Patent Application
20240138062
The present disclosure generally relates to electronic circuits and more specifically to devices, systems, and methods for making and using circuit assemblies having patterns of deformable conductive material formed therein.
The following summary is provided to facilitate an understanding of some of the innovative features unique to the aspects disclosed herein, and is not intended to be a full description. A full appreciation of the various aspects can be gained by taking the entire specification, claims, and abstract as a whole.
In various aspects, a method for manufacturing a circuit assembly is disclosed. In one aspect, the method includes providing a substrate layer including a substrate material; placing a stencil including a stencil material on a surface of the substrate layer, wherein the stencil has a thickness and a pattern of passages formed therein; depositing a deformable conductive material to at least partially fill the pattern of passages; removing the removable stencil from the surface of the substrate layer to leave a first pattern of deformable conductive material formed on the substrate layer, wherein the first pattern of deformable conductive material can include at least one gap; covering at least a portion of the first pattern of deformable conductive material with a first stacked layer, wherein the first stacked layer is an insulation layer, an encapsulation layer, or a combination thereof; and healing the at least one gap, wherein unitizing the circuit assembly causes the at least one gap to heal.
In various aspects, a circuit assembly is disclosed. In one aspect, the circuit assembly includes a substrate layer; a first pattern of deformable conductive material formed on a surface of the substrate layer using a removable stencil; and a first stacked layer configured to cover at least a portion of the first pattern of deformable conductive material.
These, and other objects, features, and characteristics of the present disclosure, as well as the methods of operation, and functions of the related elements of structure, and the combination of parts, and economies of manufacture, will become more apparent upon consideration of the following description, and the appended claims with reference to the accompanying drawings, all of which form a part of this specification. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention.
Various features of the aspects described herein are set forth with particularity in the appended claims. The various aspects, however, both as to organization, and methods of operation, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:
Corresponding reference characters indicate corresponding parts throughout the several views. Numeric reference characters followed by letters (e.g. 20A, 20B, etc.) can indicate varying instances of corresponding parts throughout the several views. The exemplifications set out herein illustrate various aspects of the present disclosure, in one form, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner.
The present application is related to the following commonly owned patent applications, the disclosures of which are hereby incorporated by reference in their entirety:
According to some non-limiting aspects, the subject matter disclosed in U.S. patent application Ser. No. 11/107,354 titled FLUID-FILLED BLADDER FOR FOOTWEAR AND OTHER APPLICATIONS, which was filed on Apr. 14, 2004 and granted on Jul. 22, 2009 as U.S. Pat. No. 7,401,369; the disclosure of which is hereby incorporated by reference in its entirety, is relevant to the devices, systems, and methods disclosed herein.
Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the aspects as described in the disclosure and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the aspects described in the specification. The reader will understand that the aspects described and illustrated herein are non-limiting aspects, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.
In the following description, like reference characters designate like or corresponding parts throughout the several views of the drawings. Also in the following description, it is to be understood that such terms as “forward”, “rearward”, “left”, “right”, “upwardly”, “downwardly”, and the like are words of convenience and are not to be construed as limiting terms.
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves any and all copyrights disclosed herein.
Conventional methods of depositing conductive materials to traditional printed circuit boards lack efficiency because these methods can require multiple operations that are high in resource consumption and produce a great deal of waste. For example, the production of FR4/copper circuit boards typically involve various curing, etching, stripping, and soldering steps that consume electricity and water and generate spent waste materials. As just one example, in the case of etching, excess copper conductor is often treated as waste after it is removed from the circuit board assembly. Moreover, spent materials, such as etching solutions, stripping solutions, solder dross, and wastewater treatment sludge, are often hazardous waste.
Yet further, even circuit board production methods that employ conductive adhesives (e.g., conductive epoxies such as silver epoxy) to replace soldering can lack efficiency. For example, conductive epoxies typically cure shortly after being applied to a circuit board assembly. This curing reaction often prevents excess conductive epoxy from being reworked or reused because the epoxy's conductive performance deteriorates if reworked after curing. Thus, excess conductive epoxy is often wasted. Moreover, cleaning solutions are often expended when removing excess conductive epoxy from the circuit board.
Various attempts have been made to improve the efficiency of traditional printed circuit boards. For example, the Environmental Protection Agency (“EPA”) has published a summary titled Workshop Materials on WEEE Management in Taiwan, Handout 10, October 2012, the disclosure of which is hereby incorporated by reference in its entirety, which provides more details related to the waste generation and recycling processes for conventional printed circuit boards. However, these recycling processes can be expensive, time consuming, and inefficient. Additionally, some conventional methods of producing printed circuit boards can involve excessive materials and/or a layered construction that add to the inefficiency of the assembly process. For example, some methods of producing circuits using a deformable conductor may require the use of intermediate layers configured to contain the deformable conductor prior to encapsulation. Aside from containing the conductor prior to encapsulation, such intermediate layers can result in the unnecessary consumption of resources.
Accordingly, there is a need for devices, systems, and methods for making and using highly efficient circuit assemblies. Making and using highly efficient circuit assemblies can not only reduce resource expenditure, minimize waste, and substantially eliminate hazardous byproducts produced during manufacturing compared to traditional methods, such highly efficient circuit boards can include components that are non-hazardous, readily reclaimable, and/or readily recyclable. These non-hazardous, readily reclaimable, and/or readably recyclable materials can be reused in the production of additional circuit assemblies, thus decreasing the need for new raw materials. The present disclosure presents such devices, systems, and methods for making and using highly efficient circuit assemblies.
Several aspects of devices, systems, and methods for making and using circuit assemblies including various components such as, for example, substrates, layers, stacks, contact points, traces, and electrical components (e.g., integrated circuits) are disclosed herein. The various aspects (e.g., features, components, materials, methods) disclosed with respect to a particular circuit assembly disclosed herein may be applied to or combined with any of the other disclosed circuit assemblies and/or methods.
According to some non-limiting aspects, the efficient devices, systems, and methods described herein can implicate the devices, systems, and methods disclosed in U.S. Provisional Patent Application No. 63/154,665, titled HIGHLY SUSTAINABLE CIRCUITS AND METHODS FOR MAKING THEM, filed Feb. 26, 2021, the disclosure of which is hereby incorporated by reference in its entirety. For example, referring to
As used herein, the term “readily reclaimable” can mean that the material may be reclaimed from a circuit assembly: (i) without intensive use of resources, such as water; (ii) using relatively low energy input; and/or (iii) using techniques and methods that do not result in significant waste and/or loss of the material. A method that does not result in significant waste and/or loss of material can mean no less than 60 wt. % of the material is wasted and/or lost during the reclaiming process, such as, for example, no less than 70 wt. %, 80 wt. (X), 90 wt. %, 95 wt. %, 96 wt. (X), 97 wt. %, 98 wt. %, 99 wt. (X), 99.5 wt. %, or 99.9 wt. % of the material is wasted and/or lost during the reclamation process. An exemplary reclamation process is described below with respect to
As used herein, the term “readily recyclable” can mean that a material can be processed for re-use in further manufacturing or other industrial uses. For example, “readily recyclable materials can include any material whose scrap can be readily reprocessed to form an article that is substantially the same material as virgin, previously unused stock such as a thermoplastic (e.g., thermoplastic polyurethane, polymers, acrylics, polyesters, polypropylenes, polystyrenes, nylons, Teflon, etc.). According to some non-limiting aspects a material may be readily recyclable if no less than 55 wt. % of the material used to originally manufacture the subsequently reclaimed material can be reprocessed and reused, such as, for example, no less than 60 wt. %, 65 wt,%, 70 wt. %, 75 wt. %, 80 wt. %, 85 wt. %, 90 wt. %, or no less than 95 wt. % of the material used to originally manufacture the subsequently reclaimed material can be reprocessed and reused. By reclaiming and reprocessing readily reclaimable, readily recyclable materials, the need to produce new base materials may generally be reduced. An exemplary recycling process for a readily recyclable material is described below with respect to
As used herein, the term “deformable conductive material” may refer to a material such as those disclosed in the aforementioned International Patent Application No. PCT/US2017/019762 titled LIQUID WIRE, which was filed on Feb. 27, 2017 and published on Sep. 8, 2017 as International Patent Publication No. WO2017/151523A1, the disclosure of which is herein incorporated by reference in its entirety. For example, a deformable conductive material can include a variety of forms, such as a liquid, a paste, a gel, and/or a powder, amongst others, that has a deformable (e.g., soft, flexible, stretchable, bendable, elastic, flowable viscoelastic, Newtonian, non-Newtonian, etc.) quality.
Ira various aspects, a deformable conductive material can include an electroactive material, such as a deformable conductor produced from a conductive gel (e.g., a gallium indium alloy). The conductive gel can have a shear thinning composition and, according to some aspects, can include a mixture of materials in a desired ratio.
