Textile Conductive Bus for Waterproof Garment Electronics

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Solution Overview

Problem

Conventional methods for interconnecting garment-integrated electronics, such as discrete wire, Kapton flex-circuit cable, and conductive inks, face limitations in flexibility, tensile strength, compatibility with textile equipment, and reliability, especially in terms of waterproofing and long-term deployments.

Innovation Solution

A textile conductive bus is developed, comprising a plurality of conductors capable of carrying up to 1 Ampere of current, with a cross-sectional diameter of less than 1.5 mm, including all dielectric layers. This bus is fabricated from liquid crystal polymer (LCP) and can be spooled onto a bobbin for integration into stitching or weaving equipment, providing a waterproof, highly flexible, and inexpensive solution for interconnecting garment-borne electronics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If discrete wire is used to interconnect electronics, then electrical connectivity is achieved, but flexibility and compatibility with textile equipment deteriorate

Engineering Contradiction:

Improveelectrical connectivityVSAvoidflexibility and textile equipment compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent transforms rigid discrete wire into a flexible textile-compatible conductor by changing the material parameters and structural form. The conductor is reimagined as a textile thread that can be woven or knitted into garments, maintaining electrical conductivity while achieving flexibility and textile equipment compatibility through parametric transformation of the conductor's physical state and structure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material structure by combining conductive materials with textile materials. The conductor consists of multiple strands including conductive cores and insulating textile fibers, creating a composite structure that simultaneously provides electrical connectivity, flexibility, and compatibility with textile manufacturing processes.

Inventive Principle:

Principle #40Composite materials

2Reliability

If Kapton flex-circuit cable is used, then electrical connectivity is achieved, but flexibility deteriorates

Engineering Contradiction:

Improveelectrical connectivityVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent fundamentally changes the flexibility parameter of the conductor by transitioning from rigid Kapton flex-circuit cable to a soft textile thread structure. This parameter change enables the conductor to bend, stretch, and conform to garment shapes while maintaining electrical connectivity, directly resolving the flexibility deterioration issue.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional wire is used, then electrical connectivity is achieved, but tensile strength deteriorates

Engineering Contradiction:

Improveelectrical connectivityVSAvoidtensile strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies composite material principles by constructing the conductor as a multi-strand assembly with conductive cores surrounded by strong insulating textile fibers. This composite structure distributes mechanical stress across multiple elements, significantly enhancing tensile strength while preserving electrical connectivity through the conductive cores.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent segments the conductor into multiple independent strands rather than using a single solid wire. This segmentation allows each strand to bear mechanical load independently, improving overall tensile strength and flexibility while maintaining electrical connectivity through the distributed conductive elements.

Inventive Principle:

Principle #1Segmentation

4Reliability

If conductive inks are used, then electrical connectivity is achieved, but waterproofing and long-term reliability deteriorate

Engineering Contradiction:

Improveelectrical connectivityVSAvoidwaterproofing and long-term durability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces conductive ink with a composite conductor structure consisting of solid conductive cores encased in waterproof insulating textile fibers. This composite structure provides inherent waterproofing and mechanical durability, eliminating the reliability issues associated with conductive inks while maintaining electrical connectivity.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250048550A1Textile conductive bus and method of making the same

Publication Date: 2025.02.06 THE CHARLES STARK DRAPER LABORATORY INC

AI summary

A textile conductor and a method of making the same including a textile thread, an electrical bus within the textile thread, wherein the electrical bus includes at least one top electrically conductive pad, at least one bottom electrically conductive pad, and a plurality of rows of a plurality of electrically conductive traces A dielectric material is positioned between the at least one of the at least one top electrically conductive pad, the plurality of rows of the plurality of electrically conductive traces, and the at least one bottom electrically conductive pad. At least one electrically conductive via connects at least one of the at least one top electrically conductive pad and the at least one bottom electrically conductive pad to at least one of the plurality of electrically conductive traces in at least one of the plurality of rows of the plurality of electrically conductive traces.