Intermediate Coupling Element for Flexible Textile Connector Mounting
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Solution Overview
Problem
Conventional retaining mechanisms for electrical connectors in flexible textile materials are not robust enough to withstand normal service forces, and existing methods for mounting electrical connectors on garments are expensive and fragile, making them prone to damage during manufacturing.
Innovation Solution
A method and apparatus involving an intermediate coupling element with a frame and flange portion attached to the textile material, allowing for the secure attachment of electrical connectors through a mechanical coupling mechanism, such as a snap-fit, which can be done during garment manufacturing and later coupled with electrical connectors separately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional retaining mechanisms (threaded panel nuts) are used to secure electrical connectors in apertures through textile material, then the connectors can be retained in the garment, but the mechanisms are not robust enough to prevent connectors from being pulled through when subjected to normal service forces
Solution Approach 1:
The solution divides the connector retention system into two separate components: a rigid retaining mechanism (such as a panel nut or clamp) and a flexible textile reinforcement patch. The patch is sewn to the garment interior to distribute loads, while the retaining mechanism is mounted on the patch to secure the connector. This segmentation allows each component to optimize its function without compromising the other.
Solution Approach 2:
The solution combines rigid and flexible materials to create a composite retention system. The rigid retaining mechanism (metal or hard plastic panel nut) is mounted on a flexible textile reinforcement patch, creating a composite structure that provides both mechanical strength for connector retention and flexibility to accommodate garment movement and textile deformation.
2Strength
If sewing techniques are used to attach the spine assembly to the textile material during garment manufacture, then a robust connection is achieved, but the expensive and fragile spine assembly is at risk of damage during the manufacturing process
Solution Approach 1:
The solution separates the attachment process into two stages: first, the flexible textile reinforcement patch is sewn to the garment during standard garment manufacturing; second, the rigid retaining mechanism and connector assembly are attached separately to the patch. This segmentation protects the expensive connector assembly from damage during the garment manufacturing process while still achieving a robust final connection.
Solution Approach 2:
The flexible textile reinforcement patch is prepared and attached to the garment in advance, creating a pre-prepared mounting surface. This preliminary action allows the expensive connector assembly to be attached later in a controlled manner, reducing the risk of damage during manufacturing while ensuring a robust final connection.
3Reliability
If the electrical connector is integrated into the garment during manufacture, then the connector is securely positioned, but the garment becomes more complex and expensive to manufacture
Solution Approach 1:
The solution divides the connector system into a permanent flexible textile reinforcement patch that is integrated into the garment during manufacture, and a separate rigid retaining mechanism that can be attached later. This segmentation allows the garment to be manufactured using standard processes while the connector assembly can be added separately, reducing overall manufacturing complexity.
Data Source
AI summary
There is described a method of establishing an electrical connection through a flexible planar material. The method involves attaching an intermediate coupling element to the flexible planar material so as to align an aperture defined by the intermediate coupling element with a hole through the flexible planar material, and coupling an electrical connector to the intermediate coupling element so as to permit electrical connection through the flexible planar material. In this way, the intermediate coupling element can be attached to the garment during the garment manufacture process, and subsequently the electrical connector can be coupled to the intermediate coupling element separately from the main garment manufacture.