In various aspects, the conductive gel can include a mixture of a eutectic gallium alloy and gallium oxide, wherein the mixture of eutectic gallium alloy and gallium oxide has a weight percentage (wt, %) in a range of 59.9% and 99.9% eutectic gallium alloy, such as a range of 67% and 90%; and a wt. % in a range of 0.1% and 2.0% gallium oxide such as a range of 0.2 and 1%. For example, the mixture of eutectic gallium alloy and gallium oxide can have 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or greater, such as 99.9% eutectic gallium alloy; and 0.1%; 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1% 1.2%, 1.3%, 1.4%. 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, and 2.0% gallium oxide.
In various aspects, the eutectic gallium alloy can include gallium-indium or gallium-indium-tin in any ratio of elements. In some aspects, a eutectic gallium alloy includes gallium and indium. In one aspect, the gallium-indium alloy has a wt. % of gallium a range of 40% and 95%, such as, for example, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%. 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%. 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%. 90%, 91%. 92%, 93%, 94%, or 95%, In one aspect, the gallium-indium alloy has a wt. % of indium in the range of 5% and 60%, such as, for example 5%, 6%, 7%, 8%, 9%, 10%. 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%. 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%. 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%. 57%, 58%, 59%, or 60%, In some aspects, a eutectic gallium alloy includes gallium and tin. In one aspect, the alloy has a wt. % of tin in range of 0,001% and 50%, such as, for example 0.001%, 0,005%, 0.01%, 0.05%, 0.1%. 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.5%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%. 23%, 24%, 25%. 26%, 27%, 28%, 29%, 30%. 31%, 32%. 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, or 50%.
In various aspects, a deformable conductive material can be a non-hazardous material. As used herein, the term “non-hazardous” can mean that a material is RoHS (Restriction of Hazardous Substances) complaint according to European Union Directive 2002/95/EC, Directive 2011/65/EU, and/or Directive 2015/863 (i.e. RoHS, RoHS 2, RoHS 3). For example, in some aspects, a non-hazardous material can include a wt. % of less than 0.01% Cadmium (Cd), less than 0.1% Lead (Pb), less than 0.1% Mercury (Hg), less than 0.1% Hexavalent Chromium (Cr VI), less than 0.1% Polybrominated Biphenyls (PBB), less than 0.1 Polybrominated Diphenyl Ethers (PBDE), less than 0.1% Bis(2-Ethylhexyl) phthalate (DEHP), less than 0.1% Benzyl butyl phthalate (BBF), less than 0.1% Dibutyl phthalate (DBP), and less than 0.1% Diisobutyl phthalate (DIBP).
The deformable conductive materials disclosed herein can be efficient in the sense that they may be readily reclaimable and readily recyclable. In some aspects, the deformable conductive materials disclosed herein can be highly efficient. As used herein, a “highly efficient” circuit and/or method of circuit assembly may be “highly sustainable,” as disclosed in U.S. Provisional Patent Application No. 63/154,665, titled HIGHLY SUSTAINABLE CIRCUITS AND METHODS FOR MAKING THEM, filed Feb. 26, 2021, the disclosure of which is hereby incorporated by reference in its entirety. In other words, “high efficiency” may refer to a material and/or article of manufacture that is readily reclaimable and/or includes readily reclaimable components, requires relatively little energy and other resources to manufacture, is non-hazardous and/or includes non-hazardous components, does not cause toxic emissions when manufactured, and/or does not generate other waste when manufactured. In some aspects, a highly-efficient, deformable conductive material may be readily reclaimable; may be non-hazardous; may be manufactured while emitting substantially no VOCs; may be deposited while consuming relatively small amounts of energy; may be deposited in a single operation; or may be deposited, reclaimed, and recycled without consuming natural resources (e.g., water) and while producing substantially no waste; or a combination thereof. In some aspects, a highly-efficient circuit assembly may include a highly-efficient, deformable conductive material; may include one or more layers (e.g., substrate layers, stencil layers, insulation layers, encapsulation layers etc.) including a highly-efficient material; and/or may be made using the various manufacturing techniques described in detail below with respect to any of
However, according to other non-limiting aspects, a “highly efficient” circuit and/or method of circuit assembly can involve fewer materials, waste, and/or steps of manufacture. In other words, according to some non-limiting aspects, the circuits disclosed herein can include an enhanced efficiency because they can be produced from fewer layers. For example, a “highly efficient” circuit may include a substrate layer and an encapsulation layer and the deformable conductor can be deposited on the substrate layer without requiring an intermediate substrate layer in the final circuit assembly, as disclosed in further detail herein.
In various aspects, a deformable conductive material may exhibit adhesion to various layers of a circuit assembly and terminal/contacts of an electric component, as determined by the “Smear Test,” The Smear Test may be performed by smearing approximately 1 cm 3 of a deformable conductive material on a test coupon of the layer material or the terminal/contact material. The deformable conductive material is smeared with a cotton swab a Q-Tip™) across the test coupon, if the deformable conductive material coats the test coupon without void formation, then the deformable conductive material exhibits adhesion to the test coupon material. Conversely, if smearing the deformable conductive material to the test coupon causes the deformable conductive material to bead, thereby leaving voids on the test coupon, then the deformable conductive material does not exhibit adhesion. For example, some formulations of deformable conductive materials may have a surface tension that causes the deformable conductive material to bead. The Smear Test should be performed for all materials that have contact interfaces with the deformable conductive material to test for adhesion (e.g., terminals, channels, leads, contact point walls, etc.).
Referring again to
In various aspects, the pattern of contact points 102 may be supported by the substrate 100, for example, by being formed directly on the surface of the substrate, by being recessed into the substrate 100, by being formed on another layer of material above the substrate 100, or in other ways. The electric component 104 may be supported by the substrate 100, for example, by being attached directly to the surface of the substrate 100, by being attached to another component that is supported by the substrate 100, for example, by being adhered to or otherwise supported by the pattern of contact points 102.
In various aspects, circuit assembly 10 can include a pattern of reusable conductive trace (not shown) formed from a deformable conductive material and supported by the substrate 100. In some aspects, the pattern of reusable conductive trace can be similar to the traces disclosed below. The pattern of reusable conductive trace may be interconnected with the pattern of contact points 102. In one aspect, the pattern of contact points 102 and the reusable conductive trace may be formed from the same deformable conductive material.
The various components of
Referring still to
Still referring to
Having described a general implementation of the circuit assembly 10, which, in some aspects, can be a highly efficient circuit 10, the disclosure turns to various other circuit assemblies. Any of the aspects of circuit assembly 10 described above (e.g., the substrate layer 100, the pattern of contact points, 102, the electrical component 104, the one or more terminals 106, etc.) may be applied to any of the various other circuit assemblies described below. Likewise, any of the aspects of the various other circuit assemblies described below may be applied to the circuit assembly 10. Thus, any of the circuit assemblies described below can be a highly efficient circuit assembly.
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In the non-limiting aspects of
In various aspects, leadless chip carriers may be used with the circuit assemblies disclosed herein. Leadless chip carriers can have terminals with flat lead surfaces that provide a good interface to any of the disclosed contact points without disrupting the patterns of deformable conductive material. In other aspects, packages with protruding solder structures such as ball grid arrays (BGAs) and wafer-level chip-scale packaging (WL-CSP), such as chip-scale package 136 shown in
Referring now to
In addition to packaged integrated circuits and other devices, bare integrated circuit dies, and other components may be used with the circuit assemblies disclosed herein. For example, an IC die including bonding or contact pads may be attached to a substrate layer having a flush or protruding pattern of contact points that corresponds to the pattern of bonding or contact pads on the die. In some aspects, the bare integrated circuits dies may be mounted with the bonding or contact pads facing the surface of the substrate including the contact points (e.g., the die may be mounted upside down). This mounting can result in the deformable conductive material of the contact points forming ohmic connections with the bonding or contact pads.
Although the deformable conductive material is generally shown as being flush with the surface of the substrate in circuit assemblies 14 and 16 of
Having described a general implementation of the circuit assemblies 10, 12, 14, and 16 which, in some aspects, can be highly efficient circuits, the disclosure turns to various other circuit assemblies and methods for their manufacture. The various other circuit assemblies described below can have stacked layers and may include patterns of deformable conductive materials formed in and/or between the stacked layers. Any of the aspects of circuit assemblies 10, 12, 14, and 16 described above (e.g., the substrate layer, the pattern of contact points, the electrical component (e.g., the IC), the one or more terminals, etc.) may be applied to any of the various other circuit assemblies described below. Likewise, any of the aspects of the various other circuit assemblies, and the methods for their manufacture, described below, may be applied to circuit assemblies 10, 12, 14, and 16 above.
