Conductive Traces via Elastomeric Stamp Transfer
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Solution Overview
Problem
Conventional screen printing processes for creating electrically conductive patterns with wide line widths face challenges in achieving high relief heights and lateral dimensions, making it difficult, time-consuming, and expensive to produce high-quality metallic traces with dimensions of at least 30 micrometers or more.
Innovation Solution
A method involving screen printing an ink pattern onto a master tool, applying a stamp-making material to form an elastomeric stamp with a negative pattern, inking the stamp, and using it to transfer the pattern onto a metalized surface for etching, which allows for the formation of electrically conductive traces with desired dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional screen printing process is used to create electrically conductive patterns with wide line widths, then the line width can be achieved (100 micrometers or greater), but the quality of metallic traces is unstable and has technology limits on performance
Solution Approach 1:
The process is segmented into multiple steps: first creating a master tool with screen printing, then using it to fabricate an elastomeric stamp, and finally using the stamp to transfer the pattern. This segmentation allows each step to be optimized independently, achieving both wide line widths and high quality traces.
Solution Approach 2:
An elastomeric stamp is introduced as an intermediary between the screen printing master tool and the substrate. The stamp acts as a mediator that transfers the pattern with high fidelity, enabling precise control of trace quality while maintaining wide line widths.
2Manufacturing precision
If conventional photolithography techniques are used to prepare photoresist patterns, then the process can be performed, but it is technically difficult, time-consuming, and expensive to obtain high relief heights and wide lateral dimensions
Solution Approach 1:
The master tool with the desired pattern is prepared in advance using screen printing, which can easily achieve high relief heights and wide lateral dimensions. This preliminary action eliminates the need for time-consuming photolithography steps during actual production.
Solution Approach 2:
Instead of using photolithography to create patterns directly on the substrate, a master tool is created first and then used to produce multiple copies via the elastomeric stamp. This copying approach is faster and can achieve the required dimensions more easily.
3Manufacturing precision
If conventional photolithography techniques are used to prepare photoresist patterns, then the process can be performed, but it is expensive to obtain high relief heights and wide lateral dimensions
Solution Approach 1:
The elastomeric stamp is a relatively inexpensive, disposable component that can be easily fabricated from the master tool. Multiple substrates can be processed using the same master tool, amortizing the cost and making high-precision wide-line patterns economically viable.
Data Source
AI summary
A master tool is provided with an ink pattern on a major surface thereof. The ink pattern is formed by a screen printing process. A stamp-making material is applied to the major surface of the master tool to form a stamp having a stamping pattern being negative to the ink pattern of the master tool. The stamping pattern is inked with an ink composition and contacted with a metalized surface to form a printed pattern on a metalized surface of a substrate according to the stamping pattern. Using the printed pattern as an etching mask, the metalized surface is etched to form electrically conductive traces on the substrate.