Multi-Material Fiber Layout for Neutral-Axis Device Integration
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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 thermoplastic elastomer overcoat to enhance mechanical stability and resistance to environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate fibers are twisted together to create multi-material functionality, then functional versatility is improved, but structural integrity and uniformity deteriorate due to differential shrinkage and twisting issues
Solution Approach 1:
The patent merges multiple material types (elastic and non-elastic fibers) into a single coextruded composite fiber structure. The multi-component fiber is formed by combining different polymer materials in specific spatial arrangements (such as core-sheath or side-by-side configurations) during the extrusion process, creating one unified fiber that provides both functional versatility and structural integrity without requiring post-manufacturing assembly of separate fibers.
Solution Approach 2:
The patent employs composite material principles by creating a multi-component fiber composed of different polymer materials with distinct properties. The coextrusion process produces a composite structure where elastic fibers and non-elastic fibers are integrated at the microstructural level, allowing the single fiber to exhibit combined properties of stretchability, recovery, and structural stability that cannot be achieved by simply twisting separate monocomponent fibers.
2Adaptability or versatility
If different polymer materials are processed separately and then combined, then material selection flexibility is improved, but manufacturing complexity and inconsistency increase
Solution Approach 1:
The patent merges the processing of different polymer materials into a single coextrusion operation. Multiple polymer streams are fed simultaneously into a coextrusion die that combines them into a unified multi-component fiber structure in one continuous process step, eliminating the need for separate processing and subsequent assembly operations.
Solution Approach 2:
The coextrusion manufacturing system is designed with multi-functionality to handle various polymer materials and create different fiber architectures (core-sheath, side-by-side, concentric) using a single integrated process platform. This universal approach allows flexible material selection while maintaining consistent manufacturing procedures regardless of the specific polymer combinations used.
3Ease of manufacture
If single fibers are used, then manufacturing simplicity is improved, but functional versatility deteriorates due to inability to provide both stretchability and structure
Solution Approach 1:
The patent creates a multi-component composite fiber that integrates both elastic and non-elastic polymer materials within a single fiber structure. This composite approach enables one fiber to simultaneously provide stretchability (from elastic components) and structural stability (from non-elastic components), achieving functional versatility without requiring multiple separate fibers or complex post-processing assembly.
Solution Approach 2:
The patent applies local quality principles by distributing different material properties to specific regions within the fiber cross-section. For example, elastic materials may be concentrated in the core or specific zones to provide stretchability where needed, while non-elastic materials form the surrounding matrix or sheath to provide structural support, creating a functionally differentiated single fiber with optimized local properties.
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 method results in multi-material fibers that are more robust and reliable, capable of withstanding typical textile use cases with improved survivability and functionality, including secure integration of semiconductor devices along the neutral axis, reducing failure due to mechanical and environmental stress.
Implementation Method 1
a metallurgical bond is formed between the first electrical conductor and the first electrode while drawing the multi-material fiber
Implementation Method 2
using a thermoplastic elastomer overcoat to enhance mechanical stability and resistance to environmental factors
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
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.