Referring now to
In various aspects, release layer(s), such as, for example, release layer 254, may be applied and removed during production of the various circuit assemblies disclosed herein. In some aspects, release layer(s) may be the only significant “waste” product generated during the manufacture of the circuit assembly. As such, preference may be given to circuit assembly designs and materials that do not include a release layer.
However, in various aspects, it may be desirable to produce the various circuit assemblies disclosed herein using a release layer, for example, to achieve the contact point configurations described below. Where a release layer is used during production, the release layer may be formed from a readily recyclable material, such as, siliconized or non-siliconized PET film, or siliconized or non-siliconized paper-based release film. Methods for recycling these release layers are described in U.S. Pat. Publication No. 8,842,840, titled PROCESS FOR RECYCLING WASTE FILM AND PRODUCT MADE THEREFROM, published Sep. 30, 2014, the disclosure of which is hereby incorporated by reference in its entirety. Methods for these recycling process have also been commercialized, for example, by Mitsubishi under the name Reprocess™. Thus, a circuit assembly including a readily recyclable release liner and/or manufactured using a readily recyclable release liner may be a highly efficient circuit assembly.
Referring again to
In various aspects, the technique used to form layers of the circuit assemblies disclosed herein may produce scrap (e.g., due to cutting passages etc.). The amount of scrap produced may be relatively small because passage features can be small and thus only small amounts of material need to be removed (e.g., passage features may generally have micron scale widths and/or depths, such as widths and/or depths in a range of 80-400 microns). Nevertheless, because the layers of the circuit assemblies disclosed herein can include readily reclaimable and readily recyclable materials, scrap produced during forming the layers may be collected, re-processed, and used in the manufacturing of subsequent layers and/or circuit assemblies.
Referring now to
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To assess the viability of collecting and reusing a deformable conductive material in a production environment, the inventors collected deformable conductive material reclaimed from several deposition and wiping operations (i.e., the same bulk material was reclaimed and reused over several circuit assembly deposition operations) and tested for performance. Reclaimed excess material from previous operations was experimentally found to offer substantially indistinguishable performance compared to virgin stock, as shown in Examples 1 and 2 below. Thus, compared to conventional circuit boards and related methods, the various circuit assemblies and related methods disclosed herein can reduce or eliminate waste production and/or reduce or eliminate resource consumption that results from the deposition of conductive materials. For example, as described in detail above, conventional methods of producing FR4/copper circuit boards often involve various resource-consuming curing, etching, and stripping steps that generate waste materials such as the etched excess copper conductor and other spent materials. Moreover, epoxy-based conductive adhesives used to replace soldering are often wasted due to their decreased ability to be reused after curing. Conversely, in various aspects, the deformable conductive material described herein can be deposited onto a circuit assembly and the excess can be collected and reused without consuming resources (e.g., water), without expending energy (e.g., without consuming electricity, without applying heat, without having to solder, etc.), without wasting the deformable conductive material (e.g., because it can be collected and reused), without generating other waste products (e.g. without using cleaning solvents, without chemical etching, etc.), and/or without producing hazardous byproducts (e.g., because the deformable conductive material can be non-hazardous).
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In various aspects, the deformable conductive material 260 can remain slightly proud of the surface 168. Thus, in one aspect, the thickness of the release layer 254 may purposely be set to a value that may cause the deformable conductive material 260 to protrude above the top surface 268 of the first stacked layer 252 by a predetermined amount.
The circuit assembly 20F of
As another example, as fabricated circuit assembly 20F can be used as a circuit element itself. For example, one or more channels 256, 258 filled with deformable conductive material 260 may function as a transmission line, such as, for example, a strip line or as a circuit capacitor. In such an implementation, an insulation layer (e.g., the second stacked layer 270 of
In various aspects, circuit assembly 20F can include additional layers to create a stacked circuit assembly. For example, referring now to
As illustrated by the non-limiting aspect of
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Similar to the patterns of passages in the first stacked layer 252 and the second stacked layers 270, the pattern of passages (e.g., channels 278 and 280) in the third staked layer 276 can serve numerous functions. For example, the pattern of passages of the third stacked layer 276 may function as contact points for one or more electric devices; the pattern of passages may function as circuit elements themselves, for example, as a transmission line or sensor; the pattern of passages may function as reusable traces that are electrically connected to the vias 272 and 274 in the second stacked layer 270; etc. The pattern of passages (i.e., channels 278 and 280) shown in
Referring now to
Similar to the patterns of passages in the first stacked layer 252, the second stacked layers 270, and the third stacked layer 276, the pattern of passages (e.g., channels 284 and 286) in the fourth staked layer 282 can serve numerous functions. For example, the pattern of passages of the fourth stacked layer 282 may function as contact points for one or more electric devices; the pattern of passages may function as circuit elements themselves, for example, as a transmission line or sensor; the pattern of passages may function as vias that are electrically connect to the channels 278 and 280 of the third stacked layer 276 to a second circuit assembly (not shown); the pattern of passages may function as contact points for making “hard-to-soft connections between hard external terminals of an electrical component; etc. The pattern of passages channels 278 and 280) shown in
As is apparent from the non-limiting aspect of
Given the number configurations of passages that may be implemented, a person of ordinary skill in the art will understand that any of the stacked layers of the circuit assembly 20 can serve an electric circuit function as well as an insulating function for the stacked layer or layers adjacent to it in the stack. For example, referring again to the non-limiting aspect of
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In some aspects, any or all of the conductive elements on and/or in layer 277 can include a deformable conductive material (e.g., deformable conductive material 260) and can be deposited using the various deposition methods described herein. In some aspects, the pattern of conductive elements included on and/or in layer 277 can include a mix of deformable and non-deformable conductive elements. The sublayer 277 can be formed from any of the stacked layer and/or substrate layer materials disclosed above and attached to other layers as described above. The pattern of elements can include reusable traces, vias, pads, or circuit elements including transmission lines and sensors, or any combination thereof. The pattern of elements may be formed on the sublayer 277 through any of the techniques described above. In one aspect, some or all of the conductive elements of sublayer 277 can be formed using a printing process, such as, for example, a reel-to-reel (R2R) process. Forming sublayer 277 via a printing process can enable the creation of finer conductive elements to accommodate smaller electric components or interconnects, or to accommodate components or interconnects having generally different characteristics.
According to the non-limiting aspect of
The pattern of conductive elements (e.g., reusable traces 288, 290) formed on or in the sublayer 277 an be interconnected with any other type of reusable traces, vias, pads, components, etc. In the non-limiting aspect of
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The removable stencil 452 may be constructed from a rigid material and/or durable material (e.g., stainless steel) that includes a pattern of one or more passages (e.g., openings; e.g., channels 453 and 455) configured to at least temporarily house a deformable conductive material in order to form a pattern of deformable conductive material on a surface of the substrate layer 450, as explained in more detail below with respect to
As mentioned above, removable stencil 452 may be a constructed from a rigid and/or durable material. The use of a rigid and/or durable material to construct removable stencil 425 can allow for the more efficient, reproducible, and cost effective manufacturing of circuit assemblies. For example, mechanically assisted and/or automated processes may be used to place and/or remove the removable stencil 425 to assist with the deposition of deformable conductive material. These mechanically assisted and/or automated processes may include the use of apparatuses such as a movable framework to which the removable stencil 452 is attached. The movable framework can be used to place and remove the stencil 425 in a consistent and reproducible manner. Such processes may also include the use of robotic equipment. Thus, the use of mechanically assisted and/or automated processes to place and remove the removable stencil 425 may allow for the stencil, and therefore the deformable conductive material, to be consistently placed on the substrate layer 450. These processes can enable more precise manufacturing tolerances to be achieved, can reduce defect rates, can create crisper trace boundaries of the patterns of deposited deformable conductive material, and can reduce potential errors related to alignment of the removable stencil 425 on the substrate layer 450. Moreover, these processes can increase manufacturing throughput and reduce labor costs.
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In some aspects, the wiping process 464 may include the use of a mechanically assisted and/or automated wiping tool 462. For example, the circuit assembly 40C may be placed on a frame attached to a wiping tool 462 configured to slide along a defined path to perform the wiping 464. The use of a mechanically assisted and/or automated wiping processes can increase efficiency, increase manufacturing throughput, and/or reduce labor costs.
As mentioned above with respect to
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The circuit assembly 40D of
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The substrate layer 450 and the first stacked layer 452 may be unitized (e.g., bonded together) using any of the techniques described above with respect to the layers of circuit assemblies 20A-20L in
In various aspects, circuit assembly 40 can include additional layers to create a stacked circuit assembly. For example, referring now to
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The circuit assembly 40 and methods of making thereof described above with respect to
A person of ordinary skill in the art will appreciate that additional stacked layers and patterns of deformable conductive material may be added to circuit assembly 40 to obtain a desired circuit assembly configuration. For example, circuit assembly 40 can include 2, 3, 4, 5, 6, 7, or more than 7 stacked layers with deformable conductive material deposited therebetween.
