Electrical device and method for making same

DC CAFC

US 7,501,582 B2
Filed: 03/01/2004
Issued: 03/10/2009
Est. Priority Date: 08/04/1997
Status: Expired due to Fees

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1. A process of making an electrical device, the process including:

removing a portion of a dielectric material in producing cavities in a surface of a remaining portion of the dielectric material; and

building up a conductive layer in the cavities in forming teeth set in and under the surface and in forming a portion of circuitry of an electrical device, wherein a plurality of the cavities are obtuse with respect to the top surface, and a plurality of the cavities are at least 1 tenth of a mil deep and less than 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the remaining portion of the dielectric material, and one of the teeth engages the remaining portion of the dielectric material at the slope.

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Abstract

A multilayer electrical device, such as a printed circuit board, having a tooth structure including a metal layer set in a dielectric. The device includes a base; a conductive layer adjacent to the base; a dielectric material adjacent to conductive layer; a tooth structure including a metal layer set in the dielectric material to join the dielectric material to the metal layer; and wherein the metal layer forms a portion of circuitry in a circuit board having multiple layers of circuitry.

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162 Claims

1. A process of making an electrical device, the process including:
- removing a portion of a dielectric material in producing cavities in a surface of a remaining portion of the dielectric material; and
  
  building up a conductive layer in the cavities in forming teeth set in and under the surface and in forming a portion of circuitry of an electrical device, wherein a plurality of the cavities are obtuse with respect to the top surface, and a plurality of the cavities are at least 1 tenth of a mil deep and less than 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the remaining portion of the dielectric material, and one of the teeth engages the remaining portion of the dielectric material at the slope.
- View Dependent Claims (2, 3, 4, 5, 6, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82)
- - 2. The process of claim 1, wherein the removing of the portion is sufficient to produce a surface gloss measurement at an angle of 60 degrees of less than 10%.
  - 3. The process of claim 1, wherein the producing cavities does not include physical roughening, and the building up the conductive layer includes building up the conductive layer in producing a dielectric surface contact area greater than a dielectric surface contact area that would be produced by a single pass roughening.
  - 4. The process of claim 1, wherein the producing cavities does not include physical roughening, and the building up the conductive layer includes building up the conductive layer in producing a peel strength greater than a peel strength that would be produced by a single desmear process, and the forming teeth includes forming a plurality of hooked teeth.
  - 5. The process of claim 1, wherein the producing cavities does not include physical roughening, and the building up the conductive layer includes filling the cavities sufficiently that separation of the conductive layer from the remaining portion of the dielectric material requires destroying integrity of at least one of the conductive layer and the remaining portion of the dielectric material.
  - 6. The process of claim 2, wherein the building up is sufficient to produce a peel strength greater than a peel strength of a single desmear process.
  - 40. The process of any one of claims 1, 7, 11, 18, 19, 23, 27, 28, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes a frequency of the teeth sufficient to provide at least 5,000 said teeth per linear inch.
  - 41. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes a frequency of the teeth sufficient to provide at least 10,000 said teeth per linear inch.
  - 42. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes a frequency of the teeth sufficient to provide at least 15,000 said teeth per linear inch.
  - 43. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes a frequency of the teeth sufficient to provide at least 25,000 said teeth per square inch.
  - 44. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes a frequency of the teeth sufficient to provide at least 100,000 said teeth per square inch.
  - 45. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes a frequency of the teeth sufficient to provide at least 200,000 said teeth per square inch.
  - 46. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 20% of the teeth are shaped to mechanically grip the dielectric material.
  - 47. The process of any one of claims 1, 12, 18, 19, 27, 28, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 50% of the teeth that are obtuse shaped.
  - 48. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 20% of the teeth that are within the range of at least 1 tenth of a mil deep to 1.75 tenths of a mil deep.
  - 49. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 50% of the teeth that are within the range of at least 1 tenth of a mil deep to 1.75 tenths of a mil deep.
  - 50. The process of any one of claims 1, 3, 7, 12, 18, 19, 27, 28, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 20% of the teeth that are within the range of 1 tenth of a mil deep to 1.5 tenths of a mil deep.
  - 51. The process of any one of claims 1, 2, 3, 7, 12, 18, 19, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 50% of the teeth that are within the range of 1 tenth of a mil deep to 1.5 tenths of a mil deep.
  - 52. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 20% of the teeth that are in the range of 1.5 tenths of a mil deep to 1.75 tenths of a mil deep.
  - 53. The process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 29, 32, 33, 38, or 39 wherein:
    - a sample of the circuitry includes at least 50% of the teeth that are in the range of 1.5 tenths of a mil deep to 1.75 tenths of a mil deep.
  - 54. The process of claim 40, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 55. The process of claim 41, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 56. The process of claim 42, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 57. The process of claim 43, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 58. The process of claim 44, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 59. The process of claim 45, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 60. The process of claim 46, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 61. The process of claim 47, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 62. The process of claim 48, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 63. The process of claim 49, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 64. The process of claim 50, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 65. The process claim 51, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 66. The process of claim 52, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 67. The process of claim 53, further including configuring the circuitry of the electrical device as multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising correspondingly made teeth.
  - 68. The process of claim 40, further including configuring the circuitry as of double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 69. The process of claim 41, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 70. The process of claim 42, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 71. The process of claim 43, further including configuring the circuitry as of double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 72. The process of claim 44, further including configuring the circuitry as of double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 73. The process of claim 45, further including configuring the circuitry as of double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 74. The process of claim 46, further including configuring the circuitry as of double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 75. The process of claim 47, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 76. The process of claim 48, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 77. The process of claim 49, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 78. The process of claim 50, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 79. The process of claim 51, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 80. The process of claim 52, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 81. The process of claim 53, further including configuring the circuitry as double sided circuitry, one side comprising said teeth and another side comprising correspondingly made teeth.
  - 82. A product produced by the process of any one of claims 1, 7, 12, 18, 19, 23, 27, 28, 32, 29, 33, 38, or 39.

