Knit Copper Fabric with Load-Carrying Yarn for 3D Structures
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Solution Overview
Problem
Small gauge copper filaments tend to break when subjected to the bending and knitting forces required to form knit fabrics with structures other than a planar layer, making it challenging to knit copper filaments into fabrics with loops at angles or interlock patterns.
Innovation Solution
The use of a load-carrying yarn with a minimum bend radius, twisted or wrapped with the copper filament to relieve stress during knitting, allowing the formation of knit copper fabrics with loops extending at angles between 15 and 165 degrees and interlock patterns, using methods like twisting, wrapping, and specific knitting programs on a machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If small gauge copper filaments are subjected to bending and knitting forces to form non-planar knit fabrics, then three-dimensional structures with loops at angles can be achieved, but the copper filaments break due to their brittleness
Solution Approach 1:
A load-carrying yarn is introduced as an intermediary element that works together with the copper filament during knitting. The load-carrying yarn has superior mechanical properties and handles the bending and knitting forces, while the copper filament provides thermal conductivity. This mediator approach allows the formation of three-dimensional knit structures with loops at angles without breaking the copper filament.
Solution Approach 2:
The invention creates a composite yarn system combining copper filament and load-carrying yarn. This composite structure leverages the thermal conductivity of copper and the mechanical strength of the load-carrying yarn, enabling the copper to survive the knitting process while maintaining its functional properties in the final three-dimensional fabric structure.
2Adaptability or versatility
If copper filaments are knitted into fabrics with loops extending at angles or interlock patterns, then thermal interface materials with enhanced functionality can be created, but the knitting process becomes significantly more difficult
Solution Approach 1:
The load-carrying yarn acts as a mediator that simplifies the knitting process for complex structures. It provides the necessary strength and flexibility to form loops at various angles and create interlock patterns, making the manufacture of versatile thermal interface materials feasible with standard knitting equipment and processes.
Solution Approach 2:
The invention changes the parameter of yarn composition by combining copper filament with load-carrying yarn. This parameter change enables the fabric to be manufactured in various configurations (loops at angles, interlock patterns) while maintaining ease of manufacture, as the load-carrying yarn handles the mechanical stresses of complex structure formation.
3Temperature
If copper filaments are used for thermal applications in heat management, then high thermal and electrical conductivity is achieved, but the filaments cannot survive certain knitting processes
Solution Approach 1:
The load-carrying yarn serves as a protective intermediary during the knitting process. It bears the mechanical loads of bending and needle forces, shielding the copper filament from damage while allowing the copper to maintain its thermal conductivity properties for heat management applications.
Solution Approach 2:
The composite yarn structure combines the thermal management capabilities of copper with the mechanical durability of the load-carrying yarn. This enables the copper filament to survive the knitting process intact, preserving its high thermal and electrical conductivity for subsequent heat management applications.
Data Source
AI summary
The present disclosure provides a knit fabric including at least one continuous copper filament formed into a knit fabric including a layer of knit copper fabric having a first major plane and at least one loop of copper filament extending out of the first major plane. A knit fabric is also provided that has an interlock pattern including at least two continuous copper filament paths per layer. A further knit fabric is provided that includes a spacer fabric knit having a first layer of knit copper fabric interconnected with a second layer of knit copper fabric. Methods of making the knit fabrics are provided, including twisting or wrapping at least one continuous copper filament with a load-carrying yarn. The load-carrying yarn exhibits a minimum bend radius that wraps around an object having a diameter of 0.43 millimeters. The methods further include setting at least one tension setting on a knitting machine and using a knitting program that defines a plurality of stitch settings to knit a fabric.