Electrical device with teeth joining layers and method for making the same
DC CAFC
First Claim
Patent Images
1. An article of manufacture, the article comprising:
- an epoxy dielectric material delivered with solid content sufficient that etching the epoxy forms a non-uniformly roughened surface of angular tooth-shaped cavities located in and underneath an initial surface of the dielectric material, sufficient that the etching of the epoxy uses non-homogeneity with the solid content in bringing about formation of the non-uniformly roughened surface of the angular tooth-shaped cavities and sufficient that the etching of the epoxy is such that a plurality of the cavities have a cross-sectional width that is greater than a maximum depth with respect to the initial surface, wherein the etching forms the non-uniformly roughened surface of angular tooth-shaped cavities, and a conductive material, a portion of the conductive material in the cavities thereby forming angular teeth in the cavities, and wherein the conductive material forms a portion of circuitry of an electrical device.
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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.
39 Citations
21 Claims
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1. An article of manufacture, the article comprising:
an epoxy dielectric material delivered with solid content sufficient that etching the epoxy forms a non-uniformly roughened surface of angular tooth-shaped cavities located in and underneath an initial surface of the dielectric material, sufficient that the etching of the epoxy uses non-homogeneity with the solid content in bringing about formation of the non-uniformly roughened surface of the angular tooth-shaped cavities and sufficient that the etching of the epoxy is such that a plurality of the cavities have a cross-sectional width that is greater than a maximum depth with respect to the initial surface, wherein the etching forms the non-uniformly roughened surface of angular tooth-shaped cavities, and a conductive material, a portion of the conductive material in the cavities thereby forming angular teeth in the cavities, and wherein the conductive material forms a portion of circuitry of an electrical device. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. An article of manufacture, the article comprising:
an epoxy dielectric material delivered with solid content sufficient that etching the epoxy forms a non-uniformly roughened surface comprising cavities located in and underneath a surface of the dielectric material, and sufficient that the etching of the epoxy uses non-homogeneity with the solid content to bring about formation of the non-uniformly roughened surface with at least some of the cavities having a first cross-sectional distance proximate the initial surface and a substantially greater cross-sectional distance distant from the initial surface, and a conductive material, whereby the etching of the epoxy forms the cavities, and a portion of the conductive material in the cavities thereby forming teeth in the cavities, wherein the etching of the non-homogeneous composition forms the cavities, and wherein the conductive material forms a portion of circuitry of an electrical device. - View Dependent Claims (15, 19)
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16. An article of manufacture, the article comprising:
an epoxy dielectric material delivered with solid content sufficient that etching the epoxy forms a non-uniformly roughened surface comprising molar-shaped cavities located in and underneath an initial surface of the dielectric material and sufficient that the etching of the epoxy uses non-homogeneity with the solid content to bring about formation of the non-uniformly roughened surface comprising the molar-shaped cavities and a plurality of the cavities have a first cross-sectional distance proximate the initial surface and a substantially greater cross-sectional distance distant from the initial surface, and a conductive material, a portion of the conductive material in the cavities thereby forming teeth in the cavities, wherein the etching of the epoxy forms the cavities, and wherein the conductive material forms a portion of circuitry of an electrical device. - View Dependent Claims (17, 20)
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18. An article of manufacture, the article comprising:
an epoxy dielectric material delivered with sufficient solid content that etching of the epoxy forms a non-uniformly roughened surface of molar-shaped cavities located in and underneath an initial surface of the dielectric material and sufficient that the etching of the epoxy uses the non-homogeneity with the solid content to bring about formation of the non-uniformly roughened surface of the molar-shaped cavities and a plurality of the cavities have a first cross-sectional distance proximate the initial surface and a substantially greater cross-sectional distance distant from the initial surface, and a conductive material, a portion of the conductive material in the cavities thereby forming teeth in the cavities, wherein the etching of the epoxy forms the cavities so that a plurality of the teeth each expand below a respective narrower region which is closer to the initial surface, and wherein the conductive material forms a portion of circuitry of an electrical device. - View Dependent Claims (21)
Specification
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Litigation Data
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Current AssigneeContinental Circuits LLC (Chicago Harbor Innovation Producers, LLC)
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Original AssigneePeter k. Trzyna Revocable Trust
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InventorsMcDermott, Brian J., McGowan, Daniel, Spotts, Jr., Ralph Leo, Tryzbiak, Sid
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Primary Examiner(s)Norris, Jeremy
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Assistant Examiner(s)Willis, Tremesha S
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Application NumberUS12/363,501Publication NumberTime in Patent Office1,341 DaysField of Search174/266US Class Current174/255CPC Class CodesH05K 1/0296 Conductive pattern lay-out ...H05K 1/032 consisting of one materialH05K 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 basesY10T 29/49155 Manufacturing circuit on or...Y10T 29/49165 by forming conductive walle...Y10T 428/12361 having aperture or cutY10T 428/24331 including nonapertured comp...
