Multi-Material Fiber Layout for Neutral-Axis Electrical Bonding
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Solution Overview
Problem
Conventional multi-material fibers used in textiles are limited in their ability to withstand mechanical and environmental stresses such as bending, stretching, and machine washing, and the incorporation of semiconductor devices during preform fabrication restricts control over device location and density within the fibers, leading to lower yields and reduced reliability.
Innovation Solution
A method of manufacturing multi-material fibers involves positioning electrically-connectable devices and conductors within a preform material, forming metallurgical bonds during the drawing process to secure the conductors along the neutral axis, and using a combination of thermoplastic materials and overcoating to enhance mechanical stability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If semiconductor devices are incorporated during preform fabrication, then multi-material fibers can be produced with functional devices, but control over device location and density is restricted
Solution Approach 1:
The preform is divided into distinct regions: a core region containing pockets for semiconductor devices and conduits for electrical conductors, and a cladding region. This segmentation allows independent positioning and control of devices within the core, enabling precise location control while simplifying the overall fabrication process.
Solution Approach 2:
Pockets and conduits are pre-formed in the preform material before semiconductor devices and electrical conductors are positioned. This preliminary action enables subsequent easy placement and precise positioning of devices, improving location control without increasing fabrication complexity.
2Reliability
If conventional preform materials and connection strategies are used, then manufacturing is simplified, but fiber reliability under mechanical and environmental stress is inadequate
Solution Approach 1:
The preform uses a composite structure with a core region made of one material and a cladding region made of another material. This composite architecture provides both mechanical protection and environmental resistance, significantly improving fiber reliability while maintaining manufacturability through established composite fabrication techniques.
Solution Approach 2:
The cladding region is designed to provide mechanical cushioning and environmental protection to the core region containing sensitive semiconductor devices and electrical conductors. This beforehand cushioning protects against bending, stretching, and other mechanical stresses, as well as environmental factors, ensuring fiber survivability.
3Reliability
If electrical conductors are positioned away from the neutral axis, then electrical connectivity is achieved, but mechanical stability under bending and stretching is reduced
Solution Approach 1:
The solution moves the electrical connection problem from the radial dimension to the longitudinal dimension by forming metallurgical bonds between electrical conductors and semiconductor device electrodes along the length of the fiber. This allows conductors to be positioned at the neutral axis for mechanical stability while maintaining reliable electrical connectivity through the bonded interface.
Solution Approach 2:
The electrical connection mechanism is changed from physical contact at a distance to metallurgical bonding. This parameter change in the connection method allows conductors to be positioned at the neutral axis without compromising electrical reliability, as the metallurgical bond provides both electrical connectivity and mechanical strength.
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
The solution results in multi-material fibers that are more robust and reliable, capable of surviving typical textile use cases with improved mechanical stability and resistance to environmental factors, while maintaining electrical connectivity and functionality.
Implementation Method 1
drawing the multi-material fiber by causing the preform material to flow
Implementation Method 2
a metallurgical bond may be formed between the first electrical conductor and the first electrode while drawing the multi-material fiber
Data Source
AI summary
Methods of manufacturing multi-material fibers having one or more electrically-connectable devices disposed therein are described. In certain instances, the methods include the steps of: positioning the electrically-connectable device(s) within a corresponding pocket provided in a preform material; positioning a first electrical conductor longitudinally within a first conduit provided in the preform material; and drawing the multi-material fiber by causing the preform material to flow, such that the first electrical conductor extends within the multi-material fiber along a longitudinal axis thereof and makes an electrical contact with a first electrode located on each electrically-connectable device. A metallurgical bond may be formed between the first electrical conductor and the first electrode while drawing the multi-material fiber and/or, after drawing the multi-material fiber, the first electrical conductor may be located substantially along a neutral axis of the multi-material fiber.