Shape Memory Resin Layers for Curved-Surface Wiring Protection

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Solution Overview

Problem

Flexible substrates with electrical elements face damage from stress caused by bending and stretching, necessitating measures to protect wiring lines.

Innovation Solution

Incorporation of a shape memory resin layer that allows the substrate to deform and attach to curved surfaces, providing protection and enabling repeated attachment and detachment while maintaining functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flexible substrates are bent and stretched to attach to curved surfaces, then adaptability is improved, but wiring lines are damaged by stress

Engineering Contradiction:
Improveadaptability to curved surfacesVSAvoidwiring line integrity
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The substrate is divided into multiple independent wiring lines that can meander independently. Each wiring line is segmented into multiple sections connected at angles, allowing individual lines to deform without transmitting stress across the entire substrate. This segmentation enables the substrate to conform to curved surfaces while protecting individual wiring lines from damage.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The wiring lines are designed with meander shapes and curved paths instead of straight lines. This curvature allows the wiring lines to flex and bend when the substrate is stretched or conform to curved surfaces, distributing mechanical stress along the curved path rather than creating concentrated stress points that would damage straight wiring lines.

Inventive Principle:
Principle #14Spheroidality (Curvature)

2Reliability

If wiring lines are made to meander to prevent damage, then reliability is improved, but area occupied by wiring increases

Engineering Contradiction:
Improvewiring line protectionVSAvoidsubstrate area
Core Design Contradiction:
ReliabilityVSArea of stationary object

Solution Approach 1:

The meander shape and buffering structures are applied locally only at critical stress points and wiring line intersections, rather than uniformly across the entire substrate. This localized application provides protection where needed while minimizing the overall area increase. The buffering structures are positioned specifically at corners and bending zones where stress concentration occurs.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies buffering structures and meander designs to only the portions of the substrate that require stress protection, rather than uniformly across the entire substrate. This partial application maintains wiring reliability in high-stress areas while minimizing the overall area occupation and maintaining substrate efficiency in low-stress regions.

Inventive Principle:
Principle #16Partial or excessive action

3Adaptability or versatility

If honeycomb-shaped openings are provided in the base material, then flexibility is improved, but structural strength decreases

Engineering Contradiction:
Improvesubstrate flexibilityVSAvoidbase material strength
Core Design Contradiction:
Adaptability or versatilityVSStrength

Solution Approach 1:

The substrate utilizes a thin film structure with controlled openings that maintains flexibility while providing sufficient structural support. The honeycomb-shaped openings are designed with specific geometry and distribution patterns that allow the thin film to bend and stretch without compromising overall structural integrity. The openings are positioned to align with stress distribution patterns, maintaining strength in critical load-bearing areas.

Inventive Principle:
Principle #30Flexible shells and thin films

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 shape memory resin layer enables flexible substrates to conform to curved surfaces, preventing damage and allowing for repeated use without overheating, thus enhancing durability and reliability.

Implementation Method 1

at least one of the first resin layer, the first portion and the second portion is a shape memory resin layer

Methodology Applied
Scientific EffectShape memory effect: Shape Memory Polymer

Data Source

PatentUS12453259B2Electronic device with shape memory resin
Publication Date: 2025.10.21 MAGNOLIA WHITE CORP
  • US12453259B2 patent drawing
  • US12453259B2 patent drawing
  • US12453259B2 patent drawing

AI summary

According to one embodiment, an electronic device, wherein a insulating base and a wiring line are located between a first resin layer and a second resin layer, the insulating base includes a plurality of line portions in which the wiring line is located, and a plurality of island-shaped portions connected to the plurality of line portions, the second resin layer includes a first portion overlapping the plurality of line portions and the plurality of island-shaped portions, and a second portion located between the plurality of line portions, the second portion is in contact with the first resin layer, and at least one of the first resin layer, the first portion and the second portion is a shape memory resin layer.