Flexible Interconnects With Meandering Sinusoid Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electronic textiles face challenges in achieving high stretchability and durability while maintaining electrical functionality, particularly under large strains and repeated deformation, due to limitations in manufacturing complexity, material costs, and scalability, which restrict their use in mass production of wearable electronics.
Innovation Solution
The development of flexible interconnects with a conductive trace encapsulated between two thermoplastic polymer films, allowing for stretchability and durability enhancements through design parameters like meandering sinusoid patterns and TPU film lamination, which improves resistance to strain and cyclic endurance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional electronic textiles are used, then electrical functionality is maintained, but stretchability and durability under large strains are insufficient
Solution Approach 1:
The interconnect is divided into multiple segments including rigid portions and flexible portions with meandering patterns. This segmentation allows different regions to perform different functions - rigid portions maintain electrical connection while flexible portions accommodate strain through deformation, resolving the contradiction between maintaining electrical functionality and achieving stretchability.
Solution Approach 2:
The flexible portions of the interconnect are designed with meandering sinusoid patterns and curved geometries. These curved paths allow the interconnect to stretch and deform elastically under strain while maintaining continuous electrical connection, enabling both stretchability and electrical functionality under large strains.
2Reliability
If rigid interconnect structures are used, then electrical connection is stable, but flexibility and stretchability are limited
Solution Approach 1:
The interconnect employs local quality by having rigid portions in areas requiring stable electrical connection and flexible meandering portions in areas requiring strain accommodation. This spatial variation in mechanical properties allows the single interconnect structure to simultaneously provide both electrical stability and flexibility.
Solution Approach 2:
The interconnect functions as a composite structure combining rigid conductive materials for stable electrical connection with flexible polymer substrates for adaptability. This composite approach allows the interconnect to maintain electrical functionality while accommodating large strains through the flexibility of the polymer portions.
3Strength
If complex manufacturing processes are used to achieve stretchability, then interconnect performance improves, but manufacturing complexity and cost increase
Solution Approach 1:
The meandering sinusoid patterns and flexible portions are designed and fabricated into the interconnect structure during the initial manufacturing process. This preliminary incorporation of strain-accommodating features eliminates the need for complex post-processing or assembly steps, achieving high cyclic endurance through straightforward manufacturing.
Solution Approach 2:
The interconnect achieves stretchability and cyclic endurance by modifying geometric parameters such as the meandering pattern dimensions, trace thickness, and flexible portion ratios. These parameter changes are implemented through standard manufacturing processes like screen printing or lithography, avoiding complex manufacturing while achieving superior mechanical 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 flexible interconnects demonstrate significant stretchability up to 103.91% strain and 1,000 cycles without electrical failure, offering improved durability and washability, making them suitable for wearable electronics and smart garments.
Implementation Method 1
heating and pressing the layers together
Implementation Method 2
melt the thermoplastic polymer films together
Implementation Method 3
stretchability up to 103.91% strain and 1,000 cycles without electrical failure
Data Source
AI summary
Provided herein are flexible interconnects, systems containing one or more flexible interconnects, and textiles including one or more flexible interconnects.