Given the number of configurations of layers, traces, vias, etc. that may be implemented, a person of ordinary skill in the art will also understand that any of the aspects of the circuit assemblies disclosed herein can be combined. For example, a stencil layer disclosed with respect to circuit assembly 20 may be used in combination with a circuit assembly that also has deformable conductive material deposited therein using the removable stencil disclosed with respect to circuit assembly 40. Moreover, any number and combination of stacked layers, patterns of deformable conductive materials, patterns of passages, etc. may be implemented to obtain a desired circuit assembly configuration.
Referring now to
The removable stencil 50 may be constructed using any of the techniques described above with respect to the removable stencil 452. The removable stencil 50 can include various openings and/or channels configured for deformable conductive material to be deposited therein. As described in detail above, after deposition of the deformable conductive material into channels of the removable stencil 50, upon removal of the removable stencil 50 from a surface of a layer, a pattern of deformable conductive material can remain on the surface of a layer. In the non-limiting aspects of
In various aspects, the removable stencil 50 may include various tabs 508, 510. These tabs 508, 510 may be configured to improve the structural characteristics of the removable stencil 50. For example, tabs 508, 510 may be included to help ensure that the removable stencil 50 does not break or otherwise fail upon construction or after repeated use, for example, because of the breaks in the structure caused by channels formed therein. However, in some aspects, the resulting pattern of deformable conductive material deposited to a layer using the removable stencil 50 may include gaps left by tabs 508, 510. Therefore, various design parameters may be optimized and/or adjusted to ensure that gaps left in the pattern of deformable conductive material by tabs 508, 510 are not retained in the competed circuit assembly. Design parameters may also be optimized to ensure that the removable stencil 50 is structurally sound. Aspects of these deign parameters are explained in more detail below.
Referring now to
In some aspects, the channel width 516 may be in a range of 0.05 mm and 2.0 mm, such as a range of 0.1 mm and 1.0 mm, and/or may be about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, or about 0.9 mm. In some aspects, the flared channel width 512 may be in a range of 0.05 mm and 5.0 mm, such as a range of 0.1 mm and 4.0 mm, or 0.5 mm and 3.0 mm, and/or may be about 0.8 mm, about 0.9 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, or about 2.0 mm. In some aspects, the tab width 514 may be in a range of 6.05 mm and 3.0 mm, such as a range of 0.05 mm and 1.0 mm, and/or may be about 0.06 mm, about 0.07 mm, about 0.08 mm, about 0.09 mm, about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, or about 0.5 mm. In some aspects, the stencil thickness may be in a range of 0.01 mm and 5.0 mm, such as a range of 0.05 mm and 1.0 mm, and/or may be about 0.06 mm, about 0.07 mm, about 0.08 mm, about 0.09 mm, about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, or about 1.0 mm. In other aspects, the flared channel width 512 may be in a range from about 1.1 to 2.2, about 1.15 to 1.75, or about 1.4 to 1.6 times the width of the channel width 516.
Referring now to
Referring now to
In some aspects, various other design parameters related to the removable stencil 50 and the unitization process may be adjusted and/or optimized to ensure that the patterns of deformable conductive material heal while also ensuring that the removable stencil 50 is structurally sound. In one aspect, the positions of the channels 504, the flared channels 506, and the tabs 508, 510 may be optimized for structural integrity. As one example, the number of tabs 508, 510 may be selected to ensure that the removable stencil 50 is structurally sound. As another example, the positions of the flared channels 506 may be selected to ensure that the removable stencil 50 is structurally sound (e.g., the positions of the flared channels 506 may be staggered as shown in
In some aspects, the properties of the deformable conductive material and/or the properties of the layers surrounding the patterns of the deformable conductive material may be adjusted and/or optimized to ensure that the patterns of deformable conductive material heal upon unitization of the surrounding layers. For example, the deformable conductive material may be optimized to have a viscosity such that the deformable conductive material is able to heal upon unitization of the layers but not such that the deformable conductive material overly deforms and does not achieve the intended pattern. As another example, an adhesive characteristic and/or viscosity of the deformable conductive material may be optimized such that it remains on the substrate layer upon removal of the removable stencil 50 and but does not adhere to the channels 504, 506 of the stencil thereby lifting the deformable conductive material off of the substrate layer. In some aspects, a viscosity of the deformable conductive material may, when under high shear (e.g., in motion), be in a range of about 10 Pascal seconds (Pats) and 500 Pa*s, such as a range of 50 Pa*s and 300 Pa*s, and/or may be about 50 Pa*s, about 60 Pa*s, about 70 Pa*s, about 80 Pa*s, about 90 Pa*s, about 100 Pa*s, about 110 Pa*s, about 120 Pa*s, about 130 Pa*s, about 140 Pa*s, about 150 Pa*s, about 160 Pa*s, about 170 Pa*s, about 180 Pa*s, about 190 Pa*s, or about 200 Pa*s. In some aspects, a viscosity of the deformable conductive material may, when under low shear (e.g., at rest), be in a range of 1,000,000 Pa*s and 40,000,000 Pa*s and/or may be about 10,000,000 Pa*s, about 20,000,000 Pa*s, about 30,000,000 Pa*s, or about 40,000,000 Pa*s.
In some aspects, parameters related to the heat, pressure, and/or other tooling used to unitize layers surrounding the deformable conductive material may be optimized to ensure that the patterns of deformable conductive material heal upon unitization of the surrounding layers. For example, the amount of heat applied (and/or temperature setting used) to unitize the surrounding layers may be optimized such that the deformable conductive material deforms enough to heal but not so much that the deformable conductive material overly deforms and does not achieve the intended pattern. As another example, the pressured applied to unitize the surrounding layers may be optimized such that the deformable conductive material deforms enough to heal but not so much that the deformable conductive material overly deforms and does not achieve the intended pattern.
In some aspects, a pressure applied to unitize layers of a circuit assembly can be in a range of 0.5 psi and 20 psi, such as a range of 1.0 psi and 10 psi, and/or may be about 1.0 psi, about 2.0 psi, about 3.0 psi, about 4.0 psi, about 5.0 psi, about 6.0 psi, about 7.0 psi, about 8.0 psi, about 9.0 psi, or about 10 psi. In some aspects, a heat applied to unitize layers of a circuit assembly can include heating the circuit assembly or a portion thereof at a temperature in range of 50° C. and 250° C., such as a range of 100 CC and 200° C., and/or at a temperature of about 100° C., about 110° C., about 120° C., about 130° C., about 140° C., about 150° C., about 160° C., about 170° C., about 180° C., about 190° C., or about 200° C.
In some aspects, tooling may be used and parameters thereof may be optimized to control the distribution of pressure applied when unitizing the circuit assembly. In some aspects, the tooling used may include a foam material, such as closed-cell silicon foam. The foam material may be positioned on one and/or both surfaces of the circuit assembly during unitization. In one aspect, the softness of the foam may be optimized to control the deformation of the deformable conductive material during unitization. In some aspects, the foam can be an ultra-soft foam.
Any of the non-limiting aspects of circuit assembly 20, circuit assembly 40, and/or any of the other circuit assemblies disclosed herein can be stacked together. In other aspects, one or more internal stacked layers can have a cutout section to accommodate the height of an electrical component (e.g., to accommodate the height of an integrated circuit package). In yet other aspects, the electrical component (e.g., resistors, capacitors, smaller IC packages, bare IC dies, etc.) may be small enough to place between layers, especially if the layers are relatively soft and or pliable.
In various aspects, one or more of the stacked layers, encapsulation layers, and/or substrate layers of any of the circuit assemblies disclosed herein may be formed from a resilient and stretchable TPU such as from the Lubrizol® Estane® 58000 series, for example, 58238. In other aspects, one or more of the stacked layers, encapsulation layers, and/or substrate layers of any of the circuit assemblies disclosed herein may be formed from a comparatively more rigid material such as injection molded using Lubrizol® Estane® S375D.
In various aspects, any of the circuit assemblies disclosed herein can include Epoxy-based materials, such as, for example, B-stage resin films. The Epoxy-based materials can be used as an additional discrete component to provide a self-adhesive surface for bonding electric components to any layer and/or for bonding layers to each other. In various other aspects, sustainability all layers, adhesives and encapsulants of any of the circuit assemblies disclosed herein can may be made from thermally activated adhesives, such as, for example, thermoplastic polyurethane (PU) adhesives (e.g., from Bemis or Framis), In yet other aspects, any of the layers, adhesives, and/or encapsulants of the circuit assembly can include thermoset adhesives such as, for example, silicones, acrylics, and any pressure sensitive adhesive of any chemistry. In the case of encapsulant materials, (e.g., encapsulates applied to terminals of an electric component), the concentration of thermoset material included in the encapsulant may be minimal, allowing the material to be readily recyclable. In one aspect, the circuit assemblies disclosed herein can include fillers including thermoset materials. Fillers including thermoset material may be reused in a “re-grind” format to strengthen, modify, or lower the cost of articles made from a similar thermosetting material.
