Direct write dispensing apparatus and method

A direct write dispensing nozzle assembly and method of forming traces and twisted pairs via direct write dispensing. The method includes dispensing conductive material via an inner nozzle so as to form a conductive core. Non-conductive material may be dispensed via a peripheral nozzle surrounding the inner nozzle so as to form a non-conductive casing surrounding the conductive core. The first conductive core and the non-conductive casing may then be deposited on a substrate or other surface. The trace may be positioned on the substrate such that the non-conductive casing contacts a previously deposited trace. An additional conductive core may be dispensed within the non-conductive casing and the direct write dispensing nozzle assembly may be rotated so as to form a twisted pair.

BACKGROUND

Direct write dispensing is often used for forming increasingly small and complex conductive traces for microelectronics. However, the smaller scale and greater complexity increases the likelihood of the traces shorting with nearby traces. Signals traveling through the traces are also more likely to be affected by noise and interference from signals traveling through nearby traces. Conventional direct write dispensing requires pattern restrictions and/or additional steps to ensure that the traces are sufficiently separated from each other or sufficiently insulated from each other. This limits the complexity and miniaturization of the traces and increases the amount of time and effort required to design the microelectronics.

SUMMARY

Embodiments of the present invention solve the above-mentioned problems and provide a distinct advance in the art of direct write dispensing. More particularly, the present invention provides a direct write dispensing nozzle assembly and a method for direct write dispensing traces adjacent to each other without shorting and with minimal signal interference therebetween.

An embodiment of the invention is a method of forming a trace via direct write dispensing. The method includes dispensing conductive material via an inner nozzle so as to form a conductive core. Non-conductive material is dispensed via a peripheral nozzle surrounding the inner nozzle so as to form a non-conductive casing surrounding the conductive core. The first conductive core and the non-conductive casing is then deposited on a substrate or other surface. The trace is positioned on the substrate such that the non-conductive casing contacts a previously deposited trace. In this way, traces may be quickly and easily formed such that the conductive cores of adjacent traces do not short together.

Another embodiment of the invention is a method of forming an electronic twisted pair via direct write dispensing. The method includes dispensing conductive material via a first inner nozzle so as to form a first conductive core. Conductive material is dispensed via a second inner nozzle spaced from the first inner nozzle so as to form a second conductive core spaced from the first conductive core. Non-conductive material is dispensed via a peripheral nozzle so as to form a non-conductive casing surrounding the conductive cores. The inner nozzles and the peripheral nozzle may be rotated about a longitudinal axis so that the first conductive core and the second conductive core form a double helix. The first inner nozzle, the second inner nozzle, and the peripheral nozzle may be independently opened and closed and rotation of the direct write dispensing nozzle assembly may be independently controlled so as to effect a number of helix variations and modifications.

DETAILED DESCRIPTION

Turning toFIGS. 1 and 2, a direct write dispensing nozzle assembly100constructed in accordance with an embodiment of the present invention is illustrated. The direct write dispensing nozzle assembly100may be used for dispensing traces adjacent to each other on a substrate or other electronic component and broadly comprises an inner nozzle10and a peripheral nozzle12for creating a trace102of an electronic circuit.

The inner nozzle10dispenses conductive material104for forming a conductive core106of the trace102and may be an open-ended conduit. The inner nozzle10may be circular, elongated, slot-like, or any other suitable shape such that the conductive core106takes the shape of the inner nozzle10. The inner nozzle10may also taper inwardly or flare outwardly near its open end for improving the dispensing of conductive material104. The inner nozzle10may be selectively and reversibly closeable and/or redirectable. For example, the inner nozzle10may be opened to begin creating the conductive core106and closed to terminate the conductive core106. The inner nozzle10may also be angled, rotated, pivoted, or translated to create essentially any desirable trace path.

The peripheral nozzle12dispenses non-conductive material108for forming a non-conductive casing110of the trace102and may be an open-ended conduit at least partially enclosing or surrounding the inner nozzle10. The peripheral nozzle12may be circular, elongated, slot-like, or any other suitable shape such that the non-conductive casing110takes the shape of the peripheral nozzle12. The peripheral nozzle12may be concentric with the inner nozzle10such that the non-conductive casing110has a uniform thickness around the conductive core106. The peripheral nozzle12may also taper inwardly or flare outwardly near its open end for improving of non-conductive material108and for conforming to the shape of the inner nozzle10. The peripheral nozzle12may be selectively and reversibly closeable and/or redirectable. For example, the peripheral nozzle12may be opened to begin creating the non-conductive casing110and closed to terminate the non-conductive casing110.

Use of the direct write dispensing nozzle assembly100will now be described in more detail. First, the direct write dispensing nozzle assembly100may be positioned near a substrate112such as a ceramic circuit board substrate, as shown in block200ofFIG. 3. To that end, the direct write dispensing nozzle assembly100may be actuated or manually shifted towards the substrate112. Alternatively, the substrate112may be brought into close proximity to the direct write dispensing nozzle assembly100.

