Extensible Wiring Board With Segmented Conductive Paste
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Solution Overview
Problem
Flexible wiring boards face issues with cracks and resistance changes when extended, leading to unstable operation in electronic apparatus due to mismatched extensibility and elasticity between the base and wiring materials, causing hindrance in deformation and potential power failures.
Innovation Solution
A wiring board design featuring a base made of elastomer with conductive paste wiring portions and metal foil conductor portions, where the conductive paste wiring portions have higher extensibility and the conductor portions have lower resistivity, allowing the wiring to extend perpendicular to the main axis, reducing the likelihood of cracks and maintaining stable resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal foil is used for wiring on elastomer base, then electrical conductivity is improved, but extensibility deteriorates causing cracks when extended
Solution Approach 1:
The wiring is divided into multiple segments along its length, with each segment capable of independent deformation. The segments are connected through conductive particles that maintain electrical continuity while allowing relative movement, enabling the wiring to extend and contract without cracking.
Solution Approach 2:
The wiring uses a composite structure combining metal particles (for conductivity) embedded in an elastomer matrix (for extensibility). This composite material integrates the advantageous properties of both materials: electrical conductivity from metal and flexibility/extensibility from elastomer.
2Adaptability or versatility
If conductive paste is used for wiring, then extensibility is improved, but electrical resistance increases
Solution Approach 1:
The conductive paste comprises metal particles dispersed in an elastomer binder, creating a composite material that balances electrical conductivity and extensibility. The metal particles provide conductive pathways while the elastomer matrix provides flexibility and stretchability.
Solution Approach 2:
The wiring structure has different properties at different scales: locally, metal particles provide high conductivity pathways, while globally, the elastomer matrix provides extensibility. This local quality differentiation allows simultaneous achievement of conductivity and flexibility.
3Reliability
If rigid wiring structure is used, then electrical stability is improved, but deformation capability deteriorates
Solution Approach 1:
The wiring transitions from a rigid static structure to a dynamic flexible structure that can adapt its shape. The segmented design with conductive particle connections allows the wiring to dynamically adjust its configuration during extension and contraction while maintaining electrical stability.
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 design enhances the extensibility and load-bearing capacity of the wiring board, reducing resistance changes and ensuring stable operation even when extended, by distributing stress effectively and maintaining low resistance across various installation environments.
Implementation Method 1
a base 10 made of an elastomer... the conductive paste wiring portions 20 have higher extensibility
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A wiring board 1 includes a base 10 having extensibility and a wiring 40 formed on the base. The wiring includes a wiring portion 20 and a conductor portion 30. The wiring portion is formed on the base and extends in a first direction P crossing (for example, perpendicular to) a longitudinal direction X of the base. The conductor portion is formed on the wiring portion and extends in the first direction. Even when the wiring board is extended along a main extension axis S in parallel with the longitudinal direction of the base, change of the resistance of the wiring is prevented. Thus, the wiring board represents stable characteristics.