JP2016519846A - 3d構造物、構造部品、ならびに構造的な電子、電磁、および電気機械部品/装置において層間導体および構成要素を接続するための方法およびシステム - Google Patents
3d構造物、構造部品、ならびに構造的な電子、電磁、および電気機械部品/装置において層間導体および構成要素を接続するための方法およびシステム Download PDFInfo
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- JP2016519846A JP2016519846A JP2016502733A JP2016502733A JP2016519846A JP 2016519846 A JP2016519846 A JP 2016519846A JP 2016502733 A JP2016502733 A JP 2016502733A JP 2016502733 A JP2016502733 A JP 2016502733A JP 2016519846 A JP2016519846 A JP 2016519846A
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
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- H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
- H05K3/103—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by bonding or embedding conductive wires or strips
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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Abstract
Description
本発明は、広くには、3D構造物ならびに3D構造の電子、電磁、および電気機械部品および装置の製造に関し、より詳しくは、三次元の構造物、構造部品、ならびに三次元構造の電子、電磁、および電気機械部品/装置において層間導体および構成要素を接続するための方法およびシステムに関する。
本発明は、幾何学的に複雑かつ入り組んでいる可能性がある3D構造物、構造部品、あるいは埋め込みの電子機器、センサ、およびアクチュエータを有する構造物の製造時に、熱可塑性の基材にフィラメント(例えば、ワイヤ、メッシュ、など)を埋め込むための方法およびシステムを提供する。さらに、フィラメントを、熱可塑性装置の複数の層に埋め込むことができる。本発明は、伝統的なプリント基板(PCB)技術と同等の導電率および耐久性を有する電気相互接続を提供する。
本発明の種々の態様の製作および使用が以下で詳しく説明されるが、本発明が、幅広く様々な具体的背景において具現化できる多数の応用可能な発明概念を提供することを、理解すべきである。本明細書において説明される具体的な態様は、あくまでも本発明を製作および使用する具体的なやり方の例示にすぎず、本発明の技術的範囲を限定するものではない。
Claims (38)
- 三次元の電子、電磁、または電気機械部品/装置において第1の構成要素または導体を第2の構成要素または導体へと接続する方法であって、以下の工程を含む方法:
前記第1の構成要素または導体が第1の層の上または内部に配置された基材材料の少なくとも第1の層を設ける工程;
第1の端部および第2の端部を有する細長い空洞を含む前記基材材料の第2の層を、前記第1の端部が前記第1の構成要素または導体の第1の露出部分の上方に配置されるように、前記第1の層上に堆積させる工程;
フィラメントの第1の端部を、前記細長い空洞の前記第1の端部を介して、前記第1の構成要素または導体の前記第1の露出部分へと取り付ける工程;
前記フィラメントの第2の端部を、前記フィラメントが前記細長い空洞内に配置されるように、前記細長い空洞の前記第2の端部内に配置する工程;
前記基材材料の第3の層を、前記細長い空洞の第1の端部の付近の前記細長い空洞の第1の部分が前記第3の層によって覆われ、かつ前記細長い空洞の第2の部分は露出されるように、前記第2の層上に堆積させる工程;
前記第2の構成要素または導体を、前記細長い空洞の前記第2の部分の付近の前記第3の層の上または内部に堆積させる工程;
