Vertical Conductive Textile Traces for Reliable ECG Signal Transfer
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Solution Overview
Problem
There is a challenge in transferring clinical-level ECG signals from dry textile electrodes embedded in tubular knitted garments to a selected area, particularly between adjacent knitting courses in the vertical direction, where conductivity may be impaired, and this needs to be maintained during stretching, washing, and across various knitting designs.
Innovation Solution
A unique knitting method using a Santoni knitting machine to create vertical conductive traces with conductive yarns, including a float-loop design with elastic non-conductive yarns like Spandex, ensuring continuous contact and conductivity even when stretched, and allowing for diagonal lines and various fabric types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional knitting methods are used to create vertical conductive traces, then the garment structure is simple and easy to manufacture, but the conductivity between adjacent knitting courses is impaired especially during stretching and washing
Solution Approach 1:
The patent applies the dynamics principle by using elastic non-conductive yarns (such as spandex) interspersed among conductive yarns in the vertical conductive traces. This dynamic structure allows the trace to stretch and return to its original configuration, maintaining continuous contact between conductive elements during garment deformation. The elastic yarns provide the necessary flexibility and recovery to ensure reliable conductivity throughout the wear cycle, including during stretching and washing activities.
Solution Approach 2:
The patent implements composite materials by combining conductive yarns with elastic non-conductive yarns (spandex) to create a hybrid conductive trace structure. This composite approach leverages the electrical conductivity of the conductive yarns while incorporating the elastic properties of spandex to maintain structural integrity and continuous contact during stretching. The composite structure ensures both conductivity and mechanical flexibility are achieved simultaneously.
2Reliability
If float-loop design with elastic yarns is used to maintain conductivity during stretching, then conductivity reliability is improved, but the knitting process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the vertical conductive trace into discrete conductive segments separated by elastic non-conductive yarns. Each conductive segment is knitted as a separate unit using conductive yarns, and the elastic yarns act as spacers and connectors between these segments. This segmented approach allows each segment to maintain its conductive properties independently while the elastic yarns ensure continuous electrical path through the structure during stretching, making the knitting process more manageable.
Solution Approach 2:
The patent uses elastic non-conductive yarns as intermediaries between conductive yarn segments. These intermediary yarns perform multiple functions: they maintain spacing between conductive elements, provide elastic recovery to restore contact after stretching, and facilitate the knitting process by acting as temporary carriers or guides. The float-loop design with elastic yarns serves as an intermediary mechanism that simplifies the overall knitting process while ensuring conductivity reliability.
3Reliability
If continuous conductive filament is used for horizontal traces, then conductivity is excellent, but the garment lacks flexibility and comfort during movement
Solution Approach 1:
The patent applies local quality by using different yarn compositions for horizontal and vertical traces. Horizontal traces use continuous conductive filaments to ensure excellent conductivity across the garment width, while vertical traces incorporate elastic non-conductive yarns (spandex) interspersed among conductive yarns to provide flexibility and stretch. This localized differentiation of material properties allows each trace orientation to optimize for its specific function: horizontal for conductivity, vertical for flexibility and stretch recovery.
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 method ensures reliable conductivity across knitting courses, maintaining signal transfer efficiency during wear and washing, and supports clinical-level ECG signal processing without significant lifestyle limitations.
Implementation Method 1
transferring ECG or other signals from textile electrodes to a selected area of the garment
Implementation Method 2
float-loop design with elastic non-conductive yarns like Spandex, ensuring continuous contact and conductivity even when stretched
Data Source
AI summary
A method for knitting a garment having a tubular form, including knitting at least one vertical conductive textile trace on a machine having N participating feeders and M needles. The method includes the steps of continuously knitting the tubular form with one or more flexible non-conductive base yarns, and knitting the vertical conductive textile trace integrally within the tubular form, using a conductive yarn, in addition to spandex yarns, but not the base yarns. The conductive yarn is knitted in a float-loop form by knitting a stitch and skipping over y needles, as follows: repeatably knitting a line segment Lk, using feeder Fi and starting at needle D1; and knitting line segment Lk+1, using the next feeder and start stitching the first float-loop at needle D1+s where 0<s<y.