Elastic Flexible Substrate with Segmented Insulating Films

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Solution Overview

Problem

Conventional flexible substrates are limited in their expanding/contracting directions, often resulting in restricted movement and twisting issues when subjected to forces, which hinders their application in diverse fields requiring flexible and expandable surfaces.

Innovation Solution

An elastic flexible substrate is designed with a surface-bonded insulating base material featuring a plurality of bonding portions and openings between them, allowing for expansion/contraction in multiple directions without twisting, achieved through a manufacturing method involving the disposition of wires on insulating films and their staggered bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional flexible substrates are used with a continuous insulating base material, then manufacturing is simple, but the substrate is limited in expanding/contracting directions and tends to twist when subjected to forces

Engineering Contradiction:

Improveexpanding/contracting directionVSAvoidinsulating base material structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The insulating base material is divided into multiple insulating films arranged in parallel, with each film separated by gaps. This segmentation allows the substrate to expand and contract independently in different directions without twisting, as each insulating film can deform autonomously while maintaining electrical connectivity through the wire patterns that span across the gaps.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the insulating base material is made with multiple bonded portions and openings, then multi-directional expansion/contraction without twisting is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveflexibility and expandabilityVSAvoidmanufacturing process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The insulating base material is segmented into multiple insulating films with gaps between them, allowing independent deformation in different directions. This segmentation enables multi-directional expansion and contraction without twisting while maintaining structural integrity through the bonding portions that connect the films.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wire patterns serve multiple functions: they provide electrical connectivity between different regions of the substrate, maintain structural integrity during deformation, and enable the substrate to expand and contract in multiple directions without twisting. This multi-functionality reduces the need for additional structural elements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of moving object

If the substrate is made thin and flexible for space saving, then it can be bent, but its ability to expand/contract in multiple directions is limited

Engineering Contradiction:

Improvesubstrate thicknessVSAvoidexpanding/contracting capability

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

The thin insulating base material is segmented into multiple parallel insulating films with gaps, allowing each film to deform independently in different directions. This segmentation enables the thin substrate to expand and contract in multiple directions simultaneously without twisting, while maintaining flexibility and space-saving characteristics.

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

The substrate can be freely expanded or contracted in various directions without twisting, enhancing its usability in applications like wearable devices and curved surfaces, while maintaining electrical connectivity and structural integrity.

Implementation Method 1

an elastic flexible substrate including an insulating base material and a wire disposed on the insulating base material. The insulating base material has a plurality of bonding portions that are surface-bonded, and openings are formed between the bonding portions. According to the one aspect, in an elastic flexible substrate of the present disclosure, an expanding/contracting direction is not limited to one direction and a twist does not occur.

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9814134B2Elastic flexible substrate and manufacturing method thereof

Publication Date: 2017.11.07 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

An elastic flexible substrate includes an insulating base material having a first insulating film and a second insulating film, and a plurality of wires, each of which is disposed on one of the first insulating film and the second insulating film. The insulating base material has a plurality of bonding portions that are surface-bonded, openings are formed between the bonding portions, and two of the plurality of wires are electrically connected in the bonding portions.