Laser Patterned Conductive Films for Reconfigurable Device Prototyping
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Solution Overview
Problem
Current methods for making electronic and optical device components require large-scale clean rooms and are not easily reconfigurable, limiting rapid device prototyping and design evolution, and are limited to producing primarily single-function components.
Innovation Solution
A process using laser processing to introduce chemical and/or structural changes in substrates and films, allowing for the creation of components with multiple functionalities integrated on the same substrate or film, without the need for large-scale clean rooms and enabling easy configurability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If current manufacturing methods are used, then components can be produced with established processes, but large-scale clean rooms are required and reconfigurability is limited
Solution Approach 1:
The patent replaces traditional mechanical and chemical manufacturing processes (requiring clean rooms) with laser-based processing. The laser system enables direct writing and patterning of conductive materials, eliminating the need for complex clean room infrastructure while providing full reconfigurability through software-controlled laser paths.
Solution Approach 2:
The invention changes the fundamental processing parameters from wet chemistry and thermal processing to laser-induced localized heating and ablation. By controlling laser power, pulse duration, and scanning speed, the system achieves precise material transformation without requiring controlled environmental conditions, thus eliminating clean room requirements.
2Productivity
If traditional assembly processes are used, then single function components can be manufactured, but multiple functions require separate components and assembly steps
Solution Approach 1:
The patent merges multiple manufacturing operations into a single laser processing step. The laser system can simultaneously or sequentially deposit, pattern, and transform materials in one continuous process, integrating what would traditionally require separate fabrication and assembly steps into a unified manufacturing approach.
Solution Approach 2:
The laser processing system performs multiple functions using a single tool: it can deposit conductive materials, pattern circuits, create thermal zones, and transform material phases. This multi-functional capability eliminates the need for separate equipment and processes for each manufacturing step, reducing overall device complexity while improving integration efficiency.
3Loss of time
If rapid prototyping is pursued, then design evolution can accelerate, but current methods lack reconfigurability and require clean rooms
Solution Approach 1:
The replacement of complex clean room infrastructure with a compact laser processing system dramatically simplifies the manufacturing setup. The laser system can be deployed in standard laboratory environments, eliminating the time and effort required to maintain clean room facilities while enabling rapid iteration and prototyping.
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 rapid device prototyping, design change, and evolution by producing components with integrated electronic and optical functionalities, enhancing flexibility and efficiency in device manufacturing.
Implementation Method 1
lasers could also be used to induce chemical and/or structural changes in substrates and films with distinct electronic properties
Implementation Method 2
uses a laser to introduce chemical and/or structural changes and/or removal of material through ablation or similar laser removal processes
Data Source
AI summary
The present invention relates to processes of making components for electronic and optical devices using laser processing and devices comprising such components. Such process uses a laser to introduce chemical and/or structural changes in substrates and films that are the raw materials from which components for electronic and optical devices are made. Such process yields components that can have one or more electronic and/or optical functionalities that are integrated on the same substrate or film. In addition, such process does not require large-scale clean rooms and is easily configurable. Thus, rapid device prototyping, design change and evolution in the lab and on the production side is realized.