Electrical device with teeth joining layers and method for making the same

DC CAFC

US 8,581,105 B2
Filed: 10/01/2012
Issued: 11/12/2013
Est. Priority Date: 08/04/1997
Status: Expired due to Fees

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1. A process of making an article of manufacture, the process comprising:

implementing a circuit design for an electrical device by coupling 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, with a conductive material, a portion of the conductive material in the cavities thereby forming angular teeth in the cavities, in circuitry of the electrical device.

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Abstract

A process of making an article of manufacture, the process including constructing an electrical device which implements circuitry having a portion in cavities, the portion defined by an epoxy dielectric material delivered with solid content sufficient that etching the epoxy forms 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 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 cavities, and a conductive material, a portion of the conductive material in the cavities thereby forming teeth in the cavities, such that the conductive material forms the portion of the circuitry of the electrical device.

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103 Claims

1. A process of making an article of manufacture, the process comprising:
- implementing a circuit design for an electrical device by coupling 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, with a conductive material, a portion of the conductive material in the cavities thereby forming angular teeth in the cavities, in circuitry of the electrical device.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70)
- - 2. The process of claim 1, wherein some of the cavities comprise veins.
  - 3. The process of claim 1, wherein the cavities comprise cavities which substantially exhibit one or more of the following shapes:
    - fanged, canine, and otherwise hooked teeth.
  - 4. The process of claim 1, wherein the cavities comprise cavities which substantially exhibit one or more of the following angled shapes:
    - equilateral, isosceles, scalene, right, obtuse, or any combination thereof.
  - 5. The process of claim 3, wherein the cavities comprise cavities which substantially exhibit one or more of the following angled shapes:
    - equilateral, isosceles, scalene, right, obtuse, or any combination thereof.
  - 6. The process of claim 1, wherein a conductive layer is intermediate the conductive material and the dielectric material, and wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 7. The process of claim 6, wherein at least one of the teeth has a depth in a range of 1 tenth of a mil and less than about 2 tenths of a mil.
  - 8. The process of claim 6, wherein a sample of the circuitry has at least about 5,000 of the teeth per linear inch.
  - 9. The process of claim 1, wherein the portion of the circuitry is multilayer circuitry of the electrical device.
  - 10. The process of claim 1, wherein the electrical device is a circuit board.
  - 11. The process of claim 1, wherein the portion of the conductive material is connected to a second portion of the conductive material through at least one micro via.
  - 12. The process of claim 1, wherein the conductive material comprises a micro via in a multi-layer circuit board.
  - 22. The process of claim 2, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 23. The process of claim 3, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 24. The process of claim 4, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 25. The process of claim 5, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 26. The process of claim 7, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 27. The process of claim 8, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 28. The process of claim 9, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 29. The process of claim 10, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 30. The process of claim 11, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 31. The process of claim 12, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 41. The process of claim 1, wherein the etching includes a first etching and a second etching.
  - 42. The process of claim 2, wherein the etching includes a first etching and a second etching.
  - 43. The process of claim 3, wherein the etching includes a first etching and a second etching.
  - 44. The process of claim 4, wherein the etching includes a first etching and a second etching.
  - 45. The process of claim 5, wherein the etching includes a first etching and a second etching.
  - 46. The process of claim 6, wherein the etching includes a first etching and a second etching.
  - 47. The process of claim 7, wherein the etching includes a first etching and a second etching.
  - 48. The process of claim 8, wherein the etching includes a first etching and a second etching.
  - 49. The process of claim 9, wherein the etching includes a first etching and a second etching.
  - 50. The process of claim 10, wherein the etching includes a first etching and a second etching.
  - 51. The process of claim 11, wherein the etching includes a first etching and a second etching.
  - 52. The process of claim 12, wherein the etching includes a first etching and a second etching.
  - 61. The process of claim 22, wherein the etching includes a first etching and a second etching.
  - 62. The process of claim 23, wherein the etching includes a first etching and a second etching.
  - 63. The process of claim 24, wherein the etching includes a first etching and a second etching.
  - 64. The process of claim 25, wherein the etching includes a first etching and a second etching.
  - 65. The process of claim 26, wherein the etching includes a first etching and a second etching.
  - 66. The process of claim 27, wherein the etching includes a first etching and a second etching.
  - 67. The process of claim 28, wherein the etching includes a first etching and a second etching.
  - 68. The process of claim 29, wherein the etching includes a first etching and a second etching.
  - 69. The process of claim 30, wherein the etching includes a first etching and a second etching.
  - 70. The process of claim 31, wherein the etching includes a first etching and a second etching.

