Circuit board and manufacturing method

• US 10,462,902 B1
• Filed: 04/11/2019
• Issued: 10/29/2019
• Est. Priority Date: 01/25/2019
• Status: Active Grant

• Current Assignee: Avary Holding (Shenzhen) Co., Limited., Hongqisheng Precision Electronics Company Limited (Monterey Park Finance Limited)
• Original Assignee: Avary Holding (Shenzhen) Co., Limited.
• Inventors: Huang, Han-Pei, Gao, Lin-Jie, Yang, Yong-Quan, Wei, Yong-Chao
• Primary Examiner(s): Norris, Jeremy C
• Application Number:
  US16/381,264
• Time in Patent Office: 201 Days
• CPC Class Codes: H05K 1/0298 Multilayer circuits
• CPC Class Codes: H05K 1/115 Via connections; Lands around holes or via connections H05K1/112 takes precedence
• CPC Class Codes: H05K 2203/1383 Temporary protective insulating layer
• CPC Class Codes: H05K 3/105 by conversion of non-conductive material on or in the support into conductive material, e.g. by using an energy beam
• CPC Class Codes: H05K 3/107 by filling grooves in the support with conductive material H05K3/045, H05K3/101, H05K3/1258 and H05K3/465 take precedence
• CPC Class Codes: H05K 3/185 by making a catalytic pattern by photo-imaging
• CPC Class Codes: H05K 3/188 by direct electroplating
• CPC Class Codes: H05K 3/4038 Through-connections; Vertical interconnect access [VIA] connections H05K3/403, H05K3/42 take precedence
• CPC Class Codes: H05K 3/4611 by laminating two or more circuit boards H05K3/4652 takes precedence
• CPC Class Codes: H05K 3/4617 characterized by laminating only or mainly similar single-sided circuit boards
• CPC Class Codes: H05K 5/0017 with operator interface units

Abstract

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.

Claims

1. A circuit board comprising at least two circuit board units, each of the circuit board units comprising:

a baseboard having a conductive hole filled with an electrical conductor;

a cover layer arranged on the baseboard and defined at least one trench and at least one opening, wherein the at least one opening exposing out the electrical conductor; and

a circuit pattern embedded in the at least one trench and comprising a connecting portion, wherein the connecting portion is embedded in the opening and is electrically coupled to the electrical conductor; and

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, and 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.

2. The circuit board of claim 1, wherein at least one of the circuit patterns is embedded in the cover layer of one of the circuit board units and the baseboard of the adjacent one of the circuit board units.

3. The circuit board of claim 1 further comprising at least one intermediate layer, wherein:

the intermediate layer comprises a substrate layer and a conductive member passing through the substrate layer;

the at least one intermediate layer is layered between adjacent two of the circuit board units; and

the conductive member electrically couples the electrical conductor to the connecting portion.

4. A method of manufacturing a circuit board comprising a plurality of circuit board units, the method comprising:

providing a baseboard and defining at least one through hole in the baseboard;

filling the at least one through hole with an electrical conductor;

covering a side of the baseboard with a cover layer, wherein the cover layer containing a laser direct structuring additive;

adhering a separation film to a side of the cover layer opposite to the baseboard;

defining at least one trench and at least one opening by laser ablation, wherein the at least one opening penetrating the separation film and the cover layer exposing out the electrical conductor;

forming a conductive circuit pattern in the at least one trench and forming a connecting portion in the at least one opening to obtain one circuit board unit;

making at least one more of the circuit board unit; and

laminating at least two of the circuit board units to obtain the circuit board.

5. The method of claim 4, wherein the laser direct structuring additive comprises at least one of copper chromium oxide spinel, copper salt, copper hydroxide phosphate, copper phosphate, copper sulphate, metal oxide containing zinc, metal oxide containing copper, metal oxide containing silver, metal oxide containing gold, metal oxide containing aluminum.

6. The method of claim 4, wherein the cover layer is formed on the baseboard by coating and is bonded to the baseboard by ultraviolet curing or heat curing.

7. The method of claim 4 further comprising:

providing at least one intermediate layer comprising a substrate layer and a conductive member passing through the substrate layer; and

laminating the at least one intermediate layer between two circuit board units.

8. The method of claim 4, wherein a depth and a width of the trench correspond to a thickness and a width of a preset circuit line.

9. The method of claim 4, wherein the conductive circuit pattern is partially embedded in the cover layer and partially extends out of the cover layer.