Skewed grooves for 3D printed nonplanar circuits

Abstract

A. method. of manufacturing‘ a product (1) with an area (2) having conductive layers (3, 4) on surfaces (5, 6) of a substrate (7), said surfaces (5, 6) being separated by a groove (8), the method comprising the steps of 3D printing and physical vapor deposition, wherein in the step of 3D printing the surfaces (5, 6) on opposite sides of the groove (8), the groove (8) is made to partially extend below one (5) of the surfaces as seen in a viewing direction (A) perpendicular to the surfaces (5, 6), and that after the 3D printing operation is complete, the area (2) comprising the surfaces (5, 6) and the groove (8) are subjected to physical vapor deposition to provide electrically conductive layers (3, 4) at least on top of the surfaces (5, 6).

Description

The invention relates to a method of manufacturing a product with an area having electrically conductive layers on surfaces of a substrate, said surfaces being separated by a groove, the method comprising the steps of 3D printing and physical vapor deposition. The website https: / / www.ipcm.it / en / article / whyandhoware3d printedpartscoated.aspx#2 discloses that 3D printed components made in the most diverse materials are increasingly widespread, thanks to the possibilities offered by this fast and inexpensive production technology conceived for prototyping' or :manufacturing' parts with complex geometries. However, even these parts are subject to wear, corrosion, and harsh environmental conditions that can compromise their aesthetic and functional characteristics. Based on and utilizing the general technologies of 3D printing and physical vapor deposition, the invention aims to provide a method of manufacturing a product with electrical signal paths on threedimensional surfaces of such product. The invention is characterized by the features of one or more of the appended claims. The method of the invention is characterized in that in the step of 3D printing' the surfaces on opposite sides of the groove, the groove is made to partially extend below one of the surfaces as seen in a viewing direction perpendicular to the surfaces, and that after the 3D printing' operation is complete, the area comprising the surfaces and the groove are subjected to physical vapor deposition to provide electrically conductive layers at least on top of the surfaces on opposite sides of the groove. Hence, the physical vapor deposition is _ 2 _ used to deposit a thin layer of electrically conducting material on top of the surfaces of the substrate. Since the groove is made to partially extend below one of the surfaces as seen in a top view, i.e. in a viewing direction perpendicular to the surfaces of the substrate, there will be a. perfect electrical DC isolation. Besides that there will only remain a moderate inductive and capacitive coupling between the electrically conductive layers on opposite sides of the groove, since the part of the groove that in the viewing' direction is behind. one of the surfaces, does not receive the electrically conducting material that is deposited on the surfaces of the substrate with the physical vapor deposition step. In a suitable arrangement the method of the invention is employed such that in a viewing direction perpendicular to the electrically conductive layers on the surfaces, the groove is made to slope down or away from a first surface of the surfaces, and to extend behind a second surface of said surfaces. Suitably at least one of the electrically conductive layers is further provided in a first part of the groove, which first part is visible in the viewing direction perpendicular to the surfaces. It is possible that the surfaces on opposite sides of the groove are flush, but the beauty of the invention is that it also makes possible that the surfaces on opposite sides of the groove are made nonplanar. Accordingly very complex and diversely shaped products can be manufactured with the method of the invention. The invention. is also embodied. in a product with an area having electrically conductive layers on surfaces of a _ 3 _ substrate, said surfaces being separated by a groove, wherein the surfaces support electrically conductive layers, one of said conductive layers extends onto a first part of the groove which is visible in the viewing direction perpendicular to the surfaces. Preferably a second part of the groove which in the viewing direction perpendicular to the surfaces extends behind one of the surfaces is free from the conductive layer. This guarantees a perfect electrical isolation between the electrically conductive layers provided on top of the surfaces of the substrate. It is further preferred that in a viewing direction perpendicular to the electrically conductive layers on the surfaces, the groove slopes down or away from a first surface of the surfaces on opposite sides of the groove, and extends below or behind a second surface of said surfaces. In a preferred embodiment the surfaces of the substrate are nonplanar. The invention opens up the way to construe very complex and diversely shaped products, however ill a favorable embodiment of the invention, the product is an electrical or radio frequency probe. The accompanying drawing, which is incorporated into and forms a part of the specification, illustrates one or more embodiments of the present invention and, together with the description, serves to explain. the principles of the invention. The drawing is only for the purpose of illustrating one or more embodiments of the invention and is not to be construed as limiting the invention. _ 4 _ In the drawing: figure 1 schematically provides a crosssectional view at the substrate having surfaces on opposite sides of a groove, wherein on top of the surfaces in electrically conductive layer is applied; figure 2 provides an image taken from. a a scanning electron microscope showing the groove between nonplanar surfaces on top of which electrically conductive layers are applied; and figure 3 provides an isometric view at the substrate manufactured according to the invention. Whenever in the figures the same