Conductive Sheet Wave Pattern for 3D Molding Extension
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Solution Overview
Problem
Three-dimensional molding causes extension failures or breakage of electrically conductive sheets with linear bodies, especially when complex shapes are involved, leading to decreased functionality due to varying degrees of straightening and increased resistance or heat generation.
Innovation Solution
An electrically conductive sheet with a pseudo-sheet structure featuring electrically conductive linear bodies in wave patterns of varying wavelengths and amplitudes, combined with a resin protective layer, to ensure uniform straightening and maintain functionality across complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrically conductive linear bodies are arranged in a straight line pattern, then the sheet structure is simple and easy to manufacture, but the sheet cannot be properly extended during three-dimensional molding causing extension failure or breakage
Solution Approach 1:
The electrically conductive linear bodies are formed in a wave pattern instead of a straight line, allowing the sheet to extend properly during three-dimensional molding while maintaining electrical conductivity. The wave pattern provides the necessary flexibility and extension capability without causing breakage.
Solution Approach 2:
The wavelength and amplitude of the wave pattern are specifically controlled within certain ranges to balance the extension capability with electrical conductivity. By adjusting these parameters, the sheet can be properly extended during molding while maintaining functional performance.
2Reliability
If electrically conductive linear bodies are formed in a wave pattern, then the sheet can be extended during three-dimensional molding, but the degree of straightening varies significantly depending on the region causing decreased function
Solution Approach 1:
The wave pattern parameters (wavelength and amplitude) are varied in different regions of the sheet according to the expected degree of extension during molding. Regions requiring greater extension have different wave characteristics compared to regions requiring less extension, ensuring uniform straightening and consistent electrical conductivity across the entire sheet.
3Adaptability or versatility
If the wave pattern has short wavelength or large amplitude, then the length of linear bodies increases allowing easy following of high degree extension, but the resistance increases and heat generation increases
Solution Approach 1:
The wavelength and amplitude of the wave pattern are optimized within specific ranges to balance extension capability with electrical resistance. By controlling these parameters, the sheet can accommodate high degree extension during molding while minimizing resistance and heat generation to acceptable levels.
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
Prevents decreases in sheet function by allowing uniform straightening of electrically conductive linear bodies, reducing resistance and heat generation, and maintaining performance even on complex three-dimensional objects.
Implementation Method 1
the electrically conductive linear bodies formed in a wave pattern can be easily extended by being straightened, in the direction in which the electrically conductive linear bodies extend, following the extension of the electrically conductive sheet
Data Source
AI summary
The present disclosure provides an electrically conductive sheet for use in three-dimensional molding including: a pseudo-sheet structure in which plural electrically conductive linear bodies extending unidirectionally are arranged spaced apart from each other; and a resin protective layer provided on a surface of the pseudo-sheet structure. In the above mentioned electrically conductive sheet, each of the electrically conductive linear bodies in the pseudo-sheet structure includes: a first portion formed in a wave pattern having a wavelength λ1 and an amplitude A1; and a second portion formed in a wave pattern having a wavelength λ2 and an amplitude A2, at least one of which is different from the wavelength λ1 or the amplitude A1 of the first portion.