Stretchable Transparent Conductor for Vehicle Lighting Heaters

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Solution Overview

Problem

Existing methods for forming transparent conductive layers on curved surfaces, such as those used in display devices and car lights, face challenges including high cost, low productivity, and visibility issues due to thick conductive wires, as well as inefficiencies in heat generation and uniformity on curved surfaces.

Innovation Solution

A method involving the use of a transparent substrate with a stretchable conductive layer formed by randomly dispersed metal nanomaterials or carbon nanotubes, and thin metal wires with a silver salt emulsion layer, which maintains electrical resistance and transparency even when stretched, allowing for efficient heat generation and uniformity on curved surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick uniform transparent conductive layer is formed to achieve low resistance, then electrical conductivity is improved, but light transmittance deteriorates and cost increases

Engineering Contradiction:
Improveelectrical conductivityVSAvoidlight transmittance
Core Design Contradiction:
ReliabilityVSIllumination intensity

Solution Approach 1:

The patent divides the conductive layer into a network pattern of thin conductive lines rather than a continuous thick layer. This segmentation maintains electrical conductivity through the interconnected network while preserving light transmittance in the spaces between the lines, resolving the contradiction between conductivity and light transmission.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent uses composite materials by combining transparent conductive materials (such as ITO, IZO, or FTO) with transparent resin materials in a layered structure. This composite approach allows the conductive layer to achieve low resistance through the network pattern while the transparent resin maintains overall light transmittance and provides mechanical flexibility.

Inventive Principle:
Principle #40Composite materials

2Reliability

If vapor deposition or sputtering methods are used to form conductive metal layers, then conductivity is improved, but productivity deteriorates and material loss increases

Engineering Contradiction:
Improveelectrical conductivityVSAvoidproduction efficiency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent replaces complex vapor deposition or sputtering processes with simpler coating methods such as solution coating, spray coating, or printing techniques. This substitution maintains conductivity by depositing conductive material in a network pattern while dramatically improving productivity and reducing material loss through more efficient deposition processes.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the formation parameters by using lower temperature processing and simpler deposition methods instead of high-energy vapor deposition. This allows the conductive network to be formed with standard coating equipment, improving productivity while maintaining the required electrical conductivity through optimized network density and material composition.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If conductive metal buslines are formed on the transparent electrode layer, then conductivity is improved, but device complexity and cost increase

Engineering Contradiction:
Improveelectrical conductivityVSAvoidnumber of processes
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the conductive network formation with the transparent electrode layer deposition into a single integrated process. The conductive network is formed directly on the transparent substrate in one coating or printing step, eliminating the need for separate busline formation processes and reducing overall device complexity while maintaining conductivity.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a multi-functional transparent electrode layer that simultaneously provides both the transparent conductive function and the conductive network function. This universal layer eliminates the need for separate conductive buslines and additional processing steps, reducing device complexity and manufacturing cost while maintaining electrical conductivity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Power

If thick conductive wires are used in the heat generator, then heat generation capability is improved, but visibility deteriorates

Engineering Contradiction:
Improveheat generation capabilityVSAvoidvisibility
Core Design Contradiction:
PowerVSIllumination intensity

Solution Approach 1:

The patent uses thin film conductive materials arranged in a network pattern instead of thick wires. This thin film approach maintains heat generation capability through the distributed network structure while preserving visibility and transparency, as the thin conductive lines and spaces between them allow light to pass through effectively.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The patent segments the conductive material into a network of thin lines rather than using continuous thick wires. This segmentation maintains the total conductive cross-section for heat generation while creating transparent spaces between the lines that preserve visibility, resolving the contradiction between heat generation capability and visibility.

Inventive Principle:
Principle #1Segmentation

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 solution enables the formation of a substantially transparent conductor on curved surfaces without wire breaking, improving conductivity and heat generation uniformity while reducing costs, and can be applied to various applications including car lights and display devices.

Implementation Method 1

a transparent heat generator excellent in visibility and heat generation

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the transparent conductor maintains the relationship: Ra≦(2×R0) when stretched by 5%

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentUS8940386B2Formed body with curved surface shape, method of producing the formed body, front cover for vehicle lighting device, and method of producing the front cover
Publication Date: 2015.01.27 FUJIFILM CORP
  • US8940386B2 patent drawing
  • US8940386B2 patent drawing
  • US8940386B2 patent drawing

AI summary

A formed body having a curved surface, a method of producing the formed body, a front cover for a vehicle lighting device, and a method of producing the front cover. A front cover for a vehicle lighting device, mounted to a front opening in a vehicle lighting device having a lamp body and a light source which is provided in the lamp body, wherein a heat generating body is provided in a substantially rectangular region of that surface of the front cover which faces the light source. The heat generating body maintains the relationship of Ra =(2 R0), where R0 is the electric resistance value (initial value) of the heat generating body before the heat generating body is elongated and Ra is the electric resistance value of the heat generating body after the heat generating body is elongated 5%.