US5220726A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for manufacturing an electrically connectable module
Assignee: Xerox Corp
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Filing: 1991-06-26
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Granted: 1993-06-22
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Expires: 2011-06-26
Abstract
Abstract An electrically connectable module is manufactured from a substrate of an electrically insulating polymer matrix doped with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler to form a fiber-doped substrate. One end of an electrical connector is embedded in the fiber-doped substrate to locate the one end adjacent the surface of the substrate while exposing an opposite end of the electrical connector. The surface of the fiber-doped substrate is locally heated preferably with a laser to form a conductive trace by the in-situ heat conversion of the electrically insulating fibrous filler, the localized heating including the one end of the electrical connector to electrically connect the electrical connector to the conductive trace. In another embodiment, a conductive material is electrodeposited on the conductive trace by applying a voltage to the opposite end of the electrical connector. The substrate is molded into a desired shape to form the module, and a plurality of electrical connectors can be embedded into the substrate in any one of several different standardized arrangements.
Inventors
- 👤 David A. Mantell
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 18:00
CPC Classifications
H; H10; H10W; H10W70/00; H10W70/01; H10W70/05; H10W70/095; H01; H01R; H01R13/00; H01R13/02; H01R13/03; H05; H05K; H05K3/00; H05K3/10; H05K3/105; H05K3/40; H05K3/4092; H10W70/60; H10W70/62; H10W70/63; H10W70/635; H01R29/00; H05K2201/00; H05K2201/03; H05K2201/0332; H05K2201/0335; H05K2201/0347; H05K2201/09; H05K2201/09009; H05K2201/09118; H05K2201/09209; H05K2201/09654; H05K2201/09754; H05K2203/00; H05K2203/10; H05K2203/107; H05K2203/11; H05K2203/1136; H05K3/403; Y; Y10; Y10S; Y10S428/00; Y10S428/901; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49117; Y10T29/49124; Y10T29/4913; Y10T29/49144; Y10T29/49155; Y10T29/49162; Y10T29/49204; Y10T29/49224
Claims Analysis
Total Claims: 29
Claim 1
Independent Claim
128 words
A method of manufacturing an electrically connectable module from a substrate of an electrically insulating polymer matrix, the method comprising the steps of: doping the substance with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler, to form a fiber-doped substrate; embedding one end of an electrical connector into the fiber-doped substrate to locate the one end adjacent a surface of the substrate while exposing an opposite end of the electrical connector; and locally heating the surface of the fiber-doped substrate to form a continuous electrically conductive trace by the in-situ heat conversion of the electrically insulating fibrous filler including the localized heating at the one end of the pre-embedded electrical connector to electrically connect the electrical connector to the conductive trace.
Claim 2
Independent Claim
128 words
A method of manufacturing an electrically connectable module from a substrate of an electrically insulating polymer matrix, the method comprising the steps of: doping the substance with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler, to form a fiber-doped substrate; embedding one end of an electrical connector into the fiber-doped substrate to locate the one end adjacent a surface of the substrate while exposing an opposite end of the electrical connector; and locally heating the surface of the fiber-doped substrate to form a continuous electrically conductive trace by the in-situ heat conversion of the electrically insulating fibrous filler including the localized heating at the one end of the pre-embedded electrical connector to electrically connect the electrical connector to the conductive trace.
Claim 3
Dependent Claim
30 words
The method of claim 1 further comprising the step of electrodepositing a conductive material on the conductive trace by applying a voltage to the opposite end of the electrical connector.
Claim 4
Dependent Claim
11 words
The method of claim 2, wherein the conductive material is copper.
Claim 5
Dependent Claim
17 words
The method of claim 2, wherein the conductive material is electrodeposited initially only on the conductive trace.
Claim 6
Dependent Claim
39 words
The method of claim 2, wherein the step of electrodepositing the conductive material onto the conductive trace includes the step of filling the conductive material into a channel created by the localized heating during formation of the conductive trace.
Claim 7
Dependent Claim
28 words
The method of claim 2, wherein the step of electrodepositing the conductive material on the conductive trace includes the step of adhering the conductive material to the substrate.
Claim 8
Dependent Claim
22 words
The method of claim 1, wherein the one end of the electrical connector is located flush with the surface of the substrate.
Claim 9
Dependent Claim
21 words
The method of claim 1, wherein the one end of the electrical connector is located below the surface of the substrate.
Claim 10
Dependent Claim
45 words
The method of claim 1, wherein the conductive trace and connection between the conductive trace and the one end of the electrical connector are formed by volatilizing the polymer matrix in the substrate and the polymer matrix surrounding the one end of the electrical connector.
