Direct Write Nozzle for Twisted Pair Traces
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Solution Overview
Problem
Conventional direct write dispensing for microelectronics faces challenges in forming small and complex conductive traces without shorting and minimizing signal interference between adjacent traces, requiring pattern restrictions and additional steps for separation or insulation.
Innovation Solution
A direct write dispensing nozzle assembly that forms conductive cores and non-conductive casings using inner and peripheral nozzles, allowing for the creation of traces adjacent to each other without shorting, with the non-conductive casing contacting previously deposited traces to prevent interference, and enabling the formation of twisted pairs through controlled rotation of nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional direct write dispensing is used to form small and complex conductive traces, then trace complexity and miniaturization are improved, but the likelihood of traces shorting with nearby traces increases
Solution Approach 1:
The patent applies nesting by placing a non-conductive casing material around the conductive trace material in concentric layers from the same nozzle. The non-conductive material forms a protective shell that encapsulates the conductive core, preventing direct contact between adjacent conductive traces while allowing complex miniaturized routing.
Solution Approach 2:
The non-conductive casing material serves as an intermediary barrier between adjacent conductive traces. This intermediate layer physically separates conductive elements that would otherwise be in direct contact, eliminating shorting risks while maintaining the ability to form complex trace patterns.
2Area of stationary object
If conventional direct write dispensing is used to form closely spaced traces, then substrate space utilization is improved, but signal interference between adjacent traces increases
Solution Approach 1:
The non-conductive casing is nested around the conductive trace, creating a shielded configuration. This nested structure allows traces to be placed closer together on the substrate while the non-conductive material acts as insulation, reducing capacitive coupling and signal interference between adjacent traces.
Solution Approach 2:
The non-conductive casing functions as a flexible insulating shell that surrounds the conductive trace. This thin film-like protective layer provides electrical isolation between adjacent traces, enabling higher density routing without excessive signal interference.
3Reliability
If pattern restrictions and additional steps are used to ensure trace separation or insulation, then shorting prevention is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent merges the functions of trace deposition and insulation application into a single simultaneous operation from one nozzle. The conductive and non-conductive materials are dispensed together in a coordinated manner, eliminating the need for separate insulation steps and reducing manufacturing complexity while ensuring reliable trace separation.
Solution Approach 2:
The non-conductive casing material is applied preliminarily around the conductive trace as it is being deposited. This preliminary insulation action ensures that separation is built into the trace structure itself during formation, rather than requiring additional post-processing steps to add insulation.
Data Source
AI summary
A direct write dispensing nozzle assembly and method of forming traces and twisted pairs via direct write dispensing. The method includes dispensing conductive material via an inner nozzle so as to form a conductive core. Non-conductive material may be dispensed via a peripheral nozzle surrounding the inner nozzle so as to form a non-conductive casing surrounding the conductive core. The first conductive core and the non-conductive casing may then be deposited on a substrate or other surface. The trace may be positioned on the substrate such that the non-conductive casing contacts a previously deposited trace. An additional conductive core may be dispensed within the non-conductive casing and the direct write dispensing nozzle assembly may be rotated so as to form a twisted pair.