The inner nozzle10may then begin dispensing conductive material104so as to form the conductive core106, as shown in block202. The inner nozzle10may initially direct the conductive material104into contact with electronic contacts, buses, or other electronic components of the substrate112for beginning or continuing portions of an electronic circuit. To that end, the inner nozzle10may be selectively opened when the nozzle assembly100is in a desired beginning position.

The peripheral nozzle12may also begin dispensing non-conductive material108so as to form the non-conductive casing110at least partially surrounding, enclosing, encasing, or enveloping the conductive core106, as shown in block204. The peripheral nozzle12may begin dispensing non-conductive material108before, after, or at the same time the inner nozzle10begins dispensing conductive material104. In this way, a first end of the conductive core106may extend beyond, even with, or short of a first end of the non-conductive casing.

The inner nozzle10and the peripheral nozzle12may deposit the conductive material104and the non-conductive material110so that the non-conductive casing110contacts the substrate112adjacent to a previously deposited trace114, as shown in block206. More specifically, the conductive core106may be spaced from a conductive core116of the previously deposited trace114while the non-conductive casing110contacts a non-conductive casing118of the previously deposited trace114.

The inner nozzle10may then discontinue dispensing conductive material104so as to terminate the conductive core106, as shown in block208. The inner nozzle10may direct the conductive material104into contact with electronic contacts, buses, or other electronic components of the substrate112for completing portions of the electronic circuit. To that end, the inner nozzle10may be selectively closed when the nozzle assembly100is in a desired finishing position.

The peripheral nozzle12may also discontinue dispensing non-conductive material108so as to terminate the non-conductive casing110, as shown in block210. The peripheral nozzle12may discontinue dispensing non-conductive material108before, after, or at the same time the inner nozzle10discontinues dispensing conductive material104. In this way, a second end of the conductive core106may extend beyond, even with, or short of a second end of the non-conductive casing.

The above-described nozzle assembly100and method of direct write depositing provides several advantages over conventional nozzles and methods. For example, direct write depositing via the nozzle assembly100optimizes space on the substrate112while preventing the conductive cores106,116from shorting between each other or causing unwanted interference therebetween. The amount of conductive material104and non-conductive material108used to create the conductive core106and the non-conductive casing110can be controlled by opening and closing the inner nozzle10and the peripheral nozzle12. The trace102can be made to follow trace paths having complicated shapes, patterns, and lengths by computer control of the nozzle assembly100. The inner nozzle10and the peripheral nozzle12may be independently controlled so that the conductive core106and the non-conductive casing110may begin and terminate at different points. This may be particularly useful for creating core leads and other circuit components.

A direct write twisted pair nozzle assembly300constructed in accordance with another embodiment of the present invention is illustrated inFIGS. 4 and 5. The direct write twisted pair nozzle assembly300broadly comprises a first inner nozzle302, a second inner nozzle304, and a peripheral nozzle306.

The first inner nozzle302dispenses conductive material for forming a first conductive core400and may be an open-ended conduit. The first inner nozzle302may be circular, elongated, slot-like, or any other suitable shape such that the first conductive core400takes the shape of the first inner nozzle302. The first inner nozzle302may also taper inwardly or flare outwardly near its open end for improving the dispensing of conductive material. The first inner nozzle302may be selectively and reversibly closeable and/or redirectable. For example, the first inner nozzle302may be opened to begin creating the first conductive core400and closed to terminate the first conductive core400. The first inner nozzle302may also be angled, rotated, pivoted, or translated to create essentially any desirable electronic wire, as described in more detail below.

The second inner nozzle304dispenses conductive material and may be an open-ended conduit spaced from the first inner nozzle302for forming a second conductive core402spaced from the first conductive core400. The second inner nozzle304may be circular, elongated, slot-like, or any other suitable shape such that the second conductive core402takes the shape of the second inner nozzle304. The second inner nozzle304may also taper inwardly or flare outwardly near its open end for improving the dispensing action of the second inner nozzle304. The second inner nozzle304may be conjoined with the first inner nozzle302at their upstream ends so that the first inner nozzle302and the second inner nozzle304receive conductive material from a common source. The second inner nozzle304may be selectively and reversibly closeable and/or redirectable. For example, the second inner nozzle304may be opened to begin creating the second conductive core402and closed to terminate the second conductive core402. The second inner nozzle304may also be angled, rotated, pivoted, or translated to create essentially any desirable electronic wire, as described in more detail below. The second inner nozzle304may be controlled independently from the first inner nozzle302.

The peripheral nozzle306dispenses non-conductive material for forming a non-conductive casing404and may be an open-ended conduit at least partially enclosing or surrounding the inner nozzles302,304. The peripheral nozzle306may be circular, elongated, slot-like, “figure-8” shaped or any other suitable shape such that the non-conductive casing404takes the shape of the peripheral nozzle306. A portion of the peripheral nozzle306may be concentric with the first inner nozzle302while another portion of the peripheral nozzle306may be concentric with the second inner nozzle304such that the non-conductive casing404has a uniform thickness around portions of the conductive cores400,402. The peripheral nozzle306may also taper inwardly or flare outwardly near its open end for improving dispensing of non-conductive material and for conforming to the shapes of the inner nozzles302,304. The peripheral nozzle306may be selectively and reversibly closeable and/or redirectable. For example, the peripheral nozzle306may be opened to begin creating the non-conductive casing404and closed to terminate the non-conductive casing404. The peripheral nozzle306may also be controlled independently from the first inner nozzle302and/or the second inner nozzle304.

