Apparatus for forming a circuit

• US 7,757,631 B2
• Filed: 05/26/2004
• Issued: 07/20/2010
• Est. Priority Date: 05/26/2004
• Status: Expired due to Fees

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Devos, John A., Nielsen, Jeffrey A., Cruz-Uribe, Tony S., Way, Olan, Weng, Jian-gang, Blakley, Daniel R., Prasad, Ravi
• Primary Examiner(s): Tadesse; Yewebdar T
• Application Number:
  US10/854,450
• Publication Number:
  US 20050266154A1
• Time in Patent Office: 2,246 Days
• Field of Search: 118/688, 118/679, 118/665, 118/680, 118/58, 118/62, 118/63, 118/641, 118/642, 118/300, 118/313, 118/46, 118/643, 118314-315, 118/302, 118/682, 427/542, 427/96.1, 427/258, 427/372.2, 347/9, 347/12, 347/107, 347/1, 347/2, 347/68, 347/200, 438/647
• US Class Current: 118/665
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 1/162 incorporating printed capacitors
• CPC Class Codes: H05K 1/167 incorporating printed resistors
• CPC Class Codes: H05K 2203/013 Inkjet printing, e.g. for printing insulating material or resist using ink-jet printing to form a conductive pattern H05K3/125
• CPC Class Codes: H05K 2203/102 Using microwaves, e.g. for curing ink patterns or adhesive
• CPC Class Codes: H05K 2203/107 Using laser light shaping a substrate by laser ablation H05K3/0026
• CPC Class Codes: H05K 2203/1105 Heating or thermal processing not related to soldering, firing, curing or laminating, e.g. for shaping the substrate or during finish plating
• CPC Class Codes: H05K 2203/1545 Continuous processing, i.e. involving rolls moving a band-like or solid carrier along a continuous production path
• CPC Class Codes: H05K 3/125 by ink-jet printing
• CPC Class Codes: H05K 3/1283 After-treatment of the printed patterns, e.g. sintering or curing methods

Abstract

Methods and apparatuses for forming components or circuits by ejecting a fluid including materials in a single ligament are disclosed.

Claims

1. An apparatus to fabricate a circuit, comprising:

means for supplying a fluid, including materials for forming the circuit, the fluid including the materials stored and supplied by the means for supplying the fluid, wherein the fluid including the materials stored and supplied by the means for supplying fluid comprises electrically conductive metal nanoparticles;

a print head to receive the fluid including the materials supplied by the means for supplying the fluid and to eject the fluid including the materials from the means for supplying fluid in a single ligament on a substrate to deposit the fluid including the materials onto the substrate in a pattern comprising at least a portion of the circuit;

means for heating the fluid including the materials to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head and the means for supplying the fluid to eject the fluid in the pattern, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of the fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

2. The apparatus as defined in claim 1, wherein the means for heating includes a configuration to sinter the materials after the materials are deposited on the substrate.

3. The apparatus as defined in claim 1, wherein the means for heating includes a configuration to at least one of evaporate or dry the fluid from the materials.

4. The apparatus as defined in claim 1, further including means for supplying the substrate to the print head.

5. The apparatus as defined in claim 1, wherein the print head comprises a thermal print head.

6. The apparatus as defined in claim 1, wherein the print head comprises a piezoelectric print head.

7. The apparatus as defined in claim 1, wherein the metal nanoparticles comprise at least one of silver, copper, nickel, aluminum or gold.

8. The apparatus as defined in claim 1, wherein the materials stored and supplied by the means for supplying fluid comprise electrically insulating polymers.

9. The apparatus as defined in claim 1, wherein said the fluid including said the materials comprises electrically resistive particles.

10. The apparatus as defined in claim 9, wherein said the resistive particles comprise carbon particles.

11. The apparatus as defined in claim 1, wherein the means for heating comprises at least one of a convection oven, a laser energy source, a microwave energy source or a direct infrared source.

