Out-of-plane spring structures with load layer and non-oxidizing coating
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Solution Overview
Problem
The manufacturing process of stress-engineered springs for out-of-plane structures, such as inductors, requires tight process controls and is costly due to the complexity of releasing and curling the springs to form interlocking coils.
Innovation Solution
A method involving a load layer that can be softened or reflowed by heat or reactant gas, allowing larger spring diameters to assemble into coils, and a non-oxidizing coating to protect the conductive layer from oxidation, enabling higher temperature processing without damaging the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight process controls are used to release and curl springs to form interlocking coils, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the spring structures with embedded latching features before release. The springs are manufactured with integrated latching structures that automatically engage when the springs curl, eliminating the need for complex post-release alignment and assembly procedures. This pre-integration of latching mechanisms simplifies the overall manufacturing process while maintaining high assembly precision.
2Reliability
If conductive material is used for spring structures, then electrical conductivity is improved, but oxidation resistance deteriorates
Solution Approach 1:
The patent employs composite materials by combining a conductive material layer (such as copper or aluminum) with a protective non-oxidizing coating layer (such as gold or inert material). The conductive layer provides the necessary electrical conductivity for the spring structures, while the outer protective layer prevents oxidation and corrosion. This multi-layer composite structure simultaneously achieves both high electrical conductivity and oxidation resistance.
3Ease of manufacture
If higher temperature processing is used to soften load layer, then ease of manufacture is improved, but reliability of conductive layer deteriorates due to oxidation
Solution Approach 1:
The patent applies beforehand cushioning by depositing a protective non-oxidizing coating layer on the conductive material before higher temperature processing steps. This protective layer acts as a barrier that prevents oxidation of the conductive material during elevated temperature processing of the load layer. The cushioning protection is in place before the harmful thermal oxidation process occurs, allowing easy manufacturing while preserving conductive layer reliability.
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 increases process tolerance by allowing larger spring diameters to assemble correctly and maintains coil performance by preventing degradation of the conductive layer, reducing the need for aggressive removal procedures and enhancing stability over time.
Implementation Method 1
A stress gradient is introduced into the metal layer by altering the stress inherent in each of the sub-layers, each sub-layer having a different level of inherent stress
Implementation Method 2
A second coating of a non-oxidizing material coats the structure at a thickness less than a thickness of the second material
Implementation Method 3
A method involving a load layer that can be softened or reflowed by heat or reactant gas
Data Source
AI summary
A structure has at least one structure component formed of a first material residing on a substrate, such that the structure is out of a plane of the substrate. A first coating of a second material then coats the structure. A second coating of a non-oxidizing material coats the structure at a thickness less than a thickness of the second material.