High-precision additive formation of electrical resistors
10366813 · 2019-07-30
Assignee
Inventors
Cpc classification
H01C17/283
ELECTRICITY
H01C1/142
ELECTRICITY
International classification
H01C7/00
ELECTRICITY
H01C1/142
ELECTRICITY
Abstract
Shown herein is a method of forming an electrical resistor comprising the steps of: forming an electrically resistive layer on a substrate; measuring an electrical resistance-related parameter of the electrically resistive layer and determining a target length of the electrically resistive layer corresponding to a target electrical resistance; and forming first and second electrically conductive terminals contacting the electrically resistive layer, said first and second electrically conductive terminals being separated by a distance corresponding to the target length.
Claims
1. A method of forming an electrical resistor having a target electrical resistance by additive manufacturing comprising the steps of: forming an electrically resistive layer on a substrate; measuring an electrical resistance-related parameter of the electrically resistive layer and determining from the electrical resistance-related parameter a target length of the electrically resistive layer corresponding to the target electrical resistance; and forming a first electrically conductive terminal and a second electrically conductive terminal contacting the electrically resistive layer, said first and second electrically conductive terminals being separated by a distance corresponding to the target length, such that an electrical resistance of a portion of the electrically resistive layer extending between the first electrically conductive terminal and the second electrically conductive terminal corresponds to the target electrical resistance.
2. The method of forming an electrical resistor of claim 1, wherein the electrically resistive layer is made of carbon, carbon composites, metal oxides, and/or mixtures thereof.
3. The method of forming an electrical resistor of claim 1, wherein forming the electrically resistive layer comprises one or more of printing, coating, vacuum coating, vacuum deposition, curing and drying.
4. The method of forming an electrical resistor of claim 1, wherein forming the first electrically conductive terminal and the second electrically conductive terminal layer comprises digital inkjet printing, digital thermo transfer printing, or digital 3-D printing.
5. The method of forming an electrical resistor of claim 1, wherein the electrical resistance-related parameter is determined by measuring an electrical resistance of a portion of the electrically resistive layer having a known length.
6. The method of forming an electrical resistor of claim 1, further comprising electrically connecting to the electrically resistive layer between the first electrically conductive terminal and the second electrically conductive terminal one or more electrically conductive elements.
7. The method of forming an electrical resistor of claim 1, further comprising measuring a final electrical resistance-related parameter of the electrically resistive layer between the first electrically conductive terminal and the second electrically conductive terminal, wherein the final electrical resistance-related parameter is indicative of an electrical resistance of the electrically resistive layer between the first electrically conductive terminal and the second electrically conductive terminal.
8. The method of forming an electrical resistor of claim 1, further comprising optically monitoring the formation of the first electrically conductive terminal and the second electrically conductive terminal.
9. The method of forming an electrical resistor of claim 1, further comprising optically monitoring the formation of the electrically isolating layer.
10. The method of forming an electrical resistor of claim 1, wherein the substrate comprises a silicon substrate, a polymer substrate, a ceramic substrate, a printed circuit board, a paper substrate or a cardboard substrate.
11. A method of forming an electrical resistor having a target electrical resistance by additive manufacturing comprising the steps of: forming an electrically resistive layer on a substrate; measuring an electrical resistance-related parameter of the electrically resistive layer and determining from the electrical resistance-related parameter a target length of the electrically resistive layer corresponding to the target electrical resistance; forming an electrically isolating layer on the electrically resistive layer having first and second ends, wherein the electrically isolating layer covers the electrically resistive layer in an overlap region extending between said first end and said second end, such that a length of the electrically resistive layer covered by the electrically isolating layer corresponds to the target length, such that an electrical resistance of a portion of the electrically resistive layer covered by the electrically isolating layer corresponds to the target electrical resistance; and forming a first electrically conductive terminal on the electrically resistive layer directly adjacent to the first end of the electrically isolating layer and forming a second electrically conductive terminal on the electrically resistive layer directly adjacent to the second end of the electrically isolating layer.
