Stretchable Conductive Tape Layout With Sinusoidal Pathways
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Solution Overview
Problem
Incorporating conductive pathways into textiles faces challenges in establishing connections and results in an increased number of fabric layers, which affects reliability and flexibility.
Innovation Solution
A method and apparatus for laying conductive pathways on a tape using a pair of surfaces with devices that vary the lateral position of conductive pathways to form sinusoidal and modified sinusoidal patterns, maintaining a tangential separation above a threshold, reducing overall width, and allowing for stretchability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive pathways are incorporated into separate fabric pieces, then connections can be established, but the number of fabric layers increases
Solution Approach 1:
The conductive pathways are integrated directly into the textile structure during the knitting or weaving process, merging the conductive function with the fabric structure itself. This eliminates the need for separate fabric pieces and reduces the total number of layers while maintaining reliable electrical connections throughout the textile product.
Solution Approach 2:
The textile structure serves multiple functions simultaneously: it provides mechanical support, flexibility, and electrical conduction. The conductive pathways are formed using the same yarns and knitting/weaving mechanisms used for structural yarns, making the textile multifunctional without requiring additional separate components.
2Reliability
If conductive pathways are formed from conductive yarns and incorporated into fabric, then reliability improves, but establishing connections becomes difficult
Solution Approach 1:
The conductive yarns are strategically positioned at specific locations within the textile structure where connections are needed, such as at boundaries or interface regions. This local concentration of conductive material facilitates easier connection establishment with external components while maintaining reliable conduction pathways throughout the fabric.
Solution Approach 2:
The conductive pathways are pre-formed and integrated into the textile structure during the manufacturing process before final assembly. Connection points are prepared in advance with exposed conductive yarns or contact points, eliminating the need for complex connection procedures during later manufacturing stages.
3Adaptability or versatility
If sinusoidal patterns are used for conductive pathways, then stretchability is improved, but tangential separation varies excessively
Solution Approach 1:
The sinusoidal pattern parameters are asymmetrically adjusted so that the amplitude and wavelength vary in different regions of the textile. This allows the conductive pathways to maintain adequate tangential separation in critical areas while still providing sufficient stretchability in regions where greater deformation is expected, optimizing both precision and adaptability.
Solution Approach 2:
Different sections of the conductive pathway have different sinusoidal characteristics tailored to local requirements. Areas requiring stable separation have smaller amplitudes, while areas requiring greater stretch have larger amplitudes. This localized optimization resolves the contradiction between uniform precision and overall stretchability.
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3a~3b
AI summary
A conductive tape formed by laying a conductive pathway on a tape layer is disclosed. Various apparatus and methods for laying conductive pathways to form conductive tape are disclosed. The conductive pathways may be laid by varying the lateral position of the conductive pathway on the tape substrate. Such patterns all stretchable conductive tape to be realized. Multiple conductive pathways may be laid in the tape and the lateral separation of the pathways in the tape may vary. In some embodiments the pathways are formed from conductive yarn or by printing or laying conductive ink.