Electrical assembly and method

• US 8,995,146 B2
• Filed: 06/19/2012
• Issued: 03/31/2015
• Est. Priority Date: 02/23/2010
• Status: Active Grant

• Current Assignee: HzO, Inc.
• Original Assignee: Semblant Limited (HzO, Inc.)
• Inventors: Von Werne, Timothy Allan, Brooks, Andrew Simon Hall
• Primary Examiner(s): Dinh, Tuan T
• Application Number:
  US13/527,305
• Publication Number:
  US 20130033825A1
• Time in Patent Office: 1,015 Days
• Field of Search: 174350-355, 361760-764
• US Class Current: 361/760
• CPC Class Codes: H05K 2201/015 Fluoropolymer, e.g. polytetrafluoroethylene [PTFE]
• CPC Class Codes: H05K 2201/09872 Insulating conformal coating foil encapsulation H05K2203/1311
• CPC Class Codes: H05K 2201/10121 Optical component, e.g. opto-electronic component
• CPC Class Codes: H05K 2203/095 Plasma, e.g. for treating a substrate to improve adhesion with a conductor or for cleaning holes
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence

Abstract

An electrical or electro-optical assembly comprising a substrate comprising an insulating material, at least one conductive track present on at least one surface of the substrate, at least one electrical or electro-optical component connected to at least one of the at least one conductive track, and a continuous coating comprising one or more plasma-polymerized polymers completely covering the at least one surface of the substrate, the at least one conductive track and the at least one electrical or electro-optical component.

Claims

1. An electrical or electro-optical assembly comprising:

a substrate comprising an insulating material, at least one conductive track present on at least one surface of the substrate, at least one electrical or electro-optical component connected to at least one of the at least one conductive track;

a continuous coating comprising a plasma polymerized polymer completely covering the insulating material, the at least one conductive track present on at least one surface of the substrate, and the at least one electrical or electro-optical component connected to at least one of the at least on conductive track; and

a second continuous coating comprising a second plasma polymerized polymer which completely covers the continuous coating, wherein;

the plasma polymerized polymer is obtainable by plasma polymerizing a xylene compound; and

the second plasma polymerized polymer is obtainable by plasma polymerizing 1,4 dimethylbenzene.

2. The electrical or electro-optical assembly of claim 1, wherein the xylene compound is 1,4 dimethylbenzene.

3. The electrical or electro-optical assembly of claim 1, wherein the electrical or electro-optical component is an electrical component and the at least one conductive track is an electrically conductive track.

4. The electrical or electro-optical assembly of claim 1, wherein the electrical or electro-optical component is an electro-optical component and the at least one conductive track is an electrically conductive or optically conductive track.

5. The electrical or electro-optical assembly of claim 1, wherein the electrical or electro-optical component is connected to at least one of the at least one conductive track by at least one bond and the continuous coating completely covers the at least one bond.

6. The electrical or electro-optical assembly of claim 1, wherein at least one of the at least one conductive track further comprises at least one external-contact and the continuous coating completely covers the at least one external-contact.

7. The electrical or electro-optical assembly of claim 4, further comprising an optical component connected to the optically conductive track.

8. The electrical or electro-optical assembly of claim 5, wherein the at least one bond is selected from the group consisting of a solder joint, a weld joint, a wire-bond joint, a conductive adhesive joint, a crimp connection, and a press-fit joint.

9. An electrical or electro-optical assembly comprising:

a substrate comprising an insulating material, at least one conductive track present on at least one surface of the substrate, at least one electrical or electro-optical component connected to at least one of the at least one conductive track;

a continuous coating comprising a plasma polymerized polymer completely covering the insulating material, the at least one conductive track present on at least one surface of the substrate, and the at least one electrical or electro-optical component connected to at least one of the at least on conductive track; and

a coating of an epoxy resin, an acrylic resin, a silicone resin, or a parylene deposited between at least a portion of the continuous coating of the plasma polymerized polymer and at least a portion of the substrate, wherein the plasma polymerized polymer is obtainable by plasma polymerizing a xylene compound.

10. The electrical or electro-optical assembly of claim 9, wherein the xylene compound is 1,4 dimethylbenzene.

11. The electrical or electro-optical assembly of claim 9, wherein the electrical or electro-optical component is an electrical component and the at least one conductive track is an electrically conductive track.

