Silicone Polymer With Embedded Metal Traces
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Solution Overview
Problem
There is a need for a soft and biocompatible polymer layer with high insulation properties that contains embedded very fine metal traces, which existing technologies have not adequately addressed.
Innovation Solution
A polymer layer comprising silicone with embedded metal traces, manufactured using a process involving laser irradiation and electroless metallization, where the silicone layer is partially decomposed by an excimer laser and then immersed in a bath containing metal ions to form a metal film, ensuring selective metallization and strong adhesion of the metal traces within the silicone layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer layer contains embedded metal traces, then electrical conductivity is improved, but insulation properties deteriorate
Solution Approach 1:
The patent applies local quality by embedding metal traces only in specific localized areas rather than throughout the entire polymer layer. The metal traces are positioned at specific locations where electrical connectivity is needed, while the surrounding polymer matrix maintains its insulating properties. This selective placement allows the structure to have both conductive and insulating characteristics in different regions.
Solution Approach 2:
The patent creates a composite material structure combining polymer and metal traces. The polymer provides insulation and mechanical flexibility, while the embedded metal traces provide electrical conductivity. This composite approach allows the material to simultaneously exhibit both insulating and conductive properties depending on the spatial distribution of the metal traces within the polymer matrix.
2Reliability
If metal traces are embedded in polymer layer, then electrical connectivity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple manufacturing steps into a single integrated process. The polymer layer is formed, metal traces are deposited, and the traces are embedded all in one continuous manufacturing sequence rather than as separate discrete steps. This merging of operations simplifies the overall manufacturing complexity while achieving the desired electrical connectivity.
Solution Approach 2:
The patent applies preliminary action by forming the polymer layer structure before embedding the metal traces. The polymer matrix is prepared in advance with appropriate thickness and geometry, then metal traces are deposited and embedded in this pre-formed structure. This sequence allows for better control of trace embedding and reduces manufacturing complexity compared to forming traces first and then surrounding them with polymer.
3Manufacturing precision
If excimer laser is used to decompose silicone, then selective metallization is improved, but energy consumption increases
Solution Approach 1:
The excimer laser is used with local quality by focusing the laser beam on specific targeted areas of the silicone polymer rather than treating the entire surface. The laser energy is applied selectively to regions where metal trace embedding is required, leaving other areas of the polymer unchanged. This localized approach improves metallization precision while minimizing overall energy consumption.
Solution Approach 2:
The laser processing employs periodic action through pulsed laser irradiation rather than continuous exposure. The laser is activated in discrete pulses, allowing precise control of energy delivery to the silicone material. This periodic pulsing enables selective decomposition of the polymer in targeted areas while minimizing total energy consumption compared to continuous laser treatment.
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 provides a flexible and biocompatible polymer layer with embedded metal traces that offers high insulation properties and improved mechanical behavior, ensuring effective protection and integration of the metal traces within the silicone matrix.
Implementation Method 1
The first step consists of the irradiation of a surface area of a polymer piece to be metalized with a light beam emitted by an excimer laser. The polymer piece is made from a polymer material and oxide particles.
Implementation Method 2
The second step consists of immersing the irradiated polymer piece in at least one autocatalytic bath containing metal ions. The immersion induces the deposit of the metal ions onto the irradiated surface area to form a metal film on the surface area.
Implementation Method 3
The third step consists of thermally processing the metalized polymer piece to induce diffusion of the deposited metal film into the polymer material of the polymer piece.
Data Source
AI summary
The present invention provides a flexible electrode array, comprising a silicone containing body, at least one metal trace layer and at least one electrode pad on the surface.