Flexible Circuit Primer Layer Adhesion Mechanism
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Solution Overview
Problem
The connection between electrically conductive structure elements in flexible electrical circuits is prone to damage, leading to a loss of electrical functionality due to weak mechanical and electrical adhesion, especially when subjected to mechanical forces.
Innovation Solution
Incorporating a primer layer between the lacquer layer and the conductive cement layer, which enhances the adhesion between the lacquer layer and the conductive cement layer, thereby providing a secure mechanical and electrical connection between the conductor tracks and the electrically conductive contact layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive cement layer is used to connect electrically conductive contact layers and conductor tracks, then electrical and mechanical connection is achieved, but the connection is weak and prone to damage under mechanical forces
Solution Approach 1:
A primer layer is introduced as an intermediary between the lacquer layer and the conductive cement layer. This primer layer serves as a mediator that enhances the bonding interface, improving both mechanical adhesion and electrical conductivity at the connection point between contact layers and conductor tracks.
Solution Approach 2:
The connection structure uses a composite material system consisting of multiple layers: lacquer layer, primer layer, and conductive cement layer. Each layer contributes specific properties (insulation, adhesion enhancement, conductivity) to create a composite structure that overcomes the limitations of single-material connections.
2Adaptability or versatility
If the flexible electrical circuit is subjected to mechanical forces, then flexibility and adaptability are achieved, but the connection between electrically conductive structure elements is damaged
Solution Approach 1:
The circuit structure is segmented into distinct functional layers (lacquer layer, primer layer, conductive cement layer, contact layers, conductor tracks). This segmentation allows each layer to be optimized for its specific function while working together to maintain overall flexibility and electrical reliability under mechanical stress.
Solution Approach 2:
The primer layer acts as a cushioning layer that is applied beforehand to protect the interface between the lacquer and conductive cement layers. This pre-applied protective layer prevents direct stress concentration at the vulnerable interface, maintaining connection integrity during subsequent mechanical deformation.
3Strength
If the connection between electrically conductive structure elements is strengthened, then mechanical and electrical adhesion is improved, but the complexity of the circuit structure increases
Solution Approach 1:
The primer layer serves as a thin intermediary coating that significantly enhances adhesion between layers without adding substantial structural complexity. It is applied as a minimal-thickness layer that provides maximum bonding benefit while maintaining manufacturing efficiency.
Solution Approach 2:
The primer layer changes the surface properties (wettability, surface energy) of the lacquer layer interface, creating optimal conditions for conductive cement adhesion. This parameter modification at the interface level achieves strong bonding without requiring complex structural modifications.
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 configuration significantly improves the adhesive force, reducing the failure rate under mechanical stress and ensuring reliable electrical and mechanical connections, even at elevated temperatures, thus extending the shelf life and maintaining functionality.
Implementation Method 1
the layer of the primer enhances the adhesion between the at least one lacquer layer and the conductive cement layer
Data Source
AI summary
A flexible electrical circuit having connection between electrically conductive structure elements includes at least one lacquer layer, at least one electrical conductor track, which is disposed above the at least one lacquer layer, and at least one electrically conductive contact layer for contacting at least one electrical component. Furthermore, the flexible electrical circuit includes a conductive cement layer and a layer of a primer. The layer of the primer is disposed on the at least one lacquer layer. The conductive cement layer is disposed underneath the at least one electrically conductive contact layer and above the layer of the primer.