13. A process of making an article of manufacture, the process comprising:
- implementing a circuit design for an electrical device by coupling 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 in bringing about formation of the non-uniformly roughened surface with at least some of the cavities having a first cross-sectional distance proximate the surface and a substantially greater cross-sectional distance distant from the surface, with 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, in circuitry of the electrical device.
- View Dependent Claims (14, 15, 32, 33, 34, 53, 54, 55, 71, 72, 73)
- - 14. The process of claim 13, wherein the substantially greater cross-sectional distance is at least twice the first cross-sectional distance.
  - 15. The process of claim 13, wherein the electrical device is a circuit board.
  - 32. The process of claim 13, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 33. The process of claim 14, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 34. The process of claim 15, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 53. The process of claim 13, wherein the etching includes a first etching and a second etching.
  - 54. The process of claim 14, wherein the etching includes a first etching and a second etching.
  - 55. The process of claim 15, wherein the etching includes a first etching and a second etching.
  - 71. The process of claim 32, wherein the etching includes a first etching and a second etching.
  - 72. The process of claim 33, wherein the etching includes a first etching and a second etching.
  - 73. The process of claim 34, wherein the etching includes a first etching and a second etching.

16. A process of making an article of manufacture, the process comprising:
- implementing a circuit design for an electrical device by coupling an epoxy dielectric material delivered with solid content sufficient that etching the epoxy forms a non-uniformly roughened surface comprising substantially 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 in bringing 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, with 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, in circuitry of the electrical device.
- View Dependent Claims (17, 18, 35, 36, 37, 56, 57, 58, 74, 75, 76)
- - 17. The process of claim 16, wherein the substantially greater cross-sectional distance is at least twice the first cross-sectional distance.
  - 18. The process of claim 16, wherein the electrical device is a circuit board.
  - 35. The process of claim 16, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 36. The process of claim 17, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 37. The process of claim 18, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 56. The process of claim 16, wherein the etching includes a first etching and a second etching.
  - 57. The process of claim 17, wherein the etching includes a first etching and a second etching.
  - 58. The process of claim 18, wherein the etching includes a first etching and a second etching.
  - 74. The process of claim 35, wherein the etching includes a first etching and a second etching.
  - 75. The process of claim 36, wherein the etching includes a first etching and a second etching.
  - 76. The process of claim 37, wherein the etching includes a first etching and a second etching.

19. A process of making an article of manufacture, the process comprising:
- implementing a circuit design for an electrical device by coupling 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 in bringing 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, in circuitry of the electrical device.
- View Dependent Claims (20, 38, 39, 59, 77, 78)
- - 20. The process of claim 19, wherein the electrical device is a circuit board.
  - 38. The process of claim 19, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 39. The process of claim 20, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 59. The process of claim 19, wherein the etching includes a first etching and a second etching.
  - 77. The process of claim 38, wherein the etching includes a first etching and a second etching.
  - 78. The process of claim 39, wherein the etching includes a first etching and a second etching.

21. A process of making an article of manufacture, the process comprising:
- implementing a circuit design for an electrical device with circuitry comprising means for interlocking a conductor part of the circuitry configured for filling cavities with an epoxy dielectric material disposed in combination with the circuitry and coupled with the conductor part in a configuration where the dielectric material comprises a non-uniformly roughened surface comprising cavities located in and underneath an initial surface of the dielectric material delivered with solid content being non-homogeneous and configured to bring about formation of the non-uniformly roughened surface by etching of the epoxy, at least some the cavities having a first cross-sectional distance proximate the initial surface and a substantially greater cross-sectional distance distant from the initial surface.
- View Dependent Claims (40, 60, 79)
- - 40. The process of claim 21, wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 60. The process of claim 21, wherein the etching includes a first etching and a second etching.
  - 79. The process of claim 40, wherein the etching includes a first etching and a second etching.

