Microwire circuit and deposition system

Abstract

A microcircuit deposition system incorporates a first printing engine for depositing a dielectric on a substrate. A microwire spooling machine houses a microwire spool and incorporates a tension guide to position a microwire trace onto the dielectric layer. A second printing engine trails the microwire spooling machine to deposit a covering dielectric layer over the microwire trace.

Claims

1. A microwire circuit comprising: a first dielectric layer printed as a first stripe shape on a substrate using a first printing engine; a drawn microwire trace positioned on the first dielectric layer by a microwire spooling machine connected to track the first printing engine and incorporating a tension guide to position the microwire trace onto the first dielectric layer while still tacky from printing to provide an adhesive effect in constraining the microwire trace; and, a second dielectric layer printed as a plurality of second stripe portions using a second printing engine connected to track the microwire spooling machine to interruptibly deposit the second dielectric layer over the drawn microwire trace.

2. The microwire circuit as defined in claim 1 wherein the second dielectric layer contains interconnection gaps introduced by the second printing engine between the second stripe portions.

3. The microwire circuit as defined in claim 2 wherein the first dielectric layer contains interconnection gaps introduced by the first printing engine.

4. The microwire circuit as defined in claim 2 further comprising conducting ink direct printed for circuit interconnection through the gaps in the second dielectric layer.

5. The microwire circuit as defined in claim 1 wherein the substrate comprises a composite skin.

6. The microwire circuit as defined in claim 1 wherein the substrate is an operational surface.

7. The microwire circuit as defined in claim 1 wherein the printed first dielectric layer and second dielectric layer comprise ultraviolet (UV) cured polymer.

8. The microwire circuit as defined in claim 3 wherein the substrate is a conductive material.

9. The microwire circuit as defined in claim 1 wherein the drawn microwire trace is oriented by a guide bale.

10. The microwire circuit as defined in claim 9 wherein the drawn microwire trace is drawn through feed rollers from a dispensing spool.

11. The microwire circuit as defined in claim 9 wherein the drawn microwire trace is severed at a termination by a transverse cutter.

12. The microwire circuit as defined in claim 11 wherein a tail of the drawn microwire trace is engaged by a positioning foot to urge contact with the first dielectric layer.

13. A drawn microwire circuit deposition system comprising: a first printing engine interruptibly depositing a dielectric with a UV sensitive polymer base on a substrate; a microwire spooling machine connected to track the first printing engine and housing a spool containing microwire and incorporating a tension guide to position a microwire trace onto the dielectric layer, said microwire drawn from the spool and fed through a set of feed rollers and wherein the microwire trace is deposited onto the dielectric layer while still tacky from printing to provide an adhesive effect in constraining the microwire trace, said spooling machine further incorporating a guide bale to orient and guide the microwire from the feed rollers for placement onto the dielectric, a tensioning guide to provide the desired linearity of the trace and a cutter to sever the microwire trace at a desired length; a UV source connected to track the spooling machine for curing of the dielectric layer with adhered microwire trace; a second printing engine connected to track the microwire spooling machine to interruptibly deposit a covering dielectric layer with a UV sensitive polymer base over the microwire trace to form a second dielectric layer as a plurality of second stripe portions; a second UV source connected to track the spooling machine for curing of the covering dielectric layer.

14. The drawn microwire circuit deposition system as defined in claim 13 further comprising a positioning foot adapted to engage a tail of the microwire trace to urge the tail into contact with the first dielectric layer.

15. The drawn microwire circuit deposition system as defined in claim 14 wherein the positioning foot is movable vertically in a telescoping fitting.

16. The drawn microwire circuit deposition system as defined in claim 15 wherein the telescoping fitting is roller mounted in a track allowing lateral motion of the foot.

17. The drawn microwire circuit deposition system as defined in claim 16 wherein the positioning foot may be withdrawn and the tensioning guide maintains tension in the microwire trace.

18. The drawn microwire circuit deposition system as defined in claim 13 wherein the second printing engine is interruptible to produce gaps in the second dielectric layer whereby cross connection with subsequently printed traces is achieved.

19. The drawn microwire circuit deposition system as defined in claim 13 wherein the substrate incorporates conductive materials and the first printing engine interruptibly deposits the dielectric whereby the microwire trace deposited on the dielectric circuit has interconnection with the conductive materials on the substrate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is schematic view of elements of a deposition system employing an exemplary embodiment;

(2) FIGS. 2A-2C are schematic representations of component layers deposited by the system of FIG. 1;

(3) FIG. 3 is a schematic detail of elements of the microwire deposition element for the exemplary embodiment of FIG. 1; and,

(4) FIG. 4 is a flow chart for a microwire deposition process employing the exemplary embodiment.