12. The method of forming an electrical resistor of claim 11, wherein the electrically isolating layer is made of a ceramic, silicon oxide, aluminum oxide or metallic oxide, paper, or an organic polymer.
13. The method of forming an electrical resistor of claim 11, wherein forming the electrically isolating layer comprises one or more of analog screen printing, analog flexo printing, analog gravure printing, analog inkjet printing, analog pad printing, analog hot stamping, analog thermo transfer printing, and analog 3-D printing.
14. The method of forming an electrical resistor of claim 11, wherein the electrically isolating layer is formed by depositing an electrically isolating element on the electrically resistive layer.
15. The method of claim 14, further comprising adjusting the length of the electrically resistive layer covered by the electrically isolating element by positioning the electrically isolating element with respect to the electrically resistive layer.
16. The method of forming an electrical resistor of claim 11, wherein forming the first electrically conductive terminal and the second electrically conductive terminal comprises forming an electrically conductive layer on the electrically isolating layer and on parts of the electrically resistive layer not covered by the electrically isolating layer, wherein the electrically conductive layer has a discontinuity that electrically isolates the first electrically conductive terminal from the second electrically conductive terminal.
17. Arrangement for forming an electrical resistor having a target electrical resistance by additive manufacturing, wherein the arrangement comprises: a first deposition device configured for depositing an electrically resistive material for forming an electrically resistive layer; a processing unit configured for measuring an electrical resistance-related parameter of an electrically resistive layer formed by the first deposition device and determining from the electrical resistance-related parameter a target length of the electrically resistive layer corresponding to the target electrical resistance; and a second deposition device configured for depositing an electrically conductive material for forming electrically conductive terminals; wherein the processing unit is further configured for controlling the second deposition device to form a first electrically conductive terminal and a second electrically conductive terminal such as to contact an electrically resistive layer formed by the first deposition device, said first and second electrically conductive terminals being separated by a distance corresponding to the target length, such that an electrical resistance of a portion of the electrically resistive layer extending between the first electrically conductive terminal and the second electrically conductive terminal corresponds to the target electrical resistance.
18. The arrangement of claim 17, wherein the second deposition device comprises a printing device configured for printing the first electrically conductive terminal and the second electrically conductive terminal by means of inkjet printing, thermo transfer printing, or 3-D printing.
19. The arrangement of claim 17, further comprising an optical device configured for optically monitoring the formation of the first electrically conductive terminal and the second electrically conductive terminal by the second deposition device and/or for optically monitoring the formation of the electrically isolating layer by the third deposition device.
20. The arrangement of claim 17, further comprising a measuring device suitable for measuring an electrical resistance-related parameter of the electrically resistive layer.
21. Arrangement for forming an electrical resistor having a target electrical resistance by additive manufacturing, wherein the arrangement comprises: a first deposition device configured for depositing an electrically resistive material for forming an electrically resistive layer; a processing unit configured for measuring an electrical resistance-related parameter of an electrically resistive layer formed by the first deposition device and determining from the electrical resistance-related parameter a target length of the electrically resistive layer corresponding to the target electrical resistance; a second deposition device configured for depositing an electrically conductive material for forming electrically conductive terminals; and a third deposition device configured for depositing an electrically isolating material for forming an electrically isolating layer; wherein the processing unit is further configured for controlling the third deposition device to form the electrically isolating layer on an electrically resistive layer formed by the first deposition device, such that the electrically isolating layer extends from a first end to a second end, wherein the electrically isolating layer covers the electrically resistive layer in an overlap region extending between said first end and said second end, such that a length of the electrically resistive layer covered by the electrically isolating layer corresponds to the target length; and wherein the processing unit is further configured for controlling the second deposition device to form a first electrically conductive terminal on the electrically resistive layer directly adjacent to the first end of the electrically isolating layer and to form a second electrically conductive terminal on the electrically resistive layer directly adjacent to the second end of the electrically isolating layer.
