Stretchable Interposer Textile Circuit Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for integrating electronic circuits with textile layers containing electrically conductive yarns face accuracy limitations due to tool alignment issues, leading to large connection points that compromise flexibility.
Innovation Solution
A method involving a stretchable interposer with contact pads aligned with electrically conductive yarns, mechanically attached using non-conductive adhesive, and subsequent local removal of insulating materials via laser ablation to establish electrical contact, reducing misalignment and contact size while maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the size of connection points is increased to compensate for alignment inaccuracies, then the reliability of electrical connection is improved, but the flexibility of the textile is reduced
Solution Approach 1:
The textile layer is pre-treated by removing insulating material from specific areas before the adapter element is placed. This preliminary action creates ready-made contact areas that guide the placement process, allowing for smaller, more precise connection points without requiring high alignment accuracy during the placement step itself.
Solution Approach 2:
The connection process is divided into two separate steps: (1) pre-treating the textile by removing insulating material to create contact areas, and (2) placing the adapter element. This segmentation allows each step to be optimized independently, enabling smaller connection points while maintaining reliability.
2Ease of manufacture
If the accuracy of placement tools is reduced to lower costs, then the manufacturing cost is decreased, but the alignment precision between adapter element and conductive lines deteriorates
Solution Approach 1:
By pre-removing insulating material from the textile at precise locations before placing the adapter element, the system creates fixed reference points that guide placement. This preliminary preparation decouples the precision requirement from the placement tool, allowing cheaper tools to be used while maintaining alignment precision through the pre-defined contact areas.
Solution Approach 2:
The removed insulating material creates an intermediary structure (exposed conductive areas) that acts as a mediator between the adapter element and the textile. This intermediary provides self-alignment functionality, allowing inexpensive placement tools to achieve precise alignment through the guiding effect of the pre-prepared contact areas.
3Strength
If pressure and elevated temperature are applied to cure adhesive, then the bonding strength is improved, but the textile material may be damaged
Solution Approach 1:
The insulating material is removed in advance before adhesive application, creating precise contact areas. This preliminary action allows the adhesive to be applied only where needed, reducing the total amount of adhesive required and enabling lower curing temperatures and pressures, thereby protecting the textile from damage while maintaining bonding strength at the critical contact points.
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 approach significantly reduces misalignment issues, allowing for smaller electrical contacts and increased flexibility of the textile layer, enabling the use of cheaper placement tools with lower accuracy and accommodating various textile types.
Implementation Method 1
The insulating material may be removed by means of a laser beam
Data Source
AI summary
The present disclosure relates to a method of integrating a interposer device with a textile layer, wherein the interposer device is a stretchable interposer device comprising a stretchable electrically conductive structure with at least one contact pad for establishing at least one electrically conductive path towards the textile layer. The interposer device is arranged to be mechanically attached to a textile layer comprising a plurality of yarns, at least one of which is an electrically conductive yarn. An electrical connection is established between the at least one conductive yarn of the textile layer and the at least one contact pad, which electrical connection is established after the interposer device has been mechanically attached to the textile layer.