阅读说明：本技术 从两侧铣削具有两个导电层的柔性箔 (Milling a flex foil with two conductive layers from two sides ) 是由 J·霍策拉 F·荣 于 2020-04-03 设计创作，主要内容包括：一种用于铣削柔性箔的方法包括提供柔性箔的网(14),柔性箔的网(14)包括：衬底；被布置在衬底的一个表面上的第一导电层；被布置在衬底的相对表面上的第二导电层；与第一导电层相邻布置的第一绝缘层；以及与第二导电层相邻布置的第二绝缘层。该方法包括使用铣轮(20-1)以及包括凸起部分和非凸起部分的第一铅版图案(25-1)(包括滚筒24-1和柔性衬底26-1)干铣网的一侧,以选择性地去除第一导电层和第一绝缘层中的至少一者。该方法包括使用铣轮(20-2)以及包括上部凸起部分、下部凸起部分和非凸起部分的第二铅版图案(25-2)干铣网的相对侧,以选择性地去除第二绝缘层。(A method for milling a flexible foil comprises providing a web (14) of flexible foil, the web (14) of flexible foil comprising: a substrate; a first conductive layer disposed on one surface of the substrate; a second conductive layer disposed on an opposite surface of the substrate; a first insulating layer disposed adjacent to the first conductive layer; and a second insulating layer disposed adjacent to the second conductive layer. The method includes dry milling one side of a web using a milling wheel (20-1) and a first cliche pattern (25-1) including raised portions and non-raised portions (including a cylinder 24-1 and a flexible substrate 26-1) to selectively remove at least one of the first conductive layer and the first insulating layer. The method includes dry milling an opposite side of the mesh using a milling wheel (20-2) and a second cliche pattern (25-2) including upper raised portions, lower raised portions, and non-raised portions to selectively remove the second insulating layer.)

1. A method for milling a flexible foil, comprising:

providing a web of flexible foil, the web of flexible foil comprising:

a substrate;

a first conductive layer disposed on one surface of the substrate;

a second conductive layer disposed on an opposite surface of the substrate;

a first insulating layer disposed adjacent to the first conductive layer; and

a second insulating layer disposed adjacent to the second conductive layer;

dry milling one side of the mesh using a first cliche pattern comprising raised portions and non-raised portions to selectively remove at least one of the first conductive layer and the first insulating layer; and

dry milling an opposite side of the mesh using a second cliche pattern comprising upper raised portions, lower raised portions, and non-raised portions to selectively remove the second insulating layer.

2. The method of claim 1, wherein the first cliche pattern removes the at least one of the first insulating layer and the first conductive layer adjacent to the raised portion and does not remove the first insulating layer and the first conductive layer adjacent to the non-raised portion.

3. The method of claim 1, wherein the upper raised portions of the second cliche pattern remove the second insulating layer on the opposite side of the mesh at locations where the at least one of the first insulating layer and the first conductive layer is removed.

4. The method of claim 3, wherein the lower raised portions of the second cliche pattern remove the second insulating layer on the opposite side of the mesh at locations where the at least one of the first insulating layer and the first conductive layer is not removed.

5. The method of claim 4, wherein the non-raised portions of the second cliche pattern do not remove the second insulating layer.

6. The method of claim 1, further comprising:

feeding the web between a first cutterhead and a first cliche, the first cutterhead being disposed on the one side of the web, the first cliche being disposed on the opposite side of the web, wherein the first cliche includes the first cliche pattern; and

feeding the web between a second cutterhead arranged on the opposite side of the web and a second cliche on the one side of the web, wherein the second cliche includes the second cliche pattern.

7. The method of claim 1, further comprising:

feeding the web between a first cutterhead and a first cliche, the first cutterhead being disposed on the one side of the web, the first cliche being disposed on the opposite side of the web, wherein the first cliche includes the first cliche pattern;

changing the first cliche pattern on the first cliche to the second cliche pattern;

inverting and aligning the web; and

feeding the web between the first cutterhead and the first cliche.

8. The method of claim 1, wherein the thickness of the first and second conductive layers is in the range of 5 μ ι η to 40 μ ι η.

