Textile Connector Patch Lamination for Stable Flexible Wiring
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Solution Overview
Problem
Smart textiles face challenges in providing a stable conductive path that remains functional despite wear and tear, requires efficient manufacturing, and ensures signal integrity between sensors and processing units.
Innovation Solution
A method involving laminating a conductive patch, thermoplastic patch, and textile patches to create a textile connector patch with a conductive resin, forming a permanent connection through a through-hole, ensuring a stable conductive path and protection from wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a textile connector is made flexible to adapt to changing shape, then adaptability is improved, but structural stability and connection reliability may deteriorate
Solution Approach 1:
The connector combines different materials (conductive fabric, thermoplastic, conductive resin) to achieve both flexibility and structural stability. The conductive fabric provides flexibility while the thermoplastic and resin provide structural support and stable connections.
Solution Approach 2:
The connector is divided into multiple functional layers (conductive patch, thermoplastic patch, outer textile patches) that can independently perform their functions. This segmentation allows each layer to be optimized for its specific purpose while working together as a unified flexible connector.
2Reliability
If a stable conductive path is provided through frequent rubbing and abrasion, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple functions are merged into a single lamination process that simultaneously bonds the thermoplastic patch, activates the conductive resin, and creates the permanent conductive connection. This reduces manufacturing complexity while ensuring reliable conductive paths.
Solution Approach 2:
The conductive resin undergoes a parameter change from non-conductive to conductive state through thermal activation during lamination. This phase transition allows the resin to be applied in a non-conductive state and then activated to provide stable conductive connections.
3Strength
If conductive resin is deformed to provide permanent connection, then connection strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connector wire is pre-positioned through the through-hole before the conductive resin is applied and activated. This preliminary positioning ensures accurate alignment while the subsequent resin deformation provides strong bonding without requiring high precision during the deformation process itself.
Solution Approach 2:
The conductive resin acts as an intermediary material that can be deformed to accommodate minor positioning variations while still providing strong connections. The resin's deformability compensates for small positioning errors, reducing the need for high manufacturing precision.
4Duration of action of stationary object
If the textile connector is protected from wear and tear, then durability is improved, but device complexity increases
Solution Approach 1:
The connector structure uses nested layers where the thermoplastic patch is embedded within the conductive and textile patches. This nested structure provides protection against wear and tear while maintaining a compact, integrated design rather than adding separate protective components.
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 method provides a durable, flexible, and efficient textile connector patch that maintains signal integrity and functionality through multiple wash cycles, with a low fault rate and minimal manufacturing complexity.
Implementation Method 1
laminating the provided patches together to obtain the textile connector patch; by the laminating, the conductive resin is deformed to provide a permanent connection between the connector wire and the conductive patch
Implementation Method 2
providing a thermoplastic patch having a through-hole onto the conductive patch
Data Source
AI summary
A method for manufacturing a textile connector patch for a textile connector, the method including: providing a first outer patch with a textile patch; applying a conductive patch on the first outer patch; placing a thermoplastic patch with a through-hole onto the conductive patch; inserting a connector wire between the conductive patch and the thermoplastic patch so that the wire is exposed through the through-hole; laminating the first outer patch, the conductive patch, and the thermoplastic patch together to form a laminated stack that clamps the connector wire; adding conductive resin into the through-hole; attaching a second outer patch with a textile patch onto the thermoplastic patch; and laminating all patches together to produce the textile connector patch; wherein, during lamination, the conductive resin deforms to establish a permanent connection between the connector wire and the conductive patch.