The various materials, methods, and components described herein can provide for highly efficient circuit assemblies. The various circuit assemblies disclosed herein may be highly efficient, for example, compared to etched FR4/copper circuit boards and circuit boards employing epoxy-based conductive adhesives. Moreover, the circuit assemblies disclosed herein, including circuit assemblies including a deformable conductive material and stacked layers, may not require the use of reinforcements in the layer materials themselves (e.g., chopped fiber reinforcements). Reinforcements used in traditional circuit boards make recycling and reusing the circuit board materials challenging, messy, and harmful for workers processing discarded electronics made from these types of circuit boards. For example, traditional circuit board materials typically must be ground up, and the resulting “re-grind” has very few uses in consumer products. The devices, systems, and methods discussed herein can enable a circular manufacturing chain, and/or an easily recyclable circuit assembly including materials may be recycled and used again in other circuit assemblies, or other consumer products.
Circuit assemblies constructed according to the various aspects disclosed herein can result in highly functional circuit assemblies that may reduce the cost of the assembly. For example, some various aspects of the circuit assemblies disclosed herein may allow for the use of less expensive unpackaged electronic devices. Moreover, other aspects of the circuit assemblies disclosed herein may eliminate the need for soldering, Yet other aspects of the circuit assemblies disclosed herein may provide for improved reliability because the elimination of soldering may reduce the energy consumption (e.g., heating) associated therewith. And yet other aspects of the circuit assemblies disclosed herein may provide for improved cooling by eliminating device packaging which can serve as a barrier to heat dissipation.
Referring now to
The method 1000 can further include 1006 separating the deformable conductive material from the melted substrate layer to obtain reclaimed deformable conductive material and reclaimed substrate layer material. In experiments, the inventors heated a highly efficient circuit assembly including a deformable conductive material (i.e., a gallium-indium alloy gel material) and TPU substrate and stacked layers to a flow temperature of the layers. The inventors discovered that heating the layers to the flow temperature allowed the deformable conductive material, by virtue of its surface tension characteristics, to be easily separate from the melted layer material.
In another aspect, the method 1000 can include heating the highly efficient circuit assembly to a melting temperature of the stacked layer to form a melted stacked layer, and separating the deformable conductive material from the melted stacked layer to obtain reclaimed deformable conductive material and reclaimed stacked layer material
In another aspect, the method 1000 can include heating the circuit assembly to a melting temperature of the encapsulant material, wherein removing the electrical component from the circuit assembly occurs after heating the circuit assembly to the glass transition temperature of the encapsulant. In yet another aspect, the method 1000 can include heating the circuit assembly to a glass transition temperature of the adhesive material, wherein removing the electrical component from the circuit assembly occurs after heating the circuit assembly to the glass transition temperature of the adhesive material. Heating the circuit assembly to the melting temperature and/or the glass transition temperature can allow the electrical component to be easily extracted for re-use in other circuit assemblies. The temperatures required for heating can be lower than those experienced by electric components in standard circuit assembly production, and as such will not damage the components.
Referring now to
Referring still to
The method 2000 can further include removing 2006 the pure liquid metal alloy from the acid solution. In some aspects, the amount of pure liquid metal alloy removed from the acid solution is no less than 55 wt. % of the metal alloy used to originally manufacture the reclaimed deformable conductive, such as, for example, no less than 55 wt,%, 60 wt. %, 65 wt. %, 70 wt. %, 75 wt,%, 80 wt. %, 85 wt. %, 90 wt. %, or no less than 95 wt. % of the metal alloy used to originally manufacture the reclaimed deformable conductive material. In another aspect, the method 2000 can further include manufacturing new deformable conductive material from the pure liquid metal alloy. Thus, recycling the reclaimed deformable conductive material can enable the deformable conductive material to be reused in production of new circuits with no degradation in electrical characteristics.
In another aspect, exposing 2004 the reclaimed deformable conductive material to an acid solution can further include mixing the deformable conductive material in the acid solution to obtain the pure liquid metal alloy. In one aspect, the reclaimed deformable conductive material includes microparticles. Mixing the deformable conductive material in the acid solution can remove the microparticles to obtain the pure liquid metal alloy. In another aspect, mixing the deformable conductive material in the acid solution can cause the microparticles to float on the surface of the acidic solution, allowing the liquid metal to be extracted. In one aspect, mixing the deformable conductive material in the acid solution to obtain the pure liquid metal alloy includes mixing the deformable conductive material in the acid solution for no less than two days. An exemplary process for recycling the reclaimed deformable conductive material carried out using the method above is detailed below with respect to Example 3.
In another aspect, the method 2000 can include extracting microparticles from the acid solution. In yet another aspect, the method 2000 can include manufacturing new deformable conductive material from the extracted microparticles.
In another aspect, the method 2000 can include collecting the acid solution for reuse in a subsequent process for recycling a reclaimed deformable conductive material. For example, the acid solution may be reused after extracting the pure liquid metal alloy and the microparticles.
In another aspect, the deformable conductive material can include a conductive gel. In one aspect, the deformable conductive material can include a gallium alloy with microparticles suspended therein. In another aspect, the pure liquid metal alloy can include the gallium alloy. In yet another aspect, the acid solution can include hydrochloric acid.
Referring now to
Still referring to
The method 3000 can further include removing 3008 the removable stencil from the surface of the substrate layer to leave a pattern of deformable conductive material formed on the substrate layer. In various aspects, the pattern of deformable conductive material can include at least one gap. In one aspect, the at least one gap can correspond to a tab of the removable stencil.
The method 3000 can further include covering 3010 at least a portion of the pattern of deformable conductive material with a first stacked layer, wherein the first stacked layer is an insulation layer, an encapsulation layer, or a combination thereof.
In one aspect of the method 3000, the first stacked layer can include the encapsulation layer. In another aspect, the method 3000 can include unitizing 3012 the circuit assembly, wherein unitizing the circuit assembly causes the at least one gap to heal. In some aspects, unitizing the circuit assembly can include heating at least a portion of the circuit assembly. In another aspect, unitizing the circuit assembly can include applying pressure to at least one surface of the circuit assembly. The heating and/or applying pressure can be optimized based on the various parameters discussed above with respect to
In another aspect, the method 3000 can include providing (e.g. forming) at least one opening in the first stacked layer, the substrate layer, or a combination thereof. In one aspect, the at least one opening can be formed prior to 3012 unitizing the circuit assembly. In another aspect, the at least one opening can be formed after 3012 unitizing the circuit assembly.
In another aspect, after covering 3010 at least a portion of the pattern of deformable conductive material with the first stacked layer, the method 3000 can include placing the removable stencil on the first stacked layer, repeating the steps of 3006 depositing the deformable conductive material and removing 3008 the removable stencil, and covering at least a portion of the pattern of deformable conductive material formed on the first staked layer with a second stacked layer. In one aspect, the method 3000 can include unitizing 3012 the circuit assembly including the substrate layer, the first stacked layer, and the second stacked layer. The unitizing can cause at least one gap of the pattern of deformable conductive material formed on the first stacked layer to heal.
In another aspect, after covering 3010 at least a portion of the pattern of deformable conductive material with the second stacked layer, the method 3000 can include placing the removable stencil on the second stacked layer, repeating the steps of 3006 depositing the deformable conductive material and removing 3008 the removable stencil, and covering at least a portion of the pattern of deformable conductive material formed on the second staked layer with a third stacked layer. In one aspect, the method 3000 can include unitizing 3012 the circuit assembly including the substrate layer, the first stacked layer, the second stacked layer, and the third stacked layer. The unitizing can cause at least one gap of the pattern of deformable conductive material formed on the first stacked layer to heal.
In another aspect, after covering 3010 at least a portion of the pattern of deformable conductive material with the third stacked layer, the method 3000 can include repeating the steps of placing the removable stencil, 3006 depositing the deformable conductive material, removing 3008 the removable stencil, and covering at least a portion of the resulting pattern of deformable conductive material until a desired number of layers has been achieved. In this aspect, the method 3000 can include unitizing 3012 the circuit assembly including the desired number of layers. The unitizing can cause at least one gap of the pattern of deformable conductive material formed between at least one of the layers to heal.
In another aspect, the method 3000 can include attaching an electrical component to the substrate layer and/or a stacked layer (e.g., the first stacked layer, the second stacked layer, etc.). The electrical component can include any of the various electrical components described herein. For example, the electrical component can include a polyimide flex circuit, a resistor, a capacitor, a processor, a chip, a contact (e.g., a copper contact, goal contact, silver contact, palladium contact, a combination thereof, etc.), a pin out, a connector, etc.
