Embedding Electrical Components in Flexible Cosmetic Substrates
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Solution Overview
Problem
Cosmetic surfaces with embedded components often disrupt the aesthetic appeal and user experience due to increased bulk and visibility of the components, as conventional flexible materials used for covers and housings are not designed to accommodate embedded features without compromising their finish and feel.
Innovation Solution
A method and system for embedding components beneath a cosmetic surface of flexible material using a carrier form with positive images, where the substrate is processed to a desired thickness, and a portion is removed to form a reduced opposing surface, allowing for the embedding of electrical components while maintaining the cosmetic surface's appeal by creating embedding cavities and deformations that obscure the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If components are embedded in flexible cosmetic surface materials, then functionality is increased, but the cosmetic surface is disrupted and aesthetic appeal is reduced
Solution Approach 1:
The patent embeds components within cavities formed in the substrate, nesting the functional elements inside the cosmetic surface structure. This allows components to be integrated without protruding or disrupting the external cosmetic surface, resolving the contradiction between functionality and aesthetic integrity.
Solution Approach 2:
The patent moves components from a two-dimensional surface level to a three-dimensional embedded space within the substrate. By creating cavities and embedding components beneath the cosmetic surface, the solution transitions the component placement to another dimension, preserving surface integrity while adding functionality.
2Shape
If material thickness is increased to limit cosmetic surface disruption, then surface integrity is improved, but overall bulk increases and user experience is reduced
Solution Approach 1:
The patent segments the substrate into distinct regions: a cosmetic surface layer and an internal cavity structure. This segmentation allows the cosmetic surface to remain thin and intact while providing embedded spaces for components, avoiding the need to increase overall material thickness.
Solution Approach 2:
The patent applies local quality changes by creating specific cavities and varying substrate thickness only where components need to be embedded. The cosmetic surface maintains its original thin, flexible properties in areas not requiring component integration, while localized thickness variations provide embedding space where needed.
3Volume of moving object
If components are embedded in thin flexible materials, then overall bulk is reduced, but the cosmetic surface is disrupted and aesthetic appeal is reduced
Solution Approach 1:
The patent embeds components within cavities formed in the substrate, nesting the functional elements inside the cosmetic surface structure. This allows components to be integrated without protruding or disrupting the external cosmetic surface, resolving the contradiction between functionality and aesthetic integrity.
Data Source
AI summary
The described embodiments relate to a method for embedding one or more electrical components in a flexible substrate. The method includes receiving a substrate of a flexible material, wherein the substrate includes a cosmetic surface and an opposing surface. The method further includes applying a carrier form to the substrate to create a carrier assembly, wherein the carrier form includes one or more positive images representative a design to be transferred to the opposing surface of the substrate. The method further includes removing or cutting a portion of material from the opposing surface of the substrate to form a new opposing surface. Subsequently, the carrier form is removed from the substrate to reveal one or more embedding cavities extending into the substrate at the new opposing surface. In some embodiments, the embedding cavities can thereafter receive one or more electrical components.