9. A flexible foil, comprising:

a substrate;

a first conductive layer disposed on one surface of the substrate;

a second conductive layer disposed on an opposite surface of the substrate;

a first insulating layer disposed adjacent to the first conductive layer; and

a second insulating layer disposed adjacent to the second conductive layer,

wherein one side of the flexible foil is dry-milled using a first cliche pattern comprising raised portions and non-raised portions to selectively remove at least one of the first conductive layer and the first insulating layer, and

wherein an opposite side of the flex foil is dry milled using a second cliche pattern including an upper raised portion, a lower raised portion, and a non-raised portion to selectively remove the second insulating layer.

10. The flexible foil of claim 9, wherein the first cliche pattern removes at least one of the first insulating layer and the first conductive layer adjacent to the bumped portions and does not remove the first insulating layer and the first conductive layer adjacent to the non-bumped portions.

11. The flexible foil of claim 9, wherein the upper raised portions of the second cliche pattern remove the second insulating layer on the opposite side of the flexible foil at locations where the at least one of the first insulating layer and the first conductive layer is removed.

12. The flexible foil of claim 11, wherein the lower raised portions of the second cliche pattern remove the second insulating layer on the opposite side of the flexible foil at locations where the at least one of the first insulating layer and the first conductive layer is not removed.

13. The flexible foil of claim 12, wherein the non-raised portions of the second cliche pattern do not remove the second insulating layer.

14. A flexible foil according to claim 9 wherein:

the flexible foil is fed between a first cutterhead arranged on the one side of the flexible foil and a first clich e arranged on the opposite side of the flexible foil, wherein the first clich e comprises the first clich pattern; and is

The flexible foil is fed between a second cutterhead arranged on the opposite side of the flexible foil and a second clich arranged on the one side of the flexible foil, wherein the second clich includes the second clich pattern.

15. The flexible foil of claim 9, further comprising:

the flexible foil is fed between a first cutterhead arranged on the one side of the flexible foil and a first clich e arranged on the opposite side of the flexible foil, wherein the first clich e comprises the first clich pattern;

the first cliche pattern on the first cliche is changed to the second cliche pattern;

the flex foil is inverted and aligned; and

the flexible foil is fed between the first cutterhead and the first cliche.

16. A flexible foil according to claim 9, wherein the thickness of the first and second electrically conductive layers is in the range of 5 μ ι η to 40 μ ι η.

17. A flexible foil, comprising:

a substrate;

a first conductive layer disposed on one surface of the substrate;

a second conductive layer disposed on an opposite surface of the substrate;

a first insulating layer disposed adjacent to the first conductive layer; and

a second insulating layer disposed adjacent to the second conductive layer,

wherein a first portion of the first insulating layer and the first conductive layer are milled to the one surface of the substrate at a first location, an

Wherein a first portion of the second insulating layer is milled on an opposite surface of the substrate at the first location.

18. A flexible foil according to claim 17, wherein the thickness of the first and second electrically conductive layers is in the range of 5 μ ι η to 40 μ ι η.

19. The flexible foil of claim 17, wherein:

the second portion of the first insulating layer and the first conductive layer are not milled on the one surface of the substrate at the second location, and

a second portion of the second insulating layer is milled on the opposing surface of the substrate at the second location.

20. The flexible foil of claim 19, wherein:

a third portion of the first insulating layer and the first conductive layer are milled to the one surface of the substrate at a third location, and

a third portion of the second insulating layer is not milled on the opposing surface of the substrate at the third location.

21. The flexible foil of claim 19, wherein:

the fourth portion of the first insulating layer and the first conductive layer are not milled on the one surface of the substrate at a fourth location, and

a fourth portion of the second insulating layer is not milled on the opposite surface of the substrate at the fourth location.

Technical Field

The present disclosure relates to the routing of electrical components, and more particularly to milling a flex foil having two conductive layers from two sides.

Background

The information provided in this section is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art within the present disclosure.

Wire harnesses are used to connect electrical components in a variety of applications. When a large number of components need to be connected at a given location, multiple wires, a Printed Circuit Board (PCB) and/or a flexible substrate with conductive traces may be used. Typically, a flexible substrate includes a single conductive layer and an outer insulating layer (referred to herein as a flexible foil or flex foil). A single conductive layer may be patterned to define traces, fingers, and other structures that may be used to provide multiple connections.

