Multi-layer laminate and method of producing same

Claim 1

A method of continuously forming a multi-layer laminate, comprising the steps of: a) forming a generally continuous first strip comprised of a polyimide film having a flash layer of metal deposited on at least one side thereof; b) moving said first strip along a first path through a metal plating bath, c) depositing metal onto said flash layer of metal as said first strip passes through said bath to form a built-up layer of metal on said flash layer of metal; d) applying a masking material to the surface of said built-up layer of metal on said first strip; e) curing portions of said masking material to define a masked circuit pattern; f) removing uncured portions of said masking material to leave exposed portions of said built-up layer of metal not covered by cured masking material; g) etching away said flash layer of metal and said built-up layer of metal on said first strip wherein said masked circuit pattern and said built-up layer and said flash layer thereunder remain on said first strip; h) removing said cured masking material wherein a first printed circuit remains on said first strip; i) moving a second strip comprised of a polyimide film along a second path that merges with said first paths said second strip having a second printed circuit formed thereon in accordance with steps b) through h), said second printed circuit having a predetermined shape adapted to mate in complimentary fashion with said first printed circuit when overlaid thereon; j) interlaying a dimensionally stable, uncured adhesive film between said first strip and said second strip; k) joining together said first strip, said adhesive film and said second strip wherein said first printed circuit on said first strip is in registry with said second printed circuit on said second strip; l) curing said adhesive film to bond said first strip to said second strip; and m) forming microvias between said first strip and said second strip to connect locations of said first printed circuit with locations of said second printed circuit.

Claim 2

A method of continuously forming a multi-layer laminate, comprising the steps of: a) forming a generally continuous first strip comprised of a polyimide film having a flash layer of metal deposited on at least one side thereof; b) moving said first strip along a first path through a metal plating bath, c) depositing metal onto said flash layer of metal as said first strip passes through said bath to form a built-up layer of metal on said flash layer of metal; d) applying a masking material to the surface of said built-up layer of metal on said first strip; e) curing portions of said masking material to define a masked circuit pattern; f) removing uncured portions of said masking material to leave exposed portions of said built-up layer of metal not covered by cured masking material; g) etching away said flash layer of metal and said built-up layer of metal on said first strip wherein said masked circuit pattern and said built-up layer and said flash layer thereunder remain on said first strip; h) removing said cured masking material wherein a first printed circuit remains on said first strip; i) moving a second strip comprised of a polyimide film along a second path that merges with said first paths said second strip having a second printed circuit formed thereon in accordance with steps b) through h), said second printed circuit having a predetermined shape adapted to mate in complimentary fashion with said first printed circuit when overlaid thereon; j) interlaying a dimensionally stable, uncured adhesive film between said first strip and said second strip; k) joining together said first strip, said adhesive film and said second strip wherein said first printed circuit on said first strip is in registry with said second printed circuit on said second strip; l) curing said adhesive film to bond said first strip to said second strip; and m) forming microvias between said first strip and said second strip to connect locations of said first printed circuit with locations of said second printed circuit.

Claim 8

A method of forming a multi-layer laminate, comprising the steps of: a) forming a generally continuous first strip comprised of a polyimide film having a flash layer of metal deposited on at least one side thereof; b) moving said first strip of polyimide film along a first path through a metal plating bath; c) depositing metal onto said flash layer of metal as said first strip passes through said bath wherein a built-up layer of metal is deposited onto said flash layer of metal; d) applying a masking material to portions of said built-up metal on said first strip to define a first masked circuit pattern thereon; e) etching away said flash layer of metal and said built-up layer of metal on strip wherein said masked circuit pattern remains on said first strip; f) removing said masking material to expose a first printed circuit formed of said flash layer of metal and said built-up layer of metal; g) moving a second strip comprised of a polyimide film along a second path that merges with said first path, said second strip having a second printed circuit formed thereon in accordance with steps b) through f), said second printed circuit having a predetermined shape adapted to mate in complimentary fashion with said first printed circuit when overlaid thereon; h) joining said first strip to said second strip wherein said first printed circuit on said first strip is in registry with said second printed circuit on said second strip and is separated by a non-conductive layer; and i) forming microvias between said first strip and said second strip to connect locations of said first printed circuit with locations of said second printed circuit.

Claim 9

A method of forming a multi-layer laminate, comprising the steps of: a) forming a generally continuous first strip comprised of a polyimide film having a flash layer of metal deposited on at least one side thereof; b) moving said first strip of polyimide film along a first path through a metal plating bath; c) depositing metal onto said flash layer of metal as said first strip passes through said bath wherein a built-up layer of metal is deposited onto said flash layer of metal; d) applying a masking material to portions of said built-up metal on said first strip to define a first masked circuit pattern thereon; e) etching away said flash layer of metal and said built-up layer of metal on strip wherein said masked circuit pattern remains on said first strip; f) removing said masking material to expose a first printed circuit formed of said flash layer of metal and said built-up layer of metal; g) moving a second strip comprised of a polyimide film along a second path that merges with said first path, said second strip having a second printed circuit formed thereon in accordance with steps b) through f), said second printed circuit having a predetermined shape adapted to mate in complimentary fashion with said first printed circuit when overlaid thereon; h) joining said first strip to said second strip wherein said first printed circuit on said first strip is in registry with said second printed circuit on said second strip and is separated by a non-conductive layer; and i) forming microvias between said first strip and said second strip to connect locations of said first printed circuit with locations of said second printed circuit.