DETAILED DESCRIPTION

(5) The embodiments described herein demonstrate a system for controlled installation of thin, uninsulated copper wire of less than 100 micrometers (about 38 gauge or less) in diameter (microwire) onto various substrates including composite skins, subsystem enclosures, and supporting structures on platforms where there is a desire to reduce discrete wiring. A spooling machine places the microwire onto the substrate with a control tip, and a direct-write deposition system will both precede and follow the tooltip to print dielectric material for insulating the microwire and conducting material where needed to bridge the microwire with other traces or circuit elements.

(6) Referring to the drawings, FIG. 1 shows an exemplary embodiment of a deposition system employing a first printing engine 10 for depositing a dielectric or insulating layer 12 on a substrate 14. A microwire spooling machine 16 houses microwire spools 18 and employs a tensioning guide 20 to position a microwire trace 22 onto the dielectric layer. The spooling machine may be mechanically or controllably connected to track the first printing engine at a desired distance. In the exemplary embodiment, the microwire trace may be deposited onto the dielectric layer while still tacky from printing to provide an adhesive effect in constraining the microwire trace. A cutter 24 severs the microwire trace at a desired length. A second printing engine 26 trails the microwire spooling machine to deposit a covering dielectric or insulating layer 28. The second printing engine may be mechanically or controllably connected to track the first printing engine at a desired distance.

(7) As shown in FIGS. 2A-2C, dielectric layer 12 as deposited on substrate 14 provides an insulating path as shown in FIG. 2A for segregation of the microwire trace from the surface of the substrate which may be a composite, titanium, aluminum or alternative material surface associated either with a system-in-a-package (SIP) integrated circuit, other printed circuit element or an operational surface such as an unmanned aerial vehicle (UAV) skin. For an exemplary embodiment, the dielectric layer incorporates Polyvinylbutyral (PVB) materials. Microwire trace 22 deposited on the dielectric layer 12 as shown in FIG. 2B provides a high conductivity trace with superior mechanical properties to a printed conductive trace. In exemplary embodiments copper (Cu) wire is employed but conductive alloys may be employed in alternative embodiments. As an example, a silver ink printed trace of 1 m in length has a resistance of approximately 1 h. For the exemplary embodiments of microwire traces with R=l/A where R is total resistance, is the resistivity (1.6810.sup.8 m for Cu), l is the length of the trace (1 m) and A is the cross sectional area of the trace (810.sup.9 m2 for exemplary 38 gauge microwire) a total resistance of 2.1 is provided for a 1 m trace. Deposition of the covering dielectric layer 28 as shown in FIG. 2C provides top insulation for the microwire trace as well as additional adhesive capability to restrain the microwire. A printing gap 30 is shown in the covering dielectric layer representative of the capability in the system to provide cross connection with subsequently printed traces of silver ink or similar materials or other micro wire traces for cross connection traces or circuits. While shown for the covering layer, similar printing gaps may be employed in the initial dielectric layer for circuit interconnection with lower layers of conductive materials on the substrate thereby enabling stacked electronic circuits.

(8) The system may also employ one or more ultraviolet (UV) curing elements 32 as shown in FIG. 1 tracking the spooling machine and second printing engine for curing after printing of dielectric layers employing a UV sensitive polymer as a portion of the dielectric layer composition.

(9) An exemplary arrangement for the Microwire spooling machine 16 shown in FIG. 3. Microwire of small gage approximately 38 or 40 (100.838 m or 79.756 m respectively) is held in a dispensing spool 18 from which the microwire is drawn and fed through a set of feed rollers 42. A guide bale 44 or similar structure orients and guides the microwire for placement onto the substrate or dielectric covering layer with tensioning guide 20. A cutter 24 is provided to severe the wire at the termination of a trace. For the embodiment shown, the cutter operates transversely to allow a micro wire tail 46 to extend from the guide bale. A positioning foot 48 is moveable vertically in a telescoping fitting 50 to engage and urge the tail into surface contact. Roller mounting of fitting 50 horizontally in track 52 allows controlled lateral motion of the foot to maintain contact of the tail during initial lateral motion of the spooling machine for sufficient adherence to the surface of the dielectric layer 12 to maintain position. The foot is then withdrawn and the guide bale and tensioning guide then maintain sufficient tension in the microwire trace as deposited to provide the desired linearity of the trace.

(10) The embodiment described provides a process as shown in FIG. 4 for creating circuits by deposition of a first dielectric or insulating layer on a substrate using a direct printing process, step 402. A microwire is then unspooled and deposited onto the dielectric layer, step 404, which may adhesively bind the wire. In certain embodiments, UV curing is then applied to dry the insulating layer and adhesive, step 406. A second dielectric or insulating layer is then deposited over the microwire with a direct printing process, step 408, with circuit interconnection gapping by suspension of printing feed at predetermined locations, step 410. In certain embodiments, UV curing of the second insulating layer is then accomplished, step 412. For exemplary applications, direct printing of conducting ink for circuit interconnection through the second layer gapping is then employed, step 414.

(11) Having now described various embodiments of the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims.