Stretchable Circuit Board Manufacturing Yield via Heat-Press Joining

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing stretchable circuit boards face challenges in positioning external terminals and stretchable wiring, leading to reduced manufacturing yield and increased complexity, particularly in the context of biological sensors where disposability and high-volume production are desired.

Innovation Solution

A method involving the formation of terminal and stretchable wiring portions on separate sheet members with differing stretchability, where the terminal portion is formed on a less stretchable film base and the stretchable wiring on a highly stretchable base, with the two being connected through positioning and application of pressure and heat to facilitate a seamless, electrically conductive joint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If external terminals and stretchable wiring are formed in separate steps and positioned to be connected, then electrical connection is achieved, but positioning difficulty reduces manufacturing yield

Engineering Contradiction:

Improveelectrical connectionVSAvoidpositioning accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent merges the formation of external terminals and stretchable wiring into a single integrated process. Both are formed on the same stretchable circuit board in one manufacturing step, eliminating the separate positioning and connection steps. This integration ensures automatic alignment and electrical connection without requiring precise manual or automated positioning, thereby resolving the contradiction between achieving electrical connection and maintaining manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary action by pre-forming both the external terminals and stretchable wiring on the same substrate before any connection operation is needed. Since both elements are created in advance on the same stretchable circuit board, their relative positions are predetermined and fixed, eliminating the need for subsequent positioning operations and ensuring manufacturing precision is maintained.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If separate positioning and connection process is used for external terminal and stretchable wiring, then electrical connection is established, but process complexity increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple manufacturing steps (forming external terminals, forming stretchable wiring, positioning, and connection) into a single integrated process. Both external terminals and stretchable wiring are formed simultaneously on the same stretchable circuit board using the same manufacturing equipment and process conditions, thereby simplifying the overall manufacturing process and reducing complexity while ensuring reliable electrical connection.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If stretchable circuit board is made disposable for biological sensors, then hygiene and safety are improved, but manufacturing cost per unit increases

Engineering Contradiction:

Improvehygiene and safetyVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameters of the stretchable circuit board to enable disposable use. By selecting materials that are inherently biocompatible, sterilizable, and suitable for single-use applications, the board can be manufactured as a disposable component. This material parameter change allows the same manufacturing process to produce both durable and disposable versions, maintaining cost-effectiveness while meeting hygiene and safety requirements for biological sensors.

Inventive Principle:

Principle #35Parameter changes

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 approach simplifies the connection process, enhances manufacturing yield, and results in a stretchable circuit board suitable for biological sensors with improved accuracy and disposability, suitable for mass production.

Implementation Method 1

applying pressure and heat to the first sheet member and the second sheet member to join them

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 2

applying pressure and heat to the first sheet member and the second sheet member to join them

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS10194527B2Method for manufacturing stretchable circuit board and stretchable circuit board

Publication Date: 2019.01.29 MEKTEC CORPORATION

AI summary

[Problem] Provided is a method for manufacturing a stretchable circuit board, which can facilitate positioning of an external terminal and a stretchable wiring, and increase manufacturing yield of a stretchable circuit board.[Solving Mean] A stretchable circuit board is manufactured through: a step in which an external terminal 31 is formed on a main surface 33b located on one side of a film base 33; a step in which a stretchable wiring portion 55 is formed on a main surface 53a located on one side of a stretchable base 53; and a step in which the stretchable wiring portion 55 is positioned with the external terminal 31, and pressure and heat are applied to the film base 33 and the stretchable wiring portion 55 to join them, whereby the external terminal 31 and the stretchable wiring portion 55 are connected with each other.