Abstract:
A process and apparatus for producing supported conductive networks (1) which can be flexible or rigid, having densely packed circuits (3). The process and apparatus for making the conductive network (1) involves forming a conductive material (8) supported on a "dynamic pressure cushion" into a non-planar pattern defining the desired conductive circuits (3) in relation to a fixed reference plane (32). The "dynamic pressure cushion" is a material having suitable viscosity and flow characteristics to flow out from under the conductive material (8) as it is being formed and fill up any voids. To ensure that the "dynamic pressure cushion" properly flows without deforming the desired circuits (3), the die (6) used to form the conductive material (8) is provided with a material flow control grid and material expansion troughs. After forming the unwanted material is then mechanically removed in dimensional relation to the reference plane (32) leaving the desired conductive circuits (3).
Abstract:
A process and apparatus for producing supported conductive networks (1) which can be flexible or rigid, having densely packed circuits (3). The process and apparatus for making the conductive network (1) involves forming a conductive material (8) supported on a 'dynamic pressure cushion' into a non-planar pattern defining the desired conductive circuits (3) in relation to a fixed reference plane (32). The 'dynamic pressure cushion' is a material having suitable viscosity and flow characteristics to flow out from under the conductive material (8) as it is being formed and fill up any voids. To ensure that the 'dynamic pressure cushion' properly flows without deforming the desired circuits (3), the die (6) used to form the conductive material (8) is provided with a material flow control grid and material expansion troughs. After forming the unwanted material is then mechanically removed in dimensional relation to the reference plane (32) leaving the desired conductive circuits (3).
Abstract:
A process and apparatus for producing supported conductive networks (1) which can be flexible or rigid, having densely packed circuits (3). The process and apparatus for making the conductive network (1) involves forming a conductive material (8) supported on a 'dynamic pressure cushion' into a non-planar pattern defining the desired conductive circuits (3) in relation to a fixed reference plane (32). The 'dynamic pressure cushion' is a material having suitable viscosity and flow characteristics to flow out from under the conductive material (8) as it is being formed and fill up any voids. To ensure that the 'dynamic pressure cushion' properly flows without deforming the desired circuits (3), the die (6) used to form the conductive material (8) is provided with a material flow control grid and material expansion troughs. After forming the unwanted material is then mechanically removed in dimensional relation to the reference plane (32) leaving the desired conductive circuits (3).
Abstract:
Methods of facilitating commercial production of supported conductive networks without the use of hazardous chemicals including using heat flowable adhesive in the formation of the networks (2), providing contact pads (8) exposed through a dielectric substrate (6) which supports a conductive network (2), using the thickness of a conductor (4) supporting dielectric layer (6) to space the conductors (2) and providing conductor and waste material (18) cross-sections trapezoidal in shape in a non-planar pattern during manufacture of the networks.