7. A process of making an electrical device, the process including:
- producing, from a dielectric material, a surface including cavities remaining from removing a portion of the dielectric material; and
  
  building up a conductive layer in the cavities in forming substantially angular teeth set in a remaining portion of the dielectric material and in forming a portion of circuitry of an electrical device, and wherein a sample of the circuitry has at least 20% of the teeth being at least 1 tenth of a mil deep and less than 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface and one of the teeth engages the remaining portion of the dielectric material at the slope.
- View Dependent Claims (8, 9, 10, 11)
- - 8. The process of claim 7, wherein the removing of the portion is sufficient to produce a surface gloss measurement at an angle of 60 degrees of less than 10%.
  - 9. The process of claim 7, wherein the removing is such that froming the cavities does not include physical roughening, and the building up the conductive layer includes building up the conductive layer in producing a dielectric surface contact area greater than a dielectric surface contact area that would be produced by a single pass roughening, and the forming substantially angular teeth includes forming a plurality of substantially angular teeth that mechanically grip the remaining portion of the dielectric material, more than by adherence.
  - 10. The process of claim 7, wherein the removing is such that forming the cavities does not include physical roughening, and the building up the conductive layer includes building up the conductive layer in producing a peel strength greater than a peel strength that would be produced by a single desmear process, and the forming substantially angular teeth includes forming a plurality of substantially angular hooked teeth.
  - 11. The process of claim 7, wherein the removing is such that forming the cavities does not include physical roughening, and the forming substantially angular teeth is such that separation of the conductive layer from the remaining portion of the dielectric material would destroy integrity of at least one of the conductive layer and the remaining portion of the dielectric material.

12. A process of making an electrical device, the process including:
- building up a conductive layer of material on a surface of a layer of dielectric material, the layers joined in a saw-tooth manner made of both materials in an interlocking bite in forming a portion of circuitry of an electrical device, the conductive layer forming teeth such that a sample of the circuitry has a frequency of the teeth sufficient to provide at least 5,000 of the teeth per linear inch, the teeth set respectively in cavities of the bite, and the sample of the circuitry has at least 20% of the teeth being at least 1 tenth of a mil deep and less than 2 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (13, 14, 15, 16, 17)
- - 13. The process of claim 12, further including providing a micro via interconnect for the circuitry.
  - 14. The process of claim 12, wherein, prior to the building up, the layer of the dielectric material has a surface gloss such that a surface gloss measurement at an angle of 60 degrees is less than 10%.
  - 15. The process of claim 12, wherein the removing is such that forming the cavities does not include physical roughening, and the building up the conductive layer includes building up the conductive layer in producing a dielectric surface contact area greater than a dielectric surface contact area that would be produced by a single pass roughening, such that a plurality of the teeth mechanically grip the layer of dielectric material, more than by adherence, at the surface contact area.
  - 16. The process of claim 12, wherein the producing the interlocking bite does not include physical roughening, and the building up the conductive layer includes building up the conductive layer in producing a peel strength greater than a peel strength that would be produced by a single desmear process, such that the forming teeth includes forming a plurality of hooked teeth.
  - 17. The process of claim 12, wherein the forming teeth is such that separation of the layers would destroy integrity of at least one of the conductive layer and the dielectric material.

