Multi-Layer Sensory Fabric via Integrated Weaving
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Solution Overview
Problem
Existing sensory textiles require complex and time-consuming production processes, involving multiple layers that need to be manually aligned and connected, leading to manufacturing tolerances that affect the accuracy and reliability of force or pressure detection.
Innovation Solution
A multi-layer fabric with at least three fabric layers, where two are conductive and one is a middle layer of fleece, foam, film, or knitted fabric, connected via weaving technology, allowing for direct or indirect bonding without additional processing steps, reducing manufacturing effort and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fabric layers are manually aligned and connected, then the sensory fabric can detect force or pressure, but the production process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple fabric layers into a single integrated woven structure where conductive threads from different layers are interlaced through the middle layer. This merging eliminates the need for separate alignment and connection steps, reducing production complexity while maintaining detection functionality.
Solution Approach 2:
The conductive threads are pre-positioned and interlaced with the middle layer during the weaving process itself, rather than being aligned and connected afterward. This preliminary action during manufacturing ensures proper spatial arrangement without requiring post-production assembly steps.
2Measurement precision
If multiple fabric layers are manually aligned and connected, then the sensory fabric can detect force or pressure, but manufacturing tolerances affect accuracy and reliability
Solution Approach 1:
By merging the conductive threads and middle layer into a single woven structure, the patent eliminates interfaces between separate layers. This removes the source of alignment tolerance errors, as there are no separate layers that could be misaligned during assembly.
Solution Approach 2:
The patent creates localized sensing zones where conductive threads from different original layers now interlace at specific points within the middle layer. Each interlacing point forms a precise, localized sensing element with consistent geometric properties, improving measurement precision.
3Reliability
If multiple fabric layers are manually aligned and connected, then the sensory fabric can detect force or pressure, but additional processing steps are required
Solution Approach 1:
The patent merges the formation of multiple fabric layers with the weaving process itself, creating the complete multi-layer structure in a single continuous operation. This eliminates subsequent assembly, alignment, and connection processing steps, significantly improving productivity.
Solution Approach 2:
The weaving machine performs multiple functions simultaneously: it creates the middle layer structure, positions conductive threads, and interlaces all layers into a unified fabric. This multi-functionality during manufacturing eliminates the need for separate specialized processing steps.
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
This approach simplifies the production of sensory textiles, enhances their spatial resolution for force or pressure detection, and minimizes tolerance-related errors, making them more reliable and easier to calibrate for various applications.
Implementation Method 1
The first fabric layer, the second fabric layer and the middle layer or fabric layer form a sensor arrangement which has an electrical property which changes when a force is acting on this fabric layer
Data Source
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AI summary
The invention relates to a multi-layer sensory fabric (20) having a plurality of fabric layers and, as an example, three fabric layers (21, 22, 23). Each fabric layer (21, 22, 23) comprises weft threads (24) and warp threads (25). Optionally, a binding system (26) having binding weft threads (27) and binding warp threads (28) can be provided. The fabric layers (21, 22, 23) are indirectly and/or directly attached to one another via the binding system (26) using weaving technology. The connection between the fabric layers (21, 22, 23) is made during the production of the fabric layers (21, 22, 23) by weaving. A subsequent connection of the fabric layers (21, 22, 23) can thus be dispensed with.