前記基材材料の第4の層を、前記第2の構成要素または導体の第2の部分が露出され、かつ前記細長い空洞の前記第2の部分が露出されるように、前記第3の層上に堆積させる工程;および
前記フィラメントの前記第2の端部を前記細長い空洞の前記第2の部分から取り出し、かつ前記フィラメントの前記第2の端部を前記第2の構成要素または導体の前記露出部分へと取り付ける工程。 - 前記細長い空洞の前記第2の端部は、前記細長い空洞の前記第1の端部よりも大きい、請求項1記載の方法。
- 前記細長い空洞は、鍵穴形状の空洞またはらせん状の空洞または逃げを備える、請求項1記載の方法。
- 前記フィラメントが前記細長い空洞内に配置された後に、前記細長い空洞の前記第1の端部を前記基材材料で覆う工程をさらに含む、請求項1記載の方法。
- 前記細長い空洞は、前記基材材料の前記第2の層が前記第1の層上に堆積させられるときに形成される、請求項1記載の方法。
- 前記細長い空洞は、前記基材材料の一部分を取り除くことによって生成される、請求項1記載の方法。
- 前記基材材料の一部分は、マイクロ加工機、CNCマイクロ加工機、マイクロ放電加工機、電気化学加工機、直描(direct write)陽子マイクロ加工機、レーザアブレーション機、放射源、超音波切断機、ホットワイヤ切断機、ウォータージェット機、エッチング機、深堀り反応性イオンエッチング機、プラズマエッチング機、結晶配向依存エッチング機、湿式バルクマイクロ加工機、UVリソグラフィまたはX線リソグラフィ(LIGA)機、ホットエンボスリソグラフィ機、精密機械式のこぎり盤、化学補助イオンミリング機、サンドブラスト機、または切断機を使用して取り除かれる、請求項6記載の方法。
- レーザマイクロ溶接プロセスを使用して、前記フィラメントの前記第1の端部は、前記第1の構成要素または導体へと取り付けられ、かつ前記フィラメントの前記第2の端部は、前記第2の構成要素または導体へと取り付けられる、請求項1記載の方法。
- ワイヤボンディング機、抵抗溶接機、超音波溶接機、またははんだ付け機を使用して、前記フィラメントの前記第1の端部は、前記第1の構成要素または導体へと取り付けられ、かつ前記フィラメントの前記第2の端部は、前記第2の構成要素または導体へと取り付けられる、請求項1記載の方法。
- 前記基材材料を層ごとのプロセスにて前記第2の層上に堆積させることによって、三次元の基材の1つまたは複数の追加の層を生成する工程をさらに含む、請求項1記載の方法。
- 前記フィラメントが埋め込まれる前記第1の層の少なくとも一部分が、平坦でない、請求項1記載の方法。
- 前記フィラメントは、導電性材料、非導電性材料、光ファイバ、またはメッシュを含む、請求項1記載の方法。
- 前記導電性材料は、金属、金属合金、導電性ポリマー、またはワイヤを含み、
前記非導電性材料は、1つまたは複数の炭素繊維または1つまたは複数のケブラー繊維を含み、
前記メッシュは、導電性メッシュまたは非導電性メッシュを含み、
前記導電性メッシュは、金属、金属合金、導電性ポリマー、またはワイヤで作られたフィラメントの組を含み、
前記非導電性メッシュは、炭素繊維またはケブラー繊維の組を含む、請求項12記載の方法。 - 前記メッシュは、ステンレス鋼メッシュ、アルミニウムメッシュ、銅メッシュ、真ちゅうメッシュ、鋼メッシュ、銅クロムメッシュ、または銅ニッケル合金メッシュを含む、請求項12記載の方法。
- 前記メッシュは、幾何学的形状を含む、請求項12記載の方法。
- 前記メッシュは、ヒートシンク、アンテナ、導電面、機械的な補強、または電磁シールドを構成する、請求項12記載の方法。
- 前記メッシュは、前記第1の層へと埋め込まれてポリマー-メッシュ複合材料を形成する、請求項12記載の方法。
- 前記メッシュは、多段階のプロセスを使用して一度に一部分ずつ前記第1の層へと埋め込まれる、請求項12記載の方法。
- 前記メッシュは、単一のプロセス段階にて前記第1の層へと埋め込まれる、請求項12記載の方法。
- 前記第1の層は、空洞を含み、かつ前記メッシュの一部分は、前記空洞内に配置される、請求項12記載の方法。
- 前記メッシュは、前記第1の層、あるいは前記三次元の構造物、構造部品、または構造的な電子、電磁、もしくは電気機械部品/装置の物理的特性、熱的特性、または電気的特性を改善する、請求項12記載の方法。
- 前記第1の層は、空洞を含み、かつ前記フィラメントの一部分は、前記空洞内に配置される、請求項1記載の方法。
- 前記フィラメントは、前記第1の層の物理的特性、熱的特性、または電気的特性を改善する、請求項1記載の方法。