12. The electrical or electro-optical assembly of claim 9, wherein the electrical or electro-optical component is an electro-optical component and the at least one conductive track is an electrically conductive or optically conductive track.

13. The electrical or electro-optical assembly of claim 9, wherein the electrical or electro-optical component is connected to at least one of the at least one conductive track by at least one bond and the continuous coating completely covers the at least one bond.

14. The electrical or electro-optical assembly of claim 9, wherein at least one of the at least one conductive track further comprises at least one external-contact and the continuous coating completely covers the at least one external-contact.

15. The electrical or electro-optical assembly of claim 12, further comprising an optical component connected to the optically conductive track.

16. The electrical or electro-optical assembly of claim 13, wherein the at least one bond is selected from the group consisting of a solder joint, a weld joint, a wire-bond joint, a conductive adhesive joint, a crimp connection, and a press-fit joint.

17. A method for coating an electrical assembly with a continuous coating, the method comprising:

providing an electrical or electro-optical assembly comprising a substrate comprising an insulating material, at least one conductive track present on at least one surface of the substrate, at least one electrical or electro-optical component connected to at least one of the at least one conductive track;

depositing a continuous coating comprising a plasma polymerized polymer completely covering the insulating material, the at least one conductive track present on at least one surface of the substrate, and the at least one electrical or electro-optical component connected to at least one of the at least on conductive track; and

depositing a second continuous coating comprising a second plasma polymerized polymer which completely covers the continuous coating, wherein;

the second plasma polymerized polymer is obtainable by plasma polymerizing 1,4 dimethylbenzene; and

the plasma polymerized polymer is obtainable by plasma polymerizing a xylene compound.

18. The method of claim 17, wherein the plasma polymerized xylene is 1,4 dimethylbenzene.

19. The method of claim 17, wherein the electrical or electro-optical component is an electrical component and the at least one conductive track is an electrically conductive track.

20. The method of claim 17, wherein the electrical or electro-optical component is an electro-optical component and the at least one conductive track is an electrically conductive or optically conductive track.

21. The method of claim 17, wherein the electrical or electro-optical component is connected to at least one of the at least one conductive track by at least one bond and the continuous coating completely covers the at least one bond.

22. The method of claim 17, wherein at least one of the at least one conductive track further comprises at least one external-contact and the continuous coating completely covers the at least one external-contact.

23. The method of claim 21, wherein the at least one bond is selected from the group consisting of a solder joint, a weld joint, a wire-bond joint, a conductive adhesive joint, a crimp connection, and a press-fit joint.

24. A method for coating an electrical assembly with a continuous coating, the method comprising:

providing an electrical or electro-optical assembly comprising a substrate comprising an insulating material, at least one conductive track present on at least one surface of the substrate, at least one electrical or electro-optical component connected to at least one of the at least one conductive track;

depositing a continuous coating comprising a plasma polymerized polymer completely covering the insulating material, the at least one conductive track present on at least one surface of the substrate, and the at least one electrical or electro-optical component connected to at least one of the at least on conductive track; and

depositing a coating of an epoxy resin, an acrylic resin, a silicone resin, or a parylene deposited between at least a portion of the continuous coating of the plasma polymerized polymer and at least a portion of the substrate, wherein the plasma polymerized polymer is obtainable by plasma polymerizing a xylene compound.

25. The method of claim 24, wherein the plasma polymerized xylene is 1,4 dimethylbenzene.

26. The method of claim 24, wherein the electrical or electro-optical component is an electrical component and the at least one conductive track is an electrically conductive track.

27. The method of claim 24, wherein the electrical or electro-optical component is an electro-optical component and the at least one conductive track is an electrically conductive or optically conductive track.

28. The method of claim 24, wherein the electrical or electro-optical component is connected to at least one of the at least one conductive track by at least one bond and the continuous coating completely covers the at least one bond.

29. The method of claim 24, wherein at least one of the at least one conductive track further comprises at least one external-contact and the continuous coating completely covers the at least one external-contact.

30. The method of claim 28, wherein the at least one bond is selected from the group consisting of a solder joint, a weld joint, a wire-bond joint, a conductive adhesive joint, a crimp connection, and a press-fit joint.