Silicone Polymer Metal Trace Embedding via Laser Metallization
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Solution Overview
Problem
There is a need for a soft and biocompatible polymer layer with high insulation properties containing embedded very fine metal traces, and an economical and ecological process for manufacturing such polymer layers.
Innovation Solution
A method involving applying a polymer layer on a substrate, thermal treatment, irradiation with an excimer laser, immersion in an autocatalytic bath for metallization, and additional thermal treatment, followed by applying a protective polymer layer to encapsulate the metallized traces, using an excimer laser to create precise metal traces within a silicone polymer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal traces are embedded in polymer layer, then insulation properties are improved, but manufacturing complexity increases
Solution Approach 1:
The polymer layer is applied and thermally treated before laser irradiation and metallization. This preliminary preparation ensures the polymer is in the optimal state for subsequent metal trace embedding, simplifying the overall process by preparing materials in advance rather than during complex multi-step operations
Solution Approach 2:
The patent replaces complex mechanical metallization processes with laser-based irradiation followed by autocatalytic bath immersion. This substitution of mechanical/chemical processes with optical and chemical reactions simplifies the manufacturing process while achieving reliable metal trace embedding for high insulation properties
2Manufacturing precision
If excimer laser irradiation is applied to polymer surface, then metal trace precision is improved, but energy consumption increases
Solution Approach 1:
The excimer laser is applied in a controlled, periodic manner through the autocatalytic bath immersion process. The laser irradiation is performed in specific cycles during the metallization process, optimizing energy usage while maintaining precise metal trace formation. The periodic application allows efficient energy transfer during the chemical reaction window without excessive energy consumption
Solution Approach 2:
The patent optimizes laser parameters (wavelength, pulse duration, energy density) specifically for excimer laser operation on polymer surfaces. By changing and optimizing these parameters, the process achieves high metal trace precision while minimizing energy consumption, as the laser is tuned to the optimal settings for the specific material and process requirements
3Reliability
If multiple thermal treatments are applied to polymer, then biocompatibility is improved, but processing time increases
Solution Approach 1:
The polymer layer undergoes thermal treatment in advance before laser irradiation and metallization. This preliminary thermal preparation optimizes the polymer structure for subsequent processing steps and enhances biocompatibility, while the timing of this step allows it to be integrated into the overall process flow efficiently rather than adding excessive time
Solution Approach 2:
The thermal treatments are sequenced continuously with the laser irradiation and metallization steps. Rather than isolating thermal treatment as a separate time-consuming operation, the process maintains continuous useful action where thermal treatment prepares the polymer for the next step, and subsequent steps build upon the thermal treatment effects, reducing total processing time while maintaining biocompatibility
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 method effectively embeds metal traces in a silicone polymer, ensuring biocompatibility and high insulation properties while providing an economical and ecological manufacturing process, resulting in a fully protected and functionalized polymer layer.
Implementation Method 1
irradiating at least one surface area of the polymer with a light beam emitted by an excimer laser
Implementation Method 2
immersing the irradiated polymer in at least one autocatalytic bath containing ions of at least one metal, and metallizing the polymer
Implementation Method 3
thermally treating the polymer; thermally treating the metallized polymer
Data Source
AI summary
The invention is a method of making a flexible electrode array, comprising a silicone containing body, a metal trace layer and an electrode pad on the surface, including the steps of irradiating a surface area of a molded silicone containing layer yielding traces with the light beam from a pulsed ultraviolet laser source; immersing said irradiated molded silicone layer for inducing the deposit of metal ions to form metal traces; applying a silicone containing layer on the silicone containing layer and the metal traces; irradiating the surface for drilling holes in the molded silicone containing layer; and immersing the irradiated molded silicone layer for inducing the deposit of metal ions to form metal electrode pads.