Flexible PCB Annular Ring Step Height Reduction

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Solution Overview

Problem

The formation of annular rings through selective copper plating on flexible circuit boards results in significant steps, typically exceeding 10 microns, which restricts the production of fine lines and increases the complexity of multilayer circuits.

Innovation Solution

A method involving copper reduction and partial plating to form annular copper rings with a reduced height step, using chemical etching and dry film processes to minimize the step height between copper layers, allowing for smoother surfaces and higher resolution circuitry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If selective copper plating is used to form annular rings, then conducting lines can be formed on flexible circuit boards, but the step height becomes excessively large (more than 10 microns)

Engineering Contradiction:
Improveline precisionVSAvoidstep height
Core Design Contradiction:
Manufacturing precisionVSShape

Solution Approach 1:

The patent applies preliminary action by performing copper reduction on the inner wall of the hole before forming the annular ring. The reducing agent is introduced to reduce copper ions on the inner wall, creating a reduced copper layer that serves as a foundation for subsequent plating. This preliminary reduction step ensures that when copper is later plated to form the annular ring, the step height is controlled because the plating builds upon the reduced copper layer rather than creating a large step from the original substrate level.

Inventive Principle:
Principle #10Preliminary action

2Adaptability or versatility

If multiple circuit layers are stacked, then circuit functionality is enhanced, but the step height increases thereby restricting fine line production

Engineering Contradiction:
Improvecircuit layer capabilityVSAvoidstep height
Core Design Contradiction:
Adaptability or versatilityVSShape

Solution Approach 1:

The patent applies local quality by introducing a reducing agent into the hole to create a localized reduced copper layer on the inner wall. This localized reduction creates different copper densities and heights at different locations: the bottom and inner wall of the hole have reduced copper layers, while the surrounding area maintains the original copper layer thickness. This local differentiation allows the formation of annular rings with controlled step heights that enable fine line production even in multilayer circuits.

Inventive Principle:
Principle #3Local quality

3Reliability

If conventional plating is used, then annular rings are formed, but the surface smoothness is compromised

Engineering Contradiction:
Improveannular ring formationVSAvoidsurface smoothness
Core Design Contradiction:
ReliabilityVSShape

Solution Approach 1:

The patent applies parameter changes by modifying the copper layer parameters through chemical reduction. The reducing agent changes the copper ion concentration and distribution on the inner wall, creating a reduced copper layer with different physical and chemical properties. This parameter change in copper density and layer thickness enables the subsequent plating process to form annular rings with smoother surfaces and reduced step heights, improving both reliability and surface quality.

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

This approach reduces the step height between copper layers to 0-3 microns, enhancing the smoothness of the panel surface, increasing product yield, and enabling the production of finer lines and more precise circuits.

Implementation Method 1

introducing a reducing agent into the hole to reduce copper ions on an inner wall of the hole, thereby forming a reduced copper layer

Methodology Applied
Scientific EffectChemical reduction: Reduction

Implementation Method 2

fine lines are formed by selective copper plating process

Methodology Applied
Scientific EffectCopper plating: Electroplating

Data Source

PatentUS10285260B2Flexible printed circuit board and method for manufacturing same
Publication Date: 2019.05.07 AVARY HLDG (SHENZHEN) CO LTD
  • US10285260B2 patent drawing
  • US10285260B2 patent drawing
  • US10285260B2 patent drawing

AI summary

The flexible printed circuit board includes a base layer, a first circuit layer and a second circuit layer, the first circuit and the second circuit layer formed on both sides of the base layer; conducting holes extending through the base layer and the first copper layer, the conducting holes include annular copper ring embedded in the first circuit layer. A height difference between a surface of the annular copper ring and a surface of the first circuit layer is in a range from 0 to 3 micrometers. A method for manufacturing the flexible printed circuit board is also provided.