Textile Connector Patch Assembly for Durable Flexible Conductive Paths
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Solution Overview
Problem
Smart textile systems 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 connector wire with a through-hole, using a deformable conductive resin to create a permanent connection, and optionally incorporating snap fasteners for secure attachment.
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 deteriorate
Solution Approach 1:
The textile connector is divided into multiple functional layers: outer textile patches for flexibility and adaptability, inner conductive patches for electrical connection, and thermoplastic patches for structural stability. Each layer performs its specific function while working together to resolve the contradiction between flexibility and connection stability.
Solution Approach 2:
The textile connector uses composite material construction combining textile materials (for flexibility and wear resistance) with conductive materials (for electrical conductivity) and thermoplastic materials (for structural stability). This composite structure allows the connector to simultaneously achieve flexibility and connection reliability.
2Ease of manufacture
If traditional manufacturing methods are used, then manufacturing simplicity is maintained, but manufacturing precision and connection reliability deteriorate
Solution Approach 1:
The connector wire is pre-positioned through the thermoplastic patch with a through-hole before lamination. This preliminary positioning action ensures accurate alignment of the conductive path components, achieving high manufacturing precision while maintaining relatively simple manufacturing processes.
3Ease of operation
If the connector wire is exposed for connection, then ease of operation is improved, but protection against wear and tear deteriorates
Solution Approach 1:
The connector wire has different exposure characteristics at different locations: it is exposed through the through-hole at the connection point for ease of operation, while remaining covered and protected by the thermoplastic and textile patches in other areas to protect against wear and tear. This local differentiation resolves the contradiction between accessibility and protection.
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 ensures a stable, flexible, and durable conductive path that withstands washing and wear, with efficient manufacturing and reduced production faults, maintaining signal integrity.
Implementation Method 1
laminating the first outer patch, the conductive patch and the thermoplastic patch together, thereby forming a laminated stack that clamps the connector wire
Implementation Method 2
by the laminating, the conductive resin is deformed to provide a permanent connection between the connector wire and the conductive patch
Data Source
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AI summary
A method for manufacturing a textile connector patch (2) for a textile connector, the method comprising: providing a first outer patch (210) comprising a first textile patch (211); providing a conductive patch (241) on the first outer patch; providing a thermoplastic patch (250) having a through-hole (245) onto the conductive patch; providing a connector wire (261) between the conductive patch and the thermoplastic patch such that the connector wire is exposed by the through-hole; laminating (500) the first outer patch, the conductive patch and the thermoplastic patch together, thereby forming a laminated stack (270) that clamps the connector wire; providing (501) a conductive resin (260) within the through-hole; providing (502) a second outer patch (220) comprising a second textile patch (221) onto the thermoplastic patch; and laminating (503) the provided patches (210, 241, 250, 220) together to obtain the textile connector patch; wherein, by the laminating, the conductive resin is deformed to provide a permanent connection between the connector wire and the conductive patch.