Printed Circuit Board with Routing of a Conductor and Dielectric Strands
20200092980 ยท 2020-03-19
Assignee
Inventors
- Yanyan Zhang (Austin, TX, US)
- Lloyd Andre Walls (Austin, TX, US)
- Jinwoo Choi (Austin, TX, US)
- Mehdi Mohamed Mechaik (Austin, TX, US)
Cpc classification
H05K3/0011
ELECTRICITY
H05K2201/0195
ELECTRICITY
H05K1/024
ELECTRICITY
H05K1/0242
ELECTRICITY
Y10T29/49155
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H05K1/025
ELECTRICITY
International classification
Abstract
Embodiments are directed to a method of manufacturing the printed circuit board. The PCB is a multi-layer component, including a dielectric material and an intermediate or second layer adjacently positioned with respect to the dielectric material. The intermediate layer or second layer is comprised of a conductor and fiberglass strands, with the fiberglass strands having an associated orientation. When assembled, the fiberglass and the conductor having a matching orientation and separation distance from a source to a destination.
Claims
1. A method of producing a printed circuit board, comprising: forming a first layer comprising a first dielectric material and positioning a first ground conductive layer in communication with the first dielectric material; forming an intermediate layer positioned between and separated from the first dielectric material and a second dielectric material, the separation forming an opening between the first and second dielectric material, the intermediate layer comprising: a conductor, a first fiberglass material, and a second fiberglass material; and positioning the conductor in the formed intermediate layer proximal to the first and second fiberglass materials.
2. The method of claim 1, wherein the first dielectric material includes a first set of fiberglass bundles in a first orientation interweaved with a second set of fiberglass bundles in a second origination.
3. The method of claim 1, further comprising positioning the second fiberglass material adjacent to a second side of the conductor, wherein the second side is oppositely disposed from the first side of the conductor, and further comprising forming a second layer comprising the second dielectric material positioned in communication with the second side of the conductor, and positioning the second layer in communication with the intermediate layer.
4. The method of claim 3, wherein the intermediate layer is positioned between and separated from the first dielectric material.
5. The method of claim 3, further comprising depositing an epoxy resin and binding the intermediate layer with the first and second layers and subjecting the resin to a curing process.
6. The method of claim 3, wherein the first layer, the intermediate layer, and the conductor have a matching orientation and separation distance from a source to a destination.
7. The method of claim 3, wherein the first fiberglass material includes one or more fiberglass strands positioned parallel to the conductor.
8. The method of claim 1, wherein the first fiberglass material includes two or more adjacently positioned first fiberglass strands forming a first co-planar arrangement with minimal openings formed between adjacently positioned strands.
9. The method of claim 1, wherein the second fiberglass material includes two or more adjacently positioned second fiberglass strands forming a second co-planar arrangement with minimal openings formed between adjacently positioned strands.
10. The method of claim 9, wherein the second fiberglass material is parallel to the conductor.
11. The method of claim 1, wherein the conductor is selected from the group consisting of: a single ended conductor and a differential pair.
12. A method of producing a printed circuit board, comprising: forming a first layer comprising a first dielectric material and positioning a first ground conductive layer in communication with the first dielectric material; forming a second layer positioned between and separated from the first dielectric material, the separation forming an opening with the first dielectric material, the second layer comprising: a conductor and a first fiberglass material; and positioning the conductor in the formed second layer proximal to the first fiberglass material.
13. The method of claim 12, wherein the first dielectric material includes a first set of fiberglass bundles in a first orientation interweaved with a second set of fiberglass bundles in a second origination.
14. The method of claim 12, further comprising depositing an epoxy resin and binding the first and second layers and subjecting the resin to a curing process.
15. The method of claim 12, wherein the first layer, the second layer, and the conductor have a matching orientation and separation distance from a source to a destination.
16. The method of claim 15, wherein the first fiberglass material includes one or more fiberglass strands positioned parallel to the conductor.
