Methods and systems for embedding electrical components in a device including a frequency responsive structure

• US 20030076276A1
• Filed: 07/02/2002
• Published: 04/24/2003
• Est. Priority Date: 02/08/2001
• Status: Abandoned Application

• Current Assignee: Sciperio, Inc.
• Original Assignee: Sciperio, Inc.
• Inventors: Taylor, Robert M., Church, Kenneth H., Werner, Douglas H., Werner, Pingjuan L., Wilhelm, Michael John
• Application Number:
  US10/188,909
• Publication Number:
  US 20030076276A1
• Time in Patent Office: Days
• US Class Current: 343/909
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 15/0013 said selective devices working as frequency-selective reflecting surfaces, e.g. FSS, dichroic plates, surfaces being partly transmissive and reflective

Abstract

Methods and systems are provided for embedding electrical components within a device including a frequency responsive structure, such as an antenna or a frequency selective surface. Electrical components are selected and locations for placing the selected components within the device are selected for optimizing performance characteristics of the structure. The selection may be performed by modeling the device with various electrical components embedded at various locations using, for example, a genetic algorithm. The selected components are embedded at the selected locations. The frequency responsive structure and the selected components embedded at the selected locations may be produced in the same manufacturing process. The selected electrical components may be embedded at the selected locations as contiguous and integral parts of the device and may be embedded within the frequency responsive structure. The selected components may also be embedded at the selected locations on a surface of a substrate opposite the surface on which the frequency responsive surface is supported. The frequency response of the structure may be tuned by adapting the electrical components.

Claims

18. A method for producing a device including a frequency responsive structure with optimal performance characteristics, the method comprising the steps of:

selecting electrical components for optimizing performance characteristics of the frequency responsive structure;

selecting locations within the device for placing the selected components for optimizing performance characteristics of the structure; and

producing the device, including the frequency responsive structure and the selected electrical components placed at the selected locations, wherein the frequency responsive structure and the selected electrical components are formed in the same manufacturing process.

19. The method of claim 18, wherein the frequency responsive structure comprises a pattern of materials with the selected electrical components embedded therein.

20. The method of claim 18, wherein the frequency responsive structure is supported by one surface of a substrate included in the device, and the electrical components are supported by another surface of the substrate.

21. The method of claim 18 wherein the frequency responsive structure comprises an antenna.

22. The method of claim 18, wherein the frequency responsive structure comprises a frequency selective surface.

23. The method of claim 18, wherein the manufacturing process includes performing at least one process in a group of contiguous and integrated manufacturing processes including direct writing, screen printing, stamping, lithography, and electroplating.

24. The method of claim 18, wherein the step of selecting electrical components comprises modeling the device with various electrical components included therein and determining the electrical components that result in optimal performance characteristics, and the step of selecting locations for placing the electrical components comprises modeling the device with electrical components placed at various locations therein and determining the locations for placing the electrical components that result in optimal performance characteristics.

25. The method of claim 24, wherein the steps of modeling are performed using a genetic algorithm.

26. The method of claim 18, wherein the electrical components are part of an impedance matching network.

27. The method of claim 18, wherein the performance characteristics enhanced include at least one of gain, frequency response, bandwidth, and loading.

28. The method of claim 18, wherein the electrical components provide the frequency responsive structure with multiband capabilities.

29. The method of claim 18, further comprising tuning a frequency response of the structure by adding material to or subtracting material from the device or performing a combination of adding material to and subtracting material from the device.

30. The method of claim 29, wherein the step of tuning adds material to or subtracts material from the frequency responsive structure or electrical components embedded within the device.

31. The method of claim 29, wherein the step of subtracting includes performing at least one process in a group of subtraction processes including laser trimming, chemical etching, ion beam etching, and scraping.

32. The method of claim 29, wherein the step of adding includes performing at least one process in a group of addition processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, conductive gluing, and soldering.

33. The method of claim 18, wherein the step of selecting electrical components comprises selecting electrically adjustable components, and the method further comprises tuning a frequency response of the structure by electrically adjusting the selected components.

