Flexible Membrane Conductor Transfer on Insulating Substrates
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Solution Overview
Problem
Existing methods for applying conductors on electrically insulating substrates face limitations in line resolution and exact placement, often requiring batch processing and separate processing of opposite sides, which are cumbersome and inefficient.
Innovation Solution
A method involving a flexible membrane with grooves filled with a composition of electrically conductive particles and adhesive, transferred to the substrate under pressure, followed by sintering to create conductive patterns, allowing for precise conductor application without batch processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If known methods of forming conductors on electrically insulating substrates are used, then conductor application can be achieved, but line resolution and exact placement are limited
Solution Approach 1:
The patent replaces conventional mechanical conductor formation methods (such as screen printing or photolithography) with a transfer printing method using a flexible membrane. The membrane is loaded with conductor material in a controlled environment and then transferred to the substrate through controlled contact and release, enabling precise placement and high-resolution conductor lines while simplifying the manufacturing process.
2Productivity
If batch processing is used for applying conductors, then processing can be performed, but the process becomes cumbersome and inefficient
Solution Approach 1:
The flexible membrane is pre-loaded with conductor material in a controlled environment before transfer to the substrate. This preliminary preparation allows the actual transfer process to be performed quickly and efficiently, eliminating the need for cumbersome batch processing while maintaining simplicity in operation.
3Manufacturing precision
If opposite sides of a substrate are processed separately, then each side can be treated individually, but the process time and complexity increase
Solution Approach 1:
The patent enables simultaneous processing of both sides of a substrate by using a flexible membrane that can be loaded with conductor material for multiple sides and then transferred in a single operation. This merging of processing steps maintains the precision of individual side treatment while dramatically reducing the total processing time and operational complexity.
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
Enables high-resolution conductor patterns with precise placement on both sides of a substrate in a single step, improving efficiency and flexibility in substrate processing, especially for non-planar and fragile substrates.
Implementation Method 1
a composition that includes, as composition components, electrically conductive particles and an adhesive
Implementation Method 2
separating the membrane from the substrate to transfer the composition from the grooves in the first surface of the membrane to the substrate
Implementation Method 3
applying sufficient energy to sinter the electrically conductive particles in order to render electrically conductive the pattern of composition transferred to the substrate from the grooves
Data Source
AI summary
A method for applying an electrical conductor to an electrically insulating substrate, the method comprising providing a flexible membrane with a pattern of grooves formed on a first surface thereof, and loading the grooves with a composition comprising particles of a conductive material. The composition is, or may be made, electrically conductive. Once the membrane is loaded, the grooved first surface of the membrane is brought into contact with a front or/and back surface of the substrate. A pressure is then applied between the substrate and the membrane(s) so that the composition loaded into the grooves adheres to the substrate. The membrane(s) may remain on the electrically insulating substrate. The electrically conductive particles in the composition can then be sintered to form a pattern of electrical conductors on the substrate, the pattern corresponding to the pattern formed in the membrane(s).