Disclosure of Invention

A method for milling a flexible foil comprises: providing a web of flexible foil, the web of flexible foil comprising: a substrate; a first conductive layer disposed on one surface of the substrate; a second conductive layer disposed on an opposite surface of the substrate; a first insulating layer disposed adjacent to the first conductive layer; and a second insulating layer disposed adjacent to the second conductive layer. The method includes dry milling one side of a mesh using a first cliche pattern including raised portions and non-raised portions to selectively remove at least one of the first conductive layer and the first insulating layer. The method includes dry milling an opposite side of the mesh using a second cliche pattern including an upper raised portion, a lower raised portion, and a non-raised portion to selectively remove the second insulating layer.

In other features, the first cliche pattern removes at least one of the first insulating layer and the first conductive layer adjacent to the raised portion and does not remove the first insulating layer and the first conductive layer adjacent to the non-raised portion. The upper raised portions of the second cliche pattern remove the second insulating layer on the opposite side of the mesh at locations where at least one of the first insulating layer and the first conductive layer were removed. The lower raised portions of the second cliche pattern remove the second insulating layer on an opposite side of the mesh at locations where at least one of the first insulating layer and the first conductive layer is not removed. The non-protruding portions of the second cliche pattern do not remove the second insulating layer.

In other features, the method includes feeding the web between a first cutterhead arranged on one side of the web and a first cliche arranged on an opposite side of the web, wherein the first cliche includes a first cliche pattern. The method includes feeding the web between a second cutterhead arranged on an opposite side of the web and a second cliche located on one side of the web, wherein the second cliche includes a second cliche pattern.

In other features, the method includes feeding a web between a first cutterhead and a first cliche, the first cutterhead being disposed on one side of the web and the first cliche being disposed on an opposite side of the web, wherein the first cliche includes a first cliche pattern; changing the first cliche pattern on the first cliche to a second cliche pattern; inverting and aligning the web; and feeding a web between the first cutterhead and the first cliche.

In other features, the first and second conductive layers have a thickness in a range from 5 μm to 40 μm.

A flexible foil comprising: a substrate; a first conductive layer disposed on one surface of the substrate; a second conductive layer disposed on an opposite surface of the substrate; a first insulating layer disposed adjacent to the first conductive layer; and a second insulating layer disposed adjacent to the second conductive layer. One side of the flexible foil is dry milled using a first cliche pattern including raised portions and non-raised portions to selectively remove at least one of the first conductive layer and the first insulating layer. The opposite side of the flex foil is dry milled using a second cliche pattern including upper raised portions, lower raised portions, and non-raised portions to selectively remove the second insulating layer.

In other features, the first cliche pattern removes at least one of the first insulating layer and the first conductive layer adjacent to the raised portion and does not remove the first insulating layer and the first conductive layer adjacent to the non-raised portion. The upper raised portions of the second cliche pattern remove the second insulating layer on an opposite side of the flexible foil at locations where at least one of the first insulating layer and the first conductive layer is removed. The lower raised portions of the second cliche pattern remove the second insulating layer on an opposite side of the flexible foil at locations where at least one of the first insulating layer and the first conductive layer is not removed. The non-protruding portions of the second cliche pattern do not remove the second insulating layer.

In other features, the flexible foil is fed between a first cutterhead arranged on one side of the flexible foil and a first cliche arranged on an opposite side of the flexible foil, wherein the first cliche includes a first cliche pattern. The flexible foil is fed between a second cutterhead arranged on the opposite side of the flexible foil and a second cliche arranged on one side of the flexible foil, wherein the second cliche comprises a second cliche pattern.

In other features, the flexible foil is fed between a first cutterhead arranged on one side of the flexible foil and a first cliche arranged on an opposite side of the flexible foil, wherein the first cliche includes a first cliche pattern. The first cliche pattern on the first cliche is changed to a second cliche pattern. The flex foil is inverted and aligned. The flexible foil is fed between the first cutterhead and the first cliche.

