Stretchable Wiring Member Extension Layer Stress Distribution

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Solution Overview

Problem

Wearable devices with stretchable wiring members face issues due to stress concentration at the boundary between hard contact points and flexible substrates, leading to potential detachment and breakage of electroconductive wires, which existing reinforcement methods cannot adequately address without increasing size and thickness.

Innovation Solution

Incorporating an extension layer between the hard member and the stretchable wiring line on a flexible substrate, which acts as a buffer to distribute stress and prevent breakage, allowing the wiring line to stretch from the extension layer rather than abruptly at the hard member's edge, thereby reducing the risk of detachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a reinforcement member is disposed to prevent wire breakage at the boundary, then the reliability is improved, but the area and thickness increase

Engineering Contradiction:
Improvewire breakage resistanceVSAvoidarea for fixation
Core Design Contradiction:
ReliabilityVSArea of stationary object

Solution Approach 1:

The patent introduces an extension layer as an intermediary component between the hard member and the stretchable wiring line. This extension layer acts as a buffer that gradually transitions the mechanical properties from the hard member to the flexible substrate, distributing stress over a larger area and preventing stress concentration at the boundary. The extension layer has a thickness that is larger than that of the stretchable wiring line, creating a gradual transition zone that prevents abrupt stress changes and wire breakage without requiring additional reinforcement members.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Device complexity

If the stretchable wiring line is directly connected to the hard member, then the device complexity is reduced, but the stress concentration causes wire breakage

Engineering Contradiction:
Improvestructure simplicityVSAvoidwire breakage resistance
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent segments the boundary region between the hard member and the flexible substrate by introducing the extension layer. This segmentation creates distinct functional zones: the hard member provides structural support, the extension layer provides stress distribution and gradual transition, and the stretchable wiring line provides electrical connectivity. By dividing the boundary region into these segments, the patent prevents stress concentration while maintaining a relatively simple overall structure without requiring complex reinforcement members.

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

This configuration effectively prevents the stretchable wiring line from breaking at the boundary with the hard member, allowing for flexible stretching without the need for additional reinforcement members, thus maintaining the device's compact size and preventing wire detachment.

Implementation Method 1

providing the extension layer portion between the hard member and the stretchable wiring line causes the flexible substrate to start to stretch from the extension layer portion laminated on the hard member. As a result, the stretch of the flexible substrate does not start abruptly at the peripheral edge of the hard member but starts from a portion laminated on the hard member, which can reduce the stress concentrated on the stretchable wiring line at the boundary

Methodology Applied
Scientific EffectStress distribution:

Implementation Method 2

a flexible substrate having stretchability, a stretchable wiring line disposed along the flexible substrate and configured to be stretched in association with stretching deformation of the flexible substrate

Methodology Applied
Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11596061B2Stretchable wiring member
Publication Date: 2023.02.28 SEKISUI POLYMATECH CO LTD
  • US11596061B2 patent drawing
  • US11596061B2 patent drawing
  • US11596061B2 patent drawing

AI summary

In a stretchable wiring member having a relatively hard portion, such as a contact point, there is provided a solution to malfunction of the stretchable wiring member caused by stress generated at a boundary between the hard portion and a flexible portion. A stretchable wiring member includes a flexible substrate having stretchability, a stretchable wiring line disposed along the flexible substrate and configured to be stretched in association with stretching deformation of the flexible substrate, and a hard member that is harder than the flexible substrate. The flexible substrate has an extension layer portion interposed between the hard member and the stretchable wiring line.