Directed Energy Carbon Patterning for Mask-Free Circuit Deposition
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Solution Overview
Problem
Existing methods for forming precise patterns of carbon and other elements in electrical circuits require complex physical and chemical processes, including the use of masks and uncontrolled decomposition, making it difficult to achieve precise, efficient deposition.
Innovation Solution
A method using directed energy to polymerize and decompose carbon-based monomers in a controlled manner, allowing for the formation of precise patterns without masks, by applying electromagnetic radiation, high kinetic energy particles, or electric currents to activate monomers and convert them into pure carbon or other elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masks and uncontrolled decomposition are used to form carbon patterns, then carbon deposition can be achieved, but manufacturing precision and process complexity increase
Solution Approach 1:
The patent removes the mask component entirely from the process. Instead of using masks to define patterns, the invention uses directed energy (electron beams, ion beams, or focused electromagnetic radiation) to selectively activate and decompose carbon-containing gases only in the desired pattern areas, eliminating the need for physical masks and their associated alignment and handling complexity
Solution Approach 2:
The patent replaces the mechanical mask system with a field-based control system. Directed energy beams (electronic, ionic, or electromagnetic fields) are used to precisely control where carbon deposition occurs, substituting mechanical pattern definition with field-based spatial control for higher precision and flexibility
2Manufacturing precision
If general heating is used to deposit carbon from gas phase, then carbon deposition is achieved, but deposition control and pattern precision deteriorate
Solution Approach 1:
The patent applies energy locally and selectively to specific regions where carbon deposition is desired. Directed energy beams can be scanned or focused to activate carbon-containing gases only in targeted areas, creating precise patterns while avoiding unnecessary heating of the entire substrate or chamber, thus improving both precision and energy efficiency
Solution Approach 2:
The patent uses pulsed or scanned directed energy beams rather than continuous general heating. The energy is applied in controlled pulses or scanned across the substrate in a systematic pattern, allowing precise temporal and spatial control over when and where carbon deposition occurs, improving pattern fidelity and reducing total energy consumption
3Manufacturing precision
If photolithography is used to form patterns, then precise patterns can be achieved, but the number of process steps and device complexity increase
Solution Approach 1:
The patent combines multiple separate process steps into a single integrated operation. Instead of requiring separate steps for mask application, photolithographic pattern formation, and carbon deposition, the invention merges these functions into one step where directed energy simultaneously defines the pattern and deposits carbon in the desired configuration, dramatically reducing process complexity and improving productivity
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 efficient production of conducting carbon networks and other elements with unique electrical properties, suitable for circuitry, capacitors, and electronic applications, by reducing the need for masks and simplifying the deposition process.
Implementation Method 1
The solid substrate is heated at the point of incidence of the directed energy emission
Implementation Method 2
causing the reactive gas to decompose or polymerize on or near the surface of the solid substrate
Implementation Method 3
causing the reactive gas to decompose or polymerize on or near the surface of the solid substrate
Data Source
AI summary
This invention claims a method for creating patterns of carbon or other elements as deposits on the surface of substrates or as self-supporting filaments in liquid or solid media by the selected application of directed energy. In some embodiments, the deposits or filaments may be of primary interest because of their mechanical properties. In other embodiments, the patterns may have useful physical properties such as being electrically conductive, semi-conductive or electric insulators. Many different deposit precursors, types of directed energy, and adjunct reagents are described. The invention anticipates numerous different embodiments created by selecting various combinations of these elements and sequences of application as a means to build complex devices. In particular, the patterns may constitute the elements of an electric circuit or device (e.g. wires, capacitors, diodes, transistors).