- 前記基材材料は、熱可塑性材料、あるいは機械、熱、絶縁、磁気、または電磁特性を向上させるために別のポリマー材料、セラミック材料、金属材料、鉱物材料、ガラスセラミック材料、半導体材料、ナノ材料、バイオ材料、有機材料、無機材料、またはこれらの任意の組み合わせが充てんされた熱可塑性材料を含む、請求項1記載の方法。
- 前記熱可塑性材料は、アクリロニトリルブタジエンスチレン(ABS)、ABSi、ABSplus、ABS-M30、ABS-M30i、ABS-ESD7、ポリカーボネート(PC)、PC-ABS、PC-ISO、ポリフェニルスルホン(PPSF/PPSU)、ULTEM 9085、またはこれらの任意の組み合わせ、ならびに熱溶融積層法または他の押し出しにもとづく熱可塑性プラスチックの付加製造(additive manufacturing)プロセスにおいて商業的に使用される任意の現在または将来の材料を含み、前記材料は、ポリアミド、ポリスチレン、ポリプロピレン、ナイロン、ポリアリルエーテルケトン、またはこれらの任意の組み合わせ、ならびにレーザ焼結付加製造プロセスにおいて使用される任意の現在または将来の材料であってもよい、請求項24記載の方法。
- 別のポリマー材料は、ポリ(メチルメタクリレート)(PMMA)、ポリプロピレン、ポリオレフィン、LL-PE、HDPE、ポリ酢酸ビニル、ポリエステル、ポリエーテル、ポリアミド、ナイロン、ポリイミド、ポリケトン、ポリエーテルエチルケトン(PEEK)、ポリブタジエン、ポリ乳酸、ポリカプロラクトン、ポリエチレンテレフタレート、液晶ポリマー(LCP)、ポリスチレン、ポリ塩化ビニル、ポリフルオロエチレン、ポリジフルオロエチレン、ポリテトラフルオロエチレン、ZEONEX RS420、Eccostock HIK-TPO、先のものの共重合体およびブロック共重合体、あるいはこれらの任意の組み合わせを含む、請求項25記載の方法。
- 1つまたは複数の層は、熱溶融積層(FDM)プロセスまたは他の押し出しにもとづく付加製造プロセス、選択的レーザ焼結(SLS)プロセスまたは他の粉末床溶融付加製造プロセス、薄膜積層(LOM)プロセスまたは熱可塑性シートを利用する他のシート積層付加製造プロセス、ステレオリソグラフィプロセスまたは光硬化性の熱可塑性プラスチックを利用する他の液槽光重合付加製造プロセス、光硬化性の熱可塑性プラスチックを利用する材料噴射プロセス(すなわち、Objet)、あるいは他の付加的な熱可塑性プラスチックにもとづく3D印刷プロセスを使用して堆積させられる、請求項1記載の方法。
- 前記第1の構成要素または導体ならびに前記第2の構成要素または導体は、電子部品、静電部品、空気圧部品、電気音響部品、マイクロ電気機械システム(MEMS)、生物医学部品、電気化学部品、電気機械部品、電磁部品、機械部品、メタマテリアル部品、光学部品、フォトニック部品、熱部品、熱管理部品、メッシュ、埋め込み導体、ワイヤ、導電パッド、導電端子、導電トレース、他の層へのビア、またはコネクタを含む、請求項1記載の方法。
- 前記電子部品は、集積回路、抵抗器、コンデンサ、インダクタ、トランジスタ、サーミスタ、サイリスタ、センサ、プロセッサ、メモリ、インターフェイス装置、表示装置、電源、エネルギ変換装置、またはアンテナを含む、請求項28記載の方法。
- 前記電子部品は、手作業でまたは構成要素配置機器を使用して配置され、該構成要素配置機器は、ピックアンドプレース(pick and place)機器、ロボットプロセス、または他の自動化された構成要素配置技術を含む、請求項28記載の方法。
- 前記第1の構成要素または導体あるいは前記第2の構成要素または導体は、埋め込み導体を含む、請求項1記載の方法。
- 前記埋め込み導体は、
ワイヤ送りおよび切断システムと、
以下を含む群から選択される、前記フィラメントまたはフィラメントメッシュを埋め込むための少なくとも1つのエネルギ源と
を使用して配置される、請求項31記載の方法:
前記フィラメントまたはフィラメントメッシュの少なくとも一部分と前記基材との間に摩擦熱を生じさせるための超音波ホーンまたはソノトロード、
前記フィラメントまたはフィラメントメッシュの少なくとも一部分の内部に渦電流、したがってジュール熱を誘導するための誘導加熱コイル、
熱を発生させ、前記フィラメントまたはフィラメントメッシュの少なくとも一部分へと伝導によって伝達するための1つまたは複数の抵抗加熱素子、
前記フィラメントまたはフィラメントメッシュの少なくとも一部分に電流を通すことによって前記フィラメントまたはフィラメントメッシュの内部にジュール熱を生じさせるための電極、
