Flexible Substrate With Thinned Insulating Base For Crack Resistance
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Solution Overview
Problem
Flexible substrates face damage from stress caused by bending or expansion and contraction, which can lead to wiring damage and cracking, particularly in areas where the insulating base material is subjected to deformation.
Innovation Solution
The flexible substrate design incorporates a thinned first area with an inclined portion and a thicker second area, along with specific notch and taper configurations in the insulating base material, to enhance elasticity and flexibility, reducing the likelihood of cracking and improving the elongation rate by promoting out-of-plane deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insulating base material is made thick to provide structural support, then strength and stability are improved, but flexibility and elasticity deteriorate, making the wiring more susceptible to damage from bending and expansion
Solution Approach 1:
The insulating base material is divided into multiple layers with different thicknesses. The first area has a first thickness while the second area has a second thickness greater than the first thickness. This segmentation allows different regions to serve different functions: thinner regions provide flexibility while thicker regions provide structural support.
Solution Approach 2:
Different areas of the insulating base material are given different local properties through varying thickness. The first area (thinner) is located where flexibility is needed, while the second area (thicker) is located where structural support is needed. This local quality differentiation resolves the contradiction between overall strength and local flexibility.
2Adaptability or versatility
If the insulating base material is made thin to enhance flexibility, then ease of bending is improved, but strength and resistance to cracking deteriorate
Solution Approach 1:
The insulating base material is segmented into multiple layers with varying thicknesses. By stacking insulating base material layers with different thicknesses, the structure achieves both flexibility (from thinner regions) and crack resistance (from thicker regions and multiple layers distributing stress).
Solution Approach 2:
The insulating base material is formed as a composite structure with multiple layers of insulating base material having different thicknesses. This composite construction combines the advantages of thin layers (flexibility) and thick layers (strength) in a single integrated structure.
3Adaptability or versatility
If honeycomb-shaped openings are provided in the base material to reduce stress, then flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of creating complex honeycomb openings within single layers, the structure segments flexibility enhancement across multiple layers with different thicknesses. This approach achieves flexibility through layer configuration rather than complex intralayer patterning, simplifying manufacturing.
Data Source
AI summary
According to one embodiment, a flexible substrate includes a flexible insulation base material and a plurality of wiring lines provided on one surface side of the insulation base material, and the insulation base material includes a thinned first area and a second area having a thickness larger than that of the first area, the first area includes a first lower surface, the second area includes a second lower surface, the first lower surface and the second lower surface are formed on an opposite side of a surface on which the wiring lines are provided, and the first lower surface includes an inclined portion inclined towards the second lower surface.