3D Printed Conductive Traces via Predefined Injection
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Solution Overview
Problem
Current methods for integrating conductive traces into three-dimensional manufactured structures face challenges such as low conductivity and manufacturing complexities, particularly in 3D printing, which limit the effectiveness and efficiency of conductive materials within these structures.
Innovation Solution
A method for forming three-dimensional objects with conductive traces involves generating an intermediate structure using additive or subtractive processes and injecting a conductive material with higher electrical and thermal conductivity into predefined locations, followed by curing and post-processing to create integrated intra-structure conductive traces and interconnects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive materials are integrated into three-dimensional manufactured structures using conventional methods, then the structures can achieve basic conductivity, but the conductivity is low and manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-defining conductive trace locations within the 3D model design before manufacturing. The intermediate structure is generated with predefined locations for conductive traces, allowing the conductive material to be precisely injected only where needed. This approach achieves high conductivity in critical areas while avoiding the complexity of post-manufacturing modifications.
Solution Approach 2:
The patent implements local quality by injecting conductive material only at specific predefined locations within the intermediate structure, rather than throughout the entire structure. This creates localized high-conductivity regions exactly where electrical connectivity is needed, improving overall conductivity while minimizing material usage and manufacturing complexity.
2Ease of manufacture
If conductive traces are added after three-dimensional structure manufacturing, then the structure can be manufactured first, but the conductivity integration becomes complex and costly
Solution Approach 1:
The patent merges the conductive trace creation process with the 3D structure manufacturing process itself. By generating an intermediate structure with predefined conductive locations and then injecting conductive material during or immediately after manufacturing, the patent combines what would otherwise be separate operations into a unified process, improving both ease of manufacture and conductivity integration.
Solution Approach 2:
The patent introduces an intermediate structure as a mediator between the 3D model design and the final conductive structure. This intermediate structure contains predefined locations that guide the conductive material injection, serving as a bridge that simplifies the manufacturing process while ensuring proper conductivity integration.
3Reliability
If conventional 3D printing methods are used for conductive materials, then the manufacturing process is simple, but the electrical and thermal conductivity is insufficient
Solution Approach 1:
The patent uses composite materials by combining a base material (from the 3D printing process) with a conductive material (injected into predefined locations). This creates a composite structure where the base material provides structural integrity and the injected conductive material provides high electrical and thermal conductivity, achieving superior performance without sacrificing manufacturing efficiency.
Solution Approach 2:
The patent applies parameter changes by transitioning the conductive material from a liquid or paste state during injection to a solidified state after injection. This phase change allows the material to be easily injected into the intermediate structure and then固化 to provide stable, high-conductivity traces, maintaining manufacturing efficiency while achieving superior conductivity.
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 three-dimensional objects with improved conductivity, overcoming the limitations of existing methods by integrating conductive materials in a truly three-dimensional manner, resulting in structures with lower resistivity and enhanced electrical connectivity.
Implementation Method 1
the solution is cured by directing an electrical current through the solution to generate Joule heating
Data Source
AI summary
A method for forming a three-dimensional object with at least one conductive trace comprises providing an intermediate structure that is generated (e.g., additively or subtractively generated) from a first material in accordance with a model design of the three-dimensional object. The intermediate structure may have at least one predefined location for the at least one conductive trace. The model design includes the at least one predefined location. Next, the at least one conductive trace may be generated adjacent to the at least one predefined location of the intermediate structure. The at least one conductive trace may be formed of a second material that has an electrical and/or thermal conductivity that is greater than the first material.