34. A method for producing a device including a frequency responsive structure supported on a surface of a substrate, the method comprising the steps of:

selecting electrical components for optimizing performance characteristics of the frequency responsive structure; and

selecting locations on another surface of the substrate, opposite the surface on which the frequency selective structure is supported, for placing the electrical components to optimize performance characteristics of the frequency responsive structure.

1. A method for producing a device including a frequency responsive structure with optimal performance characteristics, comprising the steps of:

selecting electrical components for embedding as integral and contiguous parts of the device for optimizing performance characteristics of the structure; and

selecting locations within the device for embedding the selected components as integral and contiguous parts of the device and for optimizing performance characteristics of the structure.

2. The method of claim 1, further comprising embedding the selected components at the selected locations as contiguous and integral parts of the device.

3. The method of claim 1, wherein the step of selecting selects locations within the frequency selective surface for embedding the selected components.

4. The method of claim 3, wherein the frequency responsive structure comprises a pattern of materials, and the method further comprises embedding comprises embedding the electrical components within the pattern of materials in a manner that makes the electrical components part of the pattern.

5. The method of claim 1, wherein the frequency responsive structure comprises an antenna.

6. The method of claim 1, wherein the frequency responsive structure comprises a frequency selective surface.

7. The method of claim 1, wherein the components and the locations are selected for embedding using at least one process in a group of contiguous and integrated embedding processes including direct writing, screen printing, stamping, lithography, and electroplating.

8. The method of claim 1, wherein the step of selecting electrical components comprises modeling the device with various electrical components embedded therein and determining the electrical components that result in optimal performance characteristics, and the step of selecting locations for placing the electrical components comprises modeling the device with electrical components embedded at various locations and determining the locations for placing the electrical components that result in optimal performance characteristics.

9. The method of claim 8, wherein the steps of modeling are performed using a genetic algorithm.

10. The method of claim 1, wherein the electrical components are part of an impedance matching network.

11. The method of claim 1, wherein the performance characteristics enhanced include at least one of gain, frequency response, bandwidth, and loading.

12. The method of claim 1, wherein the electrical components provide the frequency responsive structure with multiband capabilities.

13. The method of claim 1, further comprising tuning a frequency response of the structure by adding material to or subtracting material from the device or performing a combination of adding material to and subtracting material from the device.

14. The method of claim 13, wherein the step of tuning adds material to or subtracts material from the frequency responsive structure or electrical components embedded within the device.

15. The method of claim 13, wherein the step of subtracting includes performing at least one process in a group of subtraction processes including laser trimming, chemical etching, ion beam etching, and scraping.

16. The method of claim 13, wherein the step of adding includes performing at least one process in a group of addition processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, conductive gluing and soldering.

17. The method of claim 1, wherein the step of selecting electrical components comprises selecting electrically adjustable components, and the method further comprises tuning a frequency response of the structure by electrically adjusting the selected components.

35. The method of claim 34, further comprising embedding the selected electrical components at the selected locations on the surface of the substrate opposite the surface of the substrate on which the frequency responsive structure is supported and incorporating the substrate supporting the frequency responsive structure on one surface and the embedded electrical components on the opposite surface into the device.

36. The method of claim 35, wherein the electrical components are embedded within the substrate at the selected locations in a manner that makes the components integral with and contiguous to the substrate.

37. The method of claim 35, wherein the step of embedding includes performing at least one process in a group of embedding processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, conductive gluing, and soldering.

38. The method of claim 34, wherein the step of selecting electrical components comprises modeling the device with various electrical components embedded therein and determining the electrical components that result in optimal performance characteristics for the frequency responsive structure, and the step of selecting locations for placing the electrical components comprises modeling the device with the electrical components embedded at various locations and determining the locations for placing the electrical components that result in optimal performance characteristics for the frequency responsive structure.

39. The method of claim 38, wherein the steps of modeling are performed using a genetic algorithm.

40. The method of claim 34, wherein the electrical components are part of an impedance matching network.

41. The method of claim 34, wherein the performance characteristics enhanced include at least one of gain, frequency response, bandwidth, and loading.

42. The method of claim 34, wherein the electrical components provide the frequency responsive structure with multiband capabilities.

