Slit Substrate Layout for Curved-Surface Electronic Reliability
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Solution Overview
Problem
Conventional electronic devices using flexible printed circuit substrates suffer reliability issues when bent to follow non-developable curved surfaces due to the formation of pleated structures and bent wiring.
Innovation Solution
The solution involves forming slits on the substrate orthogonal to the gradient vectors of the curved surface and arranging devices at equal intervals, with wiring also oriented orthogonally to the gradient vectors, and encapsulating in a silicone elastomer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a flat substrate is bent to follow a non-developable curved surface, then the substrate can conform to the curved surface shape, but pleated structures are formed and wiring is bent, deteriorating reliability
Solution Approach 1:
The substrate is divided into multiple regions by forming slits that extend in directions substantially orthogonal to gradient vectors of the curved surface. This segmentation allows each region to independently adapt to the curved surface geometry, preventing the formation of pleated structures while maintaining overall shape conformance.
Solution Approach 2:
The slit directions are locally optimized at each point on the substrate based on the gradient vectors of the curved surface. By making the slit orientation position-dependent (orthogonal to local gradient vectors), the substrate achieves uniform adaptation across the entire curved surface, preventing localized pleating and wiring deformation.
2Reliability
If slits are formed on the substrate, then pleated structures are prevented when bent, but the substrate structure becomes more complex
Solution Approach 1:
The slit parameters (direction and position) are systematically determined by the gradient vectors of the curved surface. By using the gradient vector field as a guiding parameter, the complex pattern of slits can be automatically generated and optimized, making the complexity manageable through mathematical description rather than arbitrary design.
Data Source
AI summary
An electronic device including a plurality of devices, wiring electrically connecting each of the devices, and a substrate on which the wiring is formed and a slit is formed.