In another aspect, the method 3000 can include attaching a lockout and/or stiffener layer to the circuit assembly. For example, the lockout and/or stiffener layer can be placed in between two layers of the circuit assembly (e.g., between the substrate layer and the first stacked layer, between the first stacked layer and the second stacked layer, etc.). As another example, the lockout and/or stiffener can be placed on an outer layer of the circuit assembly (e.g., an outer surface of the substrate layer, an outer surface of the encapsulation layer). In some aspects, the lockout and/or stiffener can be similar to the layer 126 discussed above with respect to the circuit assembly 12 of
Any of the various circuit assemblies, circuit assembly components (e.g., layers, deformable conductive materials, electrical components, etc.), and methods described herein can be combined to achieve a desired circuit assembly configuration and/or a method for reclaiming/recycling various materials thereof.
Examples 1 and 2 shown in Table 1 below correspond to experimentally measured resistance values of samples of deformable conductive material virgin stock compared with experimentally measured resistance values for samples of deformable conductive material after it was reclaimed during the circuit assembly manufacturing process. Specifically, the reclaimed deformable conductive material was collected after a wiping process similar to the wiping process described with respect to
Recycling Deformable Conductive Gel the is Reclaimed from a Circuit Assembly Overview
A deformable conductive gel, designated as MG5 (Metal Gel 5), and having a composition including a eutectic alloy of gallium (68.5 wt. %), indium (21.5 wt. %), and tin (wt. 10%) with microparticles suspended therein, was reclaimed from a circuit assembly using the reclaiming process described above with respect to
Generally, a thin layer of gallium oxide can form on the surface gallium in the presence of air. To manufacture MG5 conductive gel, gallium oxide is allowed to form and is distributed through the gallium-indium-tin liquid metal alloy forming a novel microstructure/nanostructure within the liquid metal alloy to form a Bingham plastic. The micro and nanostructures are blended within the mixture, for example through sonication or other mechanical means that entrains air into the mixture. In some aspects, the sonication may introduce cavitation at the surface of the mixture thereby entraining air into the mixture. Thus, the mixture can include a colloidal suspension of micro and nanostructures within the gallium alloy/gallium oxide mixture. For a detailed description of MG5 and similar conductive gel formulations and manufacturing methods, see the aforementioned International Patent Application No. PCT/US2017/019762 titled LIQUID WIRE, which was filed on Feb. 27, 2017 and published on Sep. 8, 2017 as International Patent Publication No. WO2017/151523A1.
MG5 gel is a stiff paste which can be patterned into complex geometries. Thus, MG5 can be used to form, for example, electric circuit assemblies, circuit layups, stacks, etc. MG5 is more mechanically stable than unmodified liquid metal alloys and has excellent adhesion characteristics. Over long periods of time, or through repeated patterning and handling (typically over the course of many months or even years), or after being reclaimed from a circuit layup, the amount of oxide in the gel may increase causing deteriorated mechanical and electrical properties. In such a case, the oxide structure can be broken down to reform an unmodified liquid metal alloy, which can then be reprocessed to form “new” MG5, or other formulations. The method makes use of aggressive mixing in acidic solution to break down the gallium oxide, as described below.
Reclaimed MG5 gel was placed in a bath of 3M hydrochloric acid (HCl) solution. Initially, the hydrochloric acid appeared to have little impact on the mechanical properties of the gel. This contrasts with liquid metal, which will immediately respond to hydrochloric acid. When exposed to hydrochloric acid, the gallium oxide on the surface of the MG5 reacts to form gallium chloride, primarily via the following reaction:
Ga2O3+6HCl→2GaCl3+3H2O
Removal of the gallium oxide leaves the high surface tension of the liquid metal alloy as the dominant mechanical force. This results in the liquid metal alloy tending to bead up in as close to a spherical shape as possible, and forcing any particulates inside the metal to the exterior.
To achieve this result with the Reclaimed MG5, a stir bar was used in the bath spinning at 500 rpm to mix the solution of the MG5 gel and acid. Initially, the metal alloy is not impacted by the acid. The metal alloy appears shiny and still exhibits the characteristic mechanical properties of a moldable gel with high viscosity. After two days of mixing, it was observed that the MG5 gel structure had broken down. After this mixing, the metal alloy component took on a roughly spherical shape, more characteristic of liquid metal alloy in an acidic solution. Particles were observed floating throughout the solution.
Initial experiments (prior to the experiment described as Experiment 3 herein) resulted in 66 wt. % retrieval of the initial liquid metal alloy used to form the MG. Upon implementing the acid treatment technique described in this Experiment 3, greater than 80 wt. % retrieval of the initial liquid metal used to form the MG5 was achieved.
No harmful or toxic byproducts were produced, even the “waste” material filtered from the acidic solution being non-toxic and non-hazardous materials in very small quantities. Moreover, the acidic solution was not substantially degraded and could be used for processing further reclaimed deformable conductive material from other discarded circuit layups.
Thus, the above methods (such as the manufacturing process described above with respect to
The liquid metal alloy recovered in Example 3 may be used as a basis for fabricating more deformable conductive material (e.g., new MG5 or another deformable conductive material), It is anticipated that with further refinement of the acid treatment method, for example, using the same fundamental principles augmented by the development of bespoke equipment, substantially all the liquid metal may be reclaimed.
Two highly-efficient circuit assemblies, embodied as two sensors, were manufactured using the principles taught herein. Various tables and explanations are provided to summarize the reclamation efficiency for various components thereof:
Table 1 below summarizes the weight of the total weight of all the unprocessed layers used to make the circuit assembly (stacked layers and release layers) compared to the weight of just the release layers.
Thus, 35.5 wt. % of the initial materials layer are waste in the form of release liners while 64 wt. % of material moves into the next stage.
Table 3 below shows the total amount of TPU material used to form the stacked layers compared to the weight of the material trimmed from the TPU material from the circuit assemblies.
Thus, for every 4.485 g of TPU used, 1.39 g is “excess.” In other words, for every 1 g of TPU used, see 0.31 g of excess TPU is formed. However, the TPC may be fully reclaimed and used to make additional circuit assemblies.
Table 4 below shows the weight of the circuit assembly after the MG5 deformable conductive material is added compared to the weight of the circuit assembly prior to MG5 addition. Additionally, Table 5 shows, per sensor, the amount of MG5 actually used in the circuit assembly (calculated based on Table 4), the amount of total MG5 typically deposited during the manufacturing process, and therefore, the amount of excess MG5.
Thus, for every 28.8 mg of product that ultimately ends up in the sensor there is 435 mg of excess MG5 that is used. In other words, for every 1 mg of MG5 in the final circuit assembly, 0.015 g of excess MG5 is used. However, the excess MG5 may be substantially, reclaimed and used in subsequent circuit assembly manufacturing operations.
Table 6 below shows the total weight of the final circuit assembly components.
Notably, the components of the circuit assembly that can be reclaimed using the methods described herein include the TPC layers (83.71 wt. %), the electrical component (3.23 wt. %) and the MG5 (1.71 wt. %). These components make up 88.65% of the circuit assembly, by weight. Additionally, in some aspects, the thermoset adhesive may be reground and recycled.
Also notable was that the circuit assembly included only 1.71% deformable conductive material (MG5), and there was substantially no waste with respect to the deformable conductive material since the “excess” conductive material is fully reclaimable and can be used to manufacturing additional circuit assemblies.
It is contemplated that typical circuit assemblies may include a maximum of 10 wt, % of deformable conductive material, such as, for example, a maximum of 9 wt. %, 8 wt, %, 7 wt. %, 6 wt. %, 5 wt, %, 4 wt. %, 3 wt. %, 2 wt, %, or 1 wt, % of deformable conductive material in the final assembly. Additionally, no less than 95% “excess” deformable conductive material, such as, for example 96 wt. %, 97 wt. %, 98 wt. %, 99 wt. %, 99.5 wt, %, or 99.9 wt. % of excess deformable conductive material may be collected from the manufacturing operation and used for future manufacturing operations.
Various aspects of the subject matter described herein are set out in the following numbered clauses:
Clause 1: A method for reclaiming material from a highly sustainable circuit assembly including an electrical component, a substrate layer, and a deformable conductive material, the method including: removing the electrical component from the circuit assembly; heating the highly sustainable circuit assembly to a melting temperature of the substrate layer to form a melted substrate layer; and separating the deformable conductive material from the melted substrate layer to obtain reclaimed deformable conductive material and reclaimed substrate layer material.
Clause 2: The method according to clause 1, wherein the highly sustainable circuit assembly further includes a stacked layer, the method further including: heating the highly sustainable circuit assembly to a melting temperature of the stacked layer to form a melted stacked layer; and separating the deformable conductive material from the melted stacked layer to obtain reclaimed deformable conductive material and reclaimed stacked layer material.
