Flexible Carbon Electrode Structure for Crack-Resistant Bending
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Solution Overview
Problem
Existing electrodes with carbon thin films are prone to cracking when curved, leading to increased resistance due to their brittleness.
Innovation Solution
An electrode comprising a resin film, a metal underlying layer, and a conductive carbon layer with sp3 bonds, where the conductive carbon layer has a density of 1.8 g/cm3 or more and a thermal shrinkage of −0.2% or less when heated at 150°C for 1 hour, suppressing damage and resistance increase upon curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electrode is curved to adapt to different uses, then the adaptability is improved, but the carbon thin film is easily cracked due to brittleness, causing resistance to increase
Solution Approach 1:
The patent changes the bonding structure parameter of the carbon thin film from primarily sp2 bonds to a composite structure with sp3 bonds (ratio of sp3 to total bonds: 0.05 or more). This parameter change transforms the carbon film from brittle to flexible while maintaining conductivity, enabling the electrode to be curved without cracking and resistance increase.
2Ease of operation
If the carbon thin film is made more flexible to prevent cracking, then the ease of operation is improved, but the conductivity may be compromised
Solution Approach 1:
The patent creates a composite carbon structure containing both sp2 bonds (providing conductivity) and sp3 bonds (providing flexibility). The specific composition (sp3 bond ratio ≥ 0.05) optimizes the balance between flexibility and conductivity, allowing the carbon film to bend without cracking while maintaining electrical performance.
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 electrode effectively prevents damage to the conductive carbon layer and minimizes the rate of resistance increase even when curved, maintaining electrical conductivity and sensitivity.
Implementation Method 1
a thermal shrinkage of the electrode is −0.2% or more and 0.2% or less when the electrode is heated at 150° C. for 1 hour
Data Source
AI summary
An electrode includes a resin film and a conductive carbon layer in this order in a thickness direction. The conductive carbon layer has an sp3 bond. The electrode has a thermal shrinkage of −0.2% or more and 0.2% or less when being heated at 150° C. for 1 hour.