Antenna Contact Formation via Substrate Stretching
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Solution Overview
Problem
The decreasing size of integrated circuits complicates the manufacturing of suitable antenna or strap contacts that can be effectively connected to the contacts of the integrated circuits, as existing methods struggle to create precise and reliable connections in limited spaces.
Innovation Solution
A method involving the formation of a conductive structure on a substrate with initially short-circuited areas that are mechanically separated to create cross-shaped antenna or strap contacts, followed by stretching the substrate to widen the gaps between these contacts, allowing for precise and efficient contact formation with integrated circuits, using conventional additive or subtractive manufacturing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to form antenna contacts on substrates, then the manufacturing process is simpler, but the gap between contacts cannot be sufficiently reduced to accommodate smaller integrated circuits
Solution Approach 1:
The substrate stretching process segments the originally continuous conductive structure into four separate antenna contacts by widening the gaps between them. The mechanical separation step creates initial gaps, and subsequent stretching further divides the conductive area, enabling precise contact formation with gaps as small as 130µm between consecutive contacts.
Solution Approach 2:
The invention introduces a dimensional transformation by stretching the substrate in two perpendicular directions after mechanical separation. This dual-directional stretching converts the initial mechanical gaps into precisely controlled small gaps between contacts, accommodating the decreasing size of integrated circuits while maintaining manufacturing feasibility.
2Measurement precision
If the substrate is stretched to widen gaps between contacts, then alignment precision is improved, but the manufacturing time increases
Solution Approach 1:
The mechanical separation step performs preliminary gap creation before stretching. By pre-establishing the gap locations through mechanical separation and then applying stretching to widen and precisely position these gaps, the process achieves high alignment precision while optimizing manufacturing time compared to stretching alone.
Solution Approach 2:
The stretching process continuously widens the gaps between contacts in two directions without interruption, maintaining productive action throughout. This continuous stretching from the mechanically separated state efficiently achieves the required alignment precision while minimizing idle time in the manufacturing process.
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 enables the creation of antenna or strap contacts with small gaps between them, facilitating the use of small integrated circuits and reducing manufacturing time and costs, while allowing for precise alignment and connection, even in tight spaces with gaps as small as 130µm between consecutive contacts.
Implementation Method 1
stretching the substrate by means of stretching means after forming the respective antenna contacts or strap contacts in a first direction in order to widen a first gap between the respective antenna contacts or strap contacts; and stretching the substrate by means of stretching means after forming the respective antenna contacts or strap contacts in a second direction perpendicular to the first direction
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
In a method of manufacturing an antenna (11) formed on a substrate (1) an antenna structure (2) is formed on the substrate (1). The antenna structure (2) comprises an area (3) which initially is electrically short-circuited and is designed to be turned into an antenna contact (4a,4b) to be contacted with contacts (12,13) of an integrated circuit (IC). The antenna contact (4a,4b) is formed by mechanically separating the electrically short-circuited 5 area (3) particularly utilizing cutting or stamping means (5).