Conductor Pad with Convex Perimeter for Flexible Circuits

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Solution Overview

Problem

The use of stiff circuit substrates in electrical circuits imposes design limitations, limiting flexibility and efficiency in manufacturing and application, particularly in roll-to-roll production of flexible electronic devices such as LED lighting arrays and solar panels.

Innovation Solution

The development of a conductor pad with a conductive material having a perimeter edge featuring convex and non-convex segments, facilitating rolling and heat dissipation, which is integrated into flexible circuits manufactured using roll-to-roll techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If stiff circuit substrates are used, then structural stability is improved, but design flexibility and ease of operation deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoiddesign flexibility

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The patent applies this principle by using a flexible substrate (such as polyimide or plastic) instead of a stiff substrate, allowing the circuit to be bent and conform to various shapes while maintaining structural integrity. The flexible substrate enables design freedom and ease of operation without sacrificing structural stability.

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of manufacture

If conventional conductor pad shapes are used, then manufacturing simplicity is improved, but rolling capability and thermal management deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidrolling capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies this principle by designing conductor pads with curved perimeter edges featuring convex and concave segments. This curved geometry allows the flexible circuit to be rolled or bent without creating stress concentration points, improving rolling capability while maintaining manufacturing simplicity through standard PCB fabrication processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of manufacture

If conventional conductor pad shapes are used, then manufacturing simplicity is improved, but heat dissipation capability deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat dissipation capability

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The curved perimeter edge design with convex and concave segments increases the surface area of the conductor pad compared to conventional straight-edged pads. This increased surface area improves heat dissipation capability while maintaining compatibility with standard manufacturing processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Productivity

If roll-to-roll manufacturing is implemented, then productivity is improved, but manufacturing precision may deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidalignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The conductor pad is segmented into distinct regions including contact regions and body portions with specific geometric features. This segmentation allows for tolerance compensation in roll-to-roll manufacturing, where each segment can accommodate slight variations in positioning while maintaining overall circuit functionality and precision.

Inventive Principle:

Principle #1Segmentation

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 configuration enables efficient mass production of flexible electronic devices by allowing for easier rolling and thermal management, enhancing design flexibility and performance in devices like LED lighting arrays and solar panels.

Implementation Method 1

a conductive material having a perimeter edge with at least first and second convex segments and at least one non-convex segment disposed between the first and second convex segments. This configuration facilitates rolling of the conductor pad and a flexible substrate on which the conductor pad is formed

Methodology Applied

Scientific EffectStress distribution:

Implementation Method 2

This configuration facilitates rolling of the conductor pad and a flexible substrate on which the conductor pad is formed, and also facilitates spreading of heat from electronic devices coupled to the conductor pad

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS10368436B2Conductor pad for flexible circuits and flexible circuit incorporating the same

Publication Date: 2019.07.30 ABL IP HLDG LLC

AI summary

A conductor pad and a flexible circuit including a conductor pad are provided. The conductor pad includes a first contact region, a second contact region, and a body portion configured to establish a conductive path between the first contact region and the second contact region. The body portion includes a perimeter edge having at least a first convex segment and a second convex with a first non-convex segment disposed between the first convex segment and the second convex segment. A method of constructing a flexible circuit to facilitate roll-to-roll manufacturing of the flexible circuit is also provided.