Electronic Circuit Application on Curved Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods fail to apply precision electronic circuits to complex curved surfaces, such as ogive nose cones, due to the difficulty in achieving uniform geometry and thickness in harsh environments.
Innovation Solution
A method and apparatus that divide the curved surface into smaller sections, allowing for precise application of a dielectric material and conductive cermet using a computer-controlled spray head and stencil segments, ensuring uniform thickness and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If prior art techniques are used to apply circuits to complex curved surfaces, then the process is simpler, but manufacturing precision and uniform geometry cannot be achieved
Solution Approach 1:
The curved surface is divided into multiple discrete zones, each treated separately with its own stencil and application parameters. This segmentation allows precise control of circuit geometry on each zone while maintaining uniformity across the entire curved surface, directly resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
Different stencils with customized patterns are applied to different zones of the curved surface, allowing each region to have locally optimized circuit geometry. This local quality approach enables precise manufacturing control adapted to specific surface characteristics while keeping the overall process manageable through modular stencil design.
2Manufacturing precision
If the entire curved surface is treated as one section, then the process is faster, but manufacturing precision and uniform thickness cannot be achieved
Solution Approach 1:
The curved surface is divided into multiple discrete zones that can be treated in sequence or parallel. This segmentation enables precise thickness control in each zone through dedicated stencils while maintaining overall productivity by allowing systematic progression through zones without requiring complete surface rework.
Solution Approach 2:
Stencils are pre-configured with precise patterns and dimensions before application to the curved surface. This preliminary preparation of stencils ensures that when applied to different zones, the circuit geometry and dielectric thickness are controlled with high precision, resolving the contradiction between manufacturing precision and application efficiency.
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
Enables the precise and rugged application of electronic circuits on curved surfaces, maintaining performance in extreme conditions while reducing application costs.
Implementation Method 1
The application of dielectric is preferably performed by a computer controlled spray head
Implementation Method 2
screening or stenciling a layer of electrically conductive patterned or solid material onto the dielectric
Implementation Method 3
When fired at high temperatures, the metal particles melt and fuse together, so that the metal particles become an integral electrical conductor
Data Source
AI summary
An electric circuit is applied to an object having a curved surface. The curved surface of the object is divided into sections, and the circuit is applied one section at a time. The circuit is formed between layers of dielectric material. The dielectric is applied by a computer-controlled device, which controls the position of a spray head and the rotation of the object, such that the spray head is held substantially perpendicular to the surface of the object at all times, and such that a controlled thickness of dielectric material can be deposited. The fine-featured circuits formed by the invention are rugged, and can be used on objects intended to be exposed to harsh environments.