In other features, the first and second conductive layers have a thickness in a range from 5 μm to 40 μm.

A flexible foil comprising: a substrate; a first conductive layer disposed on one surface of the substrate; a second conductive layer disposed on an opposite surface of the substrate; a first insulating layer disposed adjacent to the first conductive layer; and a second insulating layer disposed adjacent to the second conductive layer. A first portion of the first insulating layer and the first conductive layer are milled to one surface of the substrate at a first location. A first portion of the second insulating layer is milled on the opposite surface of the substrate at the first location.

In other features, the first and second conductive layers have a thickness in a range from 5 μm to 40 μm.

In other features, the second portion of the first insulating layer and the first conductive layer are not milled on one surface of the substrate at the second location, and the second portion of the second insulating layer is milled on an opposite surface of the substrate at the second location.

In other features, the third portion of the first insulating layer and the first conductive layer are milled to one surface of the substrate at a third location. The third portion of the second insulating layer is not milled on the opposite surface of the substrate at the third location.

In other features, the fourth portion of the first insulating layer and the first conductive layer are not milled on one surface of the substrate at the fourth location. The fourth portion of the second insulating layer is not milled on the opposite surface of the substrate at the fourth location.

Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

fig. 1A is a side cross-sectional view of an example of a flex foil including two conductive layers prior to milling according to the present disclosure;

fig. 1B is a side cross-sectional view of an example of a flex foil including two conductive layers after milling one side of the flex foil according to the present disclosure;

fig. 1C is a side cross-sectional view of an example of a flex foil including two conductive layers after milling two sides of the flex foil according to the present disclosure;

fig. 2A is a side view of an example of a milling system for milling a flexible foil comprising two conductive layers from two sides according to the present disclosure;

fig. 2B is a side view of an example of another milling system for milling a flexible foil comprising two conductive layers from two sides according to the present disclosure;

FIG. 3A is a side view of a portion of a first cliche pattern for milling a first side of a flex foil according to the present disclosure;

FIG. 3B is a side view of a portion of a second cliche pattern for milling a second side of a flex foil after milling the first side according to the present disclosure; and

fig. 4 is a flow chart of an example of a method for milling a flexible foil having two conductive layers according to the present disclosure.

In the drawings, reference numbers may be repeated to identify similar and/or identical elements.

Detailed Description

Typically, a flexible substrate, collectively referred to herein as a flexible foil or flex foil, includes a single conductive layer and first and second outer insulating layers. A single conductive layer may be patterned using photolithography or dry milled to define traces, fingers, and other structures that may be used to provide multiple connections. In some cases, it is desirable to provide a higher density of traces and connections.

Additional conductive layers may be added to the flex foil. However, conventional dry milling methods are generally not applicable for patterning flexible foils from both sides. The first pattern is milled into the first conductive layer from one side. The second pattern is for the opposite side of the flexible foil. However, during milling using the second pattern, the first pattern may cause a change in the thickness of the flex foil and the spacing between the mill wheel and the clich e.

For example, a dry milling process for a flex foil including a single conductive layer is shown and described in U.S. Pat. No. 7,919,027 entitled "Methods and Devices for Manufacturing of Electrical Components and calibration Structures", issued 5/4/2011, the entire contents of which are incorporated herein by reference. During dry milling, a web of flexible foil comprising a single conductive layer and an insulating layer is fed between a metal plate and a milling wheel. The cliche includes a pattern having raised portions and non-raised portions.

In some examples, the pattern is defined on a thin flexible substrate using photolithography, and the flexible substrate is attached to the outer surface of the drum. The cutterhead is arranged on the opposite side of the net. The raised portions of the pattern on the cliche push the mesh into the cutterhead and the corresponding portions of the conductive layer and/or the outer insulating layer are removed. The portions of the conductive layer that remain are thus patterned to provide traces, pads for fingers, and the like. After milling, an insulating or capping layer (or cover film) may be added on the patterned conductive layer and an additional milling step may be performed.

However, it will be appreciated that this process cannot simply be repeated on the opposite side to pattern the second conductive layer of the flexible foil. When the second pattern is patterned using the same method as described above, the removed material of the first conductive layer causes a problem.

