Polymer Substrate Coating for Printable Electronics Adhesion
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Solution Overview
Problem
Conductive and dielectric inks for printable electronics face challenges on polymer substrates due to surface smoothness, surface energy, and substrate compatibility, affecting conductivity, adhesion, and wash-fastness, particularly in applications requiring significant stretching like wearable garments.
Innovation Solution
A composite substrate comprising an elastomer or thermoplastic elastomer polymer film with a thin coating of thermoplastic elastomer, formed from a solvent solution or water-based dispersion, enhances compatibility with inks and mechanical properties, allowing for improved adhesion and durability of printed electrical conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a polymer substrate is used for printable electronics, then flexibility and stretchability are improved, but adhesion and wash-fastness of printed conductors deteriorate
Solution Approach 1:
A polymeric coating layer is applied to the polymer substrate to serve as an intermediary between the substrate and the printed conductor. This coating layer has surface properties that improve adhesion to the conductor while maintaining the flexibility of the underlying polymer substrate, thus resolving the contradiction between flexibility and adhesion.
Solution Approach 2:
The invention uses a composite structure consisting of the polymer substrate combined with a polymeric coating layer. This composite material approach allows the substrate to provide flexibility while the coating layer provides improved adhesion and wash-fastness properties for the printed electronics.
2Adaptability or versatility
If a polymer substrate is used for printable electronics, then flexibility and stretchability are improved, but conductivity and insulating behavior of printed materials deteriorate
Solution Approach 1:
The polymeric coating layer acts as a mediator between the polymer substrate and the printed conductor. It provides a surface with appropriate surface energy and smoothness that enables the printed conductor to achieve its desired conductivity without being adversely affected by the underlying polymer substrate properties.
3Ease of manufacture
If ink is printed directly on polymer substrate, then manufacturing simplicity is maintained, but print quality and surface compatibility deteriorate
Solution Approach 1:
The polymeric coating layer is applied to the substrate before printing the electronics. This preliminary action modifies the substrate surface properties to improve ink reception, surface smoothness, and overall print quality, while the coating process itself is designed to be compatible with existing manufacturing workflows.
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 results in lower resistivity and improved stability of printed conductors, with reduced solvent damage and blistering, enabling reliable performance under stretching and washing conditions.
Implementation Method 1
wherein the coating has been formed from either a solvent solution or a water-based dispersion
Implementation Method 2
depositing an elastic conductive ink on the coating and drying the elastic conductive ink to form the printed circuit
Data Source
AI summary
This invention is directed to substrates and articles utilizing these substrates that provide improved performance of printable electronics on polymer substrates. In particular, the improved substrates relate to polymer films and electrical conductors printed on them. Application of a thin polymeric coating to the polymer film provides the improved performance of the printed conductors.