Mechanical locking between multi-layer printed wiring board conductors and through-hole plating

Claim 1

The method of forming soldering temperature resistant layer interconnecting through conductors in a printed wiring board having alternating layers of conductor material that are separated by insulating material comprising the steps of: drilling holes through said alternating layer printed wiring board at through conductor locations thereof; enlarging the diameter of said holes at the insulating layer hole depths thereof until regions of exposed conductor layer opening into said holes are formed; roughening hole residing conductor surface areas in said exposed conductor layer region, said roughening including forming U-shaped cross section voids of depth and width at least one-tenth the conductor thickness on each said conductor lateral surface; and filling said holes and said enlarged diameter regions at least partially be depositing therein additional conductive material, said conductive material also physically engaging portions of said roughened conductor surface area and said voids therein in temperature cycling resistant mechanical interlocking low electrical resistance continuity therewith.

Claim 2

The method of forming soldering temperature resistant layer interconnecting through conductors in a printed wiring board having alternating layers of conductor material that are separated by insulating material comprising the steps of: drilling holes through said alternating layer printed wiring board at through conductor locations thereof; enlarging the diameter of said holes at the insulating layer hole depths thereof until regions of exposed conductor layer opening into said holes are formed; roughening hole residing conductor surface areas in said exposed conductor layer region, said roughening including forming U-shaped cross section voids of depth and width at least one-tenth the conductor thickness on each said conductor lateral surface; and filling said holes and said enlarged diameter regions at least partially be depositing therein additional conductive material, said conductive material also physically engaging portions of said roughened conductor surface area and said voids therein in temperature cycling resistant mechanical interlocking low electrical resistance continuity therewith.

Claim 3

A method for providing thermal cycling resistant electrical interconnection for the insulating layer segregated planar conductors in a three or more metal conductor layered printed circuit board comprising the steps of: roughening the inward facing lateral surfaces of the unassembled external conductors and both lateral surfaces of the unassembled internal layer conductors, surrounding the interconnecting points thereof, said roughening displacing metal from conductor lateral surfaces surrounding the interconnecting points in a pattern of U-shaped cross section void of depth and width at least one-tenth the conductor thickness on each conductor lateral surface; assembling the conductor and insulating layer members into an alternating layer laminate sandwich having the conductor roughened lateral surface areas in axially aligned condition; drilling holes through the axially aligned roughened lateral surface area surrounded interconnection points of the assembled conductor and insulating layer sandwich; enlarging the drilled holes in the insulating layer members to a diameter exposing predetermined of the conductor lateral surface displaced metal voids surrounding the drilled holes; and depositing through-conductor metal within the drilled holes into intimate overlapping mechanical engagement with the displaced metal voids; whereby thermal cycling resistant mechanical interlocking obtains between through conductor deposited metal and the void roughened lateral surfaces.

Claim 4

A method for providing thermal cycling resistant electrical interconnection for the insulating layer segregated planar conductors in a three or more metal conductor layered printed circuit board comprising the steps of: roughening the inward facing lateral surfaces of the unassembled external conductors and both lateral surfaces of the unassembled internal layer conductors, surrounding the interconnecting points thereof, said roughening displacing metal from conductor lateral surfaces surrounding the interconnecting points in a pattern of U-shaped cross section void of depth and width at least one-tenth the conductor thickness on each conductor lateral surface; assembling the conductor and insulating layer members into an alternating layer laminate sandwich having the conductor roughened lateral surface areas in axially aligned condition; drilling holes through the axially aligned roughened lateral surface area surrounded interconnection points of the assembled conductor and insulating layer sandwich; enlarging the drilled holes in the insulating layer members to a diameter exposing predetermined of the conductor lateral surface displaced metal voids surrounding the drilled holes; and depositing through-conductor metal within the drilled holes into intimate overlapping mechanical engagement with the displaced metal voids; whereby thermal cycling resistant mechanical interlocking obtains between through conductor deposited metal and the void roughened lateral surfaces.