Wire Dispensing Device for Conformal Electronics
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Solution Overview
Problem
Current additive manufacturing techniques face limitations in automating the placement of wires, fibers, or filaments, particularly in creating complex electronic structures and conformal electronics, where versatility and precise interconnection are needed.
Innovation Solution
A wire dispensing device with a motion system, spool, feed mechanism, cutting system, and control system that allows for dispensing, cutting, and welding of various diameters of wires and filaments, integrated with other fabrication methods for creating multilayer circuit boards and conformal electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated wire placement is implemented, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The device is divided into distinct functional modules: a spool assembly for wire storage, a feed mechanism for wire transport, a dispensing mechanism for precise placement, and a cutting mechanism for wire trimming. Each module performs a specific function, allowing for modular design that reduces overall system complexity while maintaining high precision wire placement capabilities.
Solution Approach 2:
A feed mechanism acts as an intermediary between the spool and the dispensing mechanism, controlling wire tension and positioning. This intermediary component simplifies the coordination between different system elements, enabling precise wire placement without requiring complex direct control between all components.
2Adaptability or versatility
If multiple wire diameters and material types are supported, then adaptability is improved, but device complexity increases
Solution Approach 1:
The dispensing mechanism is designed with universal capabilities to handle multiple wire types including conductive wires, optical fibers, and carbon fiber filaments of various diameters. The system can accommodate different material properties and wire configurations through a single multi-functional platform, eliminating the need for separate specialized equipment for each wire type.
3Productivity
If integration with other fabrication methods is achieved, then productivity is improved, but device complexity increases
Solution Approach 1:
The wire dispensing device is integrated with other additive manufacturing components and fabrication methods into a unified system. The device can operate independently or in conjunction with 3D printing, laser processing, and other manufacturing techniques, combining multiple functions into a single system that improves overall productivity without requiring separate standalone equipment for each process.
Data Source
AI summary
A system for manufacturing electronics includes a wire dispensing tool head, a motion system for positioning a dispensing head around a part being fabricated, a spool for holding spooled wire, a feed mechanism operatively connected between the spool and the wire dispensing tool head for feeding the wire from the spool to the wire dispensing tool head, a cutting system configured to cut the wire after dispensement from the wire dispensing tool head, and a control system operatively connected to the motion system.