Touch Control Device Laser-Formed Electrodes Adhesion Failure
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Solution Overview
Problem
Conventional touch control devices face issues with durability and economic losses due to the use of Flexible Printed Circuit Board (FPCB) electrodes, which are prone to adhesion failure under heat and vibration, and are expensive with significant waste during manufacturing.
Innovation Solution
A touch control device with electrodes formed without adhesion methods, using a base with pattern grooves and wire grooves created by laser processing, where conductive materials are plated or deposited directly onto metal seeds, eliminating the need for FPCB and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If FPCB electrodes are used to connect sensing patterns to sensor circuits, then electrical connection is achieved, but adhesion failure occurs under heat and vibration
Solution Approach 1:
The patent removes the FPCB intermediate layer entirely and directly forms conductive electrodes on the substrate using laser-induced forward transfer (LIFT) technology. This eliminates the adhesion interface that fails under heat and vibration, solving the reliability problem by extracting the problematic component from the system.
Solution Approach 2:
The patent replaces the mechanical adhesion-based FPCB connection system with a direct laser-formed conductive path system. The LIFT process creates metallurgical bonds and direct conductive traces that are inherently more resistant to thermal and mechanical stress than adhesive-based mechanical connections.
2Reliability
If FPCB is used for electrode connection, then electrical connectivity is provided, but significant material waste and economic loss occur
Solution Approach 1:
The patent extracts and eliminates the FPCB material from the manufacturing process entirely. By using direct laser writing to form conductive traces on the substrate, the system removes the need for expensive FPCB materials, thereby eliminating material waste and associated economic losses while maintaining electrical connectivity.
Solution Approach 2:
The patent employs a disposable-free approach by creating permanent, direct conductive paths through laser processing. This replaces the expensive, waste-generating FPCB with a more economical laser-formed conductive structure that requires no additional materials beyond the base substrate and conductive ink or metal layer.
3Shape
If FPCB is processed to fit injection molded product shape, then shape conformity is achieved, but adhesion falls off due to heat and vibration
Solution Approach 1:
The patent merges the electrode formation process directly with the substrate manufacturing by using laser-induced forward transfer to create conductive patterns in-situ on the injection molded product. This integration eliminates the separate FPCB attachment step, ensuring shape conformity while avoiding adhesion failures by making the electrodes an integral part of the substrate structure.
4Reliability
If conventional adhesion methods are used for electrode attachment, then electrode connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts and removes the complex multi-step adhesion process from the manufacturing workflow. By using direct laser writing to form electrodes, the system eliminates steps involving FPCB cutting, shaping, adhesive application, and curing, thereby reducing manufacturing complexity while ensuring reliable electrode attachment.
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 prevents waste and economic losses, improves durability by eliminating adhesion-related failures, and simplifies manufacturing, making the touch control device more reliable and cost-effective.
Implementation Method 1
a base with pattern grooves and wire grooves created by laser processing
Implementation Method 2
conductive materials are plated or deposited directly onto metal seeds
Data Source
AI summary
A touch control device includes a base including a metal complex; a sensing pattern formed in a pattern groove formed in a touch area of the base and including a conductive material; and a wire arranged in a wire groove outside of the touch area of the base and connecting the sensing pattern and an integrated circuit, the wire including a conductive material.