Silicone Polymer Layer 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 containing embedded very fine metal traces, and an economical and ecological process for manufacturing such polymer layers.
Innovation Solution
A process involving applying a polymer layer on a substrate, thermally treating it, irradiating with an excimer laser, immersing in an autocatalytic bath for metallization, and covering with additional polymer layers to create a silicone-based polymer layer with embedded metal traces, using oxide particles like SiO2 and metals like platinum for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer layer is metallized to embed metal traces, then electrical conductivity and insulation properties are improved, but the manufacturing process complexity increases
Solution Approach 1:
The manufacturing process is divided into distinct sequential steps: applying the polymer layer, thermally treating it, irradiating with excimer laser, immersing in autocatalytic bath, and covering with additional polymer layers. This segmentation allows each step to be optimized independently while achieving the overall goal of embedded metal traces with high insulation properties.
Solution Approach 2:
An autocatalytic bath containing metal ions serves as an intermediary medium that enables the metal deposition process. The bath facilitates the transformation from polymer surface to metallized polymer by providing the necessary metal ions that deposit onto the irradiated polymer surface, simplifying the overall manufacturing process.
2Manufacturing precision
If excimer laser irradiation is applied to the polymer surface, then metal trace embedding is enabled, but energy consumption increases
Solution Approach 1:
The excimer laser irradiation is applied in a controlled, periodic manner to specific surface areas of the polymer layer. This selective periodic action enables metal trace embedding with high precision while minimizing overall energy consumption by activating the laser only where and when needed, rather than continuously or uniformly across the entire polymer surface.
3Strength
If multiple polymer layers are applied and thermally treated, then adhesion and protection of metallized layers are improved, but manufacturing time increases
Solution Approach 1:
The process applies additional polymer layers covering the metallized layers before final thermal treatment. This preliminary action of applying protective layers enables subsequent thermal treatment to enhance adhesion and protection without requiring extended processing time, as the layers are already in position to be bonded together through the thermal treatment step.
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 process results in a flexible, biocompatible polymer layer with embedded metal traces that provides high insulation and mechanical strength, while being economical and environmentally friendly, with improved adhesion and protection of the metallized layers.
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 relates to a method of embedding a metal trace in a silicone containing polymer layer, by the steps of applying an agent that does not adhere to a substrate; applying a polymer layer on the non adhering agent; irradiating a surface of the polymer with a light beam emitted by an excimer laser creating cuts, grooves, blind holes or vias; immersing the irradiated polymer in an autocatalytic bath containing metal ions and metallizing the polymer; thermally treating the metallized polymer layer to induce diffusion of the metalized metal into the first polymer layer; applying a polymer layer on the thermally treated metallized polymer; and thermally treating the metallized polymer.