17. The method of claim 12, wherein the first fiberglass material includes two or more adjacently positioned first fiberglass strands forming a first co-planar arrangement with minimal openings formed between adjacently positioned strands.
18. The method of claim 12, wherein the conductor is selected from the group consisting of: a single ended conductor and a differential pair.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] The drawings referenced herein form a part of the specification. Features shown in the drawings are meant as illustrative of only some embodiments, and not of all embodiments, unless otherwise explicitly indicated.
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DETAILED DESCRIPTION
[0017] It will be readily understood that the components of the present embodiments, as generally described and illustrated in the Figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the apparatus, system, and method of the present embodiments, as presented in the Figures, is not intended to limit the scope of the embodiments, as claimed, but is merely representative of selected embodiments.
[0018] Reference throughout this specification to a select embodiment, one embodiment, or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present embodiments. Thus, appearances of the phrases a select embodiment, in one embodiment, or in an embodiment in various places throughout this specification are not necessarily referring to the same embodiment.
[0019] The illustrated embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the embodiments as claimed herein.
[0020] Printed circuit board (PCB) laminates are comprised of woven fiberglass fabric with an epoxy resin. Mechanical and electrical properties of the PCB depend on the density of the weave, the materials, thread counts, etc. The peaks and valleys that are inherent characteristics of the woven fiberglass fabric cause resonant power loss of an associated transmission signal. The non-uniform distance between the transmission signal and the fiberglass fabric across the PCB affects the signal and associated signal resonance and loss. Accordingly, the conventional PCB laminate with the woven fiberglass fabric creates fundamental resonance caused by periodic loading of the laminate structure.
[0021] As shown and described, the structure of the PCB laminates is a modification to strengthen the mechanical and electrical properties of a composite PCB substrate. Referring to
[0022] The substrate is comprised of three layers, with an intermediate layer (130), e.g. layer.sub.1, positioned between layer.sub.0 (110) and layer.sub.2 (150). fabric.sub.0 (110). The intermediate layer (130) is shown with a conductor, a differential pair, or a combination of conductor and differential pairs. In this example, the intermediate layer (130) is shown with conductors (170a) and (170b) that form a differential pair. Although two conductors are shown herein, this embodiment should not be considered limiting. In one embodiment, the conductors (170a) and (170b) may be replaced with a single conductor, referred to herein as a single ended conductor. As shown, the conductors (170a) and (170b) are positioned between the first and third layers, (110) and (150), respectively. The intermediate layer, layer.sub.1 (130), is shown with non-woven fiberglass, e.g. strands, positioned within the substrate. More specifically, two bundles of the strands are shown in layer.sub.1 (130), including bundle.sub.0 (132) and bundle.sub.1 (134). In one embodiment, the bundle may form a row or layer of strands. Bundle.sub.0, (132), is shown herein with multiple strands of non-woven fiberglass, shown herein as strands (142) positioned across the first bundle (132). The strands (142) are positioned proximal to fabric.sub.0 (112). Similarly, bundle.sub.1 (134), also referred to herein as a second bundle, is shown herein with multiple strands of non-woven fiberglass, shown herein as strands (144) positioned across the second bundle (134). The strands (144) are positioned proximal to fabric.sub.1 (152).
[0023] Resin is used to bind all the layers of the substrate, including the first layer (110), the intermediate layer (130), and the third layer (150). The conductor pair, (170a) and (170b), is shown positioned within the intermediate layer (130) and proximal to the strands. As shown herein, the conductors (170a) and (170b) that form the conductor pair are positioned adjacent to and relatively parallel with the strands (142) and (144). A gap (180) is shown between the conductors (170a) and (170b). As further shown, a third conductor (170c), referred to as a single ended conductor, is positioned in the intermediate layer (130) and spaced apart from the differential pair (170a) and (170b) via gap (190). In the example shown herein, both a single ended conductor and a differential pair are shown within the intermediate layer. In one embodiment, additional conductors and may be positioned in the intermediate layer, and the quantity shown herein should not be considered limiting. Accordingly, the substrate may be configured with a single ended conductor and/or a differential pair, or in one embodiment, a plurality of single ended conductors and differential pairs.
