Patent Application
20170225273
Embodiments are related to the field of additive manufacturing, and more particularly to printing three-dimensional (3D) objects utilizing material extruders. Embodiments are also related to the manufacture of 3D printed components with structurally integrated metal objects that can serve as thermal or electrical interconnections.
3D printing is an AM (Additive Manufacturing) process for making three-dimensional objects of arbitrary shapes from digital models. Other terms used synonymously to refer to 3D printing include additive manufacturing, layer manufacturing, rapid prototyping, layer-wise fabrication, solid freeform fabrication, and direct digital manufacturing. In 3D printing, successive layers of a material are laid down adjacently to form the objects. Typically, a round or ribbon like material is extruded through a movable nozzle.
Examples of AM processes and 3D printers are disclosed in U.S. Patent Application Publication No. 2013/0170171, entitled “Extrusion-Based Additive Manufacturing System for 3D Structural Electronic, Electromagnetic and Electromechanical Components/Devices,” which was published on Jul. 4, 2013 and is incorporated herein by reference in its entirety. Other examples of AM processes and 3D printers are disclosed in U.S. Patent Application Publication No. 2014/0268604, entitled “Methods and Systems For Embedding Filaments in 3D Structures, Structural Components, and Structural Electronic, Electromagnetic and Electromechanical Components/Devices,” which was published on Sep. 18, 2014 and is incorporated herein by reference in its entirety. Still, other examples of AM processes and 3D printers are disclosed in U.S. Patent Application Publication No. 2014/0268607, entitled “Methods and Systems For Connecting Inter-Layer Conductors and Components in 3D Structures. Structural Components, and Structural Electronic. Electromagnetic and Electromechanical Components/Devices,” which also published on Sep. 18, 2014 and is incorporated herein by reference in its entirety.
The next generation of manufacturing technology will require complete spatial control of material and functionality as structures are created layer-by-layer, thereby providing fully customizable, high value, multi-functional products for the consumer, biomedical, aerospace, and defense industries. With contemporary AM (also known more popularly as 3D printing) providing the base fabrication process, a comprehensive manufacturing suite will be integrated seamlessly to include: 1) additive manufacturing of a wide variety of robust plastics/metals; 2) micromachining; 3) laser ablation; 4) embedding of wires, metal surfaces, and fine-pitch meshes submerged within the dielectric substrates; 5) micro-dispensing; 6) wire bonding; and 7) robotic component placement.
Collectively, the integrated technologies will fabricate multi-material structures through the integration of multiple integrated manufacturing systems (multi-technology) to provide multi-functional products (e.g., consumer wearable electronics, bio-medical devices, defense, thermal management, space and energy systems, etc.).
Paramount to this concept is the connection (thermal or electrical) between conductive traces and surfaces at different levels of the 3D printed dielectric substrate as well as connecting the traces and surfaces to metallic pins of components at the same or different levels in the substrate. Wire bonding can provide this functionality, but leaves a arching wire that can be damaged or which may obstruct the print head of a 3D printer during subsequent fabrication operations.
The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiments and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings and abstract as a whole.
It is therefore, one aspect of the disclosed embodiments to provide for a 3D printed component with structural integrated metal objects capable of serving as thermal or electrical connections.
It another aspect of the disclosed embodiments to provide for connections between conductive traces and surfaces at different levels of 3D printed dielectric substrates as well as connecting the traces and surfaces of metallic pins of components at the same or different levels in the substrate.
It is another aspect of the disclosed embodiments to provide for a wire bonding configuration with an arching wire arrangement based on a levee around the arching wire.
It is a further aspect of the disclosed embodiments to provide for a levee around the arching wire which is later filled with liquid curable polymer or thermal set polymer or other curable liquid resin, the wire can be set permanently and protected during further fabrication.
The aforementioned aspects and other objectives and advantages can now be achieved as described herein. A three-dimensional electronic, biological, chemical, thermal management or electromechanical apparatus and method of making such an apparatus are disclosed. In an example embodiment, one or more layers of a three-dimensional structure are deposited on a substrate. The three-dimensional structure is configured to include one or more internal cavities using an extrusion-based additive manufacturing system enhanced with a range of secondary embedding processes. The three-dimensional structure includes one or more structural integrated metal objects spanning the one or more of the internal cavities of the three-dimensional structure for enhanced electromagnetic properties and bonded between two or more other metal objects located at the same layer or different layers of the three-dimensional structure.
In another example embodiment, a three-dimensional electronic or electromechanical apparatus can be configured by depositing one or more layers of a three-dimensional structure on a substrate. Such a three-dimensional structure can include one or more internal layers with structurally integrated conductive traces or surfaces or components with conductive pin by using an additive manufacturing system enhanced with a range of secondary embedding processes.
Wire bonding can be used to ultrasonically connect two isolated metal structures (e.g., wire, foil, pin of component) at the same or different fabrication level and then additional polymer can be printed to provide a cavity to act as a reservoir. The cavity completely subsumes the arching wire - the top of which is below the open surface of the cavity. The reservoir cavity is then filled with a liquid curable polymer or other liquid curable resin and subsequently cured. Once hardened, the new polymer or resin sets and protects the fragile wire bond wire and helps maintain the connection between the two metal structures and provides a planar surface from which the 3D printing can resume unobstructed.
The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the, principles of the present invention.
