US6591496B2
Expired / Lapsed
US
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Method for making embedded electrical traces
Assignee: 3M Innovative Properties Co
•
Filing: 2001-08-28
•
Granted: 2003-07-15
•
Expires: 2021-08-28
Abstract
Abstract A method for making a fine electrically conductive grid embedded in a polymer substrate. The method includes the steps of providing a polymer substrate, forming a pattern of grooves in the substrate, filling the grooves with electrically conductive powder, and then applying heat and/or pressure to the substrate. The application of heat and/or pressure to the substrate causes the grooves to collapse inward against the conductive powder. Collapsing the grooves compacts the conductive powder within the groove, thereby establishing a continuously conductive grid line or circuit. The narrow grid lines that result allow more light to transmit through the substrate. The method allows grid lines to be made with higher aspect ratios (ratio of line depth to line width) than is possible by previous methods.
Inventors
- 👤 David C. Koskenmaki
- 👤 Michael N. Miller
- 👤 Naiyong Jing
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 07:30
CPC Classifications
H; H05; H05B; H05B3/00; H05B3/84; H05B3/86; H05B3/20; H05B3/22; H05B3/28; H05B3/286; H05K; H05K3/00; H05K3/10; H05K3/102; H05K3/12; H05K3/1258; G; G02; G02F; G02F1/00; G02F1/01; G02F1/13; G02F1/133; G02F1/1333; G02F1/1343; G02F1/13439; G02F1/15; G02F1/153; G02F1/155; H05B2203/00; H05B2203/017; H05K2201/00; H05K2201/01; H05K2201/0104; H05K2201/0133; H05K2201/09; H05K2201/09009; H05K2201/09036; H05K2201/091; H05K2201/09818; H05K2201/09827; H05K2203/00; H05K2203/02; H05K2203/0278; H05K2203/11; H05K2203/1105; H05K3/107; Y; Y10; Y10S; Y10S428/00; Y10S428/901; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49117; Y10T29/49124; Y10T29/49128; Y10T29/49155; Y10T29/49165; Y10T428/00; Y10T428/24; Y10T428/24802; Y10T428/24917
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
60 words
A method for fabricating a plurality of electrically conducting traces in a polymer substrate, the method comprising the steps of: providing a polymer substrate; forming a pattern of channels in a surface of the substrate; placing conductive particles into the channels; collapsing the sides of the channels inward against the conductive particles to form a conductive trace in the substrate.
Claim 2
Independent Claim
60 words
A method for fabricating a plurality of electrically conducting traces in a polymer substrate, the method comprising the steps of: providing a polymer substrate; forming a pattern of channels in a surface of the substrate; placing conductive particles into the channels; collapsing the sides of the channels inward against the conductive particles to form a conductive trace in the substrate.
Claim 3
Dependent Claim
12 words
The method of claim 1 , wherein the conductive particles are metal.
Claim 4
Dependent Claim
12 words
The method of claim 1 , wherein the conductive particles are organic.
Claim 5
Dependent Claim
12 words
The method of claim 1 , wherein the conductive particles are inorganic.
Claim 6
Dependent Claim
12 words
The method of claim 1 , wherein the conductive particles are photo-conductive.
Claim 7
Dependent Claim
12 words
The method of claim 5 , wherein the photo-conductive particles are selenium.
Claim 8
Dependent Claim
14 words
The method of claim 1 , wherein the polymer substrate is a thermoformable material.
Claim 9
Dependent Claim
14 words
The method of claim 1 , wherein the polymer substrate is an elastomeric material.
Claim 10
Dependent Claim
35 words
The method of claim 1 , wherein the step of forming a pattern of channels in the surface of the substrate includes deforming the substrate at a temperature below the glass transition of the substrate.
Claim 11
Dependent Claim
16 words
The method of claim 9 , wherein the channels are formed with a triangular cross section.
Claim 12
Dependent Claim
28 words
The method of claim 9 , wherein the step of collapsing the sides of the channels includes the step of applying force to the surface of the substrate.
Claim 13
Dependent Claim
28 words
The method of claim 9 , wherein the step of collapsing the sides of the channels includes the step of applying heat to the surface of the substrate.
Claim 14
Dependent Claim
30 words
The method of claim 9 , wherein the step of collapsing the sides of the channels includes the steps of applying force and heat to the surface of the substrate.
Claim 15
Dependent Claim
28 words
The method of claim 1 , wherein the step of collapsing the sides of the channels includes the step of applying force to the surface of the substrate.
Claim 16
Dependent Claim
28 words
The method of claim 1 , wherein the step of collapsing the sides of the channels includes the step of applying heat to the surface of the substrate.
Claim 17
Dependent Claim
30 words
The method of claim 1 , wherein the step of collapsing the sides of the channels includes the steps of applying force and heat to the surface of the substrate.
Claim 18
Dependent Claim
17 words
The method of claim 2 , further comprising the step of melting and coalescing the metal particles.
Claim 19
Dependent Claim
13 words
The method of claim 2 , wherein the metal particles include dendritic particles.
Claim 20
Dependent Claim
21 words
The method of claim 2 , wherein the particles are selected from the group of copper, tin, silver, lead, or bismuth.
Claim 21
Dependent Claim
20 words
The method of claim 1 , wherein collapsing the side walls causes only a fraction of the particles to melt.
Claim 22
Dependent Claim
12 words
The method of claim 1 , wherein the substrate is a fluoropolymer.
Claim 23
Dependent Claim
13 words
The method of claim 1 , wherein the substrate is a perfluorinated polymer.
Claim 24
Dependent Claim
14 words
The method of claim 1 , wherein the substrate is a partially fluorinated polymer.
Claim 25
Dependent Claim
27 words
The method of claim 1 , wherein prior to collapsing the sides of the channels, the channels have a ratio of depth to width greater than 1.
Claim 26
Dependent Claim
18 words
The method of claim 1 , wherein the channels are formed perpendicular to the surface of the substrate.
Claim 27
Dependent Claim
25 words
The method of claim 1 , wherein the channels are formed at an angle of less than 90 degrees with the surface of the substrate.
Claim 28
Dependent Claim
22 words
The method of claim 1 , wherein the particle size is in the range of 10-25% of the width of the channel.
Claim 29
Dependent Claim
15 words
The method of claim 1 , wherein the trace is less than 2 microns wide.
Claim 30
Dependent Claim
20 words
The method of claim 1 , wherein the trace has a ratio of depth to width of greater than 5.
Claim 31
Dependent Claim
20 words
The method of claim 1 , wherein the trace has a ratio of depth to width of greater than 10.
Claim 32
Dependent Claim
30 words
The method of claim 1 , further including the step of laminating a polymer cover layer over the patterned surface of the substrate after collapsing the sides of the channels.
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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) | 2006-07-14 | 2007-01-13 | 2007-07-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2010-07-14 | 2011-01-13 | 2011-07-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2014-07-14 | 2015-01-13 | 2015-07-15 | $7700.00 | Window Closed / Lapsed |