Direct-Write Acoustic Wave Sensors for Faster Low-Cost Fabrication
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Solution Overview
Problem
Traditional methods for fabricating bulk acoustic wave (BAW) and surface acoustic wave (SAW) sensors are time-consuming and expensive due to the use of sophisticated equipment like photo-lithography, necessitating new methodologies for cost-effective and efficient manufacturing.
Innovation Solution
A method involving aerosol jet direct digital printing is used to create acoustic wave sensors by printing a piezoelectric substrate with interdigitated acoustic wave transducers, sensing films, Bragg reflectors, and antennas, allowing for the production of high-Q factor sensors with features as small as 10 μm and enabling roll-to-roll processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional photo-lithography methods are used to fabricate acoustic wave sensors, then manufacturing precision and reliability are maintained, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent replaces traditional photo-lithography (optical/mechanical system) with direct-write printing technology that deposits materials directly onto the substrate. This substitution eliminates time-consuming photolithography steps while maintaining manufacturing precision through controlled material deposition, directly resolving the contradiction between precision and time.
Solution Approach 2:
The invention changes the fundamental manufacturing parameters from batch photo-lithography processes to continuous direct-write printing. By altering the manufacturing approach from optical patterning to direct material deposition, the system achieves comparable precision with significantly reduced manufacturing time.
2Manufacturing precision
If traditional photo-lithography methods are used to fabricate acoustic wave sensors, then manufacturing precision and reliability are maintained, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive photo-lithography equipment and processes with more cost-effective direct-write printing technology. This substitution maintains manufacturing precision through controlled material placement while significantly reducing equipment costs, material waste, and process complexity, thereby resolving the contradiction between precision and cost.
Solution Approach 2:
The direct-write printing approach uses consumable inkjet materials that can be precisely deposited and discarded, replacing expensive reusable photo-lithography equipment and chemicals. This approach maintains precision while reducing overall manufacturing cost through the use of cheaper, disposable printing materials.
3Productivity
If aerosol jet direct digital printing is used to manufacture acoustic wave sensors, then productivity and cost-effectiveness improve, but manufacturing precision must be maintained
Solution Approach 1:
The patent replaces slow, sequential photo-lithography steps with parallel direct-write printing capabilities. The aerosol jet technology enables simultaneous deposition of multiple materials and patterns, dramatically improving productivity while maintaining precision through computer-controlled material placement and deposition parameters.
Solution Approach 2:
The direct-write printing system performs multiple manufacturing functions (deposition, patterning, material placement) in a single integrated process, whereas traditional photo-lithography requires multiple separate steps. This multi-functionality increases productivity while maintaining precision through unified process control.
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 reduces manufacturing costs and time, enabling the production of high-performance acoustic wave sensors with improved detection limits, such as sub-ppm sensitivity, and allows for the creation of disposable sensors with enhanced efficiency and precision.
Implementation Method 1
providing a piezoelectric substrate layer
Implementation Method 2
The printing method can be performed by aerosol jet direct digital printing
Data Source
AI summary
A method of making an acoustic wave sensor includes the steps of providing a piezoelectric substrate layer and printing on the substrate layer a sensor layer comprising a first interdigitated acoustic wave transducer, a sensing film, and positioned on an opposing side of the sensing film from the first interdigitated acoustic wave transducer at least one selected from the group consisting of a second interdigitated acoustic wave transducer and a Bragg reflector. An insulation layer can be printed. An antenna can be printed in an antenna layer, and the insulation layer can be interposed between the antenna layer and the sensor layer. An electrical connection can be printed between the antenna and the first interdigitated acoustic wave transducer. An acoustic wave sensor is also disclosed.