80. An electrical device comprising:
- circuitry;
  
  conductive material being part of the circuitry and configured as angular teeth in filling cavities; and
  
  an epoxy dielectric material, disposed in combination with the circuitry and coupled with the conductive material in a configuration where the dielectric material comprises a non-uniformly roughened surface comprising cavities located in and underneath an initial surface of the dielectric material delivered with solid content being non-homogeneous and configured to bring about formation of the non-uniformly roughened surface by etching of the epoxy, at least some the cavities having a first cross-sectional distance proximate the initial surface and a substantially greater cross-sectional distance distant from the initial surface.
- View Dependent Claims (81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99)
- - 81. The electrical device of claim 80, wherein some of the cavities comprise veins.
  - 82. The electrical device of claim 80, wherein the cavities comprise cavities which substantially exhibit one or more of the following shapes:
    - fanged and canine, and otherwise hooked teeth.
  - 83. The electrical device of claim 80, wherein the cavities comprise cavities which substantially exhibit one or more of the following angled shapes:
    - equilateral, isosceles, scalene, right, obtuse, or any combination thereof.
  - 84. The electrical device of claim 83, wherein the cavities comprise cavities which substantially exhibit one or more of the following angled shapes:
    - equilateral, isosceles, scalene, right, obtuse, or any combination thereof.
  - 85. The electrical device of claim 80, wherein a conductive layer is intermediate the conductive material and the dielectric material, and wherein the bringing about the formation of the non-uniformly roughened surface does not include bringing about formation of cavities in the conductive material by physical roughening.
  - 86. The electrical device of claim 80, wherein at least one of the teeth has a depth in a range of 1 tenth of a mil and less than about 2 tenths of a mil.
  - 87. The electrical device of claim 80, wherein a sample of the circuitry has at least about 5,000 of the teeth per linear inch.
  - 88. The electrical device of claim 80, wherein the circuitry comprises multilayer circuitry of the electrical device.
  - 89. The electrical device of claim 80, wherein the electrical device is a circuit board.
  - 90. The electrical device of claim 81, wherein the etching includes a first etching and a second etching.
  - 91. The electrical device of claim 82, wherein the etching includes a first etching and a second etching.
  - 92. The electrical device of claim 83, wherein the etching includes a first etching and a second etching.
  - 93. The electrical device of claim 84, wherein the etching includes a first etching and a second etching.
  - 94. The electrical device of claim 85, wherein the etching includes a first etching and a second etching.
  - 95. The electrical device of claim 86, wherein the etching includes a first etching and a second etching.
  - 96. The electrical device of claim 87, wherein the etching includes a first etching and a second etching.
  - 97. The electrical device of claim 88, wherein the etching includes a first etching and a second etching.
  - 98. The electrical device of claim 89, wherein the etching includes a first etching and a second etching.
  - 99. The electrical device of claim 90, wherein the etching includes a first etching and a second etching.

100. A product produced by the process of 1.

101. A product produced by the process of 13.

102. A product produced by the process of 16.

103. A product produced by the process of 21.

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Litigation Data

Current Assignee
Continental Circuits LLC (Chicago Harbor Innovation Producers, LLC)
Original Assignee
Peter K. Trzyna
Inventors
McDermott, Brian J., McGowan, Daniel, Spotts, Jr., Ralph Leo, Tryzbiak, Sid
Primary Examiner(s)
Norris, Jeremy
Assistant Examiner(s)
Willis, Tremesha S

Application Number

US13/632,742
Publication Number

US 20130032568A1
Time in Patent Office

407 Days
Field of Search

174255-262, 174/264, 174/266, 298/29, 298/31, 216/13, 216 16- 18, 205/125
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 with teeth joining layers and method for making the same

First Claim

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103 Claims

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Electrical device with teeth joining layers and method for making the same

First Claim

10 Assignments

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103 Claims

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