18. A process of making an electrical device, the process including:
- building up a conductive layer in filling undercuttings with respect to a surface of a dielectric material so as to form a plurality of teeth in cavities, some of the teeth being obtuse to the surface and in the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, in forming a portion of circuitry of an electrical device,wherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

19. A process of making an electrical device, the process including:
- producing a surface with cavities remaining after removing portion of a dielectric material sufficient to produce a surface with a surface gloss measurement at an angle of 60 degrees of less than 10%; and
  
  building up a conductive layer in the cavities in forming electrical device circuitry, wherein the cavities are obtusoly angled and the building up the conductive layer includes forming teeth in the cavities and in the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (20, 21, 22)
- - 20. The process of claim 19, wherein producing the cavities does not include physical roughening, and the building up the conductive layer includes building up the conductive layer in producing a dielectric surface contact area greater than a dielectric surface contact area that would be produced by a single pass roughening, and the forming teeth includes forming a plurality of teeth that mechanically grip, more than by adherence, the surface contact area.
  - 21. The process of claim 19, wherein the producing cavities does not include physical roughening, and the building up the conductive layer fills the cavities sufficiently to produce a peel strength greater than a peel strength that would be produced by a single desmear process, and the forming teeth includes forming a plurality of hooked teeth.
  - 22. The process of claim 19, wherein the producing cavities does not include physical roughening, and the building up the conductive layer includes building up the conductive layer sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of at least one of the conductive layer and the dielectric material.

23. A process of making an electrical device, the process including:
- forming electrical device circuitry with teeth produced by building up a conductive layer in cavities of a dielectric material that has an exterior surface and a dielectric surface area greater than a dielectric surface area that would be produced by a single pass roughening, wherein a sample of the circuitry has at least 20% of the teeth that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the exterior surface, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (24, 25, 26)
- - 24. The process of claim 23, further including providing a micro via interconnect for the circuitry.
  - 25. The process of claim 23, further including producing the cavities without physical roughening and sufficiently to produce a peel strength greater than a peel strength that would be produced by a single desmear process, and such that a plurality of the teeth are hooked teeth.
  - 26. The process of claim 23, wherein the conductive layer is built up sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of at least one of the conductive layer and the dielectric material.

27. A process of making an electrical device, the process including:
- combining a dielectric material with a conductive layer in forming a portion of circuitry of an electrical device, said combining being carried out with means for joining the conductive layer to the dielectric material,the means including teeth built up on the dielectric material and angled sufficiently to mechanically grip the dielectric material in three dimensions, wherein a plurality of the teeth are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the teeth is in one of a plurality of cavities that includes an upgrade slope with respect to an etched surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

28. A process of making an electrical device, the process including:
- combining a dielectric material with means for joining a conductive layer built up on the dielectric material sufficient to produce a peel strength greater than a peel strength that would be produced by a single desmear process, the conductive layer forming a portion of circuitry, whereinthe combining is carried out with the means for joining comprised of teeth, a plurality of the teeth being obtuse to a top surface of the dielectric material and within cavities in the range of at least 1 tenth of a mil deep to 1.75 of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

29. A process of making an electrical device, the process including:
- forming electrical device circuitry by building up a conductive layer on a surface of dielectric material so as to produce a peel strength greater than a peel strength that would be produced by a single desmear process, whereina sample of the circuitry includes at least 20% of teeth that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of a plurality of cavities, respectively adjacent to the teeth, includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (30, 31)
- - 30. The process of claim 29, wherein the electrical device comprises a circuit board.
  - 31. The process of claim 29, wherein the building up the conductive layer includes building up the conductive layer sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of at least one of the conductive layer and the dielectric material.

