Patterned Conductor Rectangular Cross-Section Crystal Grain Orientation
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Solution Overview
Problem
Conventional patterned conductors used in heating applications, such as defrosters and touchpanel sensors, face a trade-off between conductivity and see-through properties due to their trapezoidal main cut surface shape, which impairs both conductivity and visibility.
Innovation Solution
A patterned conductor with a metal linear conductor having a rectangular main cut surface shape is achieved by controlling the metal crystal grain structure, where the length of the crystal grains along the normal direction is greater than one third of the height, and the ratio of this length to the width is optimized to ensure high conductivity and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the line width of the linear conductor is increased to improve conductivity, then the conductivity improves, but the see-through property deteriorates
Solution Approach 1:
The patent transitions from controlling conductor visibility in two dimensions (width and thickness) to utilizing the third dimension by orienting crystal grains vertically. The crystal grains extend in the thickness direction of the conductor layer, creating a rectangular cross-section that maximizes area while minimizing visible width. This dimensional approach allows the conductor to achieve high conductivity through increased sectional area without compromising see-through properties, as the vertical crystal grain orientation reduces the visible profile when viewed from the front surface.
2Illumination intensity
If the line width of the linear conductor is decreased to improve see-through property, then the see-through property improves, but the conductivity deteriorates
Solution Approach 1:
The patent fundamentally changes the geometric parameters of the conductor cross-section from a conventional trapezoidal shape to a rectangular shape through controlled crystal grain growth. By adjusting the crystal grain orientation so that grains extend vertically through the thickness direction with their long axes perpendicular to the front surface, the conductor achieves a rectangular cross-section. This parameter change allows the visible width to be minimized while the sectional area is maximized, simultaneously improving both see-through property and conductivity without the trade-off inherent in conventional designs.
3Ease of manufacture
If a trapezoidal main cut surface shape is used (conventional design), then the manufacturing process is simplified, but both conductivity and see-through property deteriorate
Solution Approach 1:
The patent changes the cross-sectional shape parameter from trapezoidal to rectangular by controlling crystal grain orientation during manufacturing. The crystal grains are oriented to extend in the thickness direction with their long axes perpendicular to the front surface, naturally forming a rectangular main cut surface. This parameter change improves both conductivity (through larger sectional area) and see-through property (through narrower visible width) while maintaining manufacturing feasibility through controlled crystal growth processes.
Solution Approach 2:
The patent utilizes the composite structure of multiple crystal grains oriented in a specific direction to achieve the desired rectangular cross-section. By controlling the crystal grain structure within the metal layer, the conductor achieves a rectangular profile that optimizes both electrical and optical properties. The composite arrangement of vertically-oriented crystal grains creates the rectangular geometry without requiring complex post-processing steps.
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 allows for a patterned conductor with improved conductivity and see-through properties, as the rectangular shape minimizes visible width while maximizing sectional area, effectively addressing the trade-off in conventional designs.
Implementation Method 1
in a section orthogonal to a longitudinal direction of the linear conductor, the linear conductor includes a metal crystal grain(s) 20a1 having a longitudinal direction, and the longitudinal direction of the metal crystal grain(s) 20a1 extends in the height direction of the linear conductor
Implementation Method 2
The patterned conductor used therein is energized to generate heat so as to serve as a defroster or a heater
Data Source
AI summary
A patterned conductor that includes a metal linear conductor positioned on one placement surface that has a main cut surface orthogonal to its longitudinal direction, a plurality of metal crystal grains. In the main cut surface of thereof, a metal crystal grain(s) having a length h0 along a normal direction to the placement surface, which length is larger than one third of a height H of the linear conductor along the normal direction to the placement surface. A minimum value of a ratio (h0/w0), which is a ratio of the length h0 of the metal crystal grain(s) along the normal direction to the placement surface with respect to a length w0 along the placement surface, is not less than 1.2.