Knitted Textile Thermal Sensor With Integrated Sensing Junctions
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Solution Overview
Problem
Existing thermal sensors, such as solid state thermocouples, are bulky, prone to damage, and can only measure local temperature, requiring multiple installations for temperature monitoring across composite structures, and are susceptible to environmental and physical stresses.
Innovation Solution
Integration of a knitted textile thermal sensor comprising electrically conductive yarns with defined thermal sensing stitch patterns, forming sensing and reference junctions within the textile, allowing for temperature measurement across the composite structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If solid state thermocouples are used for temperature measurement, then temperature monitoring is achieved, but the device becomes bulky and prone to damage
Solution Approach 1:
The patent merges the thermal sensor functionality directly into the textile structure by integrating conductive yarns into the knitting pattern. The conductive yarns are incorporated during the knitting process itself, creating a unified structure where the textile serves both as the sensor and the garment, eliminating separate bulky sensor components and improving reliability through integration.
Solution Approach 2:
The patent uses flexible conductive yarns integrated into a thin textile structure to create the thermal sensor. This thin-film approach replaces bulky solid state thermocouples with a flexible, wearable textile-based sensor that maintains measurement capability while improving comfort and reliability.
2Measurement precision
If multiple thermocouples are installed to measure temperature across composite structures, then comprehensive temperature monitoring is achieved, but device complexity and installation requirements increase
Solution Approach 1:
The patent creates a universal textile-based sensor that can be worn or integrated into various locations to measure temperature. The same knitting technology and conductive yarn integration approach can be applied universally across different textile garments or composite structures, providing comprehensive monitoring without requiring different sensor types or complex installation procedures for each location.
Solution Approach 2:
The patent segments the temperature monitoring function into distributed conductive yarn elements integrated throughout the textile structure. Multiple measurement points are achieved by incorporating conductive yarns at different locations within the knitting pattern, allowing comprehensive temperature mapping across the entire textile or composite structure through a unified integrated approach.
3Measurement precision
If externally mounted thermal sensors are used, then temperature measurement is achieved, but the sensors are exposed to environmental and physical stresses
Solution Approach 1:
The patent nests the conductive sensor yarns within the layered structure of the textile or composite material. The conductive yarns are embedded during the manufacturing process, placing the sensor elements inside the protective envelope of the textile or composite structure, thereby shielding them from environmental stresses while maintaining temperature measurement capability.
Solution Approach 2:
The patent merges the sensor function with the textile structure itself, making the textile the sensor. This integration means the textile's own structure provides protection to the conductive elements, eliminating the need for separate protective housings and shielding sensors from environmental damage through structural integration.
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
Provides accurate temperature measurement within composite structures, protected from environmental and physical stresses, with improved durability and reduced installation requirements.
Implementation Method 1
The first and second electrically conductive yarns are comprised within or applied to a textile via a plurality of stitches that form a defined sensing stitch pattern, wherein the sensing stitch pattern comprises at least one thermal sensing junction that provides an electrical connection between the first and second electrically conductive yarns
Data Source
AI summary
The invention provides a knitted textile thermal sensor. The thermal sensor comprises: a first electrically conductive yarn comprised of a first electrically conductive material; a second electrically conductive yarn that is comprised of a second electrically conductive material different from the first electrically conductive material; and electrically conductive output yarns that are in electrical connection with the first and second electrically conductive yarns. The first and second electrically conductive yarns are comprised within or applied to a textile via a plurality of stitches that form a defined sensing stitch pattern. The sensing stitch pattern comprises at least one thermal sensing junction that provides an electrical connection between the first and second electrically conductive yarns, and at a location remote from the at least one thermal sensing junction, a reference junction. The output yarns facilitate electrical connection to the thermal sensor such that at least one voltage measurement can be made.