Fusion Sheet Layout for Wire Bonding and Tape Adhesion

Solution Overview

Problem

Non-woven cloth layers in existing fusion sheets have low adhesiveness with double-sided adhesive tapes and increasing the adhesiveness leads to a potential increase in weight and decrease in fusibility with wire-like transmission members.

Innovation Solution

A fusion sheet design with alternating sections of fusion base parts and adhesive base parts on a base material layer, where the fusion base parts are stacked on one surface and adhesive base parts on the other, ensuring favorable adhesiveness and fusibility without increasing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the non-woven cloth layer is used to improve adhesiveness, then adhesiveness with adhesive member increases, but weight of the sheet member increases and fusibility with wire-like transmission member decreases

Engineering Contradiction:

ImproveadhesivenessVSAvoidweight of sheet member

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The sheet member is divided into multiple layers with distinct functions: a base material layer, a fusion base part for fusibility, and an adhesive base part for adhesiveness. This segmentation allows each layer to optimize its specific function without compromising the other, resolving the contradiction between adhesiveness and weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sheet member have different properties: the adhesive base part provides high adhesiveness where needed, while the fusion base part provides fusibility in its region. This local differentiation allows the sheet to achieve both adhesiveness and fusibility without uniformly increasing weight across the entire structure.

Inventive Principle:

Principle #3Local quality

2Strength

If the non-woven cloth layer is used to improve adhesiveness, then adhesiveness with adhesive member increases, but fusibility with wire-like transmission member decreases

Engineering Contradiction:

ImproveadhesivenessVSAvoidfusibility

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The sheet member is divided into multiple layers with distinct functions: a base material layer, a fusion base part for fusibility, and an adhesive base part for adhesiveness. This segmentation allows each layer to optimize its specific function without compromising the other, resolving the contradiction between adhesiveness and fusibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sheet member have different properties: the adhesive base part provides high adhesiveness where needed, while the fusion base part provides fusibility in its region. This local differentiation allows the sheet to achieve both adhesiveness and fusibility simultaneously.

Inventive Principle:

Principle #3Local 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

The design achieves favorable adhesiveness and fusibility while preventing weight increase, allowing for efficient fixation of wire-like transmission members without interference from adhesive base parts during fusion.

Implementation Method 1

a fusion base part partially stacked to the first surface of the base material layer and fusible to a wire-like transmission member

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

an adhesive base part partially stacked to the second surface of the base material layer and having larger adhesive strength with an adhesive member than the base material layer

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS12497544B2Fusion sheet and wiring member

Publication Date: 2025.12.16 SUMITOMO WIRING SYSTEMS LTD

AI summary

A fusion sheet includes: a base material layer including a first surface and a second surface; a fusion base part partially stacked to the first surface of the base material layer and fusible to a wire-like transmission member; and an adhesive base part partially stacked to the second surface of the base material layer and having larger adhesive strength with an adhesive member than the base material layer. A first section and a second section are provided along an extension direction of the base material layer. The first section is a section where the adhesive base part is stacked to the base material layer other than a laminated section where the adhesive base part is stacked. The second section is a section where the adhesive base part is stacked to the base material layer other than a laminated section where the fusion base part is stacked.