強制対流加熱によって前記フィラメントまたはフィラメントメッシュの少なくとも一部分へと熱を伝える空気加熱および循環装置またはシステム、ならびに
前記フィラメントまたはフィラメントメッシュの少なくとも一部分へと放射によって熱を伝えるための放射赤外熱源。 - (a)第1の構成要素または導体が第1の層の上または内部に配置された基材材料の少なくとも第1の層を設ける工程、(b)第1の端部および第2の端部を有する細長い空洞を含む前記基材材料の第2の層を、前記第1の端部が前記第1の構成要素または導体の第1の露出部分の上方に配置されるように、前記第1の層上に堆積させる工程、(c)フィラメントの第1の端部を前記細長い空洞の前記第1の端部を介して前記第1の構成要素または導体の前記第1の露出部分へと取り付ける工程、(d)前記フィラメントの第2の端部を、前記フィラメントが前記細長い空洞内に配置されるように、前記細長い空洞の前記第2の端部内に配置する工程、(e)前記基材材料の第3の層を、前記細長い空洞の前記第1の端部の付近の前記細長い空洞の第1の部分が前記第3の層によって覆われ、かつ前記細長い空洞の第2の部分は露出されるように、前記第2の層上に堆積させる工程、(f)第2の構成要素または導体を、前記細長い空洞の前記第2の部分の付近の前記第3の層の上または内部に堆積させる工程、(g)前記基材材料の第4の層を、前記第2の構成要素または導体の第2の部分が露出され、かつ前記細長い空洞の前記第2の部分が露出されるように、前記第3の層上に堆積させる工程、および(h)前記フィラメントの前記第2の端部を前記細長い空洞の前記第2の部分から取り出し、かつ前記フィラメントの前記第2の端部を前記第2の構成要素または導体の前記露出部分へと取り付ける工程を含む方法によって製作された、三次元の構造物、構造部品、あるいは構造的な電子、電磁、または電気機械部品/装置。
- 三次元の構造物、構造部品、あるいは構造的な電子、電磁、または電気機械部品/装置を製作するためのシステムであって、
三次元印刷装置と、
第1の機器と、
第2の機器と
を備えており、かつ
(a)前記三次元印刷装置は、基材材料の第1の層を生成し、(b)前記第1の機器は、前記第1の層の上または内部に第1の構成要素または導体を配置し、(b)三次元印刷機器は、第1の端部および第2の端部を有する細長い空洞を含む前記基材材料の第2の層を、前記第1の端部が前記第1の構成要素または導体の第1の露出部分の上方に配置させるように、前記第1の層上に堆積させ、(c)前記第1の機器は、フィラメントの第1の端部を、前記細長い空洞の前記第1の端部を介して、前記第1の構成要素または導体の前記第1の露出部分へと取り付け、(d)前記第2の機器は、前記フィラメントの第2の端部を、前記フィラメントが前記細長い空洞内に配置させるように、前記細長い空洞の前記第2の端部内に配置し、(e)前記三次元印刷装置は、前記基材材料の第3の層を、前記細長い空洞の前記第1の端部の付近の前記細長い空洞の第1の部分が前記第3の層によって覆われ、かつ前記細長い空洞の第2の部分が露出されるように、前記第2の層上に堆積させ、(f)前記第2の機器は、第2の構成要素または導体を、前記細長い空洞の前記第2の端部の付近の前記第3の層の上または内部に配置し、(g)前記三次元印刷装置は、前記基材材料の第4の層を、前記第2の構成要素または導体の第2の部分が露出され、かつ前記細長い空洞の前記第2の部分が露出されるように、前記第3の層上に堆積させ、(h)前記第2の機器は、前記フィラメントの前記第2の端部を前記細長い空洞の前記第2の部分から取り出し、かつ前記フィラメントの前記第2の端部を前記第2の構成要素または導体の前記露出部分の付近に配置し、かつ(i)前記第1の機器は、前記フィラメントの前記第2の端部を前記第2の構成要素または導体の前記露出部分へと取り付ける、システム。 - 前記三次元印刷装置は、熱溶融積層(FDM)機器または他の押し出しにもとづく付加製造機器、選択的レーザ焼結(SLS)機器または他の粉末床溶融付加製造プロセス、薄膜積層(LOM)機器または熱可塑性シートを利用する他のシート積層付加製造プロセス、ステレオリソグラフィ機器または光硬化性の熱可塑性プラスチックを利用する他の液槽光重合付加製造プロセス、光硬化性の熱可塑性プラスチックを利用する材料噴射プロセス、または他の付加的な熱可塑性プラスチックにもとづく3D印刷機器を含み、
前記第2の機器は、レーザマイクロ溶接機、抵抗溶接機、超音波溶接機、ワイヤボンディング機、またははんだ付け機を含み、かつ
