Interlaced Conductive Fabric for Embedded Component Connections
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Solution Overview
Problem
Incorporating electrical components into fabric items is challenging due to the flexibility of fabric, which can damage signal paths or dislodge components when bent or stretched, requiring improved techniques for mounting electrical components onto fabric without compromising their functionality.
Innovation Solution
Interlacing equipment with individually adjustable components allows for the insertion and embedding of electrical components during fabric creation, using tools like warp and weft strand positioning equipment, insulation removal tools, and heating tools to securely attach conductive strands to electrical components within the fabric, ensuring uninterrupted interlacing operations and robust connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are mounted onto fabric using conventional methods, then the fabric item can provide enhanced functionality, but the flexibility of fabric can damage signal paths or dislodge components when bent or stretched
Solution Approach 1:
The fabric is segmented into interlaced strands (warp and weft) that can move independently, allowing the fabric to flex while maintaining electrical connections through the interlaced conductive strands that remain electrically connected despite relative movement between fabric sections
Solution Approach 2:
Electrical components are embedded within pockets formed by the interlaced fabric strands, with conductive strands nested within the fabric structure to provide continuous electrical pathways that accommodate fabric deformation without disconnection
2Reliability
If electrical components are inserted into fabric during interlacing operations, then the components can be securely enclosed in the fabric, but the interlacing equipment requires individually adjustable components and gap creation
Solution Approach 1:
The interlacing equipment incorporates individually adjustable components that can dynamically adapt their position and timing to accommodate component insertion operations, with warp strand positioning equipment and weft strand positioning equipment that can be independently controlled to create gaps and restore interlacing operations
Solution Approach 2:
Gaps are created between fabric portions before electrical components are inserted, and conductive strands are positioned in advance to ensure proper alignment and electrical connection before the components are enclosed in the fabric
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
This method enables the integration of electrical components into fabric items with enhanced mechanical robustness and electrical conductivity, allowing for the creation of functional items like wearable electronics and smart fabrics without compromising the fabric's integrity or functionality.
Implementation Method 1
The insulation removal tool may include a laser that ablates an outer insulating coating to expose a conductive core on each conductive strand
Implementation Method 2
a heating tool such as an inductive heating tool, hot air, or laser may be used to reflow solder between the electrical component and the conductive strands
Implementation Method 3
a heating tool such as an inductive heating tool, hot air, or laser may be used to reflow solder
Data Source
AI summary
Interlacing equipment may be used to form fabric and to create a gap in the fabric. The fabric may include one or more conductive strands. An insertion tool may be used to align an electrical component with the conductive strands during interlacing operations. A soldering tool may be used to remove insulation from the conductive strands to expose conductive segments on the conductive strands. The soldering tool may be used to solder the conductive segments to the electrical component. The solder connections may be located in grooves in the electrical component. An encapsulation tool may dispense encapsulation material in the grooves to encapsulate the solder connections. After the electrical component is electrically connected to the conductive strands, the insertion tool may position and release the electrical component in the gap. A component retention tool may temporarily be used to retain the electrical component in the gap as interlacing operations continue.