3D Touch Sensor Film Composite for Deep Forming and Light Transmission
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Solution Overview
Problem
Existing methods fail to produce 3D formed touch-sensitive surfaces with strong deformations and small radii due to the inflexibility of PET carriers containing conductive paths, which also obstruct light transmission.
Innovation Solution
A method involving a composite of PET and PC films, where PC enhances the plastic formability and flexibility, allowing for deep deformations and small radii while maintaining mechanical stability and enabling light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If PET carriers with conductive paths are used, then manufacturing precision and stability are improved, but flexibility and deformability deteriorate
Solution Approach 1:
The patent divides the carrier structure into two separate films: a PET film providing mechanical stability and a flexible film providing deformability. The conductive paths are applied only to the flexible film, separating the functions of structural support and electrical conductivity, allowing each material to optimize its properties without compromise
Solution Approach 2:
The patent creates a composite structure combining PET film and flexible film layers. This composite material system leverages the high strength and dimensional stability of PET while incorporating the flexibility and deformability of the flexible film, enabling both precise conductive path formation and strong 3D deformations
2Adaptability or versatility
If thick and wide conductive paths are printed, then flexibility is improved, but light transmission deteriorates
Solution Approach 1:
The patent applies conductive paths only to the flexible film layer, which has different optical properties compared to the PET carrier. The conductive paths on the flexible film can be optimized for flexibility while maintaining acceptable light transmission, as the flexible film's inherent properties allow for thinner, more transparent conductive structures compared to rigid PET
3Manufacturing precision
If PET carriers are used for injection molding, then manufacturing precision is improved, but deformability deteriorates
Solution Approach 1:
The patent separates the structural function (PET film providing dimensional stability during molding) from the deformation function (flexible film enabling deep 3D deformations). This segmentation allows the PET film to maintain its shape during manufacturing while the flexible film accommodates the required deformations in the final product
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 composite film structure enables highly deformable touch sensors with deep deformation depths and small radii, preserving mechanical strength and allowing light penetration.
Implementation Method 1
PC enhances the plastic formability and flexibility, allowing for deep deformations and small radii
Implementation Method 2
the at least one film and/or the at least one sensor film has at least one thermoplastic material or at least one thermoplastic polymer
Data Source
AI summary
A method for producing at least one plastic component (1), wherein in the method the following steps, preferably in the following sequence, preferably cyclically in the following sequence, are carried out: a) providing at least one film (2) and at least one sensor film (3), wherein the at least one film (2) and/or the at least one sensor film (3) has at least one thermoplastic material or at least one thermoplastic polymer; b) applying the at least one sensor film (3) to at least one first region of a surface of the at least one film (2); c) forming the at least one film (2) having the at least one sensor film (3), wherein one or more formed film bodies (4) are made; d) punching out one or more film elements (4a) made from at least one second region of the one or more formed film bodies (4), and a device (10) and a plastic component (1).