Method, system, and apparatus for protective coating a flexible circuit

• US 20050255232A1
• Filed: 05/17/2004
• Published: 11/17/2005
• Est. Priority Date: 05/17/2004
• Status: Active Grant

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Nelson, Veronica A.
• Granted Patent: US 7,569,250 B2
• Time in Patent Office: Days
• US Class Current: 427/96.100
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 2203/0108 Male die used for patterning, punching or transferring
• CPC Class Codes: H05K 2203/0143 Using a roller; Specific shape thereof; Providing locally adhesive portions thereon
• CPC Class Codes: H05K 2203/1545 Continuous processing, i.e. involving rolls moving a band-like or solid carrier along a continuous production path
• CPC Class Codes: H05K 3/0091 Apparatus for coating printed circuits using liquid non-metallic coating compositions
• CPC Class Codes: H05K 3/28 Applying non-metallic protective coatings H05K3/0091 takes precedence; methods for intermediate insulating layers for build-up multilayer circuits H05K3/4673

Abstract

A process for applying a protective coating to a flex circuit comprises providing a flex circuit having conductive traces on one surface and applying a protective coating in substantially a liquid state to the one surface from a first roller including the protective coating in a pattern thereon. The pattern includes at least one area on the one surface of the first roller that is not covered by the protective coating.

Claims

1. A process for applying a protective coating to a flex circuit comprising:

providing a flex circuit having conductive traces on one surface; and

applying a protective coating in substantially a liquid state to the one surface from a first roller including the protective coating in a pattern thereon, wherein the pattern includes at least one area on the one surface of the first roller that is not covered by the protective coating.

2. A process according to claim 1, further comprising providing a liner and wherein applying the protective coating comprises applying the protective coating to the liner with the first roller in the predetermined pattern and then applying the liner to the one surface.

3. A process according to claim 2, further including removing the liner after applying the protective coating to the one surface.

4. A process according to claim 2, wherein providing the liner comprises providing a liner having at least one opening, and wherein applying the protective coating comprises applying the liner to the flex circuit so that the at least one opening of the liner is aligned to create at least one opening of the protective coating on the one surface.

5. A process according to claim 2 further comprising controlling the thickness of the protective coating with a thickness roller on a side of the flex circuit opposing the one side.

6. A process according to claim 1, further comprising applying a heating roller to the flex circuit after applying the protective coating.

7. A process according to claim 1, further comprising applying a cooling roller to the flex circuit after applying the protective coating.

8. A process according to claim 1, further comprising utilizing a doctor blade to remove coating to achieve a desired coat thickness.

9. A process according to claim 1, where the protective coating is a thermoplastic material.

10. A process according to claim 1, where the protective coating is a solvent based liquid suspension adhesive.

11. A process according to claim 1, wherein the one or more exposed portions of the flex circuit are configured to accommodate a print head assembly.

12. A process according to claim 1, wherein the at least one area is configured to accommodate a print head assembly.

13. A process according to claim 1, wherein the first roller is selected from a group consisting of a mitre roller, precision roller, flexography cylinder, and a gravure cylinder.

14. A process according to claim 1, further comprising applying an interleaf liner on the one after applying the protective coating.

15. A process according to claim 1, where the coating is supplied to the first roller via one of a coating bath or a slotted die dispensing system.

32. A process according to claim 12 wherein applying the protective coating to the first liner surface includes the protective coating in a pattern thereon, wherein the pattern includes at least one area on the one surface of the first roller that is not covered by the protective coating.

16. A apparatus for applying a protective coating to a flex circuit comprising:

means for providing a flex circuit in a continuous fashion; and

means for selectively applying a protective coating in a predetermined pattern to one surface of the flex circuit.

17. An apparatus according to claim 16, further comprising means for providing a liner onto the one surface and wherein applying the protective coating comprises applying the protective coating to the liner with the first roller in the predetermined pattern.

18. An apparatus according to claim 17, further comprising means for removing the liner to produce a coated flex circuit having the protective coating placed on the one surface.

19. An apparatus according to claim 17, further comprising means for controlling the thickness of the protective coating on a side of the flex circuit opposing the one side.

20. An apparatus according to claim 16, further comprising means for scraping away excess coating after selectively applying the protective coating.

21. A process for applying a protective coating to a flex circuit comprising:

providing a flex circuit having conductive traces on one surface;

providing a liner including a first liner surface; and

applying a protective coating to the first liner surface using a first roller; and

applying the protective from the first liner surface to the one surface of the flexible circuit.

22. A process according to claim 21, further including removing the liner to produce a coated flex circuit having the protective coating on the one surface.

23. A process according to claim 21, wherein providing the liner comprises providing a liner having at least one opening, and wherein applying the protective coating comprises applying the liner to the flex circuit so that the at least one opening of the liner is aligned with the at least one opening of the protective coating.

24. A process according to claim 21, further comprising applying a heating roller to the flex circuit after applying the protective coating.

25. A process according to claim 21, further comprising applying a cooling roller to the flex circuit after applying the protective coating.

26. A process according to claim 21, further comprising utilizing a doctor blade to remove excess coating to achieve a desired thickness.

27. A process according to claim 21, where the protective coating is a thermoplastic material.

28. A process according to claim 21, where the protective coating is a solvent based liquid suspension adhesive.

29. A process according to claim 21, wherein the one or more exposed portions of the flex circuit are configured to accommodate a print head assembly.

30. A process according to claim 21, wherein the first roller is selected from a group consisting of a mitre roller, precision roller, flexography cylinder, and a gravure cylinder.

31. A process according to claim 21, further comprising applying an interleaf liner on the one surface after applying the protective coating.