Capacitive Touch Sensor Vias for Flush-Mount Connectivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current touch screen manufacturing processes, particularly for capacitive sensors, involve high temperature curing stages that are costly and complex, and existing designs often require additional electrical connectors at the front surface, which can compromise durability and aesthetics.
Innovation Solution
A capacitive touch screen design featuring a plastic substrate coated with indium tin oxide (ITO) and a low-temperature silver ink, laminated with antiglare coated thin glass, and incorporating passageways or vias for electrical connectivity without additional front surface connectors, allowing for a flush-mountable and durable construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature curing stages are used in capacitive touch screen manufacturing, then the conductive coating and electrode properties are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the temperature parameter from high temperature (510°C for ATO, 480°C for silver paste, 520°C for hardcoat) to low temperature processing. This is achieved by using plastic substrates that can be processed at lower temperatures than glass, thereby simplifying the manufacturing process while maintaining the functional properties of the conductive coatings and electrodes
Solution Approach 2:
The patent employs plastic substrates which are generally cheaper and easier to process than glass substrates. The plastic substrate allows for lower temperature processing, reducing the need for complex high temperature curing equipment and multiple processing stages, thereby lowering overall manufacturing complexity and cost
2Reliability
If additional electrical connectors are placed on the front surface for electrical connectivity, then electrical connection is achieved, but durability and aesthetics are compromised
Solution Approach 1:
The patent moves the electrical connection points from the front surface (2D plane) to the edges/borders of the touch screen. By utilizing the peripheral dimension, the connectors are positioned where they do not interfere with the front surface integrity or aesthetics, thereby maintaining both electrical connectivity and durability
Solution Approach 2:
The patent extracts the electrical connectors from the front surface and relocates them to the edges or borders of the touch screen. This separation allows the front surface to remain intact and aesthetically pleasing while still providing the necessary electrical connection functionality through edge-mounted connectors
3Strength
If glass substrate is used for capacitive touch screen, then durability is improved, but manufacturing complexity and breakage risk increase
Solution Approach 1:
The patent replaces expensive, fragile glass substrates with cheaper, more flexible plastic substrates. While plastic may be perceived as less durable than glass, it offers advantages in terms of impact resistance, flexibility, and ease of processing, thereby reducing manufacturing complexity and breakage risk while maintaining adequate durability for the application
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 design reduces manufacturing complexity and costs, enhances durability, and enables a flush-mountable, bezel-free configuration with improved optical properties and reduced breakage risks, suitable for demanding applications like automotive and gaming systems.
Implementation Method 1
a substrate coated with a conductive coating and with a pattern of electrodes disposed thereon
Implementation Method 2
a plastic substrate coated with indium tin oxide (ITO)
Implementation Method 3
a low-temperature silver ink
Implementation Method 4
laminated with antiglare coated thin glass
Implementation Method 5
incorporating passageways or vias for electrical connectivity without additional front surface connectors
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A touch sensor (310), such as a capacitive touch sensor, includes a substrate (312) having at least one passageway (324) established therethrough. A first conductive coating (314) is established at a first surface of the substrate, and a conductive element (320, 322) is disposed at the substrate and at least partially through the passageway. The conductive element establishes conductive continuity between the first surface and second or opposite surface of the substrate. The passageway may comprise multiple passageways and is/are established inboard of a perimeter edge of the substrate. The conductive element may include a first conductive material (320) disposed at the first surface and partially into the passageway and a second conductive material (322) disposed at the second surface and partially into the passageway, whereby the conductive materials contact one another in the passageway to establish conductive continuity between the first and second surfaces of the substrate.