Knitted Supercapacitor Fabrics With Integrated Heating
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Solution Overview
Problem
Conventional smart fabrics for wearable electronics lack adaptability in design and effective energy storage solutions, relying on bulky batteries and capacitors, and fail to integrate heating elements seamlessly into garments for large-scale manufacturing.
Innovation Solution
Development of knitted supercapacitors and heated fabrics using conductive yarns, where a current collector and electrode yarns are knitted into predetermined designs with an ionically permeable separator, and heating elements are integrated via a switch, allowing for flexible and adaptable energy storage and heating within the fabric itself.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional batteries and capacitors are used in wearable devices, then energy storage function is provided, but the devices become bulky and heavy
Solution Approach 1:
The patent combines the energy storage function directly into the fabric structure by knitting conductive yarns into capacitor electrodes within the garment itself. This merging of energy storage with the wearable fabric eliminates the need for separate bulky battery components, achieving both energy storage functionality and weight reduction simultaneously
Solution Approach 2:
The patent uses thin, flexible conductive yarns and fabric layers to create the capacitor structure. The electrodes are formed from knitted yarns that are inherently thin and flexible, replacing traditional rigid battery housings and bulky capacitor components with lightweight textile-based energy storage elements
2Reliability
If sewn-in sensors are used in smart fabrics, then sensing function is provided, but the design adaptability to various shapes and sizes is limited
Solution Approach 1:
The patent creates a universal knitted capacitor design that can be adapted to various garment shapes and sizes through the knitting process itself. The same basic capacitor structure can be scaled and configured for different applications by adjusting knitting parameters, making the energy storage solution universally applicable across multiple wearable device designs
Solution Approach 2:
The knitted fabric structure provides dynamic adaptability, allowing the capacitor to conform to different garment shapes and movement patterns. The flexible knit structure can stretch and deform with the wearer's movements while maintaining electrical connectivity, enabling design versatility across various body parts and garment types
3Temperature
If multiple layers of thick fabrics are used in heated clothing, then heating function is provided, but the garment becomes bulky
Solution Approach 1:
The patent merges the heating function directly into the fabric structure by incorporating resistive heating elements within the knit itself. The conductive yarns serve dual purposes as both structural components and heating elements, eliminating the need for separate thick heating layers and reducing overall garment volume
Solution Approach 2:
The patent uses thin conductive yarns and single-layer fabric structures to provide heating functionality. The heating elements are integrated into the knit structure itself rather than requiring multiple thick insulating layers, achieving effective heating while maintaining a thin, non-bulky garment profile
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
Enables the creation of wearable devices with embedded energy storage and heating elements that are flexible, adaptable, and suitable for large-scale manufacturing, enhancing the functionality and comfort of smart garments while reducing bulkiness.
Implementation Method 1
an ionically permeable electronic separator is provided that allows the electrodes to be in close proximity to each other without being in electrical contact with each other
Implementation Method 2
a first conductive yarn knitted to form a current collector and a second conductive yarn knitted to form an electrode that is in electrical contact with the current collector
Implementation Method 3
a heating element is formed by knitting at least one of the first and second conductive yarns into a linear resistor
Data Source
AI summary
A garment includes a supercapacitor and/or heated fabrics including a first conductive yarn knitted to as to form a current collector and a second conductive yarn knitted to as to form an electrode that is in electrical contact with the current collector. The conductive yarns are knitted into a predetermined supercapacitor design having respective electrodes that are not in electrical contact with each other. An electrolyte saturates at least the electrode material either before or after knitting, and an ionically permeable electronic separator allows the electrodes to be in close proximity to each other without being in electrical contact with each other. A heating element may also be formed by knitting at least one of the first and second conductive yarns into a linear resistor or by knitting an insulated conductive yarn into a sheet of fabric. Such a heating element is connected to the supercapacitor via a switch.