Clause 3: The method according to any of clauses 1-2, wherein the circuit assembly includes an encapsulant material, the method further including: heating the circuit assembly to a melting temperature of the encapsulant material; wherein removing the electrical component from the circuit assembly occurs after heating the circuit assembly to the glass transition temperature of the encapsulant material.
Clause 4: The method according to any of clauses 1-3, wherein the circuit assembly includes an adhesive material, the method further including: heating the circuit assembly to a glass transition temperature of the adhesive material; wherein removing the electrical component from the circuit assembly occurs after heating the circuit assembly to the glass transition temperature of the adhesive material.
Clause 5: The method according to any of clauses 1-4, wherein the deformable conductive material includes a conductive gel.
Clause 6: The method according to any of clauses 1-5, wherein the deformable conductive material includes a gallium alloy.
Clause 7: The method according to any of clauses 1-6, further including recycling the reclaimed deformable conductive material.
Clause 8: A method for recycling a reclaimed deformable conductive material including: providing a reclaimed deformable conductive material including a metal alloy and a metal oxide formed from exposure of the metal alloy to air; exposing the reclaimed deformable conductive material to an acid solution thereby reacting the metal oxide with the acid solution to obtain a pure liquid metal alloy; removing the pure liquid metal alloy from the acid solution.
Clause 9: The method according to clause 8, further including: manufacturing new deformable conductive material from the pure liquid metal alloy.
Clause 10: The method according to any of clauses clause 8-9, wherein exposing the reclaimed deformable conductive material to an acid solution includes mixing the deformable conductive material in the acid solution to obtain the pure liquid metal alloy.
Clause 11: The method according to any of clauses clause 8-10, wherein the amount of pure liquid metal alloy removed from the acid solution is no less than 55 wt. % of the metal alloy used to originally manufacture the reclaimed deformable conductive material.
Clause 12: The method according to any of clauses 8-11, wherein the amount of pure liquid metal alloy removed from the acid solution is no less than 80 wt. % of the metal alloy used to originally manufacture the reclaimed deformable conductive material.
Clause 13: The method according to any of clauses clause 8-12, wherein the reclaimed deformable conductive material includes microparticles; and wherein mixing the deformable conductive material in the acid solution removes the microparticles to obtain the pure liquid metal alloy.
Clause 14: The method according to any of clauses 8-13, wherein mixing the deformable conductive material in the acid solution to obtain the pure liquid metal alloy includes mixing the deformable conductive material in the acid solution for no less than two days.
Clause 15: The method according to any of clauses 8-14, wherein the metal alloy includes a gallium-indium-tin alloy; and wherein the metal oxide includes gallium oxide.
Clause 16: A highly sustainable circuit assembly including: a substrate; and a pattern of contact points supported by the substrate, the pattern of contact points configured to correspond to at least one terminal of an electrical component, the pattern of contact points including a deformable conductive material; wherein the deformable conductive material includes a readily reclaimable material.
Clause 17: The highly sustainable circuit assembly of clause 16, wherein the deformable conductive material includes a readily recyclable material.
Clause 18: The highly sustainable circuit assembly of any of clauses 16-17, wherein the substrate includes a readily reclaimable material, and wherein the substrate layer includes a readily recyclable material.
Clause 19: The highly sustainable circuit assembly of any of clauses 16-18, wherein the deformable conductive material is configured to adhere to at least one terminal of the electrical component thereby electrically coupling at least a portion of the pattern of contact points to at least one terminal of the electrical component.
Clause 20: The highly sustainable circuit assembly of any of clauses 16-19, wherein supporting the electrical component on the circuit assembly causes the deformable conductive material to conform to a shape of at least one terminal of the electrical component.
Clause 21: The highly sustainable circuit assembly of any of clauses 16-20, wherein the pattern of contact points are formed on a surface of the substrate layer.
Clause 22: The highly sustainable circuit assembly of any of clauses 16-21, wherein the pattern of contact points are at least partially recessed in the substrate layer.
Clause 23: The highly sustainable circuit assembly of any of clauses 16-22, wherein the substrate includes a flexible and/or stretchable material.
Clause 24: The highly sustainable circuit assembly of any of clauses 16-23, further including an insert layer, wherein the insert layer is configured to: prevent flexing and/or stretching of a portion of the substrate layer proximate to the pattern of contact points;
dissipate heat from the electrical component; adhere the electrical component to the substrate layer; or a combination thereof.
Clause 25: The highly sustainable circuit assembly of any of clauses 16-24, further including a pattern of conductive traces supported by the substrate layer, the pattern of conductive traces electrically coupled to the pattern of contact points, the pattern of contact points including the deformable conductive material.
Clause 26: The highly sustainable circuit assembly of any of clauses 16-25, wherein the deformable conductive material includes a conductive gel.
Clause 27: The highly sustainable circuit assembly of any of clauses 16-26, wherein the deformable conductive material includes a gallium alloy.
Clause 28: The highly sustainable circuit assembly of any of clauses 16-27, further including the electrical component.
Clause 29: A method for manufacturing a highly sustainable circuit assembly including: providing a substrate layer; and depositing a deformable conductive material to the substrate layer to form a pattern of contacts that correspond to at least one terminal of an electrical component; wherein the deformable conductive material includes a readily reclaimable material.
Clause 30: The method of clause 29, wherein the deformable conductive material includes a readily recyclable material.
Clause 31: The method of any of clauses 29-30, wherein the substrate layer includes a readily reclaimable material; and wherein the substrate layer includes a readily recyclable material.
Clause 32: The method of any of clauses 29-31, further including bringing the electrical component proximate to the substrate layer; and adhering the deformable conductive material to the at least one terminal of the electrical component thereby forming an ohmic contact between at least a portion of the pattern of contacts and the at least one terminal of the electrical component; wherein brining the electrical component proximate to the substrate layer causes the deformable conductive material to conform to a shape of the at least one terminal of the electrical component.
Clause 33: The method of any of clauses 29-32, further including: securing the electrical component to a layer of adhesive attached to a surface of the substrate layer.
Clause 34: The method of any of clauses 29-33, further including: covering at least a portion of the circuit assembly with an encapsulant.
Clause 35: The method of any of clauses 29-34, further including: attaching the electrical component directly to a surface of the substrate layer.
Clause 36: The method of any of clauses 29-35, attaching an insert layer to the substrate layer, wherein the insert layer is configured to: prevent flexing and/or stretching of a portion of the substrate layer proximate to the pattern of contact points; dissipate heat from the electrical component; adhere the electrical component to the substrate layer; or a combination thereof.
Clause 37: The method of any of clauses 29-36, wherein depositing the deformable conductive material to the substrate layer to form the pattern of contacts further includes: depositing the deformable conductive material such that the deformable conductive material protrudes from a surface of the substrate layer
Clause 38: The method of any of clauses 29-37, wherein depositing the deformable conductive material to the substrate layer to form the pattern of contacts further includes: at least partially filling a recess formed in the substrate layer with the deformable conductive material.
Clause 39: The method of any of clauses 29-38, further including: depositing a deformable conductive material to the substrate layer to form a pattern of conductive traces electrically coupled to the pattern of contact points.
Clause 40: The method of any of clauses 29-39, wherein the substrate layer includes a flexible or stretchable material.
Clause 41: The method of any of clauses 29-40, wherein the deformable conductive material includes a conductive gel.
Clause 42: The method of any of clauses 29-41, wherein the deformable conductive material includes a gallium alloy.
Clause 43: A highly sustainable circuit assembly including: a substrate layer; a first stacked layer including a first pattern of passages formed in the first stacked layer, the first pattern of passages extending through a thickness of the first stacked layer, the first pattern of passages including a deformable conductive material; wherein the deformable conductive material includes a readily reclaimable material.
Clause 44: The circuit assembly of clause 43, wherein the deformable conductive material includes a readily recyclable material.
Clause 45: The circuit assembly of any of clauses 43-44, wherein the substrate layer includes a first material; wherein the first stacked layer includes the first material; wherein the first material is a readily reclaimable material; and wherein the first material is a readily recyclable material.
Clause 46: The circuit assembly of any of clauses 43-45, wherein the first stacked layer is bonded to the substrate layer.
Clause 47: The circuit assembly of any of clauses 43-46, wherein the first stacked layer includes: a first surface adjacent to the substrate layer; and a second surface opposite the first surface; wherein a surface of the deformable conductive material is flush with the second surface of the first stacked layer.
Clause 48: The circuit assembly of any of clauses 43-47, wherein a surface of the deformable conductive material protrudes beyond a surface of the first stacked layer.
Clause 49: The circuit assembly of any of clauses 43-48, wherein the first pact of passages including the deformable conductive material includes: a pattern of contact points configured to correspond to at least one terminal of an electrical component; a pattern of tracers; or a combination thereof.