32. A process of making an electrical device, the process including:
- producing a surface remaining from removing a portion of a dielectric material; and
  
  applying means for mechanically gripping a conductive layer to the surface so that a conductive layer is burrowed in and under the surface, whereinthe conductive layer forms a portion of circuitry of an electrical device, wherein the applying is carried out with the means for mechanically gripping comprising teeth, and a plurality of the teeth are within the range of 1 tenth of a mil deep to 2 tenths of a mil deep, andwherein at least one of a plurality of cavities, respectively adjacent to the teeth, includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

33. A process of making an electrical device, the process including:
- forming electrical device circuitry by building up a conductive layer on a dielectric material sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of the conductive layer and of the dielectric material, whereinthe building up the conductive layer includes forming teeth that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of a plurality of cavities, respectively adjacent to the teeth, includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

34. A process of making an electrical device, the process including:
- building up a conductive layer on a dielectric material sufficient to produce a surface gloss measurement at an angle of 60 degrees of less than 10%, in forming circuitry of an electrical device, whereinthe building up the conductive layer includes producing teeth within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of a plurality of cavities, respectively adjacent to the teeth, includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (35, 36, 37)
- - 35. The process of claim 34, wherein building up the conductive layer includes building up the conductive layer sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of the conductive layer.
  - 36. The process of claim 34, wherein the building up the conductive layer includes building up the conductive layer sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of the dielectric material.
  - 37. The process of claim 34, wherein the building up the conductive layer includes building up the conductive layer sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of the conductive material and the dielectric material.

38. A process of making an electrical device, the process including:
- combining a dielectric material with means for joining a conductive layer built up on a conductive coating on the dielectric material at a dielectric surface contact area greater than a dielectric surface contact area that would be produced by a single pass roughening,the conductive layer forming a portion of circuitry, wherein the combining is carried out with the means for joining comprised of teeth within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of a plurality of cavities, respectively adjacent to the teeth, includes an upgrade slope with respect to an etched surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

39. A process of making an electrical device, the process including:
- combining a dielectric material with means for joining a conductive layer built up on the dielectric material sufficiently that separation of the dielectric material from the conductive layer requires destroying integrity of at least one of the conductive layer and the dielectric material,said means for joining comprising filled cavities that form a portion of circuitry of an electrical device, wherein the filled cavities comprise teeth that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to an etched surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

83. An electrical device including:
- a dielectric material comprising a surface with cavities remaining from removal of a portion of the dielectric material;
  
  a conductive layer built up on the dielectric material so as to fill the cavities and form teeth set in and under the surface of the dielectric material; and
  
  wherein;
  
  the conductive layer is a portion of circuitry of an electrical device, and a plurality of the cavities are obtuse with respect to the top surface and are at least 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (84, 85, 86, 87, 88)
- - 84. The device of claim 83, wherein, prior to the conductive layer of material being built up thereon, the surface with the cavities has a gloss sufficient to produce a surface gloss measurement at an angle of 60 degrees of less than 10%.
  - 85. The device of claim 83, wherein the electrical device comprises a micro via interconnect.
  - 86. The device of claim 83, wherein the teeth have a dielectric surface contact area greater than a dielectric surface contact area that would be produced by a single pass roughening, and some of the teeth comprise hooked teeth.
  - 87. The device of claim 83, wherein the conductive layer fills the cavities sufficiently to produce a peel strength greater than a peel strength that would be produced by a single desmear process, and some of the teeth mechanically grip the dielectric material, more than by adherence.
  - 88. The device of claim 83, wherein the conductive layer fills the cavities sufficiently that separation of the conductive layer from the dielectric material requires destroying integrity of at least one of the conductive layer and the portion of the dielectric material.