reference numerals are applied, these numerals refer to the same parts. Making first reference to figure 1 it shows the product 1 resulting from the method of the invention wherein the product 1 comprises an area 2 having conductive layers 3, 4 on surfaces 5, 6 of a substrate 7, said surfaces 5, 6 being separated by a groove 8, the method comprising the steps of 3D printing and physical vapor deposition. In the step of 3D printing the surfaces 5, 6 on opposite sides of the groove 8, the groove 8 is Inade to partially extend below one of the surfaces, in this example below the surface 5, as seen in a viewing direction perpendicular to the surfaces 5, 6, which viewing direction is symbolized with the arrows A. After the 3D printing operation is complete, the area comprising the surfaces 5, 6 and the groove 8 are subjected to physical vapor deposition to provide the electrically conductive layers 3, 4 at least CHI top (of the surfaces 5, 6. It shows further in figure 1 that in the viewing direction A perpendicular to the surfaces 5, 6, the groove 8 is made to _ 5 _ slope down from a first surface 6 of the surfaces 5, 6, and to extend. below a second surface 5 of said surfaces 5, 6. A better illustration provides figure 3, in which the Z direction equates with said viewing direction A perpendicular to the surfaces 5, 6 as mentioned in relation to figure 1. Further at least one of the electrically conductive layers 4 is further provided in a first part 8 of the groove 8, which first part 8 is visible in the viewing direction A perpendicular to the surfaces 5, 6. A second part 8 of the groove 8 which in the viewing direction A perpendicular to the surfaces 5, 6 extends behind the surface 5, is free from a conductive layer. Although not shown in figure 1, with the method of the invention it is possible that the surfaces 5, 6 on opposite sides of the groove 8 are made nonplanar. Figure 2 shows as an example an image from a scanning electron microscope showing the groove between nonplanar surfaces on top of which electrically conductive layers 3, 4 are applied. It is visible that the groove 8 slopes down from the surface 4 of the substrate. Although. the invention. has been. discussed. in the foregoing with reference to EHI exemplary embodiment (Hf the invention, the invention is not restricted to this particular embodiment which can be varied in many ways without departing from the invention. The discussed exemplary embodiment shall therefore not be used to construe the appended claims strictly in accordance therewith. On the contrary the embodiment is merely intended to explain the wording of the appended claims without intent to limit the claim to this exemplary embodiment. The scope of protection of the invention shall therefore be construed in accordance with the appended claims only, wherein _ 6 _ a possible ambiguity in the wording of the claims shall be resolved using this exemplary embodiment. Variations and modifications of the present invention will be obvious to those skilled. in the art and. it is intended. to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference. Unless specifically stated as being essential above, none of the various components or the interrelationship thereof are essential to the operation. of the invention. Rather, desirable results can be achieved by substituting various components and / or reconfiguration of their relationships with one another. In the following section aspects of the invention are itemized. 1. A method of manufacturing a product (1) with an area (2) having conductive layers (3, 4) on surfaces (5, 6) of a substrate (7), said surfaces (5, 6) being separated by a groove (8), the method comprising the steps of 3D printing and physical vapor deposition, characterized in that in the step of 3D printing the surfaces (5, 6) on opposite sides of the groove (8), the groove (8) is made to partially extend below one (5) of the surfaces as seen in a viewing direction (A) perpendicular to the surfaces (5, 6) of the substrate (7), and that after the 3D printing operation is complete, the area (2) comprising the surfaces (5, 6) and the groove (8) are subjected to physical vapor deposition to provide electrically conductive layers (3, 4) at least on top of the surfaces (5, 6). 2. The method of claim 1, characterized in that in a viewing direction (A) perpendicular to the electrically conductive layers (3, 4) on the surfaces (5, 6), the groove (8) is made to slope down fran a first surface (6) of the _ 7 _ surfaces, and to extend below a second surface (5) of said surfaces. 3. The method of claim 1 or 2, characterized in that at least one of the electrically conductive layers (3, 4) is further provided in a first part (8) of the groove (8), which first part (8) is visible in the viewing direction (A) perpendicular to the surfaces (5, 6). 4. The method of any one of claims 13, characterized in that the surfaces (5, 6) on opposite sides of the groove (8) are made nonplanar. 5. A product (1) with an area (2) having conductive layers (3, 4) on surfaces (5, 6) of a substrate, said surfaces (5, 6) being separated by a groove (8), characterized in that the surfaces (5, 6) support electrically conductive layers (3, 4), one of said conductive layers extends onto a first part (8) of the groove (8) which is visible in the viewing direction (A) perpendicular to the surfaces (5, 6). 6. The product according to claim 5, characterized in that a second part (8) of the groove (8) which in the viewing direction UH perpendicular to the surfaces (5, 6) extends behind one (5) of the surfaces is free from the conductive layer. 7. The product according to claim. 5 or claim 6, characterized in that in a viewing direction (A) perpendicular to the surfaces (5, 6), the groove (8) slopes down from a first surface (6) of the surfaces on opposite sides of the groove (8), and extends behind a second surface (5) of said surfaces. 8. The product according to any one of claims 57, characterized in that the surfaces (5, 6) of the substrate are nonplanar. 9. The product according to any one of claims 58, characterized in that the product is a probe. _ 8 _

