Gyrified Metal-Elastomer Composite for Stretchable Conductivity

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Solution Overview

Problem

Existing metal-elastomer composites face challenges in achieving high electrical conductivity and mechanical stretchability due to thermodynamic immiscibility, leading to degradation of material properties.

Innovation Solution

A method involving kinetically controlled deposition of metal onto an elastomer, forming a gyrified metal-elastomer composite with nanoscale bonding and self-forming gyrifications, allowing the metal and elastomer to maintain their respective properties while being chemically hybridized.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal and elastomer are physically mixed or simply deposited, then the composite can be manufactured easily, but the electrical conductivity and mechanical stretchability are degraded due to thermodynamic immiscibility

Engineering Contradiction:

Improveease of manufactureVSAvoidelectrical conductivity and mechanical stretchability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the deposition parameters from conventional physical vapor deposition to kinetic-controlled deposition at lower temperatures (below 100°C). This parameter change enables the metal atoms to be incorporated into the elastomer matrix during the deposition process itself, creating a nanophase composite structure that maintains both high electrical conductivity and mechanical stretchability while avoiding thermodynamic phase separation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a nanophase composite material where metal atoms are dispersed at the nanoscale within the elastomer matrix. This composite structure, achieved through kinetic-controlled deposition, allows the metal and elastomer to maintain their respective properties (electrical conductivity and elasticity) while being intimately mixed at the nanoscale, preventing the phase separation that occurs in conventional composites

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If metal nanoparticles are physically mixed with elastomer, then the composite can be manufactured, but the interface adhesion is insufficient leading to phase separation

Engineering Contradiction:

Improveease of manufactureVSAvoidinterface adhesion and compositional stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent uses the elastomer matrix itself as an intermediary medium during the deposition process. The metal atoms are deposited directly into the elastomer precursor mixture, allowing the elastomer to mediate the incorporation and distribution of metal atoms throughout the matrix. This creates strong interfacial adhesion and prevents phase separation, as the metal is embedded within the elastomer network rather than simply mixed or deposited on the surface

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If planar metal layers are used on elastomer, then the manufacturing process is simple, but the metal layers crack under deformation limiting mechanical applicability

Engineering Contradiction:

Improvestructural complexityVSAvoidmechanical durability under deformation

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent segments the continuous metal layer into discrete metal atoms or nanoclusters that are individually incorporated into the elastomer matrix. This segmentation prevents the formation of continuous planar metal layers that would crack under deformation. Instead, the dispersed metal nanophases maintain electrical conductivity through percolation pathways while allowing the elastomer to deform freely without cracking the metal structure

Inventive Principle:

Principle #1Segmentation

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 composite exhibits strain-invariant electrical conductivity and durability in harsh environments, suitable for stretchable devices and soft electronics.

Implementation Method 1

depositing a metal onto the elastomer to form a metal-elastomer composite with the metal embedded in the elastomer

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 2

Nanoscale mixing not only creates a large interface that enhances adhesion between metals and polymers but also offers softened metallic nanoparticles and nanostructures due to high surface excess elasticity

Methodology Applied

Scientific EffectNanoscale mixing: Dispersion (of waves)

Implementation Method 3

self-forming gyrifications on the metal-elastomer composite

Methodology Applied

Scientific EffectSelf-assembly: Self-Assembly

Implementation Method 4

A gyrified metal-elastomer composite may have a three-dimensional structure in which gyrifications are formed on a surface of the elastomer

Methodology Applied

Scientific EffectGyrification: Corrugation

Data Source

PatentUS20250346988A1Gyrified metal-elastomer composite and method for manufacturing the same

Publication Date: 2025.11.13 UNIVERSITY INDUSTRY COOPERATION GROUP OF KYUNG HEE UNIVERSITY

AI summary

According to one embodiment, the present invention relates to a gyrified metal-elastomer composite and a method for manufacturing the same. In this embodiment of the invention, a gyrified metal-elastomer composite with nanoscale phases can be dynamically controlled and manufactured. The gyrified metal-elastomer composite simultaneously retains the electrical conductivity of the metal and the stretchability of the elastomer, making it suitable for use in stretchable electronic devices.