3D Conductive Wire Electrode on Elastomer Substrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for fabricating flexible electrodes on elastomer substrates face limitations in maintaining conductivity and mechanical integrity during stretching and contraction, requiring skilled operators and resulting in low yield and reliability, making them unsuitable for mass production.
Innovation Solution
An electrode arrangement featuring a conductive wire bent in vertical and horizontal directions on an elastomer substrate, with fixation regions to enhance elasticity and flexibility, and a fabrication method involving photoresist patterning and insulating layer processing to create a flexible and conductive structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a metal layer is formed over a corrugated PDMS substrate to provide flexibility, then the electrode gains flexibility through corrugation flattening, but the conductivity rapidly decreases as it stretches and contracts and the substrate mechanically breaks
Solution Approach 1:
The conductive wire is configured to extend in both horizontal and vertical directions relative to the substrate surface, creating a three-dimensional structure. This vertical dimension allows the wire to accommodate substrate deformation without compromising conductivity, as the wire can bend and flex in multiple directions rather than being constrained to a single plane.
Solution Approach 2:
The electrode structure combines a flexible substrate with a conductive wire that has both horizontal and vertical components. This composite structure integrates the flexibility of the substrate with the conductivity and mechanical robustness of the three-dimensional wire configuration, resolving the contradiction between flexibility and conductivity stability.
2Ease of manufacture
If existing fabrication methods are used for flexible electrodes, then electrodes can be formed on elastomer substrates, but the process requires skilled operators, has low yield and reliability, and is not suitable for mass production
Solution Approach 1:
The fabrication process is divided into distinct sequential steps: forming the substrate, depositing the conductive material, patterning the horizontal conductive layers, and forming the vertical wire structures. This segmentation allows each step to be optimized and controlled independently, reducing the skill requirement and improving reproducibility for mass production.
Solution Approach 2:
The horizontal conductive patterns and insulation layers are formed preliminarily on the substrate before the vertical wire structures are created. This preliminary action establishes a stable foundation that guides subsequent processing steps, reducing complexity and improving yield in mass production environments.
3Adaptability or versatility
If carbon nanotubes, transparent fluoride polymer, and ionic liquid are mixed to fabricate a flexible electrode in paste form, then flexibility is achieved, but the conductivity rapidly decreases as the material stretches and contracts
Solution Approach 1:
Instead of using a two-dimensional paste coating that loses conductivity when stretched, the invention uses a three-dimensional wire structure with vertical components. This additional dimension allows the conductive path to maintain integrity during substrate deformation, as the vertical wires can flex and bend without breaking the conductive connection.
Solution Approach 2:
The invention creates a composite structure combining flexible substrate material with a robust three-dimensional conductive wire architecture. This composite approach integrates the flexibility of the substrate with the mechanical and electrical stability of the wire structure, maintaining conductivity during stretching and contraction cycles.
4Adaptability or versatility
If an electrode structure is made more flexible through material selection, then elasticity improves, but the manufacturing complexity increases and yield decreases
Solution Approach 1:
The electrode structure is segmented into distinct functional components: the flexible substrate, horizontal conductive patterns, insulation layers, and vertical wire structures. This segmentation allows each component to be optimized for its specific function while using standard fabrication techniques, reducing overall manufacturing complexity despite the enhanced elasticity requirements.
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 electrode arrangement exhibits improved elasticity and flexibility, maintaining low resistance variation under strain and cyclic stretching, and can be mass-produced with high yield, suitable for flexible electronic devices.
Implementation Method 1
patterning a first pad pattern, a second pad pattern, and a conductive pattern over the substrate using photoresist
Data Source
AI summary
An electrode arrangement which is based on elastomer and has elasticity and flexibility may include: an elastomer substrate; first and second pads arranged over the substrate; and a conductive wire connecting the first and second pads. One or more regions of the conductive wire may be bent in a vertical or horizontal direction with respect to the substrate.