The dry milling system and method according to the present disclosure involves milling a flexible foil having two conductive layers from two sides. The first conductive layer and/or insulating layer is milled using a first pattern having raised portions (corresponding to locations where material is removed) and non-raised portions (corresponding to locations where material is not removed) as described above.

After milling the first conductive and/or insulating layer, the web is inverted or rotated 180 °, and then the opposite side of the flex foil is milled using the second pattern. The second pattern includes upper raised portions (corresponding to locations where material is removed from both sides of the web), lower raised portions (corresponding to locations where material is removed during the second milling step rather than the first milling step), and non-raised portions (corresponding to locations where material is not removed).

In some examples, the conductive layer is made of a metal such as Al or Cu and has a thickness in the range of 5 μm to 40 μm, but other metals or thicker or thinner layers may also be used. For example only, Cu having a thickness of 9 μm, 18 μm, or 35 μm or Al having a thickness of 9 μm or 18 μm may be used. In some examples, the insulating layer and/or the substrate include films such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), or Polyimide (PI), although other substrates or insulating materials may also be used.

Referring now to fig. 1A to 1C, milling of the flex foil 2 from both sides is shown. In fig. 1A, the flex foil 2 is shown before milling. The flexible foil 2 comprises a substrate 4, a first electrically conductive layer 5 arranged on one side of the substrate 4 and a first insulating layer 6 arranged on the first electrically conductive layer 5. The flexible foil 2 further comprises a second conductive layer 8 arranged on the opposite side of the substrate 4 and a second insulating layer 9 arranged on the second conductive layer 8. In fig. 1B, the first conductive layer 5 and the first insulating layer 6 are milled using a first cliche pattern, as shown at one or more locations identified at 7. In fig. 1C, the second insulating layer 9 is selectively milled using a second cliche pattern at one or more locations identified at 10.

Referring now to fig. 2A, a milling system 12 for milling a web 14 of a flexible foil 2 is shown. The first roll 16 supplies the web 14 of the flexible foil 2. The web 14 is fed between the cutterhead 20 and the cliche 25. In some examples, cliche 25 includes a cylinder 24. A flexible substrate 26 defining a first pattern or a second pattern is attached to the drum 24. Alternatively, the first pattern or the second pattern may be made directly on the drum 24. In some examples, the first pattern or the second pattern is defined on the flexible substrate 26 or the drum 24 using photolithographic techniques, although other techniques may also be used.

The cutterhead 20 is disposed within a predetermined distance of the drum 26 to allow for milling of the convex portions of the web 14 as the web passes. The cutterhead 20 includes teeth that cut portions of the mesh 14 that are raised by corresponding raised portions of the first pattern. The web 14 is fed around the second cylinder 28 to a roll 32.

The first conductive layer 5 and/or the first insulating layer 6 are milled using the first pattern as described above. The convex portion of the first pattern corresponds to a position where the first conductive layer 5 and/or the first insulating layer 6 is removed. The first pattern includes non-raised portions corresponding to locations where material is not removed.

After the first milling operation, the web is rotated 180 °, and the first pattern is replaced with the second pattern. Alternatively, a second cliche may be used, as shown in FIG. 2B. The second pattern includes upper raised portions (corresponding to locations where material is removed from both surfaces of web 14), lower raised portions (corresponding to locations where material is removed from the side corresponding to the second conductive layer rather than from the side corresponding to the first conductive layer), and non-raised portions (corresponding to locations where material is not removed from the side corresponding to the second conductive layer).

In FIG. 2B, the milling system 12 includes a first cliche 25-1 (including the cylinder 24-1 and the flexible substrate 26-1) disposed adjacent to the first cutterhead 20-1 and a second cliche 25-2 (including the cylinder 24-2 and the flexible substrate 26-2) disposed adjacent to the second cutterhead 20-2. A first cliche 25-1 is disposed on one side of the web 14 and a second cliche 25-2 is disposed on the opposite side of the web 14. The first cliche 25-1 mills a first pattern on one side. The second cliche 25-2 mills a second pattern on the opposite side. After milling is performed, other operations may be performed. For example, a cutting operation may be performed to separate the individual flexible foils from the web 14.

