Flexible CNT Composite Interconnects for Strain-Resilient Circuits
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Solution Overview
Problem
Conventional electrical circuits in high-impact environments, such as aerospace, are prone to failure due to strain and flexing, particularly at metal-to-metal connection points, which are not adequately resilient to withstand extreme conditions.
Innovation Solution
The development of a flexible, strain-resilient, electrically conductive material using metal-coated carbon nanotube networks, where metal nanoparticles form welded junctions between nanotubes, mixed with a liquid polymeric resin and cured to create a composite that can be printed onto a flexible substrate, enhancing conductivity and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal-to-metal bonds are used for connection points, then electrical conductivity is achieved, but reliability deteriorates due to susceptibility to failure from strain and flexing
Solution Approach 1:
The patent uses a composite material consisting of carbon nanotubes embedded in a polymer matrix to create interconnects that combine the electrical conductivity of carbon nanotubes with the flexibility and strain resistance of the polymer, eliminating the need for brittle metal-to-metal bonds while maintaining electrical connectivity
Solution Approach 2:
The patent changes the material parameters from conventional metals to carbon nanotube-polymer composites, fundamentally altering the mechanical and electrical properties to achieve both high conductivity and exceptional strain resistance, with the ability to withstand over 1000 cycles of flexing
2Adaptability or versatility
If conventional metal traces are used, then electrical conductivity is provided, but flexibility deteriorates due to susceptibility to failure in high impact environments
Solution Approach 1:
The carbon nanotube-polymer composite interconnects provide both flexibility for conformal mounting on irregular surfaces and high impact resistance, as the polymer matrix absorbs impact energy while the carbon nanotube network maintains electrical pathways even under deformation
Solution Approach 2:
The patent employs thin film structures of the composite material that can conform to curved and irregular surfaces, providing flexible electrical interconnects that maintain reliability in high-impact environments where conventional rigid metal traces would fail
3Reliability
If metal coated carbon nanotube networks are used, then electrical conductivity is enhanced, but manufacturing complexity increases due to the coating and curing process
Solution Approach 1:
The patent combines the coating and curing steps into an integrated manufacturing process where the carbon nanotube network is embedded in the polymer matrix during a single curing cycle, eliminating separate coating operations and simplifying the overall manufacturing complexity while ensuring consistent electrical properties
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 resulting material exhibits high electrical conductivity, flexibility, and shock absorption, maintaining electrical integrity under high impact conditions with improved strain resiliency and thermal transport properties, suitable for next-generation electronic device packaging.
Implementation Method 1
The metal coated carbon nanotube networks may be made by first providing a CNT network, such as a CNT yarn with highly aligned nanotubes that form both point contact junctions and sidewall-to-sidewall junctions between nanotubes. Nanoparticles of metal are deposited on the CNT network such that at least some junctions are surrounded by the metal nanoparticles to produce a metal coated CNT network that is then heated to a temperature that is sufficient to melt the nanoparticles of metal but insufficient to damage the CNT network. The melting of the nanoparticles produces welds between the junctions that are highly conductive of both electricity and heat.
Implementation Method 2
The metal coated carbon nanotube networks are mixed with a liquid polymeric resin to produce a mixture and the liquid mixture is cured to produce the electrically conductive, strain resilient, flexible material.
Implementation Method 3
After this mixing step, the liquid mixture may be printed onto a flexible substrate using a three-dimensional printer that is configured to print with the material of the selected viscosity to produce a printed mixture on the substrate. The printed mixture on the substrate is then cured for a curing period of time in an atmosphere that absorbs the solvent so that, after the curing period, the solvent evaporates from the printed mixture to produce a solid, flexible, strain resilient electrically conductive polymeric electrical circuit on the flexible substrate.
Data Source
AI summary
An electrically conductive, flexible, strain resilient product is produced by mixing metal coated carbon nanotube networks with a liquid polymeric resin to produce a liquid mixture, and the mixture is cured to produce the product. The networks may include welded junctions between nanotubes formed by depositing and melting metal nanoparticles on the nanotubes to form the metal coating. After the mixing step the liquid mixture may be deposited on a flexible substrate in the form of an electrical circuit. The mixing step may further include mixing the composite with a volatile solvent to produce a selected viscosity. Then, a three-dimensional printer may be used to print the product, such as an electrical circuit, on a substrate. The product is cured in an atmosphere that absorbs the solvent. The conductivity of the mixture may be adjusted by adjusting the weight percentage of the metal coated carbon nanotube networks from 50% to 90%, but a preferred range is between 75% and 85%.