Claims

l. A method for manufacturing a product (l) with an area (2) with conductive layers (3, 4) on surfaces (5, 6) of a substrate (7), where the aforementioned surfaces (5, 6) are separated by a groove (8), where the method the steps of 3D printing and physical includes vapor deposition, characterized by the fact that in the step of the 3D printing the surfaces (5, 6) on opposite sides sides of the groove (8), the groove (8) partially under a (5) of the surfaces (5, 6) is made, seen in a viewing direction (A) perpendicular to the surfaces (5, 6) of the substrate (7), and that after the 3D printing operation is completed, the area (2) that includes the surfaces (5, 6) and the groove (8) be subjected to physical vapor deposition to at least on top of the surfaces (5, 6) electrically conductive layers (3, 4) to provide.

2. Method according to claim 1, characterized by in a viewing direction (A) perpendicular to the electrically conductive layers (3, 4) on the surfaces (5, 6), the groove (8) becomes made to from a first surface (6) of the surfaces to incline, and to extend under a second surface (5) of the mentioned surfaces (5, 6).

3. Method according to claim 1 or 2, characterized because at least one of the electrically conductive layers (3, 4) furthermore, the first part (8') of the groove is provided (8), which first part (8') is visible in the viewing direction (A) perpendicular to the surfaces (5, 6).

4. Method according to one of the conclusions 13, characterized by the fact that the surfaces (5, 6) are opposite sides of the groove (8) are non-planar made.

5. A product (1) with an area (2) with conductive layers (3, 4) on surfaces (5, 6) of a substrate, where mentioned surfaces (5, 6) are separated by a groove _ 9 _ (8), characterized by the fact that the surfaces (5, 6) are electrical carry conductive layers (3, 4), where one of the aforementioned conductive layers extend on a first part (8) of the groove (8) that is visible in the viewing direction (A) perpendicular to the surfaces (5, 6).

6. The product referred to in claim 5, characterized because a second part (8) of the groove (8) that is in the viewing direction (A) extends perpendicular to the surfaces (5, 6) behind a (5) of. the surfaces (5, 6) is free of the conductive layer.

7. Product according to claim 5 or claim 6, characterized by the fact that in a viewing direction (A) perpendicular to the surfaces (5, 6), the groove (8) slopes from a first surface (6) of the surfaces on opposite sides of the groove (8), and extends behind a second surface (5) of the mentioned surfaces (5, 6).

8. Product according to one of the claims 57, characterized by the fact that the surfaces (5, 6) of the substrate be non-planned.

9. Product according to one of the claims 58, characterized by the fact that the product is a probe. 1 / 3

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