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WO2024253658A1 - Procédé de production d'une feuille souple étirable comprenant un circuit flexible - Google Patents

Procédé de production d'une feuille souple étirable comprenant un circuit flexible Download PDF

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Publication number
WO2024253658A1
WO2024253658A1 PCT/US2023/024842 US2023024842W WO2024253658A1 WO 2024253658 A1 WO2024253658 A1 WO 2024253658A1 US 2023024842 W US2023024842 W US 2023024842W WO 2024253658 A1 WO2024253658 A1 WO 2024253658A1
Authority
WO
WIPO (PCT)
Prior art keywords
circuitry
lines
sheet
planar
trace
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2023/024842
Other languages
English (en)
Inventor
Ezgi UCAR
Madison MAXEY
Ginette Lu
Hannah Kim
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Loomia Technologies Inc
Original Assignee
Loomia Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Loomia Technologies Inc filed Critical Loomia Technologies Inc
Priority to PCT/US2023/024842 priority Critical patent/WO2024253658A1/fr
Publication of WO2024253658A1 publication Critical patent/WO2024253658A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03K—PULSE TECHNIQUE
    • H03K17/00—Electronic switching or gating, i.e. not by contact-making and –breaking
    • H03K17/94—Electronic switching or gating, i.e. not by contact-making and –breaking characterised by the way in which the control signals are generated
    • H03K17/96—Touch switches
    • H03K17/962—Capacitive touch switches
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/02—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding
    • H05K3/04—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding the conductive material being removed mechanically, e.g. by punching
    • H05K3/046—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding the conductive material being removed mechanically, e.g. by punching by selective transfer or selective detachment of a conductive layer
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03K—PULSE TECHNIQUE
    • H03K17/00—Electronic switching or gating, i.e. not by contact-making and –breaking
    • H03K17/94—Electronic switching or gating, i.e. not by contact-making and –breaking characterised by the way in which the control signals are generated
    • H03K17/96—Touch switches
    • H03K2017/9602—Touch switches characterised by the type or shape of the sensing electrodes
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/0277—Bendability or stretchability details
    • H05K1/0283—Stretchable printed circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/03—Use of materials for the substrate
    • H05K1/0393—Flexible materials

