Stretchable Flexible Substrate Curved Wiring Stress Distribution
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Solution Overview
Problem
Conventional flexible substrates face challenges in achieving sufficient stretchability due to stress concentration at bent wiring portions, limited production methods, and difficulties in precise mounting of electronic components, especially in wearable devices that require flexibility and stretchability to fit human body contours.
Innovation Solution
A stretchable flexible substrate design featuring a central electronic component surrounded by a first insulating layer, a first metal layer, a second metal layer, and a second insulating layer, with curved wiring portions that distribute stress and allow for increased stretchability, and a production method involving a precursor member with a curved insulating layer and metal layer patterning to ensure secure and flexible connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional flexible substrates use bent wiring portions to achieve flexibility, then the substrate can bend, but stress concentrates at the bent portions causing wire breakage
Solution Approach 1:
The patent replaces conventional bent wiring portions with curved wiring portions that have smooth continuous curvature. This curvature design distributes stress along the entire curved path rather than concentrating it at discrete bend points, allowing the substrate to flex while preventing wire breakage through stress distribution.
Solution Approach 2:
The curved wiring portions are designed to dynamically adapt their stress distribution during flexing operations. As the substrate bends, the curved wiring portions redistribute mechanical stress along their length, transforming static stress concentration points into dynamic stress distribution paths that prevent failure.
2Ease of operation
If conventional flexible substrates use simple bending structures, then the substrate achieves flexibility, but stretchability is insufficient for wearable devices
Solution Approach 1:
The curved wiring portions with continuous curvature enable the substrate to accommodate both bending and stretching deformations. The curved geometry allows the wiring to elongate and redistribute stress during stretching, providing the enhanced adaptability needed for wearable devices that must conform to moving body parts.
Solution Approach 2:
The patent changes the geometric parameters of the wiring portions from simple bends to curved configurations with specific radius and length parameters. This parameter optimization enables the substrate to achieve both flexibility for bending and stretchability for wearable applications.
3Reliability
If conventional substrates use high-temperature resistant materials for durability, then reliability improves, but the substrate loses flexibility and stretchability
Solution Approach 1:
The patent employs thin film structures for the wiring portions that provide both mechanical durability and flexibility. The curved wiring portions are designed as thin films that can withstand mechanical stress while maintaining the flexibility and stretchability required for wearable devices, eliminating the need for high-temperature resistant rigid materials.
Data Source
AI summary
A stretchable flexible substrate according to one aspect of the present disclosure includes: an electronic component; a first insulating layer located around the electronic component and having first and second main surfaces facing each other; a first metal layer that is in contact with the first main surface; a second metal layer that is in contact with the second main surface and electrically connected to the electronic component; and a second insulating layer that seals the electronic component, first insulating layer, and second metal layer, in plan view, a curved wiring portion extending from a central portion made up of at least the electronic component, portions of the first insulating layer and first and second metal layers, the curved wiring portion being made up of at least other portions of the first insulating layer, first and second metal layers, and the curved wiring portion being curved at least partially.