89. An electrical device including:
- a dielectric material comprising a surface with cavities remaining after removal of some of the dielectric material;
  
  a conductive layer built up on the dielectric material so as to fill the cavities and form substantially angular teeth set in the dielectric material; and
  
  whereinthe conductive layer is a portion of circuitry of an electrical device, and a plurality of the teeth being are at least 1 tenth of a mil deep and less than 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (90, 91, 92, 93)
- - 90. The device of claim 89, wherein, prior to the conductive layer of material being built up thereon, the surface with the cavities has a gloss sufficient to produce a surface gloss measurement at an angle of 60 degrees of less than 10%.
  - 91. The device of claim 89, wherein the teeth have a dielectric surface contact area greater than a dielectric surface contact area that would be produced by a single pass roughening, and some of the teeth comprise hooked teeth.
  - 92. The device of claim 89, wherein the the conductive layer fills the cavities sufficiently so as to produce a peel strength greater than a peel strength that would be produced by a single desmear process, and some of the teeth mechanically grip the dielectric material, more than by adherence.
  - 93. The device of claim 89, wherein the conductive layer built up is built up sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of at least one of the conductive layer and the dielectric material.

94. An electrical device including:
- a conductive layer of material built up on a surface of a layer of a dielectric material, the layers joined in a saw-tooth manner made of both materials in an interlocking bite;
  
  whereinthe conductive layer is a portion of circuitry of an electrical device, the conductive layer is comprised of teeth such that a sample of the circuitry has a frequency of the teeth sufficient to provide at least 5,000 of the teeth per linear inch, the teeth the teeth set respectively in cavities of the bite and a plurality of the teeth are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (95, 96, 97, 98, 99)
- - 95. The device of claim 94, wherein the electrical device comprises a micro via interconnect.
  - 96. The device of claim 94, wherein, prior to the conductive layer of material being built up thereon, the surface has a gloss sufficient to provide a surface gloss measurement at an angle of 60 degrees of less than 10%.
  - 97. The device of claim 94, wherein the teeth have a dielectric surface contact area that is greater than a dielectric surface contact area that would be produced by a single pass roughening, and some of the teeth comprise hooked teeth.
  - 98. The device of claim 94, wherein the conductive layer built up is built up sufficiently to produce a peel strength greater than a peel strength that would be produced by a single desmear process, and some of the teeth mechanically grip the dielectric material, more than by adherence.
  - 99. The device of claim 94, wherein the conductive layer built up is built up sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of at least one of the conductive layer and the dielectric material.

100. An electrical device including:
- a conductive layer built up so as to fill undercuttings with respect to a surface of a dielectric material so as to form teeth in cavities, a plurality of the undercuttings being obtuse to the surface, whereinthe conductive layer is a portion of circuitry of an electrical device, and a plurality of the teeth are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162)
- - 122. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has a frequency of the teeth sufficient to provide at least 5,000 said teeth per linear inch.
  - 123. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has a frequency of the teeth sufficient to provide at least 10,000 said teeth per linear inch.
  - 124. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has a frequency of the teeth sufficient to provide at least 15,000 said teeth per linear inch.
  - 125. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has a frequency of the teeth sufficient to provide at least 25,000 said teeth per square inch.
  - 126. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 whereto:
    - a sample of the circuitry has a frequency of the teeth sufficient to provide at least 100,000 said teeth per square inch.
  - 127. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 whereto:
    - a sample of the circuitry has at least 200,000 said teeth per square inch.
  - 128. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 20% of the teeth have a shape that mechanically grips the dielectric material.
  - 129. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 50% of the teeth structured obtusely with respect to a line within a plane defined by a surface of the dielectric material that was removed.
  - 130. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 20% of the teeth that are at least 1 tenth of a mil deep.
  - 131. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 50% of the teeth that are at least 1 tenth of a mil deep.
  - 132. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 20% of the teeth that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep.
  - 133. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 50% of the teeth that are within the range of 1 tenth of a mil deep to 2 tenths of a mil deep.
  - 134. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 20% of the teeth that are in the range of 1.5 tenths of a mil deep to 1.75 tenths of a mil deep.
  - 135. The device of any one of claims 83, 89, 93, 100, 101, 105, 109, 110, 111, 114, 115, 116, 120, or 121 wherein:
    - a sample of the circuitry has at least 50% of the teeth that are in the range of 1.5 tenths of a mil deep to 1.75 tenths of a rail deep.
  - 136. The device of claim 124, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 137. The device of claim 125, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 138. The device of claim 126, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 139. The device of claim 127, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 140. The device of claim 128, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 141. The device of claim 129, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 142. The device of claim 130, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 143. The device of claim 131, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 144. The device of claim 132, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 145. The device of claim 133, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 146. The device of claim 134, wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 147. The device of claim 135 wherein the circuitry of the electrical device is comprised of multi-layer circuitry, one of said layers comprising said teeth and another of said layers comprising corresponding teeth.
  - 148. The device of claim 122, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 149. The device of claim 123, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 150. The device of claim 124, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 151. The device of claim 125, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 152. The device of claim 126, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 153. The device of claim 127, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 154. The device of claim 128, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 155. The device of claim 129, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 156. The device of claim 130, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 157. The device of claim 131, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 158. The device of claim 132, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 159. The device of claim 133, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 160. The device of claim 134, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 161. The device of claim 135, wherein the circuitry is comprised of double sided circuitry, one side comprising said teeth and another side comprising corresponding teeth.
  - 162. A process of making the electrical device product of any one of claims 83, 89, 94, 100, 101, 105, 109, 110, 111, 114, 116, 120, or 121, the method including:
    - forming means for joining by building up a conductive layer on a dielectric material surface remaining from removal of a portion of the dielectric material to form a portion of circuitry in the electrical device.

