand of at least 200 VAC or greater and the second insulating layer has a voltage withstand of at least 100 VAC or greater
Data Source
AI summary
An electrical system with conductive and insulating layers for application to a surface of a garment is disclosed. The electrical system includes a first insulating layer for attaching to a garment, a second insulating layer, and an electrically conductive layer encapsulated between the first insulating layer and the second insulating layer. The first and second insulating layers have a predetermined minimum voltage withstand and a predetermined minimum resistance.