Method of fabricating electro-mechanical devices by...

Details Method of fabricating electro-mechanical devices by... Method of fabricating electro-mechanical devices by...

1997-10-27

2001-03-13

Ortiz, Angela (Department: 1732)

Plastic and nonmetallic article shaping or treating: processes

Forming electrical articles by shaping electroconductive...

C264S254000, C264S255000, C264S272190, C264S308000, C264S427000

Reexamination Certificate

active

06200508

ABSTRACT:

FIELD OF THE INVENTION
This invention relates to the fabrication of electromechanical devices. In particular it relates to the fabrication of such devices by depositing successive layers of different materials.
BACKGROUND OF THE INVENTION
The invention is primarily directed to the fabrication of small devices such as miniature switches, motors and the like. The manufacture of these components with conventional techniques is difficult and expensive, and this can be an impediment to large scale use of the devices in wearable systems and other applications where size and weight are important limitations.
Accordingly, it is an object of the invention to provide an improved method of fabricating electromechanical devices. A more specific object is to provide a method which is relatively low in cost. A further object is to provide a method of fabricating electro-mechanical devices which is also efficient for low-volume production for prototypes and the like used in the development and testing of systems employing these devices.
SUMMARY OF THE INVENTION
The invention makes use of printing techniques to build three dimensional structures. Specifically, it deposits on a substrate support successive layers of a device, the layers and/or portions thereof being of different materials, e.g., conductors and insulators, to provide the desired characteristics of the device. The substrate support may be used only to provide a support for the printing process, in which case it will usually be removed after the device is fabricated. Alternatively, the support may be a functioning part of the fabricated device.
In the preferred embodiment of the invention the deposition process is accomplished by means of a conventional ink jet technique, by projecting through a set of nozzles the constituent materials of the various portions of the fabricated device. The nozzles may have a fixed orientation and be translatable along three axes, in which case the device being fabricated will be constructed as a succession of parallel planar layers. The same progression of layers may be obtained by printing the layers through a succession of masks.
In another arrangement the nozzles are provided with an essentially complete range of movement. Specifically, they are mounted for three axes translation and their orientations can be varied about two axes of rotation. This facilitates the fabrication of parts having complex structures.
While the invention is particularly useful in the fabrication of miniature components, it is by no means limited to small sizes. Larger devices can also be constructed and for such devices the invention is particularly useful when small quantities are desired.


REFERENCES:
patent: H1523 (1996-04-01), Mammone et al.
patent: 4935174 (1990-06-01), Suzuki et al.
patent: 5403527 (1995-04-01), West
patent: 5407622 (1995-04-01), Cleveland et al.
patent: 5518674 (1996-05-01), Powell et al.
patent: 5714102 (1998-02-01), Highum et al.
patent: WO 98/03896 (1998-01-01), None

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