US 5,294,290 A · Computer and electromagnetic energy based mass production method for the continuous flow make of planar electrical circuits

Abstract

The new method concerns the custom designed lowcost mass production of flexible planar circuits which suit particu-larly for one time use and carry complex prints on at least one face thereof, as may be e.g. RF sensitive tickets or marker tags for electronic security systems. The construction both of planar electrical circuit and printed outfit elements in mutual alignment with each other is based on continuous light printing routines in combination with a production carrier protection and a post etching routine. Light printing may be of the LASER, LED, LCS or like type. The method is computer orchestrated and rolls off prior art barriers in view of limits for custom designs of shape, face, outfit, electrical, and even RF properties of such circuits. Custom designs are easily layouted onscreen of a modern personal computer. The data obtained thereof are downloaded to the production line. Changing, hopping sweeping and tuning custom circuit and print designs, without any format restriction and at full process speed is unprecedentedly introduced. Forming tools have been abandoned. As an exclusive longlife production tool electromagnetic wave energy is extensively used. The production web can be selected from a wide choice of materials and thus define circuit properties from flexible printed circuit wafers over tear-resistive spunbond labels to paper-like tags or stickers which may even be washed and sewn and nicely go one way with a pretty commercial face.

Claims72

Dependent claims

A method of forming an inductive/capacitive (LC) circuit, said method comprising the steps of:

(a) forming, by aid of light printing an electrically nonconductive material, two substantially identical, conductive multi-turn spirals (37, 20-27, 36, 28-35, 5) each turn of which forms a substantially closed loop;
(b) positioning said spirals on opposite surfaces of a dielectric layer, with each spiral being oppositely wound with respect to the other when both are viewed from the same side of said dielectric layer, opposing portions of each spiral being positioned in substantial registery with opposing portions of the opposite spiral, respectively;
(c) providing a conductive connection between at least one predetermined portion (36, 37) of each spiral with an opposing portion of the other spiral, the resulting circuit thus assembling from a series of concentric path loops exhibiting both distributed inductive and capacitive components.

A method of constructing planar electrical circuits of arbitrary design and flexible shape, comprising at least the steps of:

(a) continuously providing a flexible, insulative substrate having a first and a second face;
(b) continuously providing a continuous metal foil having a first and a second face, said first face being blank,
(c) continuously providing a sealing layer depositable at least on one of said first faces of said substrate and said metal foil;
(d) continuously bringing in an at least touching superposition said first faces of said substrate and metal foil and said sealing layer spaced therebetween, thereby forming a connectable combination;
(e) continuously connecting said combination, in a manner to form an at least tri-layered flexible sandwich construction having the sealing layer as its central component, by activating said sealing layer;
(f) continuously controlling light in at least one first light printer, for continuously positively shaping and depositing, under the influence of at least one of pressure and heat, from a meltable powder a plurality of planar insulative film paths on said second face of said metal foil of said at least tri-layered sandwich construction, said plurality of insulative film paths forming at least one repetitive etchant resistive film pattern (each of which) having an outline defining the outline of at least one repetitive conductor path pattern to be successively provided on said substrate;
(g) continuously etching the thus insulativley film-patternized sandwich construction;
(h) continuously drying the etched construction;
(i) repetitively providing severing cuts or perforations in the construction for facilitating its division into individual planar electrical circuits.

6 more elements

A method of constructing planar electrical circuits of arbitrary design and shape and comprising, on the first face of an insulative sheet, conductive paths to form at least one conductive pattern, and further comprising, on the second face of said sheet, an application specific preparation, said method comprising at least the steps of:

(a) providing a sheet having a first and a second face and consisting of various layers and being--at least over part of its total thickness--insulative;
(b) at least one time application specifically treating said second face of said sheet;
(c) providing a printing substance having properties and shape to replace both material and constructive function of a commonly known toner within an electrophotographic printing system;
(d) defining and positively forming, by way of an electrophotographic printing process, from said printing substance at least one mask pattern, the outline of which defining the outline of said at least one conductive pattern to be generated;
(e) utilizing said mask pattern for forming, on the first face of said application specifically treated sheet, said at least one conductive pattern;
(f) at least one time further application specifically treating the thus obtained construction;
(g) finally shape-cutting the thus obtained construction to obtain individual planar electrical circuits.

4 more elements

Dependencies are inferred from the claim text.

Computer and electromagnetic energy based mass production method for the continuous flow make of planar electrical circuits

Life of this patent

Computer and electromagnetic energy based mass production method for the continuous flow make of planar electrical circuits

Life of this patent

Abstract

Claims72