Micro-wire electrode bus with cross-connected grid
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Solution Overview
Problem
Existing transparent micro-wire electrodes in touch screens face challenges in reducing the size of electrical busses and wires while maintaining low resistance and transparency, and in simplifying manufacturing processes to lower costs and material usage.
Innovation Solution
A conductive micro-wire structure comprising spaced-apart first and second micro-wires on a substrate, where the second micro-wires are electrically connected to at least two first micro-wires and have a width less than the first micro-wires, allowing for improved conductivity and robustness in a smaller area, constructed using common manufacturing steps with transparent micro-wire electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If transparent micro-wire electrodes are used to reduce the size of electrical busses and wires, then the area occupied by conductors is reduced, but the resistance increases and transparency is compromised
Solution Approach 1:
The electrical bus is segmented into multiple parallel micro-wires instead of using a single thick conductor. This segmentation allows the current to be distributed across multiple pathways, reducing the overall area while maintaining low resistance through parallel conduction paths.
Solution Approach 2:
The patent transitions from planar conductor layouts to three-dimensional stacked micro-wire structures. By arranging micro-wires in multiple layers (first micro-wires in a first plane, second micro-wires in a second plane), the conductor achieves lower resistance without increasing the footprint area, as current can flow through multiple vertical pathways.
2Illumination intensity
If transparent micro-wire electrodes are used, then transparency is improved, but manufacturing complexity increases and costs rise
Solution Approach 1:
The patent combines the transparency requirement with the electrical conduction function into a single micro-wire structure. The same micro-wires that provide electrical pathways also serve as the transparent electrode layer, eliminating the need for separate transparent conductor materials and simplifying the manufacturing process.
Solution Approach 2:
The micro-wire structure performs multiple functions simultaneously: it provides electrical conduction, maintains transparency, and serves as the electrode layer for the display. This multi-functionality reduces the number of manufacturing steps and materials required, lowering overall complexity and cost.
3Quantity of substance
If micro-wire width is reduced to decrease material usage, then material consumption is lowered, but resistance increases
Solution Approach 1:
Instead of using fewer thick wires, the patent uses many thin micro-wires in parallel. The total material usage is reduced because the micro-wires are extremely thin, but the electrical conductivity is maintained through the parallel arrangement, where resistance decreases inversely with the number of parallel pathways.
Solution Approach 2:
The patent adds the vertical dimension by stacking micro-wires in multiple planes. This allows the use of thinner individual wires (reducing material) while maintaining low resistance through increased vertical conduction pathways, effectively trading horizontal space for vertical conductivity.
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 conductive micro-wire structure enables efficient electrical current conduction in a smaller area with reduced resistance and transparency, while being robust against faults and manufactured using existing processes, thus reducing costs and material usage.
Implementation Method 1
a plurality of spaced-apart first micro-wires located on or in the micro-channels, the first micro-wires extending across the substrate in a first direction; and a plurality of spaced-apart second micro-wires located on or in the micro-channels, the second micro-wires extending across the substrate in a second direction different from the first direction, each second micro-wire electrically connected to at least two first micro-wires
Data Source
AI summary
An electrical conductor includes a substrate having micro-channels formed in the substrate. A plurality of spaced-apart first micro-wires is located on or in the micro-channels, the first micro-wires extending across the substrate in a first direction. A plurality of spaced-apart second micro-wires is located on or in the micro-channels, the second micro-wires extending across the substrate in a second direction different from the first direction. Each second micro-wire is electrically connected to at least two first micro-wires and at least one of the second micro-wires has a width less than the width of at least one of the first micro-wires.