Method of forming a substrate core structure using microvia laser drilling and conductive layer pre-patterning and substrate core structure formed according to the method
First Claim
1. A method of fabricating a substrate core structure comprising:
- providing a starting insulating layer;
providing a first patterned conductive layer on one side of the starting insulating layer, and a second patterned conductive layer on another side of the starting insulating layer each of the first patterned conductive layer and the second patterned conductive layer defining conductive layer openings through which a set of via openings will be formed;
providing a first supplemental insulating layer onto the first patterned conductive layer, and a second supplemental insulating layer onto the second patterned conductive layer;
providing a first supplemental conductive layer on said first supplemental insulating layer;
laser drilling said set of via openings through said second supplemental insulating layer, through said conductive layer openings in said second patterned conductive layer, through said starting insulating layer, through said conductive layer openings in said first patterned conductive layer, through said first supplemental insulating layer, and to, but not through, said first supplemental conductive layer;
filling the set of via openings with a conductive material to provide a set of conductive vias wherein said set of conductive vias includes at least one conductive via which electrically connects said first patterned conductive layer with said second patterned conductive layer;
after filling the set of via openings, patterning said first supplemental conductive layer to provide a first supplemental patterned conductive layer on the first supplemental insulating layer; and
after laser drilling the set of via openings, providing a second supplemental patterned conductive layer onto the second supplemental insulating layer, the set of conductive vias contacting the first supplemental patterned conductive layer at one side thereof, and the second supplemental patterned conductive layer at another side thereof.
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Abstract
A method of fabricating a substrate core structure comprises: providing first and second patterned conductive layers defining openings therein on each side of a starting insulating layer; providing a first and a second supplemental insulating layers onto respective ones of a first and a second patterned conductive layer; laser drilling a set of via openings extending through at least some of the conductive layer openings of the first and second patterned conductive layers; filling the set of via openings with a conductive material to provide a set of conductive vias; and providing a first and a second supplemental patterned conductive layer onto respective ones of the first and the second supplemental insulating layers, the set of conductive vias contacting the first supplemental patterned conductive layer at one side thereof and the second supplemental patterned conductive layer at another side thereof.
122 Citations
23 Claims
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1. A method of fabricating a substrate core structure comprising:
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providing a starting insulating layer; providing a first patterned conductive layer on one side of the starting insulating layer, and a second patterned conductive layer on another side of the starting insulating layer each of the first patterned conductive layer and the second patterned conductive layer defining conductive layer openings through which a set of via openings will be formed; providing a first supplemental insulating layer onto the first patterned conductive layer, and a second supplemental insulating layer onto the second patterned conductive layer; providing a first supplemental conductive layer on said first supplemental insulating layer; laser drilling said set of via openings through said second supplemental insulating layer, through said conductive layer openings in said second patterned conductive layer, through said starting insulating layer, through said conductive layer openings in said first patterned conductive layer, through said first supplemental insulating layer, and to, but not through, said first supplemental conductive layer; filling the set of via openings with a conductive material to provide a set of conductive vias wherein said set of conductive vias includes at least one conductive via which electrically connects said first patterned conductive layer with said second patterned conductive layer; after filling the set of via openings, patterning said first supplemental conductive layer to provide a first supplemental patterned conductive layer on the first supplemental insulating layer; and after laser drilling the set of via openings, providing a second supplemental patterned conductive layer onto the second supplemental insulating layer, the set of conductive vias contacting the first supplemental patterned conductive layer at one side thereof, and the second supplemental patterned conductive layer at another side thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of fabricating a substrate core structure comprising:
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providing a starting insulating layer having a first planar surface opposite a second planar surface; providing a first patterned conductive layer on said first planar surface of the starting insulating layer and a second patterned conductive layer on said second planar surface of the starting insulating layer, each of the first patterned conductive layer and the second patterned conductive layer defining conductive layer openings through which a set of via openings will be formed; providing a first supplemental insulating layer onto the first patterned conductive layer and a second supplemental insulating layer on the second patterned conductive layer; laser drilling said set of via openings through said second supplemental insulating layer, through said conductive layer openings in said second patterned conductive layer, through said starting insulating layer, through said conductive layer openings in said first patterned conductive layer, through said first supplemental insulating layer; filling the set of via openings with a conductive material to provide a set of conductive vias wherein said set of conductive vias includes at least one conductive via which electrically connects said first patterned conductive layer with said second patterned conductive layer; and after laser drilling the set of via openings, forming a supplemental conductive layer directly on said second supplemental insulating layer. - View Dependent Claims (15, 16, 17, 18)
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19. A method of fabricating a substrate core structure comprising:
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forming a core insulating layer;
providing a first patterned conductive layer on one side of the core insulating layer and a second patterned conductive layer on another side of the core insulating layer, each of the first patterned conductive layer and the second patterned conductive layer defining conductive layer openings through which a set of via openings will be formed;forming a first supplemental insulating layer onto the first patterned conductive layer and a second supplemental insulating layer on the second patterned conductive layer; laser drilling said set of via openings through said second supplemental insulating layer, through said conductive layer openings in said second patterned conductive layer, through said core insulating layer, through said conductive layer openings in said first patterned conductive layer, through said first supplemental insulating layer; filling the set of via openings with a conductive material to provide a set of conductive vias wherein said set of conductive vias includes at least one conductive via which electrically connects said first patterned conductive layer with said second patterned conductive layer; and after laser drilling said via openings, forming a supplemental conductive layer directly on said second supplemental insulating layer. - View Dependent Claims (20, 21, 22, 23)
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Specification