The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
The embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. The embodiments disclosed herein can he embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to identical, like or similar elements throughout, although such numbers may be referenced in the context of different embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Embodiments disclosed are related to the manufacture of three-dimensional printed components with structurally integrated metal objects serving as thermal or electrical interconnect. Wire embedding integrates wires into two layers of dielectric with a void (possibly circular and with one, two, or more layers of dielectric thickness). The top wire spans the void that will later be filled by dispensing of a conductive ink. This conductive ink via after curing serves as an interlayer conductor connection and connects both wires both mechanically and electrically. Optionally, a third dielectric layer can be printed before dispensing the conductive ink which provides only restricted access (choked via) that subsequently provides mechanical support and protection for the cured conductive ink via.
As depicted at step B (
As shown at Step C (
The fabrication process shown in
Note that as utilized herein, the term “structurally integrated” as utilized herein can be defined as being connected to the structure in a such a way as to: (1) require a force to remove the metal object from the structure, and (2) provide an improvement in the properties of the plastic structure mechanically, thermally, and/or electrically. Additionally, metal structures as discussed herein can include wires with diameters ranging from sub-micron sizes upwards to almost any diameter, beams of rectangular, triangular, or any other arbitrary cross-sectional geometry, lattice structures, wire meshes, metal foils, and metal sheets.
The three-dimensional electronic or electromechanical apparatus 11 can be configured by depositing one or more layers of a three-dimensional structure on a substrate. Such a three-dimensional structure can include one or more internal layers with structurally integrated conductive traces or surfaces or components with conductive pin by using an additive manufacturing system enhanced with a range of secondary embedding processes.
Wire bonding can be used to ultrasonically connect the two isolated metal structures or components 14 and 17 (e.g., wire, foil, pin of a component, etc.) at the same or different fabrication level and then additional polymer layers can be 3D printed to provide the cavity 22 to act as a reservoir. The cavity 22 completely subsumes the arching wire 18—the top of which is below the open surface of the cavity 22. The reservoir cavity 22 is then filled with a liquid curable polymer 24 and subsequently cured. Once hardened, the new polymer sets and protects the fragile wire bond wire 18, helps maintain the connection between the two metal structures/components 14, 17, and provides a planar surface from which 3D printing operations can resume unobstructed.
As shown next at block 37, a step or operation can be implemented in which one or more structural metal objects are provided, followed by a step or operation, as depicted at block 39, in which the three-dimensional structure is configured to incorporate or include said each structural integrated metal object in a manner in which each structure integrated metal object spans each respective internal cavity (for enhanced electromagnetic properties). Finally, as depicted at block 41, a step or operation can be provided to ensure that each structural metal object is bonded between at least two other metal objects located at the same layer or different layers of said three-dimensional structure.
Referring now to
The example embodiment depicted in
It can be appreciated parts produced by one or more of the disclosed embodiments can be used in various applications such as, for example: 1) unmanned aerial systems (UASs) and unmanned aerial vehicles (UAVs) by providing aerodynamic parts with embedded sensors. communications, and electronics within structural components or by directly fabricating onto UAS and UAV surfaces; 2) customized mission-specific disposable electronics; 3) truly 3D antennas and photonic devices that improve communications; 4) replacement components for virtually any electronic system on a naval vessel; 5) custom fit sailor-borne electronics and communications systems; 6) disposable floating depth-specific sensor systems; 7) biomedical devices; and 8) metamaterial structures.
Based on the foregoing, it can be appreciated that a number of varying embodiments are disclosed herein. For example, in one embodiment, a three-dimensional electronic, biological, chemical, thermal management, or electromechanical apparatus (or system) can be implemented, which includes a substrate, at least one layer of a three-dimensional structure configured on the substrate. The three-dimensional structure includes at least one internal cavity configured by an extrusion-based additive manufacturing system enhanced with a range of secondary embedding processes, the three-dimensional structure further configured with at least one structural integrated metal object spanning the at least one internal cavity of the three-dimensional structure for enhanced electromagnetic properties.
In some example embodiments, the aforementioned substrate can be configured as a 3D printed thermoplastic substrate. In another example embodiment, the at least one layer of the three dimensional structure can be a dielectric polymer. In yet another example embodiment, the at least one structural integrated metal object can be a conductive wire. In still another example embodiment, the at least one structural integrated metal object can be a conductive foil. In another example embodiment, the at least one structural integrated metal object can be configured from conductive ink.
In another example embodiment, a method of making a three-dimensional electronic, biological, chemical, thermal management, or electromechanical component/device can be implemented. Such a method can include steps or operations such as, for example: creating at least one layer of a three-dimensional structure by depositing a substrate; and configuring the three-dimensional structure to include at least one internal cavity using an extrusion-based additive manufacturing system enhanced with a range of secondary embedding processes and further configuring the three-dimensional structure with structural integrated metal objects spanning the at least one internal cavity of the three-dimensional structure for enhanced electromagnetic properties.
It may be understood that particular embodiments described herein are shown by way of illustration and not as limitations of such embodiments, The principal features of the disclosed embodiments can be employed in various embodiments without departing from the scope of such embodiments. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of the disclosed embodiments and are covered by the claims.
All publications, patents, and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications, patents, and patent applications are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value or the variation that exists among the study subjects.
As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”), or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements, or method steps.
The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as AA, AAA, BB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.
All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods the disclosed embodiments have been described in terms of preferred embodiments, it may be apparent to those skilled in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit, and scope of the disclosed embodiments. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the disclosed embodiments as defined by the appended claims.
It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. It will also be appreciated that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims.
This nonprovisional patent application claims the benefit under 35 U.S.C. §119(e) and priority to U.S. Provisional Patent Application Ser. No. 62/292,414 filed on Feb. 8, 2016, entitled “Connecting Metal Foils/Wires and Components in 3D Printed Substrates with Wire Bonding,” which is hereby incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62292414 | Feb 2016 | US |