12. The apparatus as defined in claim 1, wherein the substrate is flexible.

13. The apparatus as defined in claim 12, wherein the substrate comprises at least one of paper or plastic.

14. The apparatus as defined in claim 1, wherein said the substrate is rigid.

15. The apparatus as defined in claim 1, wherein the substrate is glass.

16. An apparatus to fabricate a circuit, comprising:

means for supplying a fluid, including materials for forming the circuit, the fluid including the materials stored and supplied by the means for supplying the fluid, wherein the fluid including the materials stored and supplied by the means for supplying fluid comprises electrically conductive polymers;

a print head to receive the fluid including the materials supplied by the means for supplying the fluid and to eject the fluid including the materials from the means for supplying the fluid in a single ligament on a substrate to deposit the fluid including the materials onto the substrate in a pattern comprising at least a portion of the circuit;

means for heating the fluid including the materials to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head and the means for supplying the fluid to eject the fluid in the pattern, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

17. The apparatus as defined in claim 16, wherein the polymers comprise at least one of PEDOT or polyaniline.

18. The apparatus as defined in claim 17, wherein the insulating polymers comprise at least one of polyvinyl pyrrolidone or polyvinyl phenol.

19. The apparatus as defined in claim 16, wherein the means for heating includes a configuration to sinter the materials after the materials are deposited on the substrate.

20. The apparatus as defined in claim 16, wherein the means for heating includes a configuration to at least one of evaporate or dry the fluid from the materials.

21. The apparatus as defined in claim 16, further including means for supplying the substrate to the print head.

22. The apparatus as defined in claim 16, wherein the print head comprises a thermal print head.

23. The apparatus as defined in claim 16, wherein the print head comprises a piezoelectric print head.

24. The apparatus as defined in claim 16, wherein the materials stored and supplied by the means for supplying fluid comprise electrically insulating polymers.

25. The apparatus as defined in claim 16, wherein the fluid including the materials comprises electrically resistive particles.

26. The apparatus as defined in claim 16, wherein the means for heating comprises at least one of a convection oven, a laser energy source, a microwave energy source or a direct infrared source.

27. The apparatus as defined in claim 16, wherein the substrate is flexible.

28. The apparatus as defined in claim 16, wherein the substrate is rigid.

29. The apparatus as defined in claim 16, wherein the substrate is glass.

30. An apparatus to fabricate a circuit, comprising:

means for supplying a fluid, including materials for forming the circuit, the fluid including the materials stored and supplied by the means for supplying the fluid, wherein the fluid including the materials comprises dielectric polymers;

a print head to receive the fluid including the materials supplied by the means for supplying the fluid and to eject the fluid including the materials from the means for supplying the fluid in a single ligament on a substrate to deposit the fluid including the materials onto the substrate in a pattern comprising at least a portion of the circuit;

means for heating the fluid including the materials to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head and the means for supplying the fluid to eject the fluid in the pattern, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

31. The apparatus as defined in claim 30, wherein said the dielectric polymers comprise at least one of polyvinyl pyrrolidone or polyvinyl phenol.

32. The apparatus as defined in claim 30, wherein the means for heating includes a configuration to sinter the materials after the materials are deposited on the substrate.

33. The apparatus as defined in claim 30, wherein the means for heating includes a configuration to at least one of evaporate or dry the fluid from the materials.

34. The apparatus as defined in claim 30, further including means for supplying the substrate to the print head.

35. The apparatus as defined in claim 30, wherein the print head comprises a thermal print head.

36. The apparatus as defined in claim 30, wherein the print head comprises a piezoelectric print head.

37. The apparatus as defined in claim 30, wherein the materials stored and supplied by the means for supplying fluid comprise electrically insulating polymers.

38. The apparatus as defined in claim 30, wherein the fluid including the materials comprises electrically resistive particles.

39. The apparatus as defined in claim 30, wherein the means for heating comprises at least one of a convection oven, a laser energy source, a microwave energy source or a direct infrared source.

