FCCL Conductive Pattern Flexibility Stiffness Control

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Solution Overview

Problem

Conventional Flexible Copper Clad Laminates (FCCLs) lack the ability to precisely control the thickness and physical characteristics of copper clad patterns, such as flexibility and stiffness, which are crucial for manufacturing Flexible Printed Circuit Boards (FPCBs, leading to manufacturing cost increases due to the limited selection of standardized products.

Innovation Solution

A method involving electroforming and electroplating processes to form conductive patterns with specific metal alloys on a polymer plastic film, allowing for the adjustment of composition ratios and thicknesses of copper, tin, and nickel to achieve desired mechanical characteristics, including flexibility and stiffness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional standardized FCCL products are used, then manufacturing process is simple, but the flexibility and stiffness of conductive pattern cannot be precisely controlled

Engineering Contradiction:

Improvethickness control of copper clad patternVSAvoidcomplexity of FCCL manufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The copper clad pattern is divided into multiple layers (first copper layer, second copper layer) with different thicknesses. The first copper layer has a first thickness and the second copper layer has a second thickness greater than the first thickness, allowing independent control of different regions to achieve precise overall thickness control

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the copper clad pattern have different thicknesses to provide different mechanical properties. The first copper layer provides flexibility while the second copper layer provides stiffness, creating local quality variations within the same conductive pattern

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If copper clad thickness is reduced to improve flexibility, then flexibility increases, but stiffness decreases

Engineering Contradiction:

Improveflexibility of FCCLVSAvoidstiffness of copper clad pattern

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The copper clad is segmented into multiple layers with different thicknesses. The first copper layer has smaller thickness for flexibility, while the second copper layer has greater thickness for stiffness, allowing both properties to coexist in the same FCCL product

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The FCCL uses a composite structure combining copper clad layers of different thicknesses with a polyimide insulating layer. This composite material approach allows the system to exhibit both flexible and stiff characteristics simultaneously

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If multiple types of standardized FCCL are selected to achieve desired mechanical characteristics, then flexibility and stiffness can be adjusted, but manufacturing cost increases

Engineering Contradiction:

Improvemechanical characteristics controlVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

A single FCCL product design can achieve multiple mechanical characteristics through the multi-layer copper structure. Instead of requiring multiple different standardized FCCL types, one universal design with adjustable layer thicknesses can provide various flexibility and stiffness combinations

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mechanical characteristics are controlled by changing the thickness parameters of the copper layers rather than selecting different material types. By adjusting the first thickness and second thickness parameters, desired flexibility and stiffness can be achieved without increasing material costs

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the precise control of flexibility and stiffness in conductive patterns, reducing manufacturing costs by providing a customizable FCCL suitable for various mechanical requirements.

Implementation Method 1

an electroforming step of forming a conductive pattern on a mold for electroforming through electroforming

Methodology Applied

Scientific EffectElectroforming: Electrodeposition

Implementation Method 2

a transfer step of transferring the conductive pattern from the mold for electroforming to the bottom of a polymer plastic film

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS11665828B2Method for manufacturing FCCL capable of controlling flexibility and stiffness of conductive pattern

Publication Date: 2023.05.30 SAMWON ACT CO LTD

AI summary

Disclosed is a method for manufacturing an FCCL capable of controlling flexibility and stiffness of a conductive pattern. The method for manufacturing an FCCL (Flexible Copper Clad Laminate) includes: an electroforming step of forming a conductive pattern on a mold for electroforming through electroforming; and a transfer step of transferring the conductive pattern from the mold for electroforming to the bottom of a polymer plastic film, wherein the electroforming process is performed in a plating bath equipped with a first metal, a second metal and a third metal, wherein the first metal is copper (Cu), the second metal serves to add flexibility and is one of tin (Sn), gold (Au), silver (Ag) and aluminum (Al), and the third metal serves to add stiffness and is one of nickel (Ni), cobalt (Co), chrome (Cr), iron (Fe), tungsten (W) and titanium (Ti).