Flexible Conductive Interface for Rigid-Flexible Signal Transmission
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Solution Overview
Problem
Existing flexible and stretchable devices with rigid components face discontinuity issues and conductor breakage at points of high pressure change, leading to signal transmission failures and manufacturing challenges.
Innovation Solution
A flexible structural system with a conductive interface portion, made from materials like textile, carbon nanotubes, or conductive ink, is used to bridge the gap between conductors and rigid components, ensuring electrical connection even if the conductor breaks, and is easy to manufacture and integrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid snap connection is used to connect the printed wire to the rigid component, then the electrical connection is established, but the printed wire tends to break at the discontinuity point due to high pressure and rigidity mismatch
Solution Approach 1:
A flexible connector is introduced as an intermediary element between the printed wire on the flexible substrate and the rigid component. This connector acts as a mediator that bridges the mechanical property gap between flexible and rigid elements, distributing connection forces and preventing stress concentration at the printed wire's discontinuity points, thereby maintaining electrical connection reliability without compromising the printed wire's strength
Solution Approach 2:
The system transitions from a purely rigid connection interface to a hybrid flexible-rigid interface by changing the mechanical properties of the connection path. The flexible connector introduces compliance and elasticity parameters that were previously absent, allowing the connection to accommodate differential movement and reduce peak stresses on the printed wire while maintaining adequate electrical contact
2Reliability
If the snap connection applies high pressure to conduct the signal, then the electrical connection is ensured, but the area around the snap experiences high pressure changes that can damage the circuit board
Solution Approach 1:
The flexible connector serves as a cushioning element that is positioned in advance between the rigid snap and the flexible substrate. It absorbs and distributes the high contact pressure from the snap connection, preventing direct transmission of peak forces to the printed wire and circuit board. This beforehand cushioning protects the circuit board from pressure-induced damage while maintaining adequate electrical contact
3Ease of manufacture
If the snap attaches slightly sideways to the print, then the connection is made, but the edge of the snap plate can carve into the print during attachment or use
Solution Approach 1:
The flexible connector acts as a protective intermediary layer between the snap plate and the printed wire. Even when the snap attaches slightly sideways, the flexible connector absorbs the lateral forces and prevents the snap plate edge from directly contacting and carving into the printed wire, thereby maintaining printed wire integrity while preserving the ease of snap-on assembly
Data Source
AI summary
A flexible and/or stretchable structural system for transmitting electrical signal between first and second rigid portions comprises a body structure and said first and second portions arranged to said body structure. The modulus of elasticity of said first portion is lower than the corresponding modulus of elasticity of said second portion. In addition the modulus of elasticity of said body structure is lower than the corresponding modulus of elasticity of said second portion. The system comprises also an interface portion, such as e.g. an electrically conducting fabric, textile or knit, which is arranged to said body structure and between said first and second portions. The interface portion electrically connects said first and second portions. The modulus of elasticity of said interface portion is lower than the corresponding modulus of elasticity of said second portion.