22. The arrangement of forming an electrical resistor of claim 21, wherein the third deposition device comprises a robot device configured for depositing a prefabricated electrically isolating element on an electrically resistive layer formed by the first deposition device, wherein the electrically isolating element extends from a first end to a second end, wherein a distance between the first end and the second end corresponds to the target length, such that an electrical resistance of a portion of the electrically resistive layer covered by the electrically isolating element corresponds to the target electrical resistance.
23. The arrangement of forming an electrical resistor of claim 21, wherein the third deposition device comprises a printing device configured for printing the electrically isolating layer by means of analog screen printing, analog flexo printing, analog gravure printing, analog inkjet printing, analog pad printing, hot stamping, and analog thermo transfer printing.
24. The arrangement of claim 21, wherein the third deposition device comprises a printing device configured for printing the electrically isolating layer by means of digital inkjet printing, digital thermo transfer printing, or digital 3-D printing.
25. The arrangement of claim 21, further comprising a subtractive device suitable for forming a discontinuity in an electrically conductive layer formed by the second deposition device on the electrically isolating layer to thereby form the first electrically conductive terminal and the second electrically conductive terminal, such that the first electrically conductive terminal and the second electrically conductive terminal are electrically isolated from each other.
Description
BRIEF DESCRIPTION OF THE FIGURES
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DESCRIPTION OF PREFERRED EMBODIMENTS
(13) Certain embodiments of the present invention are described in detail herein below with reference to the accompanying drawings, wherein the features of the embodiments can be freely combined with each other unless otherwise described. However, it is to be expressly understood that the description of certain embodiments is given by way of example only, and that it should not be understood to limit the invention.
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(15) The method 50 further comprises a step 54 of measuring an electrical resistance-related parameter of the electrically resistive layer 14 along a first direction and determining from the electrical resistance-related parameter a target length L of the electrically resistive layer 14 along the first direction corresponding to the target electrical resistance. In
(16) The measurement of the electrical resistance-related parameter allows determining an electrical resistance to length ratio of the electrically resistive layer 14 and hence using a desired target electrical resistance as an input variable for determining, in view of said ratio, a target length L of the electrically resistive layer 14 along the first direction corresponding to the target electrical resistance.
(17) The method 50 further comprises a step 56 of forming a first electrically conductive terminal 16a and a second electrically conductive terminal 16b on the electrically resistive layer 14 separated by a distance along the first direction corresponding to the target length L. This way, an electrical resistance of a portion of the electrically resistive layer 14 extending between the first electrically conductive terminal 16a and the second electrically conductive terminal 16b along the first direction corresponds to the target electrical resistance. In the embodiment shown, the first electrically conductive terminal 16a and the second electrically conductive terminal 16b are inkjet printed on the electrically resistive layer 14 with a high degree of spatial accuracy such that the distance between the first electrically conductive terminal 16a and the second electrically conductive terminal 16b precisely corresponds to the target length L.
(18) Thus, the electrical resistor 10 is suitable for being connected to external electronic components through the first electrically conductive terminal 16a and the second electrically conductive terminal 16b and for working as a passive circuit element having an electrical resistance corresponding to the target electrical resistance.
(19) In the embodiment shown in
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(21) The method 60 further comprises a step 64 of measuring an electrical resistance-related parameter of the electrically resistive layer 14 along a first direction and determining from the electrical resistance-related parameter a target length L of the electrically resistive layer 14 along the first direction corresponding to the target electrical resistance. Method step 64 of the method 60 illustrated in
(22) The method 60 further comprises a step 66 of forming an electrically isolating layer 20 on the electrically resistive layer 14 that extends along the first direction between a first end 20a and a second end 20b of the electrically isolating layer 20, wherein a distance between the first end 20a and the second end 20b along the first direction corresponds to the target length L. Therefore, an electrical resistance of a portion of the electrically resistive layer 14 covered by the electrically isolating layer 20 along the first direction corresponds to the target electrical resistance. In the embodiment shown, the electrically isolating layer 20 is formed on the electrically resistive layer 14 by means of screen printing using a printing screen or mask corresponding to a negative image of the electrically isolating layer 20 having a length precisely corresponding to the target length L. For example, an electrically resistive printing polymer fluid can be pressed though the printing screen onto the electrically resistive layer 14 so that an electrically isolating layer 20 made of a polymer is formed on the electrically resistive layer 14 having a length along the first direction precisely corresponding to the target length L.
