HYBRID PROCESS FOR PCB PRODUCTION BY LAD SYSTEM
20230240022 · 2023-07-27
Inventors
- Ralph S. Birnbaum (Nes Ziona, IL)
- Guy Nesher (Nes Ziona, IL)
- Alexander Slavomir Stepinski (Saunderstown, RI, US)
- Michael Zenou (Hashmonaim, IL)
Cpc classification
H05K3/4664
ELECTRICITY
H05K3/4682
ELECTRICITY
H05K2203/1131
ELECTRICITY
H05K2203/1492
ELECTRICITY
International classification
Abstract
Systems and methods for printing a printed circuit board (PCB) from substrate to full integration utilize a laser-assisted deposition (LAD) system to print a flowable material on top of a substrate by laser jetting to create a PCB structure to be used as an electronic device. One such system for PCB printing includes a jet printing unit, an imaging unit, curing units, and a drilling unit to print metals and other materials (e.g., epoxies, solder masks, etc.) directly on a PCB substrate such as a glass-reinforced epoxy laminate material (e.g., FR4). The jet printing unit can also be used for sintering and/or ablating materials. Printed materials are cured by heat or by infrared (IR) or ultraviolet (UV) radiation. PCBs produced according to the present systems and methods may be single-sided or double-sided.
Claims
1. A method of fabricating of a printed circuit board (PCB) assembly, comprising: depositing a first dielectric layer on a first region of a PCB substrate by a laser-assisted deposition (LAD) process; depositing a first metal layer on a second region of the PCB substrate by a second LAD process in which jetting of metal droplets from a first donor substrate onto the second region of the PCB substrate and/or into one or more through holes in the second region of the PCB substrate is effected using a laser to form the first metal layer on the second region of the PCB substrate, the first metal layer being subsequently dried and sintered, with the jetting, drying, and sintering being repeated until the first metal layer reaches a desired thickness; and forming at least one passivation layer over the first metal layer.
2. The method of claim 1, further comprising ablating the first metal layer.
3. The method of claim 2, wherein the ablating is performed using the laser that is used to jet the metal droplets from the donor substrate.
4. The method of claim 1, wherein the passivation layer comprises a second dielectric layer deposited or coated over the first metal layer using a roller or blade.
5. The method of claim 1, wherein the passivation layer comprises a second dielectric layer printed over the first metal layer from a dielectric coat on a second donor substrate by a third LAD process.
6. The method of claim 5, further comprising printing a second metal layer over the second dielectric layer by a fourth LAD process.
7. The method of claim 6, wherein the first metal layer includes a first metal trace, the first dielectric layer includes at least a first portion of dielectric that covers at least a first portion of the first metal trace, and the second metal layer includes a second metal trace having at least a portion disposed over the first portion of the first dielectric layer that covers the first portion of the first metal trace.
8. The method of claim 5, further comprising curing the first dielectric layer by hot air and/or infrared (IR) irradiation.
9. The method of claim 1, further comprising compressing, using a hot press, at least the first metal layer after the first metal layer has reach the desired thickness.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings, in which:
[0032]
[0033]
[0034]
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[0039]
DETAILED DESCRIPTION OF THE INVENTION
[0040] PCB production is a highly developed field with a significant number of stages. The object of the present invention is to simplify the production process through the provision and use of a single system with several sub-modules that can construct a PCB assembly from the prepreg (i.e., a type of base material, fiberglass or fabric, that has been pre-impregnated or reinforced with resin, typically epoxy, or polyimide that is partially cured) and laminate (e.g., copper clad laminate (CCL), which is a common PCB material, and copper on one or both sides) up to a base board. Systems and methods configured in accordance with the present invention need not necessarily employ materials that are different from those used today for conventional PCB production (although such new materials may be used), but may instead use those same materials in new and different ways. Hence, in various embodiments, the present invention relates to systems and methods for printing PCB or a flexible PCB, from substrate level to full integration. As described below, embodiments of the invention may utilize LAD systems to print any flowable material on top of a substrate by laser jetting to create a PCB structure to be used as an electronic device in a production line.
