Laser Direct Structured Circuit Board Seed Layer Elimination

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Solution Overview

Problem

The existing manufacturing process of circuit boards is complex and not environmentally friendly due to the need for multiple steps, including forming a seed layer and its subsequent removal.

Innovation Solution

A method involving a thermoplastic resin substrate with a laser-processed through hole filled with an electrical conductor, covered by a laser direct structuring additive layer, and a separation film that is laser-ablated to form trenches and openings, allowing direct formation of a conductive circuit pattern without a seed layer, simplifying the process and reducing environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a seed layer is formed on the substrate and circuits are formed on the seed layer, then reliable electrical connections can be achieved, but the manufacturing process becomes complex and environmentally harmful due to multiple steps and excess material removal

Engineering Contradiction:
Improveelectrical connection reliabilityVSAvoidmanufacturing process complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the seed layer from the manufacturing process. Instead of forming circuits on a seed layer that requires subsequent removal, the invention directly forms conductive circuits on the substrate using laser direct structuring technology, thereby removing the unnecessary seed layer formation and removal steps while maintaining electrical connection reliability

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical/chemical process of seed layer deposition and removal with a laser-based direct structuring process. The laser directly writes conductive circuit patterns onto the substrate, substituting the multi-step mechanical manufacturing process with a more efficient energy-based process that achieves the same functional result without the complexity

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If a seed layer is formed and then removed after circuit formation, then circuits can be created on the substrate, but material is wasted and environmental harm is caused

Engineering Contradiction:
Improvecircuit formation capabilityVSAvoidseed layer material waste
Core Design Contradiction:
Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent extracts the problematic seed layer material from the process entirely. By using laser direct structuring to directly form conductive circuits on the substrate, the invention eliminates the need for seed layer materials that would otherwise be deposited and then removed, preventing material waste and environmental harm

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The substrate itself serves as the base for direct circuit formation without requiring an intermediate seed layer. The laser direct structuring process enables the substrate to be directly modified into conductive circuits, making the system self-sufficient and eliminating the need for additional material layers that would be wasted

Inventive Principle:
Principle #25Self-service

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 method simplifies the circuit board manufacturing process by eliminating the need for a seed layer, allowing for precise control of circuit thickness and width, and ensures reliable electrical connections through press-fitting, while being more environmentally friendly.

Implementation Method 1

portions of the separation film and the cover layer are removed by laser ablation

Methodology Applied
Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

a laser direct structuring (LDS) additive is activated by laser ablation

Methodology Applied
Scientific EffectLaser direct structuring: Laser

Data Source

PatentUS10462902B1Circuit board and manufacturing method
Publication Date: 2019.10.29 AVARY HLDG (SHENZHEN) CO LTD
  • US10462902B1 patent drawing
  • US10462902B1 patent drawing
  • US10462902B1 patent drawing

AI summary

A circuit board includes at least two circuit board units. Each of the circuit board units includes a baseboard having a conductive hole filled with an electrical conductor, and a cover layer arranged on the baseboard and defining at least one trench and at least one opening. The at least one opening exposes out the electrical conductor. A circuit pattern is embedded in the at least one trench and includes a connecting portion. The connecting portion is embedded in the opening and is electrically coupled to the electrical conductor. The at least two circuit board units are stacked. Two sides of the at least one cover layer are respectively adhered to the corresponding baseboard. Two ends of the at least one connecting portion are respectively electrically coupled to the corresponding electrical conductor and electrically coupled the two adjacent circuit patterns.