Panel Heater Comb-Shaped Conductive Layer for Reliable Bonding
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Solution Overview
Problem
Conventional panel heaters face challenges with the flow of anisotropic conductive material during pressure-bonding and do not adequately address mechanical stress and thermal expansion differences between the flexible wiring substrate and the transparent conductive film, leading to potential connection issues and deformation under temperature changes.
Innovation Solution
A panel heater design featuring a comb-shaped patterned conductive layer with tooth portions and gaps, allowing easy flow of anisotropic conductive material and reducing mechanical stress through strategic grouping and spacing, ensuring reliable connection between the electric heating layer and the power supplying member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode terminal is pressure-bonded onto the transparent conductive film using an anisotropic conductive material, then electrical connection is achieved, but the anisotropic conductive material does not flow easily in the principal portion, making the connection unreliable
Solution Approach 1:
The electrode terminal is divided into multiple independent contact portions instead of a single continuous structure. Each contact portion is separated by spaces that allow the anisotropic conductive material to flow freely during pressure bonding, ensuring reliable electrical connection without manufacturing difficulties
Solution Approach 2:
Different portions of the electrode terminal have different structures: the contact portions are designed to make electrical connection with the transparent conductive film, while the spaces between them allow free flow of the anisotropic conductive material. This local differentiation solves both connection reliability and manufacturing ease
2Reliability
If the flexible wiring substrate and transparent conductive film are coupled together, then electrical connection is established, but thermal expansion differences cause mechanical stress and deformation under temperature changes
Solution Approach 1:
The coupled structure is segmented into discrete contact portions separated by spaces. This segmentation allows each segment to expand or contract independently under temperature changes, reducing cumulative mechanical stress while maintaining overall connection stability
Solution Approach 2:
The design explicitly accounts for thermal expansion differences between materials by incorporating spaces that accommodate dimensional changes. The segmented structure allows the flexible wiring substrate and transparent conductive film to undergo thermal expansion/contraction without generating excessive mechanical stress
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 design facilitates uniform and easy flow of anisotropic conductive material, enhances manufacturing flexibility, and maintains a reliable connection between the electric heating layer and power supplying member even under extreme temperature changes, reducing deformation risks.
Implementation Method 1
the electric heating layer and the conductive layer are made physically contact with each other via the anisotropic conductive film only by the tooth portions
Implementation Method 2
the transparent conductive film is heated by applying a voltage to the transparent conductive film through the electrode terminal to warm liquid crystal display elements
Data Source
AI summary
A panel heater includes: a heater main part including a substrate and an electric heating layer; an intervening terminal part including a base layer and a patterned conductive layer; and an anisotropic conductive film for coupling the heater main part and the intervening terminal part to electrically connect the electric heating layer to the conductive layer. The conductive layer is formed in a comb-shaped pattern including a plurality of tooth portions arranged in line at intervals and a portion connecting the tooth portions in common, the tooth portions being connected to the electric heating layer via the anisotropic conductive film, the intervening terminal part has a conducting wire-connective portion for connecting a power supply conductive wire to the conductive layer, and the electric heating layer and the conductive layer are made physically contact with each other via the anisotropic conductive film only by the tooth portions.