Sheet Conductive Member Layout for Continuous Embroidery Isolation
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Solution Overview
Problem
The existing method of forming flexible conductors in sheet type conductive members using embroidering or weaving conductive threads is time-consuming and labor-intensive, requiring separate formation of each conductor to avoid shorts.
Innovation Solution
A method of manufacturing a sheet type conductive member involves continuously embroidering or weaving conductive threads to form flexible conductors on a sheet member, with a joint portion connecting each conductor, and then separating the peripheral region to create a connector that electrically connects wiring portions to contacts, using a connector mounting method on a garment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible conductors are formed by embroidering or weaving conductive thread separately for each conductor, then short circuits between adjacent conductors are avoided, but manufacturing time and labor increase significantly
Solution Approach 1:
The patent applies segmentation by dividing the sheet member into a sheet body region and a peripheral region. Multiple flexible conductors are formed in the sheet body region through continuous embroidery, while the peripheral region contains connection conductors that electrically connect the flexible conductors. This spatial segmentation allows continuous manufacturing while maintaining electrical isolation where needed and providing connection paths where required.
Solution Approach 2:
The patent introduces connection conductors as intermediary elements in the peripheral region that serve as mediators to electrically connect the flexible conductors formed in the sheet body region. These connection conductors act as intermediate connection points, allowing multiple flexible conductors to be electrically linked without requiring separate embroidery operations for each conductor path.
2Reliability
If multiple flexible conductors are formed individually to prevent shorts, then electrical isolation is ensured, but the number of embroidery operations increases proportionally
Solution Approach 1:
The patent implements continuity of useful action by forming all flexible conductors and connection conductors through a single continuous embroidery operation. The embroidery needle continuously moves across the sheet member, forming conductive threads in the sheet body region and connection conductors in the peripheral region without stopping or repositioning, thereby maintaining continuous productive action throughout the manufacturing process.
Solution Approach 2:
The patent merges the formation of multiple flexible conductors and their connection conductors into a single integrated embroidery process. Instead of performing separate embroidery operations for each conductor, the system combines all conductor formation activities into one continuous operation, merging multiple manufacturing steps into a unified process that reduces total manufacturing time.
3Productivity
If conductive threads are continuously embroidered to form multiple conductors, then manufacturing efficiency improves, but electrical connection control between conductors becomes more difficult
Solution Approach 1:
The patent applies local quality by creating different electrical connection characteristics in different regions of the sheet member. The sheet body region contains flexible conductors with specific electrical properties, while the peripheral region contains connection conductors with different electrical connection characteristics. This local differentiation allows precise control of electrical connections in specific areas while maintaining manufacturing efficiency through continuous embroidery.
Solution Approach 2:
The patent uses segmentation to divide the embroidery process into distinct functional regions: the sheet body region for forming flexible conductors and the peripheral region for forming connection conductors. This spatial segmentation allows the manufacturing system to maintain continuous operation while precisely controlling where electrical connections are established, thereby managing manufacturing precision alongside productivity.
Data Source
AI summary
A method of manufacturing a sheet type conductive member is a method in which, by continuously embroidering or weaving a conductive thread on or into an insulating sheet member including a sheet body region and a peripheral region, a plurality of flexible conductors situated inside the sheet body region and at least one connection conductor situated in the peripheral region and interconnecting corresponding two flexible conductors are formed, and thereafter, the peripheral region of the sheet member is separated from the sheet body region, and the at least one connection conductor is separated from the plurality of flexible conductors.