Reel-to-Reel Electrical Bridge Formation via Foil Strip Folding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing electrical bridges in reel-to-reel production of RFID antennas and conductive patterns are costly, mechanically weak, and inefficient, often requiring additional materials and protective layers, and are difficult to implement in high-speed manufacturing due to the need for precise alignment and handling of thin, easily damaged foil strips.
Innovation Solution
The method involves creating a foil strip tongue unattached to the substrate, which is folded over or across the conductive pattern to form a bridge, utilizing the existing foil and eliminating the need for additional materials or protective layers, and can be done using suction or blowing techniques without separate tools, allowing for continuous reel-to-reel processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive printing ink is used to create bridges over conductor turns, then the bridge can be formed, but the electroconductivity is poor and resistance is high
Solution Approach 1:
The bridge is made from the same metal foil material as the conductive pattern, ensuring homogeneous electrical properties throughout. This eliminates the interface between different materials (printing ink and foil) that causes high resistance, while also eliminating the need for expensive conductive printing ink.
Solution Approach 2:
The invention changes the physical state and form of the metal foil from a continuous layer to a folded bridge structure. By controlling the folding process and creating precise creases, the foil can be shaped into bridges that maintain excellent electrical conductivity while crossing over conductor turns.
2Strength
If a foil bridge is made by etching laminate coated with foil on both sides, then the bridge structure is formed, but additional protective layers are required and costs increase
Solution Approach 1:
The invention extracts only the necessary metal foil for the bridge from the continuous foil layer, leaving the substrate single-sided. This eliminates the need for a second foil layer on the rear side of the substrate and removes the requirement for additional protective layers to cover exposed bridges.
Solution Approach 2:
The bridge is formed by folding the foil in three-dimensional space rather than creating it through etching on both sides of the substrate. This dimensional approach allows the bridge to cross over conductor turns while maintaining a single-sided substrate structure.
3Ease of manufacture
If stage holes or incisions are made in the substrate for folding the bridge, then the bridge can be formed, but the substrate thickness is doubled and reliability deteriorates
Solution Approach 1:
Instead of making holes or incisions through the entire substrate thickness, the invention applies local quality changes only to the metal foil layer. The foil is folded and creased at specific locations to form bridges, while the substrate remains intact and maintains its original single-layer structure, preserving mechanical strength and reliability.
4Strength
If heavy-duty tools are used to grip and fold the substrate with the bridge, then the bridge can be formed, but the process is difficult to implement in rapid reel to reel manufacturing
Solution Approach 1:
The invention segments the metal foil from the substrate by creating a fold line or separation zone. This allows the foil to be folded independently without requiring heavy-duty tools to grip the entire substrate-foil composite. The separated foil can be manipulated with lighter, faster tools suitable for reel-to-reel manufacturing.
Solution Approach 2:
The invention replaces heavy mechanical gripping and folding of the substrate-foil composite with a lighter system that manipulates only the folded foil structure. This substitution enables high-speed processing compatible with reel-to-reel manufacturing while maintaining bridge formation quality.
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
This approach reduces costs, improves mechanical strength and electroconductivity, and enables efficient, high-speed manufacturing of reliable electrical bridges without the need for additional insulation or protective layers, while maintaining the integrity of the circuit board during bending.
Implementation Method 1
utilizing the existing foil and eliminating the need for additional materials or protective layers, and can be done using suction or blowing techniques without separate tools
Data Source
AI summary
A manufacturing method of electrical bridges, wherein a conductive pattern (2) from electroconductive material, such as metal foil, is applied over a substrate (1) made of electrically insulating material and the electroconductive material has at least one strip tongue (3) unattached to the substrate, one side of the tongue is attached to the conductive pattern (2), and the said strip tongue (3) is folded over an area insulated electrically from the conductive pattern (2), and the strip tongue (3) is connected electroconductively to a predetermined other part (5) of the conductive pattern (2).