Foldable Sensor With Anisotropic Adhesive for Trace Continuity
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Solution Overview
Problem
Conventional foldable sensors face issues with reliability and manufacturability due to potential short circuits and breakage of conductive traces during folding, and the addition of protective layers increases bulk.
Innovation Solution
A foldable sensor design utilizing anisotropic adhesive to ensure functional continuity of conductive traces across substrates, allowing for a structurally discontinuous but functionally continuous connection, thereby maintaining reliability and flexibility without adding bulk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the substrate is folded to manufacture sensor elements faster and more cost-effectively, then manufacturing efficiency is improved, but the conductive traces may break or short circuit reducing reliability
Solution Approach 1:
The patent introduces an intermediary alignment structure consisting of registration marks and guide features on the substrate that mediate between the folding process and the conductive traces. These alignment features ensure that when the substrate is folded, the conductive traces from opposite sides align precisely without breaking or short-circuiting, thus maintaining reliability while enabling efficient folding manufacturing
2Reliability
If a protective layer is added to prevent short circuits and breakage during folding, then reliability is improved, but the sensor bulk increases
Solution Approach 1:
The patent extracts the protective function from a separate bulky protective layer and integrates it into the substrate design itself through alignment structures and spaced-apart conductive trace routing. The substrate's own structural features serve as the protection mechanism, eliminating the need for additional protective layers and reducing overall sensor bulk
3Area of stationary object
If conductive traces are positioned closer together to reduce sensor size, then miniaturization is achieved, but the risk of short circuits during folding increases
Solution Approach 1:
The patent applies local quality by creating different spatial arrangements of conductive traces in different regions of the substrate. In areas prone to folding stress, conductive traces are positioned with increased spacing and reinforced by alignment structures, while in other areas they can be closer together. This localized optimization allows miniaturization where safe while maintaining reliability in critical folding regions
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 anisotropic adhesive ensures reliable electrical connectivity and structural integrity of the sensor, enabling cost-effective and efficient manufacturing while maintaining sensor functionality and flexibility.
Implementation Method 1
an anisotropic adhesive disposed on a portion of the conductive trace
Data Source
AI summary
A foldable sensor that can operate without a continuous structural connection is provided. The foldable sensor may be made from a continuous flexible substrate or may be made of two separate pieces of substrate. The foldable sensor is held together with an anisotropic adhesive. The continuous flexible sensor is still operative, via the anisotropic adhesive, if the folded portion severs or if the conductive trace is otherwise disconnected.