40. The apparatus as defined in claim 30, wherein the substrate is flexible.

41. The apparatus as defined in claim 30, wherein the substrate is rigid.

42. The apparatus as defined in claim 30, wherein the substrate is glass.

43. An apparatus to fabricate a circuit, comprising:

means for supplying a fluid, including materials for forming the circuit, the fluid including the materials stored and supplied by the means for supplying the fluid, wherein the fluid including the materials comprises alpha-terpineol mixed with ethanol or toluene;

a print head to receive the fluid including the materials supplied by the means for supplying the fluid and to eject the fluid including the materials from the means for supplying the fluid in a single ligament on a substrate to deposit the fluid including the materials onto the substrate in a pattern comprising at least a portion of the circuit;

means for heating the fluid including the materials to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head and the means for supplying the fluid to eject the fluid in the pattern, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

44. The apparatus as defined in claim 43, wherein the means for heating includes a configuration to sinter the materials after the materials are deposited on the substrate.

45. The apparatus as defined in claim 43, wherein the means for heating includes a configuration to at least one of evaporate or dry the fluid from the materials.

46. The apparatus as defined in claim 43, further including means for supplying the substrate to the print head.

47. The apparatus as defined in claim 43, wherein the print head comprises a thermal print head.

48. The apparatus as defined in claim 43, wherein the print head comprises a piezoelectric print head.

49. The apparatus as defined in claim 43, wherein the materials stored and supplied by the means for supplying fluid comprise electrically insulating polymers.

50. The apparatus as defined in claim 43, wherein the fluid including the materials comprises electrically resistive particles.

51. The apparatus as defined in claim 43, wherein the means for heating comprises at least one of a convection oven, a laser energy source, a microwave energy source or a direct infrared source.

52. The apparatus as defined in claim 43, wherein the substrate is flexible.

53. The apparatus as defined in claim 43, wherein the substrate is rigid.

54. The apparatus as defined in claim 43, wherein the substrate is glass.

55. An apparatus to form a circuit, comprising:

at least one fluid tank containing a fluid including materials to form at least a portion of a circuit, wherein the fluid including the materials comprises electrically conductive metal nanoparticles;

a print head to receive the fluid including the materials from the at least one fluid tank and to eject the fluid including the materials in a single ligament to deposit the fluid and the materials onto a substrate in a pattern comprising at least a portion of the circuit;

a media supply to supply and position the substrate relative to the printhead;

a heating device to heat the fluid including the materials on the substrate to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head, the media supply and the heating device to form at least a portion of the circuit, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

56. The apparatus as defined in claim 55, wherein the print head comprises a thermal inkjet print head.

57. The apparatus as defined in claim 55, wherein the print head comprises a piezoelectric inkjet print head.

58. The apparatus as defined in claim 55, wherein the heating device includes a configuration to sinter the materials after the materials are deposited on the substrate.

59. The apparatus as defined in claim 55, wherein the metal nanoparticles comprise at least one of silver, copper, nickel, aluminum or gold.

60. The apparatus as defined in claim 55, wherein the fluid including said the materials comprise electrically insulating polymers.

61. The apparatus as defined in claim 55, wherein the fluid including the materials comprise electrically resistive particles.

62. The apparatus as defined in claim 61, wherein the resistive particles comprise carbon.

63. An apparatus to form a circuit, comprising:

at least one fluid tank containing a fluid including materials to form at least a portion of a circuit, wherein the fluid including the materials comprises electrically conductive polymers;

a print head to receive the fluid including the materials from the at least one fluid tank and to eject the fluid including the materials in a single ligament to deposit the fluid and the materials onto a substrate in a pattern comprising at least a portion of the circuit;

a media supply to supply and position the substrate relative to the printhead;

a heating device to heat the fluid including the materials on the substrate to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head, the media supply and the heating device to form at least a portion of the circuit, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

64. The apparatus as defined in claim 63, wherein the polymers comprise at least one of PEDOT or polyaniline.

65. The apparatus as defined in claim 63, wherein the print head comprises a thermal inkjet print head.

66. The apparatus as defined in claim 63, wherein the print head comprises a piezoelectric inkjet print head.

67. The apparatus as defined in claim 63, wherein the heating device includes a configuration to sinter the materials after the materials are deposited on the substrate.