Use of the direct write twisted pair nozzle assembly300will now be described in more detail. First, the first inner nozzle302and the second inner nozzle304may dispense conductive material so as to form the first conductive core400and the second conductive core402spaced from the first conductive core400, as shown in block500ofFIG. 6. The first inner nozzle302and the second inner nozzle304may begin dispensing the conductive material simultaneously or independently from each other.

The peripheral nozzle306may also dispense non-conductive material such that the non-conductive material at least partially surrounds, encloses, or encases the conductive cores400,402, as shown in block502. The non-conductive material may also be dispensed between the conductive cores400,402to electrically isolate the conductive cores400,402from each other. The peripheral nozzle306may begin dispensing the non-conductive material before, after, or the same time that the first inner nozzle302and/or the second inner nozzle304begin dispensing the conductive material.

The direct write twisted pair nozzle assembly300may be rotated while the conductive cores400,402and the non-conductive casing404are being formed such that the conductive cores400,402twist about each other so as to form a double helix, as shown in block504. Distal ends of the conductive cores400,402, and/or the non-conductive casing404may need to be anchored or fixed so that the rotation of the twisted pair nozzle assembly300twists the conductive cores400,402.

The above-described direct write twisted pair nozzle assembly300and method of forming a twisted pair provide several advantages over conventional nozzles and methods. For example, formation of the conductive cores400,402and non-conductive casing404can be independently controlled so that complex twisted pairs can be created. The speed at which the conductive material and non-conductive material are dispensed and the rate of rotation can be controlled to create twisted pairs having tight or loose helixes and even helixes of varying periods.

A direct write twisted pair nozzle assembly600constructed in accordance with yet another embodiment of the present invention is similar to the direct write twisted pair nozzle assembly300except the direct write twisted pair nozzle assembly600includes a first inner nozzle602, a second inner nozzle604, a first peripheral nozzle606, and a second peripheral nozzle608, as shown inFIGS. 7 and 8. The first inner nozzle602and the second inner nozzle604are similar to the inner nozzles302,304described above and form the first and second conductive cores700,702.

The first peripheral nozzle606is similar to the peripheral nozzle306except the first peripheral nozzle606may be an open-ended conduit at least partially enclosing or surrounding the first inner nozzle602but not the second inner nozzle604for forming a first non-conductive casing704. The first peripheral nozzle606may be circular, elongated, slot-like, or any other suitable shape. The first peripheral nozzle606may be concentric with the first inner nozzle602. The first peripheral nozzle606may also taper inwardly or flare outwardly near its open end for improving the dispensing of non-conductive material and for conforming to the shape of the first inner nozzle602. The first peripheral nozzle606may be selectively and reversibly closeable and/or redirectable. For example, the first peripheral nozzle606may be opened to begin creating the first non-conductive casing704and closed to terminate the first non-conductive casing704.

The second peripheral nozzle608is similar to the first peripheral nozzle606except the second peripheral nozzle608may be an open-ended conduit at least partially enclosing or surrounding the second inner nozzle604but not the first inner nozzle602. The second peripheral nozzle608may be adjacent to or spaced from the first peripheral nozzle606for forming a second non-conductive casing706adjacent to or spaced from the first non-conductive casing704. The second peripheral nozzle608may be circular, elongated, slot-like, or any other suitable shape. The second peripheral nozzle608may be concentric with the second inner nozzle604. The second peripheral nozzle608may also taper inwardly or flare outwardly near its open end for improving the dispensing action of the second peripheral nozzle608and for conforming to the shape of the second inner nozzle604. The second peripheral nozzle608may be selectively and reversibly closeable and/or redirectable independently from the first peripheral nozzle606. For example, the second peripheral nozzle608may be opened to begin creating the second non-conductive casing706and closed to terminate the second non-conductive casing706.

The direct write twisted pair nozzle assembly600may form twisted pairs in substantially the same way as the direct write twisted pair nozzle assembly300. That is, the direct write twisted pair nozzle assembly600may be rotated while the conductive cores700,702and the non-conductive casings704,706are being formed such that the conductive cores700,702twist about each other and the non-conductive casings704,706twist about each other so as to form a double helix.

It will be understood that aspects of the above-described direct write dispensing nozzle assembly100and the direct write twisted pair nozzle assemblies300,600, may be used together or in conjunction with each other. Similarly, steps for forming traces and twisted pairs via the dispensing nozzle assembly100and the direct write twisted pair nozzle assemblies300,600may be used together or in conjunction with each other. For example, adjacent traces may be formed simultaneously and twisted via the direct write twisted pair nozzle assembly300while being deposited on a substrate.