Method to genberate an ultra-stretchable electrical and heat conductive arrangement
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Solution Overview
Problem
Current technologies fail to produce low-cost, highly stretchable and robust electrical and heat transfer arrangements that can efficiently conduct electricity or manage heat transfer, especially for wearable applications where reliability and stretchability are limited.
Innovation Solution
A novel sew-and-transfer method using a sewing machine to embed conductor wires or heat conduits in a moldable medium, allowing for the creation of stretchable interconnects with up to 500% stretchability without altering electrical resistance or fluid mechanics, utilizing a dissolvable filament for temporary placement and a polymeric medium for adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fabrication processes are used for stretchable interconnects, then electrical connectivity can be achieved, but the devices exhibit limited stretchability, poor reliability, and large gauge factors
Solution Approach 1:
The interconnect is segmented into discrete conductor wire sections separated by insulating moldable medium segments. This segmentation allows the conductor to stretch and deform while maintaining electrical connectivity, resolving the contradiction between reliability and stretchability
Solution Approach 2:
The invention uses a composite structure combining conductor wire (metal), moldable medium (polymer/elastomer), and dissolvable filament (temporary support). This composite approach enables the interconnect to achieve both mechanical stretchability and electrical reliability simultaneously
2Measurement precision
If conventional fabrication processes are used for stretchable interconnects, then electrical connectivity can be achieved, but the devices exhibit large gauge factors
Solution Approach 1:
The moldable medium is formulated as a flexible, moldable polymer or elastomer that can be shaped around the conductor wire. This flexible matrix allows the interconnect to deform with minimal resistance change, achieving low gauge factor while maintaining ease of manufacture through simple molding processes
3Temperature
If wearables are designed for heat transfer, then thermal exchange with body can be achieved, but the arrangements need to be highly stretchable and low cost
Solution Approach 1:
The moldable medium serves multiple functions: it provides electrical insulation for the conductor wire, acts as a thermal interface material for heat transfer applications, and provides mechanical support. This multi-functionality enables the same basic structure to achieve both electrical connectivity and thermal exchange without increasing complexity
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 fabrication of highly elastic, reliable, and cost-effective stretchable interconnects that maintain electrical conductivity and heat transfer capabilities, suitable for wearable devices and medical applications, with minimal resistance change under high strain and repeated cycles.
Implementation Method 1
securing a dissolvable filament for temporary maintenance of placement of the conductor wire on the substrate
Implementation Method 2
crosslinking the moldable medium thereby allowing the conductor wire to adhere to the moldable medium
Implementation Method 3
dissolving the dissolvable filament
Implementation Method 4
the moldable medium having a thermal conductivity coefficient suitable for exchanging heating to or from a subject's body
Data Source
AI summary
A wearable accessory capable of communicating data to actuators or from sensors is disclosed. The wearable accessory includes a conductor wire disposed in a moldable medium according to a predetermined pattern, the moldable medium being an electrically insulating material, the conductor wire terminating at an input and an output.