Shaping method and shaping device

Patent metadata

Field	Value
Publication number	US-12594716-B2
Application number	US-201917613636-A
Country	US
Kind code	B2
Filing date	Jun 14, 2019
Priority date	Jun 14, 2019
Publication date	Apr 7, 2026
Grant date	Apr 7, 2026

Abstract

A shaping method includes a first ejection step of ejecting a first curable viscous fluid, a planarization step of planarizing the first curable viscous fluid, a first curing step of curing the first curable viscous fluid, a cured layer forming step of repeatedly executing the first ejection step, the planarization step, and the first curing step to form a cured layer, a second ejection step of ejecting a second curable viscous fluid onto a surface of the cured layer, a second curing step of forming a smooth surface on the surface of the cured layer by curing the second curable viscous fluid, a third ejection step of ejecting a fluid containing metal particles onto the smooth surface, and a third curing step of curing the fluid containing the metal particles ejected in the third ejection step to form a metallic conductor on the smooth surface.

First claim

The invention claimed is:

1 . A shaping device comprising:
an ejection device; a planarization device; a curing device; a heater; and a control device including a processor configured to
cause the ejection device to eject a first curable viscous fluid, cause the planarization device to planarize the ejected first curable viscous fluid, and cause the curing device to cure the planarized ejected first curable viscous fluid to form a cured layer having a surface with an unevenness formed thereon,
determine a size of the unevenness formed on the cured layer,
cause the ejection device to eject a second curable viscous fluid onto the surface of the cured layer, an injection amount of the second curable viscous fluid corresponding to the determined size of the unevenness formed on the surface of the cured layer,
cause the heater to heat the ejected second curable viscous fluid ejected by the second ejection section,
cause the curing device to cure the second curable viscous fluid heated by the heater and ejected by the second ejection section to form a smooth surface on the surface of the cured layer without planarizing the second curable viscous fluid by the planarization device,
cause the ejection device to eject a fluid containing metal particles onto the smooth surface,
cause the curing device to cure the fluid containing the ejected metal particles,
determine whether a metal wiring has been formed on the smooth surface having at least one of a predetermined thickness, shape, or electrical characteristic, and
when it determined that the metal wiring has not been formed, cause the ejection device to eject the fluid containing metal particles and cause the curing device to cure the fluid containing the ejected metal particles.

2 . The shaping device according to claim 1 , further comprising an inspection unit configured to measure the size of the unevenness formed on the cured layer, wherein the control unit is configured to set the injection amount of the second curable viscous fluid from the size of the unevenness formed on the cured layer measured by the inspection unit.

3 . The shaping device according to claim 1 , wherein the control unit is configured to set the injection amount of the second curable viscous fluid from a programmed size of the unevenness formed on the cured layer.

4 . A shaping method comprising:
providing the shaping device according to claim 1 ; a first ejection step of ejecting, by the ejection device, a first curable viscous fluid; a planarization step of planarizing, by the planarization device, the first curable viscous fluid ejected in the first ejection step; a first curing step of curing, by the curing device, the first curable viscous fluid planarized in the planarization step; a cured layer forming step of repeatedly executing the first ejection step, the planarization step, and the first curing step to form a cured layer having a surface with an unevenness formed thereon; a size determining step of determining a size of the unevenness formed on the cured layer; a second ejection step of ejecting, by the ejection device, a second curable viscous fluid onto a surface of the cured layer injection amount of the second curable viscous fluid corresponding to the determined size of the unevenness formed on the surface of the cured layer, the second curable viscous fluid being an ultraviolet curable resin; a heating step of heating, by the heater, the second curable viscous fluid in the second ejection step; a second curing step of forming a smooth surface on the surface of the cured layer by curing, by the curing device, the second curable viscous fluid ejected in the second ejection step and heated in the heating step without planarizing the second curable viscous fluid by the planarization device; a third ejection step of ejecting, by the ejection device, a fluid containing metal particles onto the smooth surface; a third curing step of curing, by the curing device, the fluid containing the metal particles ejected in the third ejection step; a determining step of determining whether a metal wiring has been formed on the smooth surface having at least one of a predetermined thickness and shape; and when it is determined that the metal wiring having at least one of the predetermined thickness and shape has not been formed, repeating the third ejection step and the third curing step.

5 . The shaping method according to claim 4 , wherein
the first curable viscous fluid is a resin having an insulating property, and in the first curing step, an insulating layer having an insulating property is formed as the cured layer.

Assignees

• Fuji Corp

Inventors

• Tsukada Kenji
• Takeuchi Tasuku
• Tominaga Ryojiro

Classifications

• B29L2031/34

  Electrical apparatus, e.g. sparking plugs or parts thereof · CPC title

• B29K2995/0073

  smooth · CPC title

• B29K2995/0007

  Insulating · CPC title

• B29K2105/251

  Particles, powder or granules (expandable particles B29K2105/046) · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title