43. The method of claim 34, further comprising tuning a frequency response of the structure by adding material to or subtracting material from the device or performing a combination of adding material to and subtracting material from the device.

44. The method of claim 43, wherein the step of tuning adds material to or subtracts material from the frequency responsive structure or electrical components embedded within the device.

45. The method of claim 43, wherein the step of subtracting includes performing at least one process in a group of subtraction processes including laser trimming, chemical etching, ion beam etching, and scraping.

46. The method of claim 43, wherein the step of adding includes performing at least one process in a group of addition processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, conductive gluing, and soldering.

47. The method of claim 34, wherein the step of selecting electrical components comprises selecting electrically adjustable components, and the method further comprises tuning a frequency response of the structure by electrically adjusting the selected components.

36-1. The method of claim 34, wherein the frequency responsive structure comprises a frequency selective surface.

48. A system for producing a device including a frequency responsive structure with optimal performance characteristics, the system comprising:

means for selecting electrical components for embedding as integral and contiguous parts of the device and for optimizing performance characteristics of the structure; and

means for selecting locations within the device for embedding the selected components as integral and contiguous parts of the device and for optimizing performance characteristics of the structure.

49. The system of claim 48, further comprising means for embedding the selected components at the selected locations as contiguous and integral parts of the device.

50. The system of claim 48, wherein the means for selecting locations selects locations within the frequency selective surface for embedding the selected components.

51. The system of claim 50, wherein the frequency responsive structure comprises a pattern of materials, and the system further comprises means for embedding the electrical components within the pattern of materials in a manner that makes the electrical components part of the pattern.

52. The system of claim 48, wherein the frequency responsive structure comprises an antenna.

53. The system of claim 48, wherein the frequency responsive structure comprises a frequency selective surface.

54. The system of claim 48, wherein the components and the locations are selected for embedding using at least one process in a group of contiguous and integrated embedding processes including direct writing, screen printing, stamping, lithography, and electroplating.

55. The system of claim 48, wherein the means for selecting electrical components models the device with various electrical components embedded therein and determines the electrical components that result in optimal performance characteristics, and the means for selecting locations for placing the electrical components models the device with electrical components embedded at various locations and determines the locations for placing the electrical components that result in optimal performance characteristics.

56. The system of claim 55, wherein the modeling is performed using a genetic algorithm.

57. The system of claim 48, wherein the electrical components are part of an impedance matching network.

58. The method of claim 48, wherein the performance characteristics enhanced include at least one of gain, frequency response, bandwidth, and loading.

59. The system of claim 48, wherein the electrical components provide the frequency responsive structure with multiband capabilities.

60. The system of claim 48, further comprising means for tuning a frequency response of the structure by adding material to or subtracting material from the device or performing a combination of adding material to and subtracting material from the device.

61. The system of claim 60, wherein the tuning means adds material to or subtracts material from the frequency responsive structure or electrical components embedded within the device.

62. The system of claim 60, wherein the subtracting means includes means for performing at least one process in a group of subtraction processes including laser trimming, chemical etching, ion beam etching, and scraping.

63. The system of claim 60, wherein the adding means includes means for performing at least one process in a group of addition processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, conductive gluing, and soldering.

64. The system of claim 48, wherein the means for selecting electrical components selects electrically adjustable components, and the system further comprises means for tuning a frequency response of the structure by electrically adjusting the selected components.

65. A system for producing a device including a frequency responsive structure with optimal performance characteristics, the system comprising:

means for selecting electrical components for optimizing performance characteristics of the frequency responsive structure;

means for selecting locations within the device for placing the selected components for optimizing performance characteristics of the structure; and

means for producing the device, including the frequency responsive structure and the selected electrical components placed at the selected locations,

wherein the frequency responsive structure and the selected electrical components are formed in the same manufacturing process.

66. The system of claim 65, wherein the frequency responsive structure comprises a pattern of materials with the selected electrical components embedded therein.

67. The system of claim 65, wherein the frequency responsive structure is supported by one surface of a substrate included in the device, and the electrical components are supported by another surface of the substrate.

