Method for manufacturing layered electronic devices

Abstract

A method for fabricating printed electronics includes printing a trace of an electrical component on a first substrate to form a first layer. The method further includes printing a trace of an electrical component on at least one additional substrate to form at least one additional layer. The first layer is stacked with the at least one additional layer to create an assembled electrical device. At least one of the layers is modified after printing.

What is claimed is: 
     
         1 . An electrical device manufactured by the process comprising:
 printing a trace of an electrical component on a first substrate to form a first layer;   printing a trace of an electrical component on at least one additional substrate to form at least one additional layer; and   stacking the first layer with the at least one additional layer to create an assembled electrical device, wherein at least one of the layers is modified after printing.   
     
     
         2 . The electrical device of  claim 1 , wherein printing includes printing the first layer of the electrical device including multiple electrical components with varying electrical functionalities. 
     
     
         3 . The electrical device of  claim 2 , wherein the printed material is at least one of an ink, paste, slurry, dispersion, solution or a powder. 
     
     
         4 . The electrical device of  claim 1 , wherein modifying includes shrinking at least one of the layers from an original size to a target size where the target size is less than the original size. 
     
     
         5 . The electrical device of  claim 1 , wherein the trace of the electrical component is at least one of electrically conductive, semiconductive, or insulating material. 
     
     
         6 . The electrical device of  claim 1 , wherein printing includes printing the first layer of the electrical device including multiple electrical components with varying electrical functionalities. 
     
     
         7 . The electrical device of  claim 1 , wherein modifying includes shrinking the substrates for the first layer and the at least one additional layer to a target size prior to stacking by heating the substrates at a predetermined temperature for a predetermined duration based on properties of the substrates. 
     
     
         8 . The electrical device of  claim 1 , further including shrinking the assembled electrical device to a target size by heating the assembled electrical device at a predetermined temperature for a predetermined duration based on properties of the substrates. 
     
     
         9 . The electrical device of  claim 1 , further including shrinking the substrates for the first layer and the at least one additional layer to a target size prior to stacking by heating the substrates at a predetermined temperature for a predetermined duration based on properties of the substrates and shrinking the assembled electrical device to a target size by heating the assembled electrical device at a predetermined temperature for a predetermined duration based on properties of the substrates. 
     
     
         10 . The electrical device of  claim 1 , wherein modifying includes curing, cutting, embossing, stamping, plating and/or etching the substrate. 
     
     
         11 . The electrical device of  claim 1 , wherein stacking includes rolling the first layer and the at least one additional layer. 
     
     
         12 . The electrical device of  claim 1 , wherein stacking includes vertical layering of the first layer and the at least one additional layer. 
     
     
         13 . The electrical device of  claim 12 , wherein vertical layering includes placing the at least one additional layer on top of the first layer. 
     
     
         14 . The electrical device of  claim 1 , wherein stacking includes positioning vertical interconnectors between at least two different layers.