Nanostructure Layer Coating for EMI Shielding and Electrical Contact

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Solution Overview

Problem

Existing technologies for forming conductive layers in flat panel electrochromic displays face challenges in achieving efficient electrical communication between nanostructure layers and external components, particularly in providing effective electromagnetic interference (EMI) and electrostatic discharge (ESD) shielding while maintaining transparency and mechanical protection.

Innovation Solution

A layered structure comprising a nanostructure layer with a coating layer that includes a reflowable polymer and conductive plugs extending from the inner to the outer surface, allowing for electrical communication and enhanced adhesion, and optionally incorporating UV curable resins and adhesion promoters to improve mechanical and chemical protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a coating layer is formed over the nanostructure layer to provide mechanical protection and adhesion, then the mechanical strength and adhesion are improved, but electrical communication between the nanostructure layer and external components is blocked

Engineering Contradiction:

Improvemechanical strengthVSAvoidelectrical communication

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The coating layer is segmented into multiple functional layers: a lower adhesion promoter layer that maintains electrical continuity with the nanostructure layer, and an upper protective coating layer that provides mechanical protection. This segmentation allows each layer to specialize in its function while working together as an integrated system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An adhesion promoter layer acts as an intermediary between the nanostructure layer and the protective coating layer. This intermediate layer facilitates both mechanical adhesion and electrical communication, bridging the gap between the conductive nanostructure layer and the insulating protective coating.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the coating layer is made thicker to enhance mechanical protection and chemical resistance, then the protection capability is improved, but transparency of the layered structure is reduced

Engineering Contradiction:

Improveprotection capabilityVSAvoidtransparency

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The refractive index and thickness parameters of the coating layer are optimized to achieve a balance between protection and transparency. By controlling these parameters, the coating provides enhanced mechanical and chemical protection while maintaining optical clarity through refractive index matching with the nanostructure layer.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional coating materials are used to form the coating layer, then the manufacturing process is simple, but adhesion to the nanostructure layer is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidadhesion

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The coating layer is formed using composite materials that combine adhesion promoters with protective coating materials. This composite approach enhances adhesion to the nanostructure layer while maintaining the protective functions and can be applied using conventional coating processes.

Inventive Principle:

Principle #40Composite materials

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 solution enables effective EMI and ESD shielding, maintains transparency, and provides mechanical and chemical protection, ensuring reliable electrical communication and durability of the conductive layers in display applications.

Implementation Method 1

The coating layer includes a reflowable polymer that may include poly(methyl methacrylate) (PMMA)... The conductive plug is configured to be placed in electrical communication with the nanostructure layer

Methodology Applied

Scientific EffectThermal reflow: Melting

Implementation Method 2

The coating layer may also include a UV curable resin, a blocked isocyanate and/or a melamine based cross-linker and/or other adhesion promoters

Methodology Applied

Scientific EffectUV curable: Photopolymerisation

Data Source

PatentUS10852614B2Method of forming electrical contacts in layered structures

Publication Date: 2020.12.01 PINE CASTLE INVESTMENTS LTD

AI summary

The present disclosure is directed to a method of forming a layered structure including a nanostructure layer having nanostructures. The method includes: forming a coating layer on the surface of the nanostructure layer, reflowing the coating layer, depositing one or more conductive plugs into the coating layer, and hardening the coating layer. The one or more conductive plugs each has a first portion configured to be placed in electrical communication with the nanostructure layer and a second portion not covered by the coating layer.