Thermal Conductive Strip Packaging with Broken Plastic Envelope

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for packaging thermal conductive strips with power supply terminals result in high rejection rates due to the terminals cutting or ripping the carbon fibers during clamping, and repeated bending causes further damage.

Innovation Solution

A method involving a plastic envelope with a broken portion that exposes the carbon fiber connecting end, allowing partial clamping and electrical contact with the power supply terminal, enhancing yield and durability by using a positioning and pulling mould to create a broken portion for secure clamping and electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the power supply terminal is directly clamped on the carbon fiber connecting section, then the packaging process is simple, but the terminal cuts the carbon fiber causing high rejection ratio

Engineering Contradiction:

Improvepackaging process simplicityVSAvoidyield rate

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The plastic envelope is pre-pulled to create an exposed section of the carbon fiber connecting end before the power supply terminal is attached. This preliminary action prepares the structure to avoid direct clamping on the carbon fiber, preventing cutting damage while maintaining packaging simplicity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plastic envelope acts as an intermediary between the power supply terminal and the carbon fiber connecting section. The terminal clamps on the plastic envelope rather than directly on the carbon fiber, preventing cutting damage while maintaining electrical connection through the exposed carbon fiber section

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the power supply terminal is directly clamped on the carbon fiber connecting section, then the packaging process is simple, but the carbon fiber is ripped off during repeated bending

Engineering Contradiction:

Improvepackaging process simplicityVSAvoidbending durability

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The plastic envelope is pre-pulled to create an exposed section of the carbon fiber connecting end before the power supply terminal is attached. This preliminary action creates a structure where the terminal clamps on plastic rather than carbon fiber, preventing ripping during repeated bending while maintaining packaging simplicity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plastic envelope serves as a mediator that protects the carbon fiber connecting section from mechanical stress during repeated bending. The terminal clamps on the plastic envelope which flexes without ripping the carbon fiber, while the exposed carbon fiber section maintains electrical connection

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If the plastic envelope fully encapsulates the carbon fiber connecting end, then the carbon fiber is protected, but the power supply terminal cannot make electrical contact

Engineering Contradiction:

Improvecarbon fiber protectionVSAvoidelectrical contact stability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The plastic envelope partially encapsulates the carbon fiber connecting end rather than fully encapsulating it. This partial action exposes a section of the carbon fiber for electrical contact while still providing protection for the majority of the connecting end, balancing protection and electrical connectivity

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The plastic envelope is segmented into an encapsulated portion and an exposed portion of the carbon fiber connecting end. This segmentation allows different sections to serve different functions: the encapsulated portion provides protection while the exposed portion enables electrical contact

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 approach improves the yield rate and bending durability of the thermal conductive strip by preventing direct clamping damage and ensuring stable electrical contact, allowing for effective heat production while minimizing resistance and heat accumulation.

Implementation Method 1

preparing carbon fibers 12; placing thermoplastic materials at two opposite sides of the carbon fiber; bonding the thermoplastic materials together by heating and rolling method to encapsulate the carbon fibers

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS10368400B2Method and package for packaging a thermal conductive strip with power supply terminals

Publication Date: 2019.07.30 TAIWAN TECH

AI summary

A thermal conductive strip with a power supply terminal includes: a carbon fiber unit including a carbon fiber connecting end; a plastic envelope which encapsulates the carbon fiber unit and has a length smaller than a length of the carbon fiber connecting end, and further includes a broken portion which covers a part of the carbon fiber connecting end; and the power supply terminal sleeved onto the broken portion and the carbon fiber connecting end, and including a clamping section for clamping the broken portion, and an electrically conductive section for contacting the carbon fiber connecting end. The power supply terminal is partially clamped on the plastic envelope and partially eclectically connected to the carbon fiber, which improves the yield rate and the bending durability of the thermal conductive strip of the present invention.