Inkjet Micro-Lens Formation for Multilayer PCB Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing high-density interconnection printed circuit boards, such as lithography, face challenges in achieving precise micro-scale patterns and vias due to complex processes and non-uniformity, leading to degraded reproducibility and increased costs.
Innovation Solution
A manufacturing method for multilayered boards that forms hemispherical micro-lens shapes using inkjet technology to create precise connection portions, involving dot, stack, and cover patterns with adjustable characteristics, allowing for high-precision connections between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lithography or screen printing methods are used to form circuit patterns, then manufacturing process can be implemented, but manufacturing precision and reproducibility of micro-size patterns deteriorate
Solution Approach 1:
The patent replaces conventional mechanical lithography and screen printing systems with an inkjet printing system that uses controlled droplet deposition. The inkjet method forms patterns by jetting material droplets that self-assemble into precise hemispherical micro-lens shapes, eliminating the need for complex mechanical exposure and etching processes while achieving superior micro-size pattern precision
Solution Approach 2:
The patent changes the fundamental parameter of pattern formation from mechanical contact and chemical etching to controlled material deposition through inkjet droplet jetting. By controlling droplet size, deposition frequency, and material properties, the system achieves precise micro-size patterns with consistent hemispherical shapes, improving both manufacturing precision and simplifying the overall process
2Quantity of substance
If pattern size is reduced to achieve high-density interconnection, then integration density is improved, but pattern shape quality and reproducibility deteriorate
Solution Approach 1:
The inkjet printing system replaces mechanical lithography methods that struggle with micro-size patterns. The inkjet process maintains excellent shape control and reproducibility even at reduced pattern sizes by precisely controlling droplet deposition, enabling high-density interconnection while preserving pattern quality through material self-assembly into consistent hemispherical shapes
Solution Approach 2:
The patent utilizes the natural tendency of deposited droplets to form hemispherical micro-lens shapes. This spherical geometry provides consistent optical and structural properties that maintain pattern quality at reduced sizes, enabling high integration density while preserving shape fidelity through the self-organizing behavior of the deposited material
3Ease of manufacture
If conventional lithography methods are used, then circuit patterns can be formed, but process costs increase due to complex processes and waste treatment
Solution Approach 1:
The inkjet printing system replaces the complex sequence of lithography, etching, and plating processes with a direct-write material deposition method. This substitution eliminates the need for specialized facilities for waste water treatment and complex process equipment, reducing facility complexity while maintaining pattern formation capability through controlled droplet jetting and material self-assembly
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 realization of high-precision connection portions between layers of multilayered boards, improving reproducibility and reducing process complexity and costs by using inkjet-based formation of micro-lens patterns.
Implementation Method 1
a dot pattern forming process that forms a dot pattern including at least one hemispherical micro-lens shape by repeating a process of forming one hemispherical micro-lens shape by jetting one droplet for forming the dot pattern in an inkjet manner
Implementation Method 2
the surface of the board may be surface-treated to adjust a diameter or a height of the hemispherical micro-lens shape. In an embodiment, the surface treatment may be a hydrophilic treatment or a hydrophobic treatment.
Implementation Method 3
the surface treatment may be a hydrophilic treatment or a hydrophobic treatment
Data Source
AI summary
A manufacturing method of a multilayered board, includes: a dot pattern forming process that forms a dot pattern comprising at least one hemispherical micro-lens shape by repeating a process of forming one hemispherical micro-lens shape by jetting one droplet for forming the dot pattern in an inkjet manner; and a stack pattern forming process that forms a stack pattern having a thickness less than that of the micro-lens by jetting a droplet for forming the stack pattern on a predetermined area around the dot pattern in the inkjet manner.