Smart Garment Contact Electrode With Conductive Thermoadhesive
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Solution Overview
Problem
Existing methods for attaching electrodes to intelligent garments are unsuitable due to the lack of process know-how in the textile industry, poor resistance to washing, and the complexity of soldering or crimping connections, which can damage the textile and are not durable or safe for everyday use.
Innovation Solution
An electrode arrangement featuring a flat electrode carrier made of textile or non-textile material with an electrically conductive electrode on one side and a thermally conductive adhesive on the other, allowing for a reliable and simple electrical connection via a thermal transfer process, enabling the use of incompatible materials like silicone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or crimping connections are used to attach electrodes to intelligent garments, then electrical connection is established, but the textile material is damaged or visibly impaired and the connection is not resistant to washing processes
Solution Approach 1:
The patent introduces an intermediate carrier structure that mediates between the electrode and the textile garment. This carrier serves as a buffer zone that protects the delicate textile from direct exposure to harsh connection processes like soldering or crimping, while still enabling reliable electrical connection through the carrier's conductive properties.
Solution Approach 2:
The connection system is divided into separate functional components: the electrode, the carrier structure, and the textile garment. This segmentation allows each component to be optimized independently - the electrode for electrical contact, the carrier for connection stability and textile protection, and the garment for comfort and flexibility - while working together as an integrated system.
2Reliability
If conventional connection techniques are used to attach electrodes to intelligent garments, then electrical connection is established, but the process is complex and requires process know-how not available in the textile industry
Solution Approach 1:
The carrier acts as an intermediary that simplifies the manufacturing process by providing a pre-prepared platform for electrode attachment. This carrier can be manufactured separately using suitable techniques and then integrated into the garment through simple processes like sewing or adhesive bonding, eliminating the need for complex in-line soldering or crimping equipment in textile factories.
Solution Approach 2:
The electrode and carrier are prepared as a pre-assembled unit before integration into the garment. This preliminary preparation of the connection system allows the main garment manufacturing process to remain simple and familiar to textile workers, while the complex electrode attachment has already been completed in a specialized setting.
3Reliability
If electrodes made of skin-friendly materials like silicone or PTFE are used, then good electrical contact is achieved, but these materials adhere poorly or not at all to many connection materials
Solution Approach 1:
The carrier serves as a critical intermediary between the silicone/PTFE electrode and the garment material. This carrier is specifically designed with surface properties that enable strong adhesion to both the electrode material and the textile, solving the incompatibility issue without compromising the skin-friendly properties of the electrode material.
Solution Approach 2:
The carrier structure functions as a composite material system that combines different material properties: one surface is optimized for bonding to silicone or PTFE electrodes, while the other surface is optimized for bonding to textile materials. This composite approach allows incompatible materials to be joined effectively through the intermediate carrier layer.
4Reliability
If liquid adhesives or compounds are used to create electrical connections on smart clothing, then electrical connection is established, but the process is extremely time-consuming and the connections are not sufficiently reliable or durable
Solution Approach 1:
The connection system is segmented into a pre-assembled electrode-carrier unit that can be manufactured efficiently in advance. This pre-assembly eliminates the need for time-consuming liquid adhesive application and curing steps during garment production, as the electrode-carrier unit is already prepared with reliable mechanical and electrical connections.
Solution Approach 2:
The patent replaces liquid adhesive bonding with a mechanical connection system using the carrier structure. This mechanical approach provides immediate, reliable connection without the time-consuming wetting, positioning, and curing steps required by liquid adhesives, significantly improving manufacturing productivity while maintaining connection durability.
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 solution provides a cost-effective, durable, and process-reliable method for attaching electrodes to intelligent garments, ensuring good electrical contact and stability, even with materials that are difficult to adhere to, such as silicone, and allows for easy application and integration into smart textiles.
Implementation Method 1
an electrically conductive thermal adhesive is applied to the opposite side of the electrode carrier, wherein the electrode and the thermal adhesive are electrically conductively connected for an electrical connection
Data Source
Figure 1~2
Figure 3~5
AI summary
In order to allow a contact electrode (11) to be arranged on a smart garment (10) to produce an electrical connection in a simple and process-safe manner, an electrode arrangement (1) is provided having an electrode carrier (2) in the form of a flat material piece consisting of a textile or non-textile material, wherein the electrode carrier (2) is connected on one side to an electrically conductive electrode (4), and an electrically conductive thermoadhesive (3) bears against the opposite side of the electrode carrier (2), via which thermoadhesive the electrode arrangement (1) can be attached to a smart garment (10), wherein the electrode (4) and the thermoadhesive (3) are electrically conductively connected for an electrical connection.