Rockwell International Corporation

John Simone

Joseph M Shaheen

A multi-layer board is fabricated by plating up conductive posts on a nonconductive layer. The tops of the posts are planarized, resulting in sharp corners. The posts are aligned with a template, which has a hole above each post, and a second nonconductive layer is placed between the top of the posts and the bottom of the template. The two layers are laminated together by compressing the second layer between the first layer and the template, and the posts punch through the second layer. Conductive traces may then be etched or deposited between the posts tops, and the process may be repeated as many times as desired.

Method of fabricating multi-layer board

A method for producing beam leads, i.e. electrical contacts, on flexible circuits or multilayer circuits for interconnecting devices is disclosed. The method consists of processing a metal foil to expose a beam lead interconnection pattern, plating the exposed pattern with metal, coating a base insulating layer with an adhesive, punching cavities in the adhesive coated insulating layer, engaging the coated side of the base insulating layer to the metal foil, and applying a cushioning material on the opposite side of the adhesive coated insulating layer. The metal foil and the insulating layer are then laminated causing the cushioning material to flow into the pre-punched cavities thereby providing a protective cushioning-type backing for the metal-plated beam lead interconnection pattern. The exposed metal foil is etched away, the photoresist is removed and the cushioning material is stripped off the insulating layer leaving beam leads extending over the cavity for a device which can have the beam leads connected to its contacts (pads).

Growing community of inventors

Anaheim, CA, United States of America

John Simone