Definitions

  • the present invention relates to a method for producing a laminated sheet comprising a soft and flexible structure having an electronic circuit. More particularly, the invention pertains to a method for manufacturing of an electrically conductive laminated sheet which is stretchable in one or multiple directions and having a specific circuitry which supports a range of functionalties such as heating, capacitive touch sensing and cabling, and making itsuitable for applications that require electronic functionality on special surfaces.
  • the invention provides also a flexible circuit for use in the method of the present invention.
  • Background of the Invention Electric heating is used in a range of industries such as medical and automotive to bring comfort or therapy to patients and passengers. In many of these applications, it is desirable to have a heating element integrated easily into a textile. For example, in the automotive industry, one may have the desire to heat a steering wheel with a soft, flexible circuit layer that can be easily wrapped around the steering wheel. It is a requirement for many of these applications that the heating element can have 2-way or 4-way stretch of up to 50% and that the heating element can be easily integrated using bonding or sewing into the substrate good. These requirements make traditional flexible electronics and wire-based heating methods unsatisfactory for many applications.
  • WO 2014/184743 discloses a combination heater and sensor comprising: a heating layer and a sensing layer wherein the heating layer is a nonwoven layer that is comprised of a plurality of metallized fibers.
  • the combined system suggested herein can be implemented in a seat or steering wheel of a vehicle, but it relies only on a serpentine trace for stretchability, not the combination of trace patterning and a stretchable carrier, and it requires multiple layers of circuitry in order to achieve heating and sensing together, which inhibits mechanical properties.
  • flexible materials comprising heating elements, cabling and antenna (for capacitive touch sensing, for example) have certain limitations in creating a very thin, flexible and stretchable circuit that is soft in nature.
  • the present invention solves existing drawbacks of the prior art with a method for producing a hybrid product comprising a polymeric film layer and a patterned conductive sheet featuring a heating circuitry according to the appended claims.
  • Summary of the Invention The present invention relates to a method for producing an electrically conductive laminated sheet having a flexible circuit comprising provision of a flexible circuit comprising a planar circuitry sheet (2) having a circuitry trace (1) placed in between dielectric layers made of polymeric films having a preferable stretchability between 10% and 60%, more preferably between 20% and 50%, and most preferably between 30% and 50%.
  • the circuitry trace (1) comprises conductive lines (11) that can be patterned to function as a resistive heater, anteanna, capacitive touch sensor, or cables of the conductor tuned by the circuit design.
  • the circuitry trace (1) for supporting heating and/or capacitive touch sensing is designed to have a pulse wave form having elongated lines (111) corresponding to pulse amplitude and extending in vertical direction (y), and shorter lines (112) corresponding to pulse length and extending in horizontal direction (x).
  • Each wave consists of two elongated lines (111) arranged substantially parallel to eachother and one shorter line (112) perpendicular to the neighbouring elongated lines 2 33033/002/4370661.1 Int’l PCT Patent Application A ttorney Ref: 33033-002-PCT (111).
  • the elongated lines (111) forming the waves in outermost edge of the circuitry trace (1) have advantageously a bending portion (20) whereby a horizontally elongated line (201) extending in horizontal direction (x) is connected with said elongated line (111), and said horizontally elongated line (201) extends inwardly between the borderlines (A, A’) forming the outermost edges of the circuitry trace (1).
  • Figure 1 presents a circuitry trace produced, according to the method of the present invention.
  • Figure 2 shows the circuitry trace according to another embodiment of the present invention.
  • Soft and flexible sheets containing electronic circuits for a range of applications such as heating and sensing properties are known in the art.
  • sheets may provide multiple functionalities such as a combination of capacitive touch sensor and heating which inherently produces heat by virtue of resistors which can also be used as an antenna for capacitive touch sensing.
  • the circuit produces an electric field through an antenna (which can double as a heater) whereby an object (i.e.
  • a method for producing an electrically conductive laminated sheet having a flexible circuit comprising the steps of: - providing a planar carrier sheet made of a polymeric film, - printing a desired circuit pattern with adhesive onto the polymeric film by using a screen, - sheeting of a flexible circuit comprising a planar circuitry sheet (2) having a circuitry trace (1) and placing the same onto the polymeric film so that it overlays the surface of the film and lays on top of the screened adhesive, said circuitry trace (1) may comprise conductive lines (11) with resistance forming resistors for producing heat, capacitive sensing means for activating resistors, and/or electrodes connected to the conductive lines (11) of the
  • the conductive lines (11) of the circuitry trace (1) in between the polymeric planar carrier sheet and the polymeric top layer is inherently configured to function as the capacitive sensing means because the polymeric layers behave as dielectric (i.e., insulating) layers. Therefore, a control circuitry can be provided for receiving electrical signals received from the circuitry trace (1) and producing a control signal for controlling supply of electricity to the circuitry trace (1). For this purpose, the control circuitry is calibrated so that electrically conductive laminated sheet is made sensitive to a desired electromagnetic field threshold signal.
  • the polymeric film used in the planar carrier sheet and the top layer as mentioned hereinabove is a dielectric material advantageously stretchable in multiple directions according to the objectives of the invention.
  • the polymer material mentioned herein is selected from the group consisting of polyethylene terephthalate (PET), polyimide (PI), polyetherimide (PEI), polyethylene naphthalate (PEN), polyoxymethylene (POM), polyamide (PA), polyphthalamide (PPA), polyether ether ketone (PEEK), thermoplastic olefins (TPO), silicone and polyurethane (PU).
  • PET polyethylene terephthalate
  • PI polyimide
  • PEI polyetherimide
  • PEN polyethylene naphthalate
  • POM polyoxymethylene
  • PA polyamide
  • PPA polyphthalamide
  • PEEK polyether ether ketone
  • TPO thermoplastic olefins
  • silicone and polyurethane (PU) silicone and polyurethane
  • PU polyurethane
  • the polymer material is most preferably thermoplastic polyurethane (TPU) which is highly stretchable and flexible being also suitable for use in automotive.
  • the top layer polymeric film in any case, is selected as a dielectric polymeric film that is heat sealed to 4 33033/002/4370661.1 Int’l PCT Patent Application A ttorney Ref: 33033-002-PCT close the layer with auxiliary electronic components and circuitry.
  • the film may be hot melt, or have an adhesive layer inside.
  • Application of the desired circuit pattern with adhesive onto the planar carrier sheet by using a screen and masking is advantageous because of the controlled usage of the adhesive. Otherwise, without masking, excessive adhesive reduces stretchability and flexibility of the polymeric film. It is also noted that applying the adhesive to the planar circuitry sheet (2) and then bonding it with the planar carrier sheet causes irregularities in the polymeric film and limited stretchability of the planar circuitry sheet (2).