101. An electrical device including:
- a dielectric material surface with cavities sufficient to produce a surface gloss measurement at an angle of 60 degrees of less than 10%; and
  
  electrical device circuitry comprised of a conductive layer built up so as to fill in the cavities and form teeth, wherein a plurality of the cavities are obtusely angled with respect to the surface, and a plurality of the teeth are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (102, 103, 104)
- - 102. The device of claim 101, wherein the teeth have a dielectric surface contact area that is greater than a dielectric surface contact area that would be produced by a single pass roughening, and some of the teeth comprise hooked teeth.
  - 103. The device of claim 101, wherein the conductive layer fills in the cavities sufficiently to produce a peel strength greater than a peel strength that would be produced by a single desmear process, and some of the teeth mechanically grip the dielectric material, more than by adherence.
  - 104. The device of claim 101, wherein the conductive layer is sufficiently built up that separation of the conductive layer from the dielectric material destroys integrity of at least one of the conductive layer and the dielectric material.

105. An electrical device including:
- a dielectric material; and
  
  electrical device circuitry comprising a conductive layer built up on the dielectric material at a dielectric surface having an area greater than a dielectric surface area that would be produced by a single pass roughening; and
  
  whereinthe conductive layer is comprised of plurality of the teeth within cavities that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (106, 107, 108)
- - 106. The device of claim 105, wherein the electrical device comprises a micro via interconnect.
  - 107. The device of claim 105, wherein the conductive layer built up is built up in the cavities sufficiently to produce a peel strength greater than a peel strength that would be produced by a single desmear process, and some of the teeth mechanically grip the dielectric material, more than by adherence.
  - 108. The device of claim 105, wherein the conductive layer built up is built up sufficiently that separation of the conductive layer from the dielectric material requires destroying integrity of at least one of the conductive layer and the dielectric material.

109. An electrical device including:
- a dielectric material comprising a surface;
  
  a conductive layer forming a portion of circuitry of an electrical device; and
  
  means for joining the conductive layer to the dielectric material, the means including a structuring of teeth built up on the dielectric material and comprised of the conductive layer and angled sufficiently for mechanically gripping the dielectric material in three dimensions, wherein a plurality of the teeth are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

110. An electrical device including:
- a dielectric material comprising a surface; and
  
  means for joining a conductive layer built up on the dielectric material so as to produce a peel strength greater than a peel strength that would be produced by a single desmear process, wherein the conductive layer is a portion of circuitry, and portions of the conductive layer are in cavities obtuse to a top surface of the dielectric material, wherein the means for joining is comprised of teeth, and a plurality of the teeth that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

111. An electrical device including:
- a dielectric material; and
  
  electrical device circuitry comprising a conductive layer built up on a surface of the dielectric material so as to produce teeth set in cavities and a peel strength greater than a peel strength that would be produced by a single desmear process; and
  
  whereinplurality of the teeth that are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, and wherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (112, 113)
- - 112. The device of claim 111, wherein the electrical device comprises a circuit board.
  - 113. The device of claim 111, wherein the conductive layer built up is built up sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of at least one of the conductive layer and the dielectric material.

