An electrically conductive textile element and method of producing same
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Solution Overview
Problem
Current methods for producing electrically conductive textiles face challenges such as inflexibility, chemical instability, high production costs, hazards, and difficulties in large-scale production due to requirements for specialized equipment and expertise, as well as issues with metal adhesion and conductivity.
Innovation Solution
A method involving silanization of textile surfaces with carbon-carbon double bond-bearing silane, followed by in-situ free radical polymerization of negatively-charged polyelectrolytes, ion exchange with metal ions, reduction to elemental metal, and electroless metal deposition to create flexible and durable conductive textiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal coatings are deposited on textile substrate surfaces using metal particle deposition techniques, then electrical conductivity is improved, but device complexity and manufacturing cost increase due to requirements for advanced instrumentation and specialized workforce expertise
Solution Approach 1:
The patent uses polyelectrolyte brushes as an intermediary layer between the textile substrate and metal particles. The polyelectrolytes with charged functional groups attract and bind metal particles, serving as a mediator that enables conductivity without requiring complex deposition equipment. This resolves the contradiction by providing a simple, chemistry-based approach instead of complex physical deposition techniques.
Solution Approach 2:
The patent changes the chemical parameters of the textile surface by grafting polyelectrolyte brushes with specific charge densities and functional groups. This modification of surface chemistry parameters enables metal particle attachment through electrostatic interactions, eliminating the need for sophisticated deposition equipment while achieving reliable conductivity.
2Reliability
If surface architecture is modified by grafting functionalized polymer brushes using SI-ATRP, then adhesion and conductivity are improved, but production time increases to approximately 24 hours which is not cost-effective for mass production
Solution Approach 1:
Instead of using the complex SI-ATRP method that requires nitrogen protection and long reaction times, the patent inverts the approach by using simple in-situ free radical polymerization that proceeds rapidly under ambient conditions. This reverses the conventional wisdom that controlled polymerization is necessary, achieving both good adhesion and high productivity.
Solution Approach 2:
The patent changes the polymerization parameters from controlled SI-ATRP conditions (nitrogen atmosphere, 24 hours) to free radical polymerization conditions (ambient air, 1-3 hours). This parameter change maintains the beneficial effects of polyelectrolyte grafting while dramatically improving production throughput for mass manufacturing.
3Productivity
If in-situ free radical polymerization is used to prepare conductive fibers, then production throughput is improved with reaction time of 1-3 hours under ambient conditions, but adaptability decreases because cationic PMETAC is restricted to couple with anionic [PdCl4]2- moieties which are expensive
Solution Approach 1:
The patent creates polyelectrolyte brushes with versatile functional groups that can interact with multiple types of metal ions through different mechanisms (electrostatic attraction, coordination, ion exchange). This universality allows the same polyelectrolyte platform to work with various metal salts without requiring expensive or specialized catalysts, maintaining both high throughput and adaptability.
Solution Approach 2:
The patent replaces expensive, reusable catalyst systems like [PdCl4]2- with inexpensive, single-use metal salts that can be directly incorporated through ion exchange or electrostatic binding. This substitution with cheaper materials maintains production efficiency while eliminating the need for costly catalytic moieties and their associated handling requirements.
4Reliability
If SI-ATRP method is used for polyelectrolyte grafting, then adhesion properties are improved, but manufacturing cost increases due to requirement for nitrogen protection and long reaction periods
Solution Approach 1:
The patent employs in-situ free radical polymerization that proceeds automatically under ambient conditions without requiring nitrogen protection or specialized equipment. The process uses readily available materials and proceeds spontaneously, making it self-service oriented and eliminating the need for costly controlled atmosphere equipment and expertise, while still achieving good adhesion 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 enables the production of flexible, durable, and cost-effective electrically conductive textiles that maintain conductivity and adhesion even after repeated washing and stretching cycles, suitable for mass production without the need for nitrogen protection or expensive catalysts.
Implementation Method 1
silanising a surface of the textile element with a carbon-carbon double bond-bearing silane to provide a silanised surface
Implementation Method 2
grafting monomers of a negatively-charged polyelectrolyte onto the silanised surface by in-situ free radical polymerisation
Implementation Method 3
adding metal ions to the polyelectrolyte by ion exchange
Implementation Method 4
reducing the metal ions to elemental metal
Implementation Method 5
coating the textile element with metal particles
Data Source
Figure 1~2
Figure 3
Figure 4~5F
AI summary
An electrically conductive textile element and method of producing same. The method including the steps of: (i) modifying a surface of a textile element with a negatively-charged polyelectrolyte; and (ii) coating the modified surface of the textile element with metal particles.