  • the planar circuitry sheet (2) of the flexible circuit is preferably a conductive fabric or conductive textile which may have a polymeric core material that is woven or knit.
  • This material is preferably electroplated with an electrically conductive material such as copper and/or nickel. Deposition of copper and/or nickel by electroplating is advantageous because of the highly intense and homogenous conductivity which is substantially not affected by the stretching forces in any direction. This also alleviates the drawbacks of the alternative techniques such as conductive ink which generally require more conductive and expensive material such as silver.
  • the adhesive used in the method mentioned above is preferable curable with UV.
  • the adhesive may have been pre-applied by lining covered with a mask in a ready to use form such that the mask is removed just before bonding with the planar circuitry sheet (2).
  • Cutting of the planar circuitry sheet for removing the material not bonded by the adhesive can be carried out by kiss cutting which can be advantageously automatized and carry out a sensitive cutting without deteriorating the circuit.
  • the auxiliary electronic components added to the circuit include any desired component such as terminations, wires, PCBs, switches and control circuitry necessary for the control and power supply to the flexible circuitry.
  • the auxiliary electronic components may include also an illumination means such as LED either for indication of functionality of heating, solely for lighting the environment or a combination thereof.
  • the illumination means can be located in an appropriate area of the electrically conductive laminated sheet such that when the user approaches or touches a particular area on the electrically conductive sheet, illumination means are activated.
  • a control circuitry for this purpose is designed and placed into the electrically conductive laminated sheet.
  • the auxiliary electronic components can be fixed to the 5 33033/002/4370661.1 Int’l PCT Patent Application A ttorney Ref: 33033-002-PCT electrically conductive laminated sheet by using electrically conductive or non-conductive adhesive or epoxy.
  • the electrically conductive laminated sheet according to the present invention can be formed with a multi-layer circuit by repetition of the sheeting step whereby a further planar circuitry sheet is laminated to the initial planar circuitry sheet (2).
  • the circuit is designed to allow maximum stretchability while providing sufficient durability and circuit intensity per area.
  • a serpentine pattern for obtaining stretch within a heating element of the circuitry consists of a sinusoidal wave shape that either snakes around a volume, or is connected by parallel bars to create several heating lines (i.e. resistors) in parallel.
  • This technique is not suitable for this method of making a soft, flexible circuit from conductive fabric because it may not adequately fill space and trace-width for kiss cutting which results in wider conductive traces that require different space filling approaches.
  • This invention improves on this approach with a more angular “space filling” approach to circuit design.
  • a circuitry trace (1) is provided with electrically cunductive lines (11) and regions (12) for a plurality of electrodes according to an embodiment of the present invention.
  • the conductive line (11) is configured to form a pulse wave form, more particularly a rectangular pulse wave form having elongated lines (111) corresponding to pulse amplitude and extending in vertical direction (y) and shorter lines (112) corresponding to pulse length extending in horizontal direction (x).
  • the shorter lines (112) are substantially perpendicular to the elongated lines (111) and said elongated lines (111) are arranged in a row being substantially parallel to eachother so that a plurality of waves can be formed in a row extending in horizontal direction (x) in order to ensure stretchability in that direction (x).
  • Each wave consists of two elongated lines (111) arranged substantially parallel to eachother and one 6 33033/002/4370661.1 Int’l PCT Patent Application A ttorney Ref: 33033-002-PCT shorter line (112) perpendicular to the neighbouring elongated lines (111).
  • the elongated lines (111) are arranged to have a length much more than the shorter lines (112) (e.g. at least two fold), and width (w) of the conductive lines (11) ranges from 0.05" to 3" (1.27 mm to 76.20 mm).
  • At least one of the elongated lines (111) forming the waves in outermost edge of the circuitry trace (1) has a bending portion (20) whereby a horizontally elongated line (201) extending in horizantal direction (x) is connected with said elongated line (111).
  • the horizontally elongated line (201) extends inwardly between the borderlines (A, A’) forming the outermost edges of the circuitry trace (1).
  • the horizontally elongated line (201) extends in the direction of the waves and in an area thereunder.
  • the length of the horizontally elongated line (201) is much more than the length of the shorter lines (112).
  • the ratio of the length of the horizontally elongated line (201) to the length of the shorter lines (112) ranges from 1.5 to 50, more preferably from 2 to 20 and most preferably from 2 to 10.
  • Horizontally elongated line (201) is preferably a straight line but it can also be a curved line terminating at an electrode (not shown). With the foregoing arrangement, stretchability in the vertical direction (y) is improved. While the length of the shorter lines (112) are generally contemplated to be substantially equal throughout the circuitry trace, in the event that the length of the shorter lines (112) differ from eachother, above mentioned ratios are calculated based on the longest one of the shorter lines (112) forming the each wave.
  • elongated lines (111) extending in vertical direction (y), except the ones in outermost edges in borderlines (A, A’), are designed substantially to have equal length.
  • the circuitry trace (1) is provided on a polymeric planar carrier sheet (2) as in the previous embodiment.
  • This embodiment also provides a plurality of electrode regions (12), and conductive lines (11) configured to form a pulse wave form, more particularly a rectangular pulse wave form having elongated lines (111) corresponding to pulse amplitude and extending in vertical direction (y) and shorter lines (112) corresponding to pulse length extending in horizontal direction (x).
  • the length of the horizontally elongated line (201) 7 33033/002/4370661.1 Int’l PCT Patent Application A ttorney Ref: 33033-002-PCT is more than the length of the shorter lines (112).
  • the ratio of the length of the horizontally elongated line (201) to the length of the shorter lines (112) ranges from 1.5 to 50, more preferably from 2 to 20 and most preferably from 2 to 10.
  • Horizontally elongated line (201) is preferably a straight line but it can also be a curved line.
  • the flexible circuit and the method according to the present invention are perfectly convenient for the applications in wellness, such as therapeutic heating pads and beds, and automotive, such as upholstery work in vehicles including trims and steering wheel.
  • the flexible circuit and the method according to the present invention are particularly suitable for medical products or vehicle parts that require wrapping with a textile or leather such as seats, steering wheels and door panels.
  • the flexible circuit technique is also ideal for multi-function applications, such as combining heating and capacitive touch sensing, because the functionality can be executed in a single layer, saving cost and improving mechanical properties. 8 33033/002/4370661.1