(23) The method 68 further comprises a step 68 of forming a first electrically conductive terminal 16a on the electrically resistive layer 14 directly adjacent to the first end 20a of the electrically isolating layer 20 and forming a second electrically conductive terminal 16b on the electrically resistive layer 14 directly adjacent to the second end 20b of the electrically isolating layer 20. The first electrically conductive terminal 16a and the second electrically conductive terminal 16b are separated along the first direction by the electrically isolating layer 20, which has a length that corresponds to the target length L. Consequently, an electrical path joining the first electrically conductive terminal 16a and the second electrically conductive terminal 16b extends through a portion of the electrically resistive layer 14 having a length corresponding to the target length L and hence an electrical resistance corresponding to the target electrical resistance. Thus, the electrical resistor 10 is suitable for being connected to external electronic components through the first electrically conductive terminal 16a and the second electrically conductive terminal 16b and for working as a passive circuit element having an electrical resistance corresponding to the target electrical resistance.
(24) As shown in
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(26) As shown in
(27) As shown in
(28) As shown in
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(30) As shown in
(31) As shown in
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(35) The electrically isolating element 22 then covers the electrically resistive layer 14 in an overlapping region, which is correspondingly L-shaped and extends between a first end 22a and a second end 22b of the electrically isolating element 22. Subsequently, the first electrically conductive terminal 16a is formed adjacent to the first end 22a of the electrically isolating element 22 and the second electrically conductive terminal 16b is formed adjacent to the second end 22b of the electrically isolating element 22. The first and second electrically conductive terminals 16a, 16b partly overlap the electrically isolating element 22.
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(37) The arrangement 100 further comprises a processing unit 300 that is configured for measuring an electrical resistance-related parameter of an electrically resistive layer 14 formed by the first deposition device 140 along a first direction and for determining from the electrical resistance-related parameter a target length L of the electrically resistive layer 14 along the first direction corresponding to the target electrical resistance. In the embodiment shown, the processing unit 300 comprises a software tool configured for accurately controlling the printing of the first electrically conductive terminal 16a and the second electrically conductive terminal 16a by the second deposition device 160 such that a distance between them precisely corresponds to the target length L. Further, the processing unit 300 comprises a measuring device 310 suitable for measuring the electrical resistance-related parameter. For example, the measuring device 310 may comprise an ohmmeter and/or means for determining a length of the electrically resistive layer 14 along the first direction. In the embodiment shown, the measuring device 310 is suitable for measuring a final electrical resistance-related parameter.
(38) The arrangement 100 further comprises an optical device 400, which in the embodiment shown comprises a photographic camera. The optical device 400 is configured for monitoring and tracking the formation of the first electrically conductive terminal 16a and the second electrically conductive terminal 16b by the second deposition device 160 and for providing information about the corresponding formation process to the processing unit 300.
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(40) The arrangement 100 further comprises a subtractive device 240 configured for forming an opening in an electrically conductive layer 16 formed by the second deposition device 160 according to corresponding embodiments of the invention described above.
(41) Although preferred exemplary embodiments are shown and specified in detail in the drawings and the preceding specification, these should be viewed as purely exemplary and not as limiting the invention. It is noted in this regard that only the preferred exemplary embodiments are shown and specified, and all variations and modifications should be protected that presently or in the future lie within the scope of protection of the invention as defined in the claims.