Polymer-Infused Inorganic Matrix for Flexible Conductors

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Solution Overview

Problem

Copper conductors on flexible substrates oxidize over time, leading to delamination, stress-corrosion-cracking, increased resistance, and brittleness, making them incompatible with flexible substrates that are repeatedly flexed.

Innovation Solution

An inorganic matrix precursor is printed on a flexible substrate, cured with a light pulse to form a porous film, and then infused with a polymer to enhance mechanical stability and prevent corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If copper is used as printed conductor material to reduce costs, then manufacturing cost is reduced, but the conductor oxidizes over time causing delamination, stress-corrosion-cracking, increased resistance, and brittleness

Engineering Contradiction:

Improvemanufacturing costVSAvoidconductor stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a composite structure consisting of a copper conductor layer combined with a polymer coating layer. The copper provides electrical conductivity and cost-effectiveness, while the polymer coating prevents oxidation and provides mechanical flexibility. This composite material approach resolves the contradiction by combining materials with complementary properties to achieve both low cost and high reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polymer coating acts as an intermediary layer between the copper conductor and the external environment. This intermediate layer protects the copper from direct exposure to oxygen and moisture, preventing oxidation while maintaining the electrical functionality of the copper conductor. The polymer mediator thus enables the use of inexpensive copper without suffering from its oxidation problems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If copper conductor is formed on flexible substrate, then cost is reduced, but the conductor becomes brittle and incompatible with repeated flexing

Engineering Contradiction:

Improvemanufacturing costVSAvoidmechanical flexibility

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The composite structure of copper conductor plus polymer coating provides both cost-effectiveness and mechanical flexibility. The polymer layer has inherent flexibility that allows the composite structure to withstand repeated flexing without becoming brittle, while the copper core maintains electrical conductivity. This resolves the contradiction between cost and mechanical strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polymer coating forms a flexible thin film around the copper conductor. This flexible shell allows the conductor to bend and flex without cracking or becoming brittle, enabling the conductor to maintain its mechanical integrity during repeated flexing operations while keeping the overall structure cost-effective.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If copper oxidizes over time, then bulk resistance and contact resistance increase, but the conductor structure remains initially conductive

Engineering Contradiction:

Improveinitial conductivityVSAvoidconductor lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The polymer coating serves as a protective intermediary that prevents oxygen and moisture from reaching the copper conductor. This barrier layer maintains the copper's initial conductivity over an extended period by preventing oxidation, thus resolving the contradiction between initial conductivity and long-term durability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent addresses the harmful effect of copper oxidation by applying a polymer coating that converts the potential harm (oxidation leading to increased resistance) into a benefit (protected conductivity). The coating transforms the vulnerable copper surface into a protected interface, maintaining low resistance over the conductor's entire lifespan.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 polymer infusion supports the metal network mechanically, inhibits corrosion, and maintains low contact resistance, even when the substrate is flexed, significantly improving the stability and durability of the conductive film.

Implementation Method 1

The inorganic precursor is then cured with a light pulse to form a porous inorganic matrix thin film

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

A polymer is subsequently infused into the porous inorganic matrix thin film

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS9237637B2Method for forming and stabilizing printed conductors on a flexible substrate

Publication Date: 2016.01.12 PULSEFORGE INC

AI summary

A method for forming printed conductors on a flexible substrate is disclosed. Initially, an inorganic matrix precursor is printed onto a flexible substrate. The inorganic precursor is then cured with a light pulse to form a porous inorganic matrix thin film. A polymer is subsequently infused into the porous inorganic matrix thin film to form a polymer infused inorganic matrix thin film.