Flexible Input-Output Devices With Mesh Substrates
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Solution Overview
Problem
Conventional input-output components for electronic devices face challenges in form factor integration, reliability, and stress-induced failures, especially in devices with bendable portions, limiting their use in flexible or deformable electronic devices.
Innovation Solution
A flexible input-output device is formed using an elastomeric substrate with serpentine signal paths and through-hole openings, allowing for stretchability and deformation without cracking, incorporating light-emitting diodes, sensors, and actuators, and featuring a mesh-shaped substrate for enhanced flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional displays and touch sensors are mounted in electronic devices with bendable portions, then the device can achieve flexible form factors, but the components are subject to stress-induced failures
Solution Approach 1:
The patent applies this principle by replacing traditional rigid display and sensor components with flexible alternatives that can withstand bending and deformation. The flexible display and touch sensor are mounted on flexible substrates, allowing them to conform to bendable device portions without failing under stress.
Solution Approach 2:
The patent uses composite materials by integrating multiple flexible layers including flexible substrate, flexible display, flexible touch sensor, and flexible circuit boards. This composite structure distributes mechanical stress across different materials with complementary properties, preventing failure at any single interface while maintaining flexibility.
2Device complexity
If conventional input-output components are used in electronic devices, then the device structure remains simple, but form factor integration becomes challenging
Solution Approach 1:
The patent applies this principle by using flexible circuit boards that can serve multiple functions: providing electrical interconnections, accommodating bending, and enabling various form factor configurations. The same flexible substrate serves as both the mounting platform and the interconnection medium, reducing the need for additional rigid structural components.
3Ease of manufacture
If rigid input-output components are used, then manufacturing is straightforward, but the components cannot accommodate deformation in bendable devices
Solution Approach 1:
The patent applies this principle by transitioning from static rigid components to dynamic flexible components that can adapt their shape during device operation. The flexible display, touch sensor, and circuit boards are designed to dynamically conform to bending and deformation without compromising electrical connectivity or component functionality.
Data Source
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AI summary
An electronic device may have control circuitry coupled to input-output devices such as a display. A flexible input-output device (20) may be formed from an elastomeric substrate layer (44). The substrate layer may have signal paths (42) to which components (24) are mounted. Openings may be formed in the elastomeric substrate layer between the signal paths to create a stretchable mesh-shaped substrate. The electrical components may each include an interposer having solder pads soldered to the elastomeric substrate. Electrical devices such as micro-light-emitting diodes may be soldered to the interposers. The electrical components may also include electrical devices such as sensors and actuators. A stretchable lighting unit may have a stretchable light guide illuminated by a stretchable light source.