Flexible Electronic Device Manufacturing via Nanostructured Filtration
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Solution Overview
Problem
Existing methods for manufacturing electronic devices are limited by the rigidity of materials used, restricting their ability to conform to complex surfaces and extend applications beyond traditional product ranges.
Innovation Solution
A method involving filtering electrically conducting nanostructured materials through a membrane, followed by embedding them in an elastomeric polymer using a curing process, to create flexible electronic devices that can be stretched and deformed without losing functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If silicon-based materials are used for electronic devices, then manufacturing precision and reliability are improved, but flexibility and adaptability to complex surfaces deteriorate
Solution Approach 1:
The patent changes the material parameter from rigid silicon to flexible elastomeric polymers, enabling the electronic device to deform and conform to complex non-planar surfaces while maintaining functionality. This parameter change resolves the contradiction by sacrificing some manufacturing precision for gain in adaptability.
Solution Approach 2:
The patent uses composite materials consisting of elastomeric polymer matrices combined with conductive fillers (such as silver nanowires, carbon nanotubes, or conductive polymers) to create flexible electronic components. This composite approach maintains electrical conductivity while achieving flexibility and adaptability to complex surfaces.
2Strength
If rigid materials are used for electronic devices, then strength and stability are improved, but flexibility and stretchability deteriorate
Solution Approach 1:
The patent employs flexible elastomeric polymer shells and thin films as the base material for electronic devices, replacing rigid structures. This allows the device to be stretched, bent, and deformed while maintaining structural integrity and electrical functionality, resolving the contradiction between strength and flexibility.
Solution Approach 2:
The patent fundamentally changes the mechanical parameter of the substrate material from rigid to elastomeric, enabling the device to undergo large deformations and stretching while maintaining strength and functionality through the elastic properties of the polymer material.
3Adaptability or versatility
If flexible materials are used for electronic devices, then adaptability to complex surfaces is improved, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The patent employs preliminary patterning techniques where conductive elements are pre-formed on flat substrates with precise manufacturing control, and then the entire structure is transferred or conformally deposited onto complex non-planar surfaces. This preliminary action on a flat substrate maintains manufacturing precision while achieving final adaptability to complex surfaces.
Solution Approach 2:
The patent uses an intermediary elastomeric polymer layer that can be precisely manufactured in a controlled environment and then conformally applied or stretched onto complex surfaces. This intermediary layer acts as a mediator that preserves manufacturing precision during fabrication while enabling final adaptability to irregular geometries.
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 method enables the production of flexible electronic devices that maintain functionality even when stretched to high strains, opening up applications in wearable, implantable, and biomedical devices, as well as in photodetectors, sensors, and energy devices.
Implementation Method 1
filtering a mixture comprising an electrically conducting nanostructured material through a membrane such that the electrically conducting nanostructured material is deposited on the membrane
Implementation Method 2
depositing an elastomeric polymerisable material on the electrically conducting nanostructured material and curing the elastomeric polymerisable material thereby embedding the electrically conducting nanostructured material in an elastomeric polymer thus formed
Data Source
AI summary
A method of manufacturing a flexible electronic device is provided. The method includes a) filtering a mixture including an electrically conducting nanostructured material through a membrane such that the electrically conducting nanostructured material is deposited on the membrane; b) depositing an elastomeric polymerizable material on the electrically conducting nanostructured material and curing the elastomeric polymerizable material thereby embedding the electrically conducting nanostructured material in an elastomeric polymer thus formed; and c) separating the elastomeric polymer with the embedded electrically conducting nanostructured material from the membrane to obtain the flexible electronic device. Flexible electronic device manufactured by the method, and use of the flexible electronic device are also provided.