68. The system of claim 65, wherein the frequency responsive structure comprises an antenna.

69. The system of claim 65, wherein the frequency responsive structure comprises a frequency selective surface.

70. The system of claim 65, wherein the means for producing the device performs at least one process in a group of contiguous and integrated manufacturing processes including direct writing, screen printing, stamping, lithography, and electroplating.

71. The system of claim 65, wherein the means for selecting electrical components models the device with various electrical components included therein and determines the electrical components that result in optimal performance characteristics, and the means for selecting locations for placing the electrical components models the device with electrical components placed at various locations therein and determines the locations for placing the electrical components that result in optimal performance characteristics.

72. The system of claim 71, wherein the modeling is performed using a genetic algorithm.

73. The system of claim 65, wherein the electrical components are part of an impedance matching network.

74. The system of claim 65, wherein the performance characteristics enhanced include at least one of gain, frequency response, bandwidth, and loading.

75. The system of claim 65, wherein the electrical components provide the frequency responsive structure with multiband capabilities.

76. The system of claim 65, further comprising means for tuning a frequency response of the structure by adding material to or subtracting material from the device or performing a combination of adding material to and subtracting material from the electrical components within the device.

77. The system of claim 76, wherein the tuning means adds material to or subtracts material from the frequency responsive structure or electrical components embedded within the device.

78. The system of claim 76, wherein the subtracting means includes means for performing at least one process in a group of subtraction processes including laser trimming, chemical etching, ion beam etching, and scraping.

79. The system of claim 76, wherein the adding means includes means for performing at least one process in a group of addition processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, and conductive gluing.

80. The system of claim 65, wherein the means for selecting electrical components selects electrically adjustable components, and the system further comprises means for tuning a frequency response of the structure by electrically adjusting the selected components.

81. A system for producing a device including a frequency responsive structure supported on a surface of a substrate, the system comprising:

means for selecting electrical components for optimizing performance characteristics of the frequency responsive structure; and

means for selecting locations on another surface of the substrate, opposite the surface on which the frequency selective structure is supported, for placing the electrical components to optimize performance characteristics of the frequency responsive structure.

82. The system of claim 81, further comprising means for embedding the selected electrical components at the selected locations on the surface of the substrate opposite the surface of the substrate on which the frequency responsive structure is supported and means for incorporating the substrate supporting the frequency responsive structure on one surface and the embedded electrical components on the opposite surface into the device.

83. The system of claim 81, wherein the electrical components are embedded within the substrate at the selected locations in a manner that makes the components integral with and contiguous to the substrate.

84. The system of claim 81, wherein the frequency responsive structure comprises a frequency selective surface.

85. The system of claim 82, wherein the embedding means includes means for performing at least one process in a group of embedding processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, and conductive gluing.

86. The system of claim 81, wherein the means for selecting electrical components models the device with various electrical components embedded therein and determines the electrical components that result in optimal performance characteristics for the frequency responsive structure, and the means for selecting locations for placing the electrical components comprises models the device with the electrical components embedded at various locations and determines the locations for placing the electrical components that result in optimal performance characteristics for the frequency responsive structure.

87. The system of claim 86, wherein the modeling is performed using a genetic algorithm.

88. The system of claim 81, wherein the electrical components are part of an impedance matching network.

89. The system of claim 81, wherein the performance characteristics enhanced include at least one of gain, frequency response, bandwidth, and loading.

90. The system of claim 81, wherein the electrical components provide the frequency responsive structure with multiband capabilities.

91. The system of claim 81, further comprising means for tuning a frequency response of the structure by adding material to or subtracting material from the device or performing a combination of adding material to and subtracting material from the device.

92. The system of claim 91, wherein the tuning means adds material to or subtracting material from the frequency responsive structure or electrical components embedded within the device.

93. The system of claim 91, wherein the subtracting means includes means for performing at least one process in a group of subtraction processes including laser trimming, chemical etching, ion beam etching, and scraping.

94. The system of claim 91, wherein the adding means includes mean for performing at least one process in a group of addition processes including direct writing, screen printing, stamping, lithography, electroplating, wire bonding, conductive gluing, and soldering.

95. The system of claim 81, wherein the means for selecting electrical components selects electrically adjustable components, and the system further comprises means for tuning a frequency response of the structure by electrically adjusting the selected components.