[0024] The strands are shown positioned within the intermediate layer (130) at discrete locations and relative to conductors, shown herein as the conductor pair, (170a) and (170b), and single ended conductor (170c). As shown, first bundle (132) is parallel or relatively parallel to the second bundle (134), with the first bundle (132) positioned above the conductors (170a), (170b), and (170c) and the second bundle (134) positioned below the conductors (170a), (170b), and (170c). More specifically, one side of the conductors is positioned in communication with the first bundle (132) and an oppositely disposed side of the conductors is in communication with the second bundle (134). As shown herein, and further described in
[0025] Referring to
[0026] As shown, strand.sub.0 (232) has a first side (232a) positioned proximal to a first side (212) of the first layer, layer.sub.0 (210). Strand.sub.0 (232) has a second side (232b) positioned proximal to a first side (272) of the conductor (270). Similarly, strand.sub.1 (234) has a first side (234a) positioned proximal to a first side (252) of the third layer, layer.sub.2 (250), and a second side (234b) positioned proximal to a second side (274) of the conductor (270). Accordingly, the layers (210), (230), and (250) are stacked an in contact with each other at their respective surfaces, without any spacing, or in one embodiment minimal spacing, between the layers. The first and third layers (210) and (250), each comprised of dielectric material, provide strength to the PCB, and the strands (232) and (234) mitigate resonant power loss associated with the signal transmitted through the conductor (270).
[0027] Referring to
[0028] As shown and described in
[0029] The embodiments shown and described in
[0030] Referring to
[0031] Referring to
[0032] Referring to
[0033] Referring to
[0034] As shown in
[0035] As shown and described the intermediate layer of the PCB is formed with non-woven fiberglass components positioned adjacent and parallel to the signal trace while maintaining a distance between adjacently positioned conductors. In one embodiment, the non-woven fiberglass strands are positioned relatively close to the conductor to effectively remove power resonance. When positioned with respect to the first and second fiberglass weaves, a separation distance is maintained between the first fiberglass weave and the second fiberglass weave by the intermediate layer, e.g. the non-woven bundles and the conductor(s). In one embodiment, the fiberglass weave(s) are utilized to provide strength to the formed micro-strip or PBC. The structure of the intermediate layer with the fiberglass strands, e.g. non-woven fiberglass bundles, mitigates or removes resonance caused by periodic loading inherent within the woven fiberglass weaves.
[0036] It is well known in the art that many different materials or composition of materials available for the fiberglass weave and fiberglass strands. The weave may be a single ply or multiple ply weave. The specific material or composition of the materials should not be considered limiting and may be any material used to form the PCB.
[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the embodiments. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0038] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present embodiments has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the embodiments in the form disclosed.
[0039] It will be appreciated that, although specific embodiments have been described herein for purposes of illustration, various modifications may be made without departing from the sprit and scope of the embodiments. Accordingly, the scope of protection of the embodiments is limited only by the following claims and their equivalents.
[0040] The description of the present embodiments has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the embodiments. The embodiments were chosen and described in order to best explain the principles of the embodiments and the practical application, and to enable others of ordinary skill in the art to understand the embodiments for various embodiments with various modifications as are suited to the particular use contemplated. Accordingly, the structure and positioning of the intermediate layer with respect to the fiberglass weaves is directed at improving signal transmission across the PCB.
[0041] It will be appreciated that, although specific embodiments have been described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the embodiments. In particular, the multi-layered composite PCB laminates may have additional features suitable for particular uses. Accordingly, the scope of protection of the embodiments is limited only by the following claims and their equivalents.