Screening process for manufacturing a Z-directed component for a printed circuit board
First Claim
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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:
- adding a substrate material to a mold defining the shape of a layer of the z-directed component;
leveling a top surface of the substrate material in the mold;
treating the substrate material in the mold and forming the layer of the z-directed component;
applying a conductive material to at least one surface of the formed layer; and
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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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 adding a substrate material to a mold defining the shape of a layer of the z-directed component. A top surface of the substrate material in the mold is leveled. The substrate material in the mold is treated and the layer of the z-directed component is formed. A conductive material is applied to at least one surface of the formed layer. The z-directed component is formed that includes a stack of component layers that includes the formed layer.
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Citations
28 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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adding a substrate material to a mold defining the shape of a layer of the z-directed component; leveling a top surface of the substrate material in the mold; treating the substrate material in the mold and forming the layer of the z-directed component; applying a conductive material to at least one surface of the formed layer; and 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, 16, 17, 18, 19)
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20. A method for manufacturing a z-directed component for insertion into a mounting hole in a printed circuit board, comprising:
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adding a substrate material to a first cavity portion that defines the shape of a first layer of the z-directed component; leveling a top surface of the substrate material in the first cavity portion; treating the substrate material in the first cavity portion and forming the first layer of the z-directed component; applying a conductive material to at least one surface of the first formed layer; adding the substrate material to a second cavity portion positioned on top of the first cavity portion, the second cavity portion defining the shape of a second layer of the z-directed component; leveling a top surface of the substrate material in the second cavity portion; treating the substrate material in the second cavity portion and forming 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 a 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 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. - View Dependent Claims (21, 22, 23, 24)
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25. A method for manufacturing a z-directed component for insertion into a mounting hole in a printed circuit board, comprising:
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adding a substrate material to a first cavity portion that defines the shape of a first layer of the z-directed component; leveling a top surface of the substrate material in the first cavity portion; treating the substrate material in the first cavity portion and forming the first layer of the z-directed component; applying a conductive material to at least one surface of the first formed layer; adding the substrate material to a second cavity portion positioned on top of the first cavity portion, the second cavity portion defining the shape of a second layer of the z-directed component; leveling a top surface of the substrate material in the second cavity portion; treating the substrate material in the second cavity portion and forming 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. - View Dependent Claims (26, 27, 28)
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Specification