3D Printed Circuit Wiring Heating to Prevent Swelling and Cracking

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Solution Overview

Problem

Existing methods for manufacturing circuit wiring through three-dimensional additive manufacturing face issues of swelling and cracking due to thermal expansion of the insulating layer when metal ink is fired, which can distort the circuit wiring.

Innovation Solution

The method involves discharging a fluid containing metal particles onto a resin member and forming circuit wiring by heating at a temperature based on the glass transition point, linear expansion coefficient, and room temperature to control thermal expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the metal ink is fired by heating to form circuit wiring, then the circuit wiring is successfully formed, but the insulating layer expands causing swelling or cracking of the circuit wiring

Engineering Contradiction:
Improvecircuit wiring integrityVSAvoidthermal expansion of insulating layer
Core Design Contradiction:
Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter changes by carefully controlling the heating temperature and heating speed during the firing process. By optimizing these thermal parameters, the metal ink is successfully fired to form conductive circuit wiring while the insulating layer's thermal expansion is kept within acceptable limits, preventing swelling and cracking of the circuit wiring.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent directly addresses thermal expansion by selecting an insulating layer material with appropriate thermal expansion characteristics. The material is chosen so that its linear expansion coefficient produces expansion within a specific range when heated to the firing temperature, ensuring that the circuit wiring formed on top does not suffer from swelling or cracking while still allowing successful formation of the wiring.

Inventive Principle:
Principle #37Thermal expansion

2Productivity

If the heating temperature is increased to cure the metal ink faster, then the productivity is improved, but the thermal expansion of the insulating layer increases causing more swelling or cracking

Engineering Contradiction:
Improvecircuit wiring formation speedVSAvoidcircuit wiring integrity
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent optimizes the heating temperature parameter to achieve the right balance between productivity and quality. By conducting experiments and simulations, the patent determines the optimal heating temperature range that allows the metal ink to be cured efficiently while keeping the insulating layer's thermal expansion within acceptable limits, thus preventing circuit wiring defects.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies partial action by using a heating temperature that is sufficient to cure the metal ink but not excessively high. This controlled approach ensures that the thermal energy provided is just enough to achieve the desired curing effect without causing excessive thermal expansion of the insulating layer that would lead to circuit wiring swelling or cracking.

Inventive Principle:
Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach effectively suppresses the swelling and cracking of circuit wiring by managing thermal expansion within desired limits, ensuring the integrity and performance of the circuit wiring.

Implementation Method 1

heating being performed at a heating temperature based on a glass transition point of the resin material, a linear expansion coefficient of the resin material, and a room temperature

Methodology Applied
Scientific EffectGlass transition:

Implementation Method 2

the insulating layer expands in response to the linear expansion coefficient of the resin material constituting the insulating layer

Methodology Applied
Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12550268B2Method for manufacturing circuit wiring by three-dimensional additive manufacturing
Publication Date: 2026.02.10 FUJI CORP
  • US12550268B2 patent drawing
  • US12550268B2 patent drawing
  • US12550268B2 patent drawing

AI summary

In a case where a circuit wiring is formed on a resin member by three-dimensional additive manufacturing, a method for manufacturing the circuit wiring by three-dimensional additive manufacturing capable of suppressing swelling or cracking of the circuit wiring is provided. A method for manufacturing a circuit wiring by three-dimensional additive manufacturing includes a discharging step of discharging a fluid containing a metal particle onto a resin member formed of a resin material; and a circuit wiring forming step of forming a circuit wiring by heating the fluid containing the metal particle discharged onto the resin member at a heating temperature to be cured, and the heating being performed at the heating temperature based on a glass transition point of the resin material, a linear expansion coefficient of the resin material, and a room temperature.