Referring now to fig. 3A, the surface of the substrate 26 defines a portion of a first pattern 48 for milling one side of the web 14. First pattern 48 includes non-raised portions 50 (where no milling of web 14 occurs) and raised portions 50 portions 52 (where insulating material and/or first conductive layer is removed from one side of web 14).

Referring now to fig. 3B, the surface of the substrate 26 defines a second pattern 58 for milling the opposite side of the web 14. The second pattern 58 includes upper raised portions 54 (corresponding to locations where material is removed from both sides of the web 14). Second pattern 58 includes lower raised portions 52 (corresponding to locations where material is removed from the side of web 14 adjacent the second conductive layer rather than from the side adjacent the first conductive layer). Second pattern 58 includes non-raised portions 50 (corresponding to locations where material is not removed from the second conductive layer).

Returning to fig. 1C, in position a milling is performed on both sides of the flexible foil 2. The corresponding portion of the first pattern at location a will have a raised portion (to remove the insulating layer and/or the first conductive layer). The corresponding portion of the second pattern will have an upper raised portion to offset the material removed by the first pattern and mill the second insulating layer. In position B no milling from either side occurs. The corresponding portions of the first and second patterns will have non-raised portions.

At position C, the corresponding portion of the first pattern will have a raised portion to remove the first conductive layer and/or the insulating layer. Since the second insulating layer is not removed, the corresponding portion of the second pattern will have a non-convex portion.

At position D, the corresponding portion of the first pattern will have a non-raised portion so that no material is removed. The corresponding portion of the second pattern will have a lower convex portion to remove the second insulating layer.

Referring now to fig. 4, a method 200 for milling a flexible foil/mesh from two sides is shown. At 210, first and second patterns are defined for the first and second conductive layers of the flexible foil based on a desired layout. At 214, a first pattern is created on a substrate or drum to define raised portions and non-raised portions. If a substrate is used, the substrate is attached to a cliche. At 218, the mesh/flex foil is milled using the first pattern on the cliche and a milling wheel to dry pattern one side of the mesh/flex foil.

At 224, a second pattern is created on the substrate or drum to define upper raised portions, lower raised portions, and non-raised portions. If a substrate is used, the substrate with the first pattern is removed and a second pattern is attached to the cliche. Alternatively, a second cliche is used, as shown in FIG. 2B. At 276, the web including the flex foil is optionally inverted and aligned with the second cliche pattern. The web is milled using a second cliche pattern and a milling wheel to dry pattern the opposite side of the web/flex foil.

The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent from the study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method may be performed in a different order (or simultaneously) without altering the principles of the present disclosure. Moreover, although each embodiment is described above as having certain features, any one or more of the features described with respect to any embodiment of the present disclosure may be implemented in and/or combined with the features of any other embodiment, even if such a combination is not explicitly described. In other words, the described embodiments are not mutually exclusive and the arrangement of one or more embodiments with respect to each other is still within the scope of the present disclosure.

Spatial and functional relationships between elements (e.g., between modules, circuit elements, between semiconductor layers, etc.) are described using various terms, including "connected," joined, "" coupled, "" adjacent, "" beside … …, "" above … …, "" above, "" below, "and" disposed. Unless explicitly described as "direct," when a relationship between a first and second element is described in the above disclosure, the relationship may be a direct relationship without other intervening elements between the first and second elements, but may also be an indirect relationship with one or more intervening elements (spatially or functionally) between the first and second elements. As used herein, at least one of the phrases A, B and C should be construed to mean logical (a OR B OR C), using a non-exclusive logical OR, and should not be construed to mean "at least one a, at least one B, and at least one C. "

In the drawings, the direction of an arrow, as the arrow points, generally indicates the flow of information (e.g., data or instructions) of interest through the diagram. For example, when element a and element B exchange various information, but the information transferred from element a to element B is related to an illustration, an arrow may point from element a to element B. This one-way arrow does not indicate that no other information is being transferred from element B to element a. Further, for information sent from element a to element B, element B may send a request for the information or an acknowledgement of receipt to element a.