Method of manufacturing textile with conductive yarns and integrated electronics
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Solution Overview
Problem
Current methods for manufacturing textiles with integrated electronics face challenges in maintaining electrical connections when the textile is subjected to loading, such as stretching or bending, due to breakage at connection points between conductive paths or electronic devices.
Innovation Solution
A computer-aided method and system that uses knitting machines, ultrasonic welding machines, and material handling robots to create bonds between conductive yarn paths and integrate electronic devices within textiles, employing computer-readable instructions to define knitting patterns and operating parameters for forming and welding the conductive paths, ensuring durable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive yarn and electronic devices are integrated in textile articles, then the textile article can transmit electrical signals, but connection points between conductive paths or electronic devices may break when the textile is subjected to loading
Solution Approach 1:
The patent merges the conductive path formation with the knitting process itself, creating integrated conductive paths within the textile structure. Electronic devices are then bonded directly to these knitted conductive paths, combining multiple functions (conduction, structural integration, and device mounting) into a unified system that maintains reliability under loading.
Solution Approach 2:
The patent changes the bonding parameters by using welding technology with specific energy input and temperature control to create strong bonds between conductive paths and electronic devices. This parameter optimization ensures the bonds can withstand textile loading without breaking, resolving the strength-reliability contradiction.
2Ease of manufacture
If conventional connection methods using glue or clips are used to connect conductive paths and electronic devices, then the manufacturing process is simple, but the connections are not durable under loading
Solution Approach 1:
The patent replaces mechanical connection methods (glue, clips, stitching) with a welding-based bonding system. This substitution creates metallurgical or molecular-level bonds that are significantly more durable under loading while maintaining manufacturing efficiency through automated welding processes controlled by computer-readable instructions.
3Adaptability or versatility
If conductive paths are knitted into the textile, then the textile has flexibility and can be stretched or bent, but the conductive paths may break at junctions when loaded
Solution Approach 1:
The patent applies preliminary action by pre-forming the conductive paths through knitting before the textile is subjected to loading. The knitting process creates continuous, flexible conductive paths that are inherently more resistant to breaking at junctions compared to post-formed connections. The computer-controlled knitting ensures proper tension and alignment before any bonding operations.
Solution Approach 2:
The patent uses composite materials by combining conductive yarn with non-conductive yarn in the knitting process. This creates a composite textile structure where conductive paths are integrated within a flexible textile matrix, allowing the conductive elements to move and deform with the textile while maintaining structural integrity at junctions.
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 maintains electrical connections in textiles during loading, enabling reliable data and power transmission, and integrates various electronic devices by forming strong bonds between conductive paths and devices, enhancing the durability of textile electronics.
Implementation Method 1
apply a weld at the junction to create a bond between the conductive paths that meet at the junction
Data Source
AI summary
Methods for manufacturing a textile article having conductive yarn and an integrated electronic device are disclosed. An embodiment of the method includes receiving computer-readable instruction indicative of a knitting pattern of the textile article. Based on the instructions, a textile is formed by knitting conductive yarn and non-conductive yarn. A weld is applied at a junction where two or more conductive paths meet to create a bond between the two or more conductive paths.