Flexible Electronic Foil With Integrated Mechanical Fastening

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Solution Overview

Problem

Current methods for joining flexible electronic foils, such as using rigid connectors or conductive tapes/glues, compromise mechanical durability, increase costs, and are not practical for uniform stretching or easy disassembly, while lamination technologies require specialized equipment and result in permanent connections.

Innovation Solution

A flexible electronic foil with integrated mechanical fastening means, such as tabs and openings, that allow for mechanical and electrical connection without additional components, enabling cost-effective manufacturing and easy alignment of foils, while allowing for detachment without damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid connectors are used for joining electronic foils, then mechanical strength of the connection is improved, but the structure becomes much thicker and costs increase remarkably

Engineering Contradiction:

Improvemechanical strength of connectionVSAvoidthickness of structure

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The patent merges the mechanical fastening function and electrical connection function into a single integrated connector. The connector includes both a fastening element (such as a snap-fit mechanism) and conductive elements (such as spring fingers or contact pads) that simultaneously provide mechanical attachment and electrical connectivity when two electronic foils are joined, eliminating the need for separate mechanical fasteners and electrical connectors.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector is designed to perform multiple functions: mechanical fastening (through snap-fit or similar mechanisms), electrical connection (through conductive contact elements), and alignment (through integrated positioning features). This multi-functional design eliminates the need for multiple separate components and reduces overall structure thickness while maintaining connection strength.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If rigid connectors are used for joining electronic foils, then mechanical durability is improved, but device complexity and manufacturing costs increase

Engineering Contradiction:

Improvemechanical durabilityVSAvoidnumber of additional components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (mechanical fastening, electrical connection, and alignment) into a single integrated connector component. This reduces the number of additional parts needed while maintaining mechanical durability through the snap-fit mechanism and ensuring reliable electrical connectivity through integrated conductive elements.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If conductive tapes or glues are used for joining electronic foils, then electrical connectivity is provided instantaneously, but mechanical strength is limited especially under static loading

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmechanical strength under static loading

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent merges mechanical fastening and electrical connection into a single connector where conductive elements (such as spring fingers or contact pads) are integrated with the mechanical fastening structure. This provides both immediate electrical connectivity and strong mechanical attachment under static loading, overcoming the limitations of using conductive tapes or glues alone.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If lamination based joining technologies are used, then mechanical and electrical connection is achieved, but specific lamination machines with heating and pressure devices are required

Engineering Contradiction:

Improvemechanical connectionVSAvoidmanufacturing equipment requirements

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the thermal and pressure-based lamination process with a mechanical snap-fit connection system. The connector uses elastic deformation of flexible elements (such as spring fingers or bending tabs) to create a secure mechanical attachment that does not require heating or pressure equipment, simplifying the manufacturing process while maintaining both mechanical and electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11388815B2Electronic foil

Publication Date: 2022.07.12 TEKNOLOGIAN TUTKIMUSKESKUS VTT OY

AI summary

A flexible electronic foil (1,1′,1″) comprising a flexible substrate (2) and at least one electrically conducive portion (3) arranged to the substrate (2). The foil (1,1′,1″) comprises mechanical fastening means (6,6′,7) for mechanical fastening of the electronic foil (1,1′,1″), the mechanical fastening means being part of the substrate (2) of the electronic foil (1,1′,1″).