[0041]
[0042] As shown in the cross section depicted in
[0043] The dielectric layer 16 is an important part of the PCB assembly since its properties are essential for the overall quality of the PCB assembly. Properties of the dielectric layer include: [0044] a. Mechanical properties—the dielectric layer provides the PCB assembly its strength and flexibility. During production, the PCB assembly undergoes a series of heating cycles and during those cycles, the dimensions of the PCB should remain unchanged. For that end, the board glass temperature (Tg) should be very high in the range of 250° C. and preferably should be above such temperature. [0045] b. Coefficient of thermal expansion (CTE)—the dielectric material is positioned in the same layer as the metal traces and during the above mentioned heating cycles, both the metal trace and the dielectric material will expand. However, if the CTE of both materials is not similar enough, cracks will develop in the interfaces between the two materials during the heating cycles. Therefore, the dielectric material CTE should be very low, lower than 40° C..sup.−1 and preferably lower than 25° C..sup.−1. [0046] c. Dielectric constant and dielectric loss—the dielectric material is used as a dielectric barrier between the metal traces to avoid interference between the electronic conduction in the different lines. For that end, both the dielectric constant and its loss need to be tailored for the application. Typical values of the dielectric constant that are used are 2.8-3 and the loss should be lower than 0.01. However, there is a continuous demand to reduce both of these numbers. [0047] d. Adhesion—the dielectric material is used for connecting the different layers (metal or dielectric layers) and the adhesion between the layers during the heating cycles is a very important parameter. A good adhesion between the layers will decrease the rate of delamination and increase the production yield.
[0048] The dielectric material that is used in the LAD system preferably has all the above-noted properties and some industrial materials are known to have those properties. For example, KERIMID® polyimide resin, distributed by Huntsman Corporation of The Woodlands, Tex., is one possible dielectric material for the LAD system that would possess the above-described properties.
[0049] The main advantage provided by the LAD system for printing the dielectric material is its ability to print high viscosity materials that have a high percentage of large particles. That property of the LAD system enables one to design a material according to the above demands rather easily as compared to any other system in the market.
[0050] The dielectric material that will be used by the system can be a UV cured or heat cured material and for that end, a UV system 20 and a drying system 22 are provided in the LAD system to post process the dielectric material, as depicted in
[0051]
[0052]
[0053] If liners 10 were in use in the process, they can be removed after the hot press process, as shown in
[0054]
[0055] First, lithography is used to create the outer metal traces (
[0056] A solder mask layer 26 is then deposited over one or both sides of the structure (leaving some metal contact regions 14′ exposed for electrical connection with electronic components) to produce the PCB assembly (
[0057] The metallization process, which is the most important part of the PCB production, may be performed by paste printing.
[0058] Laser induced jetting is a form of LAD in which a laser beam 204 is used to create a patterned surface by controlled material deposition. In particular, laser photons provide the driving force to catapult a small volume of metal paste 206 from a donor film 208 toward an acceptor substrate such as PCB substrate 104. Typically, the laser beam 202 interacts with an inner side of the donor film 208, which is coated onto a non-absorbing carrier substrate 210 (also called a donor substrate). In other words, the incident laser beam 204 propagates through the transparent carrier substrate 210 before the photons are absorbed by the inner surface of the film 208. Above a certain energy threshold, metal paste 206 is ejected from the donor film 208 toward the surface of the PCB substrate 104, which is situated on a stage (not shown in this view) in a work area.
[0059] Once deposited on the PCB substrate 104, including in through holes 106, the metal paste 202 is dried by hot air 212, see
[0060] Because the printing of the conductive film is an intermediate step, it is desirable that the formation of this layer does not take a long time. Accordingly, the metal paste from which the conductive film is formed should only take a short amount of time to cure (whether by IR irradiation, hot air, or both) and should not shrink much (if at all) during the curing process. Materials that take an excessive amount of time to cure will impede the overall speed of the process, and those that shrink (more than a negligible amount) during curing will impart mechanical stress on the PCB substrate, which may lead to failure.
[0061] The active or conductive material used for the conductive film may comprise one or more metals. Metals that are contemplated include pure metals, metal alloys, and refractory metals. Copper is a common choice for PCB metallization, and may be used in embodiments of the present invention. The active material may be applied (printed) using LAD either from a solid state, e.g., small metal particles that are deposited on a plastic film can be used in the LAD process to generate a conductive layer, or in the form of a paste carried on a donor film 208 as described above. The conductive film should be applied in an amount sufficient to fully support the subsequent electronic connections. This may mean applying several layers of paste, one atop the other, with curing steps after each application of a layer.
[0062] One embodiment of the metallization process is illustrated schematically in the flow diagram 300 depicted in
[0063] At any layer of the PCB assembly, after the metallization has been carried out, a dielectric layer may be added to the board to reduce capacitance and avoid short circuits. There are several ways to add the dielectric layer, for example, by coating a liquid material and curing it or by hot pressing of a prepreg. Examples of such processes will now be explained.
