Spin coat process for manufacturing a Z-directed component for a printed circuit board
First Claim
1. A method for manufacturing a z-directed component for insertion into a mounting hole in a printed circuit board, comprising:
- depositing a liquid based material onto a top surface of a rotatable plate, the top surface of the rotatable plate having at least one cavity formed thereon defining the shape of a layer of the z-directed component;
spinning the rotatable plate to level a top surface of the liquid based material in the at least one cavity;
curing the liquid based material to form the layer of the z-directed component;
applying a conductive material to at least one surface of the formed layer;
forming the z-directed component, the z-directed component including a stack of component layers that includes the formed layer,wherein applying the conductive material to the at least one surface of the formed layer includes;
positioning the formed layer in a constraining plate having a side wall surface that is spaced from a side wall channel in the formed layer forming a gap therebetween; and
applying conductive material in the gap formed between the side wall surface of the constraining plate and the side wall channel in the formed layer to plate the side wall channel in the formed layer with the conductive material.
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Accused Products
Abstract
A method for manufacturing a z-directed component for insertion into a mounting hole in a printed circuit board according to one example embodiment includes depositing a liquid based material onto a top surface of a rotatable plate. The top surface of the rotatable plate has at least one cavity formed thereon that defines the shape of a layer of the z-directed component. The rotatable plate is spun to level a top surface of the liquid based material in the at least one cavity. The liquid based material is cured to form the layer of the z-directed component. A conductive material is applied to at least one surface of the formed layer. The z-directed component is formed including a stack of component layers that includes the formed layer.
139 Citations
17 Claims
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1. A method for manufacturing a z-directed component for insertion into a mounting hole in a printed circuit board, comprising:
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depositing a liquid based material onto a top surface of a rotatable plate, the top surface of the rotatable plate having at least one cavity formed thereon defining the shape of a layer of the z-directed component; spinning the rotatable plate to level a top surface of the liquid based material in the at least one cavity; curing the liquid based material to form the layer of the z-directed component; applying a conductive material to at least one surface of the formed layer; forming the z-directed component, the z-directed component including a stack of component layers that includes the formed layer, wherein applying the conductive material to the at least one surface of the formed layer includes; positioning the formed layer in a constraining plate having a side wall surface that is spaced from a side wall channel in the formed layer forming a gap therebetween; and applying conductive material in the gap formed between the side wall surface of the constraining plate and the side wall channel in the formed layer to plate the side wall channel in the formed layer with the conductive material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method for manufacturing a z-directed component for insertion into a mounting hole in a printed circuit board, comprising:
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depositing a liquid based material onto a top surface of a rotatable plate, the rotatable plate having a first cavity portion formed thereon defining the shape of a first layer of the z-directed component; spinning the rotatable plate to level a top surface of the liquid based material in the first cavity portion; curing the liquid based material to form the first layer of the z-directed component; applying a conductive material to at least one surface of the first formed layer; forming a second cavity portion on top of the first cavity portion defining the shape of a second layer of the z-directed component and depositing additional liquid based material onto the top surface of the rotatable plate; spinning the rotatable plate to level a top surface of the liquid based material in the second cavity portion; curing the liquid based material to form the second layer of the z-directed component stacked on top of the first layer; and forming the z-directed component, the z-directed component including a stack of component layers that includes the first and second layers, wherein the first cavity portion is formed in a first plate and the second cavity portion is formed in a second plate, the second plate being stacked on top of the first plate so that the second layer of the z-directed component is formed stacked on top of the first layer.
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17. A method for manufacturing a z-directed component for insertion into a mounting hole in a printed circuit board, comprising:
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depositing a liquid based material onto a top surface of a rotatable plate, the rotatable plate having a first cavity portion formed thereon defining the shape of a first layer of the z-directed component; spinning the rotatable plate to level a top surface of the liquid based material in the first cavity portion; curing the liquid based material to form the first layer of the z-directed component; applying a conductive material to at least one surface of the first formed layer; forming a second cavity portion on top of the first cavity portion defining the shape of a second layer of the z-directed component and depositing additional liquid based material onto the top surface of the rotatable plate; spinning the rotatable plate to level a top surface of the liquid based material in the second cavity portion; curing the liquid based material to form the second layer of the z-directed component stacked on top of the first layer; and forming the z-directed component, the z-directed component including a stack of component layers that includes the first and second layers, wherein the first cavity portion is formed in a cavity in the rotatable plate, the bottom surface of the first cavity portion is formed by a raisable elevator therein, and the second cavity portion is formed by lowering the elevator to create additional space in the cavity in the rotatable plate after the first layer of the z-directed component is formed so that the second layer of the z-directed component is formed stacked on top of the first layer.
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Specification