Stretchable Electrical Interconnect Curved Wall Design

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Solution Overview

Problem

Existing methods for manufacturing curved electronics face challenges in achieving long-term performance, industrial scalability, and minimizing mechanical stress, while maintaining stretchability and durability.

Innovation Solution

The development of a stretchable electrical interconnect with a curved wall that is stretchable lengthwise, featuring a height extending perpendicularly to its plane, allowing connection to electronic devices and conformability to curved surfaces. This interconnect is integrated into a flexible electronic system fabricated using a silicon-based MEMS process, with polymer and metal layers ensuring flexibility and conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If inherently stretchable materials are used to achieve stretchability, then the stretchability is improved, but the conductivity deteriorates

Engineering Contradiction:

ImprovestretchabilityVSAvoidconductivity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs composite material structures combining elastomeric substrates with metallic interconnect layers. The metallic layers provide high conductivity while the elastomeric substrate provides stretchability. This composite approach resolves the contradiction by integrating materials with complementary properties rather than relying on inherently stretchable materials alone.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes serpentine and wavy geometric patterns for the interconnect structures. These curved, non-linear pathways allow the interconnect to stretch and deform elastically while maintaining electrical continuity. The curved geometry enables the conductive path to accommodate strain without breaking, resolving the contradiction between stretchability and conductivity maintenance.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Adaptability or versatility

If structural designs like wavy or serpentine shapes are used to provide flexibility, then the stretchability is improved, but mechanical stress is introduced

Engineering Contradiction:

ImproveflexibilityVSAvoidmechanical stress

Core Design Contradiction:

Adaptability or versatilityVSStress or pressure

Solution Approach 1:

The patent employs thin-film metallic layers deposited on flexible elastomeric substrates. These thin-film structures inherently possess flexibility and can deform without generating excessive stress. The thin-film nature allows the interconnect to bend and stretch while distributing mechanical stress across the entire structure, preventing stress concentration that would lead to failure.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent designs the interconnect structure to dynamically adapt its geometry during deformation. The serpentine patterns are engineered to unfold and redistribute strain during stretching, and the structure returns to its original configuration when relaxed. This dynamic behavior allows the interconnect to accommodate mechanical stress reversibly, preventing permanent deformation or failure.

Inventive Principle:

Principle #15Dynamics

3Shape

If pre-stretching elastomers or conformal additive stamping is used to transform planar devices into curved forms, then the curved form is achieved, but material fatigue or location distortion occurs

Engineering Contradiction:

Improvecurved formVSAvoidmaterial fatigue

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent incorporates pre-stretching of the elastomeric substrate during the fabrication process itself, before final device assembly. By pre-programming the substrate geometry with embedded stretch zones and using conformal stamping techniques during manufacturing, the device is transformed into its final curved configuration without requiring post-fabrication stretching that would cause fatigue. The preliminary action is built into the fabrication process, preventing subsequent material fatigue.

Inventive Principle:

Principle #10Preliminary action

4Shape

If origami-based methods are used to fold 2D tessellations into 3D shapes, then the 3D shape is achieved, but undesirable angles and restricted application scenarios result

Engineering Contradiction:

Improve3D shapeVSAvoidapplication scenarios

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The patent transitions from traditional 2D planar interconnects to 3D vertically-curved interconnect structures. By adding the vertical dimension with curved walls extending perpendicular to the substrate plane, the interconnect can achieve complex 3D configurations that accommodate various application scenarios. This dimensional transition allows the interconnect to wrap around objects and conform to three-dimensional surfaces, greatly expanding applicability beyond flat surfaces.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250136435A1Stretchable electrical interconnect, flexible electronic system, and fabrication method thereof

Publication Date: 2025.05.01 THE HONG KONG UNIV OF SCI & TECH

AI summary

A stretchable electrical interconnect comprises: a curved wall that is stretchable lengthwise towards two ends of the curved wall, wherein the curved wall has a height that extends perpendicularly to a plane in which the two ends of the curved wall extend, and wherein the two ends of the curved wall are configured to be connectable to one or more electronic devices.