Methods of forming a variable watt density layered heater
First Claim
1. A method of forming a trace of a resistive circuit pattern of a layered heater, the trace defining a length, a width, and a spacing, the method comprising the steps of:
- (a) dispensing a conductive ink through an orifice of a single writing tip at a rate onto a surface; and
(b) selectively varying the dispensing rate of the conductive ink through the orifice of the writing tip to form a variable thickness trace of the resistive circuit pattern.
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Abstract
Methods of forming a layered heater are provided that comprise at least one resistive layer comprising a resistive circuit pattern, the resistive circuit pattern defining a length, a thickness, and a spacing, wherein the thickness varies along the length of the trace of the resistive circuit pattern for a variable watt density. The methods include achieving the variable thickness by varying a dispensing rate of a conductive ink used to form the resistive circuit pattern, varying the feed rate of a target surface relative to the dispensing of the ink, and overwriting a volume of conductive ink on top of a previously formed trace of the resistive circuit pattern.
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Citations
20 Claims
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1. A method of forming a trace of a resistive circuit pattern of a layered heater, the trace defining a length, a width, and a spacing, the method comprising the steps of:
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(a) dispensing a conductive ink through an orifice of a single writing tip at a rate onto a surface; and (b) selectively varying the dispensing rate of the conductive ink through the orifice of the writing tip to form a variable thickness trace of the resistive circuit pattern.
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2. A method of forming a trace of a resistive circuit pattern of a layered heater, the method comprising the steps of:
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(a) dispensing a conductive ink through an orifice of a single writing tip at a rate onto a surface; and (b) selectively varying a feed speed of the substrate relative to the dispensing of conductive ink through the orifice of the writing tip to form a variable thickness trace of the resistive circuit pattern.
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3. A method of forming a trace of a resistive circuit pattern of a layered heater, the method comprising the steps of:
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(a) applying a volume of conductive ink onto a surface with a single dispensing element to form the trace; and (b) subsequently applying an additional volume of conductive ink onto the trace with the single dispensing element after the volume of step (a) has been applied along the entire trace, wherein a variable thickness trace of the resistive circuit pattern is produced. - View Dependent Claims (4, 5, 6, 11, 12, 13, 14)
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- 7. A method of forming a trace of a resistive circuit pattern of a layered heater, the trace defining a length, a width, and a spacing, the method comprising forming the trace with a variable thickness.
Specification