Layered Structure Electrical Contacts via Segmented Overcoat

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Solution Overview

Problem

Existing methods for forming conductive layers in flat panel electrochromic displays face challenges in creating efficient electrical contacts through thick coating layers, which affects electromagnetic interference (EMI) shielding and electrostatic discharge (ESD) protection, as well as transparency and conductivity.

Innovation Solution

A layered structure is formed by depositing a conductive layer with networking conductive nanostructures, followed by forming electrical contacts and an overcoat layer with via holes that extend to these contacts, allowing for the insertion of conductive plugs to establish electrical communication, using materials like reflowable polymers and functional films.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick overcoat layer is formed to protect the conductive layer and enable EMI/ESD shielding, then protection and shielding performance are improved, but electrical contact efficiency and conductivity are worsened

Engineering Contradiction:

ImproveEMI and ESD shieldingVSAvoidelectrical contact efficiency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent divides the overcoat layer into multiple segments: a first overcoat layer with via holes for electrical contact, and a second overcoat layer without via holes for EMI/ESD shielding. This segmentation allows each layer to perform its specific function optimally - the first layer enables electrical connection while the second layer provides protection and shielding without interfering with conductivity.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If via holes are formed in the overcoat layer to establish electrical contact, then electrical conductivity is improved, but the protective shielding function is worsened

Engineering Contradiction:

Improveelectrical contact efficiencyVSAvoidEMI and ESD shielding

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different structural qualities to different regions of the overcoat system. The first overcoat layer has localized via holes at specific contact points to enable electrical connection, while the second overcoat layer maintains continuous coverage for uniform EMI/ESD shielding. This local differentiation of quality allows simultaneous optimization of both electrical contact and shielding functions.

Inventive Principle:

Principle #3Local quality

3Illumination intensity

If conductive nanostructures are used to maintain transparency and conductivity, then optical and electrical performance are improved, but the ability to form reliable electrical contacts through coating layers is worsened

Engineering Contradiction:

ImprovetransparencyVSAvoidelectrical contact formation

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The patent introduces electrical conduits as intermediary elements that bridge the gap between the conductive nanostructures in the conductive layer and the external electrical contacts. These conduits pass through the overcoat layers and provide a reliable conductive path, mediating the connection between the transparent but difficult-to-contact nanostructures and the external circuitry.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances EMI and ESD shielding while maintaining transparency and conductivity, enabling effective electrical communication through thick coating layers, thus improving the performance of flat panel displays.

Implementation Method 1

forming the one or more via holes comprises laser ablating the overcoat layer at predetermined locations

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

the overcoat material may be a reflowable polymer

Methodology Applied

Scientific EffectReflowable polymer phase transition: Phase Change

Implementation Method 3

one or more electrically conductive paths are established through continuous physical contacts among the conductive nanostructures

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9801287B2Electrical contacts in layered structures

Publication Date: 2017.10.24 PINE CASTLE INVESTMENTS LTD

AI summary

Provided herein are layered structures and methods for forming the same, the layered structures including a conductive layer and an overcoat layer formed on a surface thereof, one or more electrical contacts formed on the surface of the conductive layers and via openings extending through the overcoat layer and reaching the electrical contacts.