[0064] Referring to
[0065] Alternatively, as shown in
[0066] Once coated, the donor substrate 404 with the layer of epoxy 402 thereon is positioned in the laser jetting system and dots 406 of the epoxy 402 are jetted onto the metal layer 214 and/or PCB substrate 104 using the laser beam 204. In one example, the laser beam 204 is focused onto the interface between the layer of epoxy 402 and the substrate 404 causing local heating followed by a phase change and high local pressure which drives jetting of the epoxy onto the metal layer 214 and/or PCB substrate 104. After printing the epoxy 402 to the metal layer 214 and/or PCB substrate 104, the donor substrate 404 can be returned for a second (or additional) coating of epoxy 402 by reversing the direction of a transport mechanism or, where the donor substrate 404 is a continuous film, by moving the donor substrate 404 through the coating system in a loop-like process.
[0067] In still further embodiments, the donor substrate 404 may be a screen or grid in which the epoxy 402 is introduced into holes of the screen by a coater, which may be a roller or blade, and the incident laser beam 204 used to displace the epoxy 402 from the holes in the screen onto the metal layer 214 and/or PCB substrate 104.
[0068] Referring to
[0069] Yet another approach for passivation is to use a dielectric material to create a passivation layer. The use of dielectric material reduces height differences in a surface and creates a much more uniform height PCB surface. A dielectric material passivation layer can be formed by printing the metal (e.g., Cu) onto the dielectric material and attaching the resulting structure to the surface (
[0070] In this process, a dielectric layer 502 is formed on a substrate 504 (this substrate distinct from the PCB substrate) and a laser beam 506 is used to engrave/cut the dielectric layer 502 into a desired configuration, e.g., by creating through holes 508 and/or channels 510 in the dielectric material 502 (
[0071] In
[0072] Although not discussed in detail above, imaging sub-system 603 may be employed in connection with any or all of the above-described etching and deposition procedures. For example, the imaging sub-system 603 may include one or more two-dimensional and/or three-dimensional imaging units (e.g., cameras, scanning laser arrangements, etc.) that image the PCB assembly, PCB substrate 104 or portions thereof at various stages during the production process. Vias, through holes and/or features of the PCB assembly may be imaged so as to ensure they are free from debris and regular in shape. Deposited layers may be imaged so as to ensure they are uniform in coverage and/or accurately positioned. This may be especially important where layers are printed through successive jetting of small droplets of material. The imaging may also be used to ensure accurate registration of the PCB substrate 104 on a holder 120. Imaging in this fashion can allow for in-line repair of a process step, such as additional or re-coating of a layer, or rejection of an in-process PCB when necessary. Stage 630, which can translate in two dimensions (and where necessary, raise and lower the PCB 104), facilitates movement of the PCB between the various units of systems 600b and the sub-systems within those units during processing.
[0073] As mentioned above, the UV light sub-system 608, whether modularized or not, is optional. As all of the deposited layers can be heat-cured, the use of UV curing is not mandatory, hence, the need for the UV light sub-system 608 is only in cases where UV curing is preferred. When modularized, the UV light sub-system 608 can be included in the overall system 600a, 600b or removed therefrom as desired.
[0074] The heating sub-system 612 is used for curing heat sensitive materials and/or for drying solvent base materials. It can be a part of an overall system 600a, but it preferably is modularized (as part of heater unit 610) so that it can be easily replaced, if necessary, in a system 600b.
[0075] An additional hot press sub-system 620 is used for fusing the different layers together to form the PCB substrate 104.
[0076]
[0077] Although not illustrated in detail, it should be appreciated that the various components of the printing systems described herein operate under the control of one or more controllers, which, preferably, are processor-based controllers that operate under the instruction of machine-executable instructions stored on tangible machine-readable media. Such controllers may include a microprocessor and memory communicatively coupled to one another by a bus or other communication mechanism for communicating information. The memory may include a program store memory, such as a read only memory (ROM) or other static storage device, as well as a dynamic memory, such as a random-access memory (RAM) or other dynamic storage device, and each may be coupled to the bus for providing and storing information and instructions to be executed by the microprocessor. The dynamic memory also may be used for storing temporary variables or other intermediate information during execution of instructions by the microprocessor. Alternatively, or in addition, a storage device, such as a solid state memory, magnetic disk, or optical disk may be provided and coupled to the bus for storing information and instructions. The controller may also include a display, for displaying information to a user, as well as various input devices, including an alphanumeric keyboard and a cursor control device such as a mouse and/or trackpad, as part of a user interface for the printing system. Further, one or more communication interfaces may be included to provide two-way data communication to and from the printing system. For example, network interfaces that include wired and/or wireless modems may be used to provide such communications.