Stretchable Conductor Circuit Mesh Structure
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Solution Overview
Problem
Current stretchable and flexible circuits using meandering copper foils are prone to high stress concentration along curves, leading to plastic deformation and eventual circuit failure due to limited flexibility in multiple axes.
Innovation Solution
A stretchable conductor circuit comprising conductive wires patterned in a mesh structure, encapsulated in a stretchable laminate that allows for manipulation while maintaining electrical conductivity and returning to the original state, minimizing stress concentrations and enhancing flexibility across multiple axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solid copper foils are patterned in a meandering trace and embedded in a polymer, then the conductor provides stretchable and flexible properties, but high stress concentration along the curves leads to plastic deformation and circuit failure
Solution Approach 1:
The conductor is segmented into discrete wire elements arranged in a mesh structure, where each wire segment can independently deform during stretching. This segmentation distributes stress across multiple discrete elements rather than concentrating it along continuous meandering curves, preventing plastic deformation while maintaining flexibility and circuit reliability
Solution Approach 2:
The conductor transitions from a two-dimensional meandering trace pattern to a three-dimensional mesh structure with wires extending in multiple directions. This dimensional change allows the conductor to accommodate stretching in multiple axes simultaneously, distributing stress more uniformly throughout the structure and eliminating the stress concentration points that cause failure in planar meandering designs
2Duration of action of moving object
If solid copper foils are used in a meandering pattern, then the conductor can stretch in one axis, but it lacks flexibility in multiple axes and suffers from stress concentration
Solution Approach 1:
The mesh structure segments the conductor into discrete wire elements that can independently deform, allowing the overall structure to stretch and flex in multiple directions without requiring a continuous meandering pattern. This enables multi-axis flexibility while distributing mechanical stress across numerous discrete segments
Solution Approach 2:
By transitioning from a planar meandering trace to a three-dimensional mesh architecture, the conductor gains the ability to accommodate deformation in multiple spatial dimensions. The mesh structure allows simultaneous stretching in orthogonal directions, providing true multi-axis flexibility that single-axis meandering patterns cannot achieve
3Ease of operation
If meandering copper foil traces are used, then the circuit can be made flexible, but stress concentration along curves causes plastic deformation over time
Solution Approach 1:
Segmenting the conductor into discrete mesh wires eliminates the continuous curved paths that create stress concentration points. Each wire segment in the mesh can deform independently during flexing, distributing mechanical stress uniformly across the structure and preventing the accumulation of plastic deformation that occurs in meandering traces
Solution Approach 2:
The mesh structure functions as a flexible framework that can bend and deform elastically without permanent damage. The discrete wire elements and their connection points create a structure analogous to flexible shells, allowing repeated flexing operations while maintaining structural integrity and resistance to plastic deformation
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 solution provides a flexible and durable conductor circuit capable of withstanding stretching, twisting, and bending manipulations without plastic deformation, ensuring prolonged circuit functionality and reliability.
Implementation Method 1
the stretchable laminate is configured to return the mesh structure of the set of conductive wires to an original state after the manipulation
Data Source
AI summary
This disclosure provides a stretchable conductor structure, a garment with a stretchable conductor structure, and a method for producing a stretchable conductor structure. The conductive structure includes a set of conductive wires and a stretchable laminate. The set of conductive wires, each including a protective surface, the set of conductive wires patterned in a mesh structure to accommodate a manipulation while providing electrical conductivity across the set of conductive wires. The stretchable laminate encapsulates the mesh structure, the stretchable laminate can return the mesh structure of the set of conductive wires to an original state after the manipulation.