Hook-And-Loop Busbars for Reconfigurable Flexible Circuits

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Solution Overview

Problem

Existing electrical systems with stiff busbar architectures face challenges in reconfigurability, energy efficiency, and integration of detachable electrical components, particularly in soft circuit systems and wearable garments.

Innovation Solution

A flexible circuit module utilizing a fabric member with conductive fibers and hook-and-loop busbars, allowing for reconfigurable and robust electrical connections with low resistive losses, suitable for optoelectronic or optoelectrofluidic fiber-based devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If stiff busbar architectures are used to connect flexible electrical components with arc-welding or spot-welding, then robust electrical contacts are maintained over long periods, but the integration process becomes energy-intensive and lacks reconfigurability

Engineering Contradiction:

Improverobust electrical contactVSAvoidenergy-intensive integration process

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the mechanical welding system (arc-welding or spot-welding) with a magnetic coupling system. The magnetic busbar uses magnetic attraction forces to establish electrical connections, eliminating the need for high-energy welding processes while maintaining robust electrical contact over long periods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the connection mechanism from permanent welding to magnetically-coupled detachable connections. This parameter change enables reconfigurability while maintaining electrical reliability, allowing components to be connected and disconnected without energy-intensive welding processes.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If stiff busbar architectures are used with arc-welding or spot-welding, then robust electrical contacts are maintained, but reconfigurability and ease of integrating detachable components are lost

Engineering Contradiction:

Improverobust electrical contactVSAvoidreconfigurability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent introduces dynamic, detachable magnetic connections that allow the electrical system to be reconfigured. The magnetic busbar enables components to be easily connected and disconnected, providing adaptability and reconfigurability while maintaining robust electrical contact through magnetic attraction forces.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention replaces the permanent mechanical welding system with a magnetic coupling system that enables detachable connections. This substitution provides both robust electrical contact and reconfigurability, allowing the system to adapt to different configurations as needed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If manual weaving processes are used to integrate conducting wires into busbars, then integration is achieved, but the process becomes complex and challenging for integrating electronic components such as diodes and resistors

Engineering Contradiction:

Improveintegration processVSAvoidcomplexity of integrating electronic components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent segments the electrical connection system into modular magnetic busbar units that can independently connect to different components. This segmentation simplifies the integration process, allowing electronic components like diodes and resistors to be easily connected without complex manual weaving procedures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces the complex manual weaving process with a simplified magnetic coupling system. Electronic components can be directly attached to the magnetic busbar through magnetic attraction, eliminating the need for manual wire weaving and reducing integration complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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, conformable, and easily reconfigurable connection layout that maintains good electrical contact under wear and tear, supporting the integration of electronic components in soft circuit systems and wearable garments.

Implementation Method 1

a first conductive layer between the first fiber element strands and the first hook-and-loop busbar; and a second conductive layer between the second fiber element strands and the second hook-and-loop busbar

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12302491B2Electrical system with hook-and-loop busbars

Publication Date: 2025.05.13 UNIV OF MASSACHUSETTS

AI summary

A flexible circuit module is disclosed. The flexible circuit module includes a fabric member including a plurality of fibers having non-conductive elements, and conductive elements oriented through the plane of the fabric. Each conductive element includes a first fiber element strand and a first unterminated end opposite the first fiber element strand, and a second fiber element strand having second unterminated end opposite the second fiber element strand. The fabric member further includes a first side with the first fiber element strands extending therefrom and a second side with second fiber element strands extending therefrom. A first hook-and-loop busbar is conductively connected to the first fiber element strands and a second hook-and-loop busbar is conductively connected to the second fiber element strands.