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un procédé de production d'une feuille stratifiée électriquement conductrice comprenant une structure souple et flexible ayant une trace de circuit. La trace de circuit a une conception améliorée qui permet une extensibilité et une robustesse dans plusieurs directions, et peut être utilisée pour des circuits multifonctions qui peuvent effectuer un chauffage et une détection tactile capacitive et un câblage, et la rendre appropriée pour des applications qui nécessitent une fonctionnalité électronique sur des surfaces spéciales. Dans d'autres aspects, l'invention concerne également un circuit flexible destiné à être utilisé dans le procédé de la présente invention.
PCT/US2023/024842 2023-06-08 2023-06-08 Procédé de production d'une feuille souple étirable comprenant un circuit flexible Pending WO2024253658A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2023/024842 WO2024253658A1 (fr) 2023-06-08 2023-06-08 Procédé de production d'une feuille souple étirable comprenant un circuit flexible

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2023/024842 WO2024253658A1 (fr) 2023-06-08 2023-06-08 Procédé de production d'une feuille souple étirable comprenant un circuit flexible

Publications (1)

Publication Number Publication Date
WO2024253658A1 true WO2024253658A1 (fr) 2024-12-12

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2023/024842 Pending WO2024253658A1 (fr) 2023-06-08 2023-06-08 Procédé de production d'une feuille souple étirable comprenant un circuit flexible

Country Status (1)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190297729A1 (en) * 2005-10-26 2019-09-26 Second Sight Medical Products, Inc. Flexible circuit electrode array and method of manufacturing the same
US20210076485A1 (en) * 2018-10-29 2021-03-11 Cellink Corporation Flexible hybrid interconnect circuits
US20210144858A1 (en) * 2018-05-31 2021-05-13 Loomia Technologies, Inc. Drapable, flexible circuitry layers and methods therefor
US20220201850A1 (en) * 2019-04-18 2022-06-23 Panasonic Intellectual Property Management Co., Ltd. Stretchable laminate, material for stretchable device, and stretchable device

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190297729A1 (en) * 2005-10-26 2019-09-26 Second Sight Medical Products, Inc. Flexible circuit electrode array and method of manufacturing the same
US20210144858A1 (en) * 2018-05-31 2021-05-13 Loomia Technologies, Inc. Drapable, flexible circuitry layers and methods therefor
US20210076485A1 (en) * 2018-10-29 2021-03-11 Cellink Corporation Flexible hybrid interconnect circuits
US20220201850A1 (en) * 2019-04-18 2022-06-23 Panasonic Intellectual Property Management Co., Ltd. Stretchable laminate, material for stretchable device, and stretchable device

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