Claim 11
Dependent Claim
30 words
The method of claim 1 further comprising the step of conducting electrical power through the conductive trace by connecting the opposite end of the electrical connector to an electrical component.
Claim 12
Dependent Claim
26 words
The method of claim 1 further comprising the step of conducting electrical power through the electrical connection by connecting the conductive trace to an electrical component.
Claim 13
Dependent Claim
26 words
The method of claim 1 further comprising the step of molding of the substrate into the desired shape prior to the localized heating of the substrate.
Claim 14
Dependent Claim
45 words
The method of claim 1, wherein a plurality of electrical connectors are embedded into the fiber-doped substrate in a standardized arrangement, each electrical connector being connected to a corresponding conductive trace for electrical connection of the electrical connectors and conductive traces to an electrical component.
Claim 15
Dependent Claim
20 words
The method of claim 1 wherein the step of localized heating includes using a laser to form the conductive trace.
Claim 16
Independent Claim
156 words
A method of manufacturing an electrically connectable module from a substrate of an electrically insulating polymer matrix, the method comprising the steps of: doping the substrate with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler, to form a fiber-doped substrate; embedding one end of an electrical connector into the fiber-doped substrate to locate the one end adjacent a surface of the substrate while exposing an opposite end of the electrical connector; locally heating the surface of the fiber-doped substrate to form a continuous electrically conductive trace by the in-situ heat conversion of the electrically insulating fibrous filler including the localized heating at the one end of the pre-embedded electrical connector to electrically connect the electrical connector to the conductive trace; and applying a voltage to the opposite end of the electrical connector to apply a voltage to the conductive trace for electrodepositing a conductive material on the conductive trace.
Claim 17
Independent Claim
156 words
A method of manufacturing an electrically connectable module from a substrate of an electrically insulating polymer matrix, the method comprising the steps of: doping the substrate with an electrically insulating fibrous filler capable of heat conversion to an electrically conductive fibrous filler, to form a fiber-doped substrate; embedding one end of an electrical connector into the fiber-doped substrate to locate the one end adjacent a surface of the substrate while exposing an opposite end of the electrical connector; locally heating the surface of the fiber-doped substrate to form a continuous electrically conductive trace by the in-situ heat conversion of the electrically insulating fibrous filler including the localized heating at the one end of the pre-embedded electrical connector to electrically connect the electrical connector to the conductive trace; and applying a voltage to the opposite end of the electrical connector to apply a voltage to the conductive trace for electrodepositing a conductive material on the conductive trace.
Claim 18
Dependent Claim
11 words
The method of claim 15, wherein the conductive material is copper.
Claim 19
Dependent Claim
17 words
The method of claim 15, wherein the conductive material is electrodeposited initially only on the conductive trace.
Claim 20
Dependent Claim
39 words
The method of claim 15, wherein the step of electrodepositing the conductive material onto the conductive trace includes the step of filling the conductive material into a channel created by the localized heating during formation of the conductive trace.
Claim 21
Dependent Claim
28 words
The method of claim 15, wherein the step of electrodepositing the conductive material on the conductive trace includes the step of adhering the conductive material to the substrate.
Claim 22
Dependent Claim
22 words
The method of claim 15, wherein the one end of the electrical connector is located flush with the surface of the substrate.
Claim 23
Dependent Claim
21 words
The method of claim 15, wherein the one end of the electrical connector is located below the surface of the substrate.
Claim 24
Dependent Claim
44 words
The method of claim 15, wherein the conductive trace and connection between the conductive trace and one end of the electrical connector are formed by volatilizing the polymer matrix in the substrate and the polymer matrix surrounding the one end of the electrical connector.
Claim 25
Dependent Claim
31 words
The method of claim 15 further comprising the step of conducting electrical power through the conductive trace by connecting the opposite end of the electrical connector to an external electrical component.
Claim 26
Dependent Claim
26 words
The method of claim 15 further comprising the step of conducting electrical power through the electrical connection by connecting the conductive trace to an electrical component.
Claim 27
Dependent Claim
26 words
The method of claim 15 further comprising the step of molding of the substrate into the desired shape prior to the localized heating of the substrate.
Claim 28
Dependent Claim
45 words
The method of claim 15, wherein a plurality of electrical connectors are embedded into the fiber-doped substrate in a standardized arrangement, each electrical connector being connected to a corresponding conductive trace for electrical connection of the electrical connectors and conductive traces to an electrical component.
Claim 29
Dependent Claim
20 words
The method of claim 15 wherein the step of localized heating includes using a laser to form the conductive trace.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-06-21 | 1996-12-21 | 1997-06-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-06-21 | 2000-12-21 | 2001-06-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-06-21 | 2004-12-21 | 2005-06-22 | $7700.00 | Window Closed / Lapsed |