前記第3の機器は、構成要素配置機器を含む、請求項34記載のシステム。 - 前記第1の構成要素または導体あるいは前記第2の構成要素または導体は、埋め込み導体を含む、請求項34記載のシステム。
- 前記埋め込み導体は、
ワイヤ送りおよび切断システムと、
以下を含む群から選択される、前記フィラメントまたはフィラメントメッシュを埋め込むための少なくとも1つのエネルギ源と
を使用して配置される、請求項36記載のシステム:
前記フィラメントまたはフィラメントメッシュの少なくとも一部分と前記基材との間に摩擦熱を生じさせるための超音波ホーンまたはソノトロード、
前記フィラメントまたはフィラメントメッシュの少なくとも一部分の内部に渦電流、したがってジュール熱を誘導するための誘導加熱コイル、
熱を発生させ、前記フィラメントまたはフィラメントメッシュの少なくとも一部分へと伝導によって伝達するための1つまたは複数の抵抗加熱素子、
前記フィラメントまたはフィラメントメッシュの少なくとも一部分に電流を通すことによって前記フィラメントまたはフィラメントメッシュの内部にジュール熱を生じさせるための電極、
強制対流加熱によって前記フィラメントまたはフィラメントメッシュの少なくとも一部分へと熱を伝える空気加熱および循環装置またはシステム、ならびに
前記フィラメントまたはフィラメントメッシュの少なくとも一部分へと放射によって熱を伝えるための放射赤外熱源。 - 三次元の基材を各々の機器へと運ぶスライダ、コンベア、またはロボット装置をさらに備える、請求項34記載のシステム。
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US13/829,921 | 2013-03-14 | ||
US13/829,921 US9414501B2 (en) | 2012-01-04 | 2013-03-14 | Method for connecting inter-layer conductors and components in 3D structures |
PCT/US2014/028206 WO2014152911A1 (en) | 2013-03-14 | 2014-03-14 | Methods and system for connecting inter-layer conductors and components in 3d structures, structural components, and structural electronic electromagnetic and electromechanical components/devices |
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JP2016519846A true JP2016519846A (ja) | 2016-07-07 |
JP6557209B2 JP6557209B2 (ja) | 2019-08-07 |
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US (2) | US9414501B2 (ja) |
EP (1) | EP2974567B1 (ja) |
JP (1) | JP6557209B2 (ja) |
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KR20160026833A (ko) | 2016-03-09 |
EP2974567A4 (en) | 2016-12-07 |
US10660214B2 (en) | 2020-05-19 |
WO2014152911A1 (en) | 2014-09-25 |
US20140268607A1 (en) | 2014-09-18 |
EP2974567B1 (en) | 2019-01-30 |
US20160324009A1 (en) | 2016-11-03 |
CN105409335A (zh) | 2016-03-16 |
EP2974567A1 (en) | 2016-01-20 |
CN105409335B (zh) | 2018-06-22 |
JP6557209B2 (ja) | 2019-08-07 |
US9414501B2 (en) | 2016-08-09 |
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