Stretchable Electrical Connecting Element with Thermal Adhesive Resin Threads
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Solution Overview
Problem
Existing methods for connecting stretchable electronics to sensors, such as sewing with conductive threads, are labor-intensive and lack reliability.
Innovation Solution
An electrical connecting element with a stretchable insulation sheet, conductive threads, and thermally adhesive resin threads that are sewn together to form a mechanical and electrical connection with stretch wiring by melting the resin upon heating, allowing easy and reliable attachment to stretchable electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive threads are sewn to connect stretch wiring to sensors, then electrical connection is achieved, but the process becomes labor-intensive and reliability becomes insufficient
Solution Approach 1:
The patent merges the mechanical connection function and electrical connection function into a single integrated connecting element. The connecting element includes conductive threads embedded within a non-conductive thread structure, allowing both mechanical attachment (through the non-conductive thread) and electrical connection (through the conductive threads) to be achieved simultaneously in one component, rather than through separate sewing operations.
Solution Approach 2:
The patent introduces a connecting element as an intermediary component between the stretch wiring and the sensor. This intermediary structure includes a non-conductive thread for mechanical attachment and conductive threads for electrical connection, serving as a mediator that simplifies the overall connection process while improving reliability compared to direct sewing of conductive threads.
2Productivity
If conductive threads are used for connection, then electrical connection is achieved, but the process becomes labor-intensive
Solution Approach 1:
The connecting element combines mechanical attachment and electrical connection functions into a single component that can be attached in one operation. The non-conductive thread provides mechanical attachment while conductive threads provide electrical connection, eliminating the need for separate sewing steps and reducing overall connection time.
Solution Approach 2:
The conductive threads are pre-integrated into the connecting element structure during manufacturing. This preliminary action of embedding conductive threads within the non-conductive thread structure means that when the connecting element is attached to the sensor, both mechanical and electrical connections are established simultaneously, rather than requiring subsequent separate operations to establish electrical connectivity.
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 reliable and efficient method for connecting stretchable electronics to sensors, ensuring mechanical and electrical integrity while maintaining the stretchiness and bendability of the wearable devices.
Implementation Method 1
solid resin and two or more conductive threads on one surface of the insulation sheet. The resin is, for example, threadlike synthetic resin having thermal adhesiveness
Implementation Method 2
solidifying resin melted by heating the electrical connecting element with the electrical connecting element pressed against the target object
Data Source
AI summary
An electrical connecting element includes a stretchable insulation sheet, two or more first conductive threads on one surface of the insulation sheet, and two or more first resin threads on the one surface of the insulation sheet. The first conductive threads extend in a predetermined direction and are disposed in parallel with each other orthogonally to the predetermined direction. The first resin threads have thermal adhesiveness. The first resin threads do not overlap with any of the first conductive threads.