LCP Composite Sheet Pattern Positioning
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Solution Overview
Problem
During thermocompression bonding of resin sheets with liquid crystal polymer (LCP) and conductive patterns, the resin flow causes undesirable displacement of conductive patterns, leading to positional variations across multiple layers.
Innovation Solution
A composite sheet is created with a resin film and a conductor film on one surface, and a powder layer of fibrillated liquid crystal polymer on the other, which undergoes surface treatments like ultraviolet exposure or plasma treatment to enhance bonding and reduce positional variation of conductive patterns during thermocompression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermocompression bonding is performed on stacked resin sheets with conductive patterns, then the sheets are integrated into a resin multilayer substrate, but the resin flow causes displacement of conductive patterns leading to positional variation
Solution Approach 1:
A powder layer of liquid crystal polymer is applied to the resin sheet before thermocompression bonding. This preliminary action creates a barrier that prevents resin flow from displacing the conductive patterns during the subsequent bonding process, while still allowing the bonding to proceed effectively.
Solution Approach 2:
The powder layer acts as an intermediary substance between the resin sheets during thermocompression bonding. It mediates the bonding process by controlling resin flow and preventing direct contact between the resin and conductive patterns, thereby maintaining pattern position stability while enabling sheet integration.
2Reliability
If conductive patterns are disposed to overlap at the same position across multiple layers, then the electrical connectivity is improved, but the positional variation of conductive patterns increases due to resin flow
Solution Approach 1:
The powder layer is applied in advance to all resin sheets that will have overlapping conductive patterns. This preliminary protective layer ensures that when thermocompression bonding occurs, the resin flow does not displace the conductive patterns, thereby maintaining both their overlapping alignment and positional accuracy.
Solution Approach 2:
The powder layer serves as a protective intermediary that allows conductive patterns to be positioned in overlapping configurations without suffering from resin-induced displacement. It enables the realization of electrically connected multi-layer patterns while maintaining manufacturing precision.
3Manufacturing precision
If a powder layer of liquid crystal polymer is applied to the resin sheet, then the positional variation of conductive patterns is reduced, but the device structure becomes more complex
Solution Approach 1:
The invention changes the physical state and distribution parameters of the liquid crystal polymer by using a powder layer instead of a continuous film. This parameter change achieves the dual benefit of maintaining manufacturing precision while avoiding excessive structural complexity, as the powder layer can be applied as a simple coating rather than requiring complex multi-layer construction.
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
The solution effectively minimizes the variation of conductive pattern positions, enhancing the reliability and precision of the resin multilayer substrate by stabilizing the conductive patterns and improving interlayer adhesion.
Implementation Method 1
at least one of the second surface and the powder included in the powder layer undergoes at least one of ultraviolet ray exposure, a plasma treatment, and a corona discharge treatment
Implementation Method 2
at least one of the second surface and the powder included in the powder layer undergoes at least one of ultraviolet ray exposure, a plasma treatment, and a corona discharge treatment
Implementation Method 3
at least one of the second surface and the powder included in the powder layer undergoes at least one of ultraviolet ray exposure, a plasma treatment, and a corona discharge treatment
Implementation Method 4
forming a stack by stacking the prepared plurality of composite sheets; and compressing and heating the stack to integrate the stack
Data Source
AI summary
A composite sheet includes a resin layer including a liquid crystal polymer as a main material and a first surface and a second surface facing away from each other, a conductor foil disposed on the first surface, and a powder layer including a powder of a liquid crystal polymer as a major component and located on an entirety of the second surface.