114. An electrical device including:
- a dielectric material having a surface remaining from removal of a portion of the dielectric material; and
  
  means for mechanically gripping a conductive layer to the surface of the dielectric material so that the conductive layer is burrowed in and under the top surface of the dielectric material, wherein the conductive layer forms a portion of circuitry of an electrical device, wherein the means for mechanically gripping is comprised of teeth, and a plurality of the teeth are within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

115. An electrical device including:
- a dielectric material; and
  
  electrical device circuitry comprising a conductive layer built up on the dielectric material sufficiently that separation of the conductive layer from the dielectric material would require destroying integrity of the conductive layer and of the dielectric material, wherein the conductive layer is comprised of teeth in cavities, a plurality of the teeth being within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

116. An electrical device including:
- a dielectric material having a surface with a gloss sifficient for surface gloss measurement at an angle of 60 degrees of less than 10%; and
  
  circuitry of an electrical device comprised of a conductive layer on the dielectric material, wherein the conductive layer is comprised of teeth in cavities, a plurality of the teeth being within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.
- View Dependent Claims (117, 118, 119)
- - 117. The device of claim 116, wherein the conductive layer built up on the dielectric material is built up sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of the conductive layer.
  - 118. The device of claim 116, wherein the conductive layer built up on the dielectric material is built up sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of the dielectric material.
  - 119. The device of claim 116, wherein the conductive layer built up on the dielectric material is built up sufficiently that separation of the conductive layer from the dielectric material would destroy integrity of the conductive layer and the dielectric material.

120. An electrical device including:
- a dielectric material having a surface; and
  
  means for joining a conductive layer built up on the dielectric material at a surface having a contact area greater than a dielectric surface contact area that would be produced by a single pass roughening, wherein the conductive layer is a portion of circuitry of an electrical device, wherein the conductive layer is comprised of teeth in cavities, a plurality of the teeth being within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

121. An electrical device including:
- a dielectric materialincluding a surface; and
  
  means for joining a conductive layer built up on the dielectric material sufficiently that separation of the conductive layer from the dielectric material requires destroying integrity of at least one of the conductive layer and the dielectric material, said means for joining comprising filled cavities that form a portion of circuitry of the electrical device comprised of teeth, a plurality of the teeth being within the range of 1 tenth of a mil deep to 1.75 tenths of a mil deep, andwherein at least one of the cavities includes an upgrade slope with respect to the surface of the dielectric material, and one of the teeth engages a portion of the dielectric material at the slope.

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Litigation Data

Current Assignee
Continental Circuits LLC (Chicago Harbor Innovation Producers, LLC)
Original Assignee
Peter K. Trzyna
Inventors
McGowan, Daniel, Tryzbiak, Sid, McDermott, Brian J., Spotts, Jr., Ralph Leo
Primary Examiner(s)
Dinh, Tuan T.

Application Number

US10/790,363
Publication Number

US 20040163847A1
Time in Patent Office

1,835 Days
Field of Search

174255-262, 29850-853, 216 15- 16
US Class Current

174/255
CPC Class Codes

H05K 1/0296   Conductive pattern lay-out ...

H05K 1/032   consisting of one material

H05K 2203/0796   Oxidant in aqueous solution...

H05K 3/0017   Etching of the substrate by...

H05K 3/0023   by exposure and development...

H05K 3/0055   After-treatment, e.g. clean...

H05K 3/10   in which conductive materia...

H05K 3/381   by special treatment of the...

H05K 3/4661   Adding a circuit layer by d...

Y10T 29/49117   Conductor or circuit manufa...

Y10T 29/49126   Assembling bases

Y10T 29/49155   Manufacturing circuit on or...

Y10T 29/49165   by forming conductive walle...

Y10T 428/12361   having aperture or cut

Y10T 428/24331   including nonapertured comp...

Electrical device and method for making same

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Abstract

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162 Claims

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Electrical device and method for making same

First Claim

10 Assignments

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Subscription Required

Litigations

0 Petitions

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Accused Products

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Abstract

6 Citations

162 Claims

Specification

Subscription Required

Solutions

Use Cases

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