68. The apparatus as defined in claim 63, wherein the fluid including the materials comprise electrically insulating polymers.

69. The apparatus as defined in claim 63, wherein the fluid including the materials comprise electrically resistive particles.

70. An apparatus to form a circuit, comprising:

at least one fluid tank containing a fluid including materials to form at least a portion of a circuit, wherein the fluid including the materials comprises at least one of polyvinyl pyrrolidone or polyvinyl phenol;

a print head to receive the fluid including the materials from the at least one fluid tank and to eject the fluid including the materials in a single ligament to deposit the fluid and the materials onto a substrate in a pattern comprising at least a portion of the circuit;

a media supply to supply and position the substrate relative to the printhead;

a heating device to heat the fluid including the materials on the substrate to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head, the media supply and the heating device to form at least a portion of the circuit, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

71. The apparatus as defined in claim 70, wherein the print head comprises a thermal inkjet print head.

72. The apparatus as defined in claim 70, wherein the print head comprises a piezoelectric inkjet print head.

73. The apparatus as defined in claim 70, wherein the heating device includes a configuration to sinter the materials after the materials are deposited on the substrate.

74. The apparatus as defined in claim 70, wherein the fluid including the materials comprise electrically insulating polymers.

75. The apparatus as defined in claim 70, wherein the fluid including the materials comprise electrically resistive particles.

76. An apparatus to form a circuit, comprising:

at least one fluid tank containing a fluid including materials to form at least a portion of a circuit, wherein the fluid including the materials comprises dielectric polymers;

a print head to receive the fluid including the materials from the at least one fluid tank and to eject the fluid including the materials in a single ligament to deposit the fluid and the materials onto a substrate in a pattern comprising at least a portion of the circuit;

a media supply to supply and position the substrate relative to the printhead;

a heating device to heat the fluid including the materials on the substrate to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head, the media supply and the heating device to form at least a portion of the circuit, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

77. The apparatus as defined in claim 76, wherein the dielectric polymers comprise at least one of polyvinyl pyrrolidone or polyvinyl phenol.

78. The apparatus as defined in claim 76, wherein the print head comprises a thermal inkjet print head.

79. The apparatus as defined in claim 76, wherein the print head comprises a piezoelectric inkjet print head.

80. The apparatus as defined in claim 76, wherein the heating device includes a configuration to sinter the materials after the materials are deposited on the substrate.

81. The apparatus as defined in claim 76, wherein the fluid including the materials comprise electrically insulating polymers.

82. The apparatus as defined in claim 76 wherein the fluid including the materials comprise electrically resistive particles.

83. An apparatus to form a circuit, comprising:

at least one fluid tank containing a fluid including materials to form at least a portion of a circuit, wherein the fluid including the materials comprises at least one of alpha-terpineol mixed with ethanol or toluene;

a print head to receive the fluid including the materials from the at least one fluid tank and to eject the fluid including the materials in a single ligament to deposit the fluid and the materials onto a substrate in a pattern comprising at least a portion of the circuit;

a media supply to supply and position the substrate relative to the printhead;

a heating device to heat the fluid including the materials on the substrate to evaporate the fluid and bond the materials to the substrate; and

a controller to control the print head, the media supply and the heating device to form at least a portion of the circuit, the controller to control the print head during the depositing of a continuous pattern to adjust the speed of fluid ejection of each quantity of fluid from the print head such that a subsequently formed quantity of fluid merges with a previously formed quantity of fluid before contacting the substrate to form the single ligament.

84. The apparatus as defined in claim 83, wherein the print head comprises a thermal inkjet print head.

85. The apparatus as defined in claim 83, wherein the print head comprises a piezoelectric inkjet print head.

86. The apparatus as defined in claim 83, wherein the heating device includes a configuration to sinter the materials after the materials are deposited on the substrate.

87. The apparatus as defined in claim 83, wherein the fluid including the materials comprise electrically insulating polymers.

88. The apparatus as defined in claim 83, wherein the fluid including the materials comprise electrically resistive particles.