Conductive Module Wavy Extending Portion Junction Stress
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Solution Overview
Problem
Conventional electronic devices with flexible conductive structures, such as wearable displays, are prone to junction failures between stretchable and non-stretchable conductive components due to stress accumulation during deformation, leading to non- or mal-function.
Innovation Solution
A conductive module design featuring flexible extending portions with a wavy or sine wave shape, connected to rigid contact portions and conductive layers, reduces stress at junctions by allowing deformation while maintaining electrical connectivity, thereby enhancing the durability and functionality of the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stretchable conductive structure is directly connected to a non-stretchable conductive structure, then electrical connectivity is achieved, but the junction is susceptible to breaking under tensile force
Solution Approach 1:
The connecting line is divided into three distinct segments: a first conductive layer (non-stretchable), an intermediate extending portion (stretchable with wavy shape), and a second conductive layer (non-stretchable). This segmentation allows each part to perform its specific function - the rigid layers provide stable electrical connection while the flexible intermediate section absorbs deformation stress, preventing junction failure.
Solution Approach 2:
The extending portion with wavy configuration serves as an intermediary element between the two non-stretchable conductive layers. This intermediate component acts as a stress buffer that can elongate and deform under tensile force, protecting the rigid conductive layers from direct mechanical stress and preventing connection failure.
2Reliability
If the conductive structure is made rigid to maintain electrical connection, then electrical connectivity is stable, but the device cannot deform flexibly
Solution Approach 1:
The conductive structure exhibits spatially varying properties: the contact portions and conductive layers are rigid and non-stretchable to ensure stable electrical connection, while the extending portion is flexible and stretchable to enable device deformation. This local differentiation of mechanical properties allows the structure to simultaneously achieve connection stability and deformation capability.
Solution Approach 2:
The connecting line transitions from a static rigid structure to a dynamic structure with a wavy extending portion that can change its configuration under load. The wavy structure can dynamically adjust its shape during deformation, absorbing mechanical stress while maintaining electrical connectivity, thus enabling the device to adapt to various deformation states.
3Reliability
If the connecting line is made straight to minimize path length, then electrical resistance is reduced, but stress concentration occurs at junctions during deformation
Solution Approach 1:
The extending portion is designed with a wavy or curved configuration instead of a straight line. This curvature allows the connecting line to distribute mechanical stress along its length during deformation, preventing stress concentration at the junctions. The wavy structure effectively transforms the stress distribution pattern while maintaining electrical connectivity.
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 design effectively reduces the risk of fracture in connecting lines and improves the overall deformation capacity and electrical connection strength, ensuring reliable operation of flexible electronic devices under tensile forces.
Implementation Method 1
A junction between the stretchable conductive structure and the non-stretchable conductive structure is susceptible to breaking, causing non- or mal-function
Data Source
AI summary
A conductive module includes spaced conductive layers and connecting lines. Adjacent conductive layers are electrically connected by one connecting line. Each connecting line includes a contact portion and an extending portion, the contact portion is electrically connected to one conductive layer and the extending portion. The extending portion is very stretchable in effective length to render the conductive module stretchable and deformable. A projection of the contact portion on a plane where the extending portion extends is a square, a width of the extending portion is equal to a side length of the contact portion.