Process of making an electrical resistance device

• US 4,888,089 A
• Filed: 01/11/1988
• Issued: 12/19/1989
• Est. Priority Date: 12/29/1987
• Status: Expired due to Fees

• Current Assignee: Calorique Limited
• Original Assignee: Flexwatt Corporation
• Inventors: Marstiller, John A., Bodensiek, Paul H., Grise, Frederick G.
• Primary Examiner(s): Powell, William A.
• Application Number:
  US07/142,625
• Time in Patent Office: 708 Days
• Field of Search: 427/101, 427/102, 427/103, 156/644, 156/656, 156/659.1, 156/901, 156/902, 338/308, 29/610.1, 29/611, 29/620, 29/621
• US Class Current: 216/16
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/037 Heaters with zones of different power density
• CPC Class Codes: H05B 3/10 Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
• CPC Class Codes: H05B 3/26 heating conductor mounted on insulating base for transparent areas H05B3/84, H05B3/86
• CPC Class Codes: H05B 3/36 heating conductor embedded in insulating material
• CPC Class Codes: Y10T 29/49099 Coating resistive material on a base

Abstract

An electrical resistance device includes a conductive metal pattern carried on an insulating surface. A portion of the conductive metal pattern includes a two-dimensional array of areas devoid of conductive material ("voids") within a mesh of conductive material. Typically, the voids are hexagonal and are arranged such that the adjacent edges of adjacent hexagons are parallel to each other and spaced apart a distance not more than about 0.10 in. The hexagonal voids typically are arranged so that the centers of sets of three adjacent voids lie on the corners of equilateral triangles.

Claims

1. In the method of making an electric resistance device in which a thin layer or film of metal is uniformly deposited on an insulating substrate, that improvement comprising the steps of thereafter selectively removing portions of the metal so deposited such that in a selected area of said device the remaining metal defines a conductive metal pattern comprising a two-dimensional regular array of areas devoid of conductive material ("voids") within a mesh of conductive material,

said voids being arranged such that the centers of the voids forming a set of three adjacent voids are positioned at the corners of an equilateral triangle.

10. The method of claim 1 wherein said voids are regular polygons.

2. In the method of making an electric resistance device in which a thin layer or film of metal is uniformly deposited on an insulating substrate, that improvement comprising the steps of thereafter selectively removing portions of the metal so deposited such that in a selected area of said device the remaining metal defines a conductive metal pattern comprising a two-dimensional array of areas devoid of conductive material ("voids") within a mesh of conductive material, said voids being regularly spaced hexagons arranged such that the sides of adjacent hexagons are parallel to each other.

3. The method of claim 2 wherein the distance between the sides of adjacent hexagons in not more than about 0.010 in.

4. The method of claim 2 including the steps of forming an acid resist pattern over said metal layer, said resist pattern covering the portions of said metal layer that are not to be selectively removed, and thereafter passing said device through an acid bath to remove the portions of said metal layer that are not covered by said resist pattern.

5. The method of claim 2 including the step of selectively removing metal in a second portion of said device to form in said second portion a mesh-void pattern different from that in said first portion.

7. The method of claim 2 wherein the centers of the voids forming a set of three adjacent voids are positioned at the corners of an equilateral triangle.

8. The method of claim 2 wherein said metal is silver or nickel deposited at a thickness less than about 100 Angstroms.

6. In the method of making an electric resistance device in which a thin layer or film of metal is uniformly deposited on an insulating substrate, that improvement comprising the steps of thereafter selectively removing portions of the metal so deposited such that in a selected area of said device the remaining metal defines a conductive metal pattern comprising a two-dimensional regular array of areas devoid of conductive material ("voids") within a mesh of conductive material,

said voids being arrange such that the centers of the voids forming a set of three adjacent voids are positioned at the corners of a triangle and the overall direction of current flow in said device is not parallel to any of the sides of said triangle.

9. The method of claim 6 wherein said triangles are equilateral triangles.