Double-Sided Conductive Laminate with Dry Milled Traces
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Solution Overview
Problem
Complex electronic systems in vehicles require efficient and reliable connection methods, as traditional wiring harnesses are prone to failures and difficult to manufacture.
Innovation Solution
A method for manufacturing a double-sided, single conductor laminate involves providing a laminated substrate with a conductive layer, adhesive layer, and support layer, dry milling trace patterns, and attaching cover layers with adhesive to create access holes, allowing connections to both sides of the conductive layer, using materials like copper, aluminum, PET, PEN, or PI, and applying adhesive layers on outer surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring harnesses with individual wires are used to connect complex electronic systems, then connectivity between devices can be achieved, but the system becomes difficult to manufacture and is prone to failures
Solution Approach 1:
Multiple individual wire connections are merged into a single integrated laminate structure. The conductive layer with trace patterns provides multiple connection paths within one laminated substrate, eliminating the need for separate wiring harnesses and reducing overall system complexity while improving reliability.
Solution Approach 2:
The mechanical wiring harness system is replaced with a printed circuit board-like laminate structure. Instead of using physical wire bundles that require manual routing and connection, the invention uses a manufactured laminate with pre-defined conductive traces that provide structured electrical connections.
2Adaptability or versatility
If access holes are created in the support layer to access traces from both sides, then double-sided connectivity is achieved, but additional manufacturing steps are required
Solution Approach 1:
Access holes are precut in the cover layer during the manufacturing process before final assembly. This preliminary action allows for precise alignment and simplified subsequent assembly steps, as the access holes are already positioned correctly to match the trace patterns on the conductive layer.
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 method simplifies the manufacturing of reliable, double-sided conductive laminates, reducing the complexity and failure rates of vehicle wiring by enabling efficient access and connection to trace patterns from both sides, thus improving the connectivity and durability of vehicle electronic systems.
Implementation Method 1
dry milling a trace pattern in the laminated substrate by removing selected areas of the conductive layer and the adhesive layer
Implementation Method 2
attaching a first cover layer using a first adhesive layer to the conductive layer
Implementation Method 3
The first cover layer includes one or more precut access holes that align with one or more traces of the trace pattern
Data Source
AI summary
A method for manufacturing a double-sided, single conductor laminate includes providing a laminated substrate that includes a conductive layer, an adhesive layer and a support layer; dry milling a trace pattern in the laminated substrate by removing selected areas of the conductive layer and the adhesive layer; and attaching a first cover layer using a first adhesive layer to the conductive layer. The first cover layer includes one or more precut access holes that align with one or more traces of the trace pattern.