Clause 50: The circuit assembly of any of clauses 43-49, further including the electrical component.
Clause 51: The circuit assembly of any of clauses 43-50, further including: a second stacked layer including a second pattern of passages formed in the second stacked layer, the second pattern of passages extending through a thickness of the second stacked layer, the third pattern of passages including the deformable conductive material.
Clause 52: The circuit assembly of any of clauses 43-51, further including a sublayer interposed between the first stacked layer and the second stacked layer, the sublayer including a pattern of conductive elements.
Clause 53: The circuit assembly of any of clauses 43-52, wherein the pattern of conductive elements are electrically coupled to the second pattern of passages extending through the thickness of the second stacked layer; and wherein the second pattern of passages are configured to correspond with at least one terminal of an electrical component.
Clause 54: The circuit assembly of any of clauses 43-53, wherein a first portion of the second pattern of passages aligns with a first portion of the first pattern of passages; and wherein the deformable conductive material forms a continuous structure extending from the first portion of the first pattern of passages to the first portion of the second pattern of passages.
Clause 55: The circuit assembly of any of clauses 43-54, further including: a third stacked layer including a third pattern of passages formed in the third stacked layer, the third pattern of passages extending through a thickness of the third stacked layer, the third pattern of passages including the deformable conductive material.
Clause 56: The circuit assembly of any of clauses 43-55, wherein a first portion of the third pattern of passages aligns with a second portion of the second pattern of passages; and wherein the deformable conductive material forms a continuous structure extending from the first portion of the first pattern of passages to the first portion of the third pattern of passages.
Clause 57: The circuit assembly of any of clauses 43-56, further including: a fourth stacked layer including a fourth pattern of passages formed in the fourth stacked layer, the fourth pattern of passages extending through a thickness of the fourth stacked layer, the fourth pattern of passages including the deformable conductive material.
Clause 58: The circuit assembly of any of clauses 43-57, wherein a first portion of the fourth pattern of passages aligns with a second portion of the third pattern of passages; and wherein the deformable conductive material forms a continuous structure extending from the first portion of the first pattern of passages to the first portion of the fourth pattern of passages.
Clause 59: The circuit assembly of any of clauses 43-58, wherein the deformable conductive material includes a conductive gel.
Clause 60: The circuit assembly of any of clauses 43-59, wherein the deformable conductive material includes a gallium alloy.
Clause 61: A method for manufacturing a highly sustainable circuit assembly including: providing a substrate layer; placing a first stacked layer on a surface of the substrate layer, the first stacked layer including a first pattern of passages formed in the first stacked layer, the first pattern of passages extending through a thickness of the first stacked layer; over-filling the first pattern of passages with a deformable conductive material; removing excess deformable conductive material from the circuit assembly; and collecting the excess deformable conductive material.
Clause 62: The method of clauses 61, using the collected excess deformable conductive material to fill a second pattern of passages included in a second stacked layer; using the collected excess deformable conductive material to manufacture a different circuit assembly; or a combination thereof.
Clause 63: The method of any of clauses 61-62, further including: bonding the first stacked layer to the substrate layer.
Clause 64: The method of any of clauses 61-63, wherein removing excess deformable conductive material from the circuit assembly includes wiping excess deformable conductive material from a release liner attached to a surface of the first stacked layer, the method further including: removing the release liner from a surface of the first stacked layer.
Clause 65: The method of any of clauses 61-64, wherein removing excess deformable conductive material from the circuit assembly includes wiping excess deformable conductive material from a surface of the first stacked layer.
Clause 66: The method of any of clauses 61-65, further including: attaching an electrical component to the circuit assembly, wherein at least one terminal of the electrical component corresponds to the first pattern of passages formed in the first stacked layer.
Clause 67: The method of any of clauses 61-66, further including: placing a second stacked layer on a surface of the first stacked layer, the second stacked layer including a second pattern of passages formed in the second stacked layer, the second pattern of passages extending through a thickness of the second stacked layer; over-filling the second pattern of passages with the deformable conductive material; removing excess deformable conductive material from the circuit assembly; and collecting the excess deformable conductive material.
Clause 68: The method of any of clauses 61-67, further including: interposing a sublayer between the first stacked layer and the second stacked layer, the sublayer including a pattern of conductive elements.
Clause 69: The method of any of clauses 61-68, wherein the second pattern of passages are configured to correspond with at least one terminal of an electrical component, the method further including: electrically coupling the pattern of conductive elements to the deformable conductive material filled in the second pattern of passages.
Clause 70: The method of any of clauses 61-69, wherein placing the second stacked layer on the surface of the first stacked layer includes aligning a first portion of the second pattern of passages with a first portion of the first pattern of passages; and wherein over-filling the second pattern of passages with the deformable conductive material includes forming a continuous structure extending from the first portion of the first pattern of passages to the first portion of the second pattern of passages.
Clause 71: The method of any of clauses 61-70, further including: placing a third stacked layer on a surface of the second stacked layer, the third stacked layer including a third pattern of passages formed in the third stacked layer, the third pattern of passages extending through a thickness of the third stacked layer; over-filling the third pattern of passages with the deformable conductive material; removing excess deformable conductive material from the circuit assembly; and collecting the excess deformable conductive material.
Clause 72: The method of any of clauses 61-71, wherein placing the third stacked layer on the surface of the second stacked layer includes aligning a first portion of the third pattern of passages with a second portion of the second pattern of passages; and wherein over-filling the third pattern of passages with the deformable conductive material includes forming a continuous structure extending from the first portion of the first pattern of passages to the first portion of the third pattern of passages.
Clause 73: The method of any of clauses 61-72, further including: placing a fourth stacked layer on a surface of the third stacked layer, the fourth stacked layer including a fourth pattern of passages formed in the fourth stacked layer, the fourth pattern of passages extending through a thickness of the fourth stacked layer; over-filling the fourth pattern of passages with the deformable conductive material; removing excess deformable conductive material from the circuit assembly; and collecting the excess deformable conductive material.
Clause 74: The method of any of clauses 61-73, wherein placing the fourth stacked layer on the surface of the third stacked layer includes aligning a first portion of the fourth pattern of passages with a second portion of the third pattern of passages; and wherein over-filling the fourth pattern of passages with the deformable conductive material includes forming a continuous structure extending from the first portion of the first pattern of passages to the first portion of the fourth pattern of passages.
Clause 75: The method of any of clauses 61-74, wherein the deformable conductive material includes a conductive gel.
Clause 76: The method of any of clauses 61-75, wherein the deformable conductive material includes a gallium alloy.
Clause 77: A highly sustainable circuit layup may include a non-toxic and readily reclaimable deformable conductive material in combination with at least one layer of a readily recyclable material. The conductive material may form a pattern of reusable traces and/or contact points on the layer. The method of forming the reusable traces on the layer may include one operation, produces substantially no waste (toxic or otherwise), and consumes no additional natural resources apart from those that constitute the layup materials. The method consumes substantially less energy compared to methods used to produce conventional circuit boards.
Clause 78: A highly sustainable circuit assembly may include at least one electric component having terminals arranged in a pattern corresponding to a pattern of contact points of the circuit layup. The electric component may have one or more terminals contacting one or more contact points. The electric component is assembled to the layup using a method that provides a reliable electrical connection without the need for soldering, eliminates the need for substantial energy consumption, produces substantially no waste, and emits substantially no volatile organic compounds (VOC's).
Clause 79: A highly sustainable circuit layup may be formed from at least one stack of layers including at least one substrate layer, one or more stencil layers, and one or more insulation layers. One or more of the layers in the stack may be formed from a readily recyclable material. The stack of layers may include at least one pattern of reusable traces and/or contact points and/or vias formed from a non-toxic and readily reclaimable conductive material. The pattern of reusable conductive trace may be interconnected with the pattern of contact points and/or vias. A first pattern of reusable traces, vias, and contact points may be formed on or recessed into a surface of the substrate layer. One or more stencil layers may be supported by the substrate layer with a second pattern of reusable traces and/or contact points and/or vias extending through the entire thickness of the stencil layer. At least a portion of the stencil layer pattern may correspond to the substrate layer pattern. At least one insulation layer may be supported by the substrate and/or at least one stencil layer. The insulation layer may have a pattern of contact points and/or vias on or extending through a surface of the insulation layer. At least a portion of the insulation layer pattern may correspond the substrate and/or stencil layer pattern. The conductive material may be deposited to one or more layers of the stack in a single operation that produces substantially no waste (toxic or otherwise), consumes no additional natural resources apart from those that constitute the layup materials, uses comparatively little energy, and emits substantially no VOC's. The various layers may be joined together to form the stack. The circuit layup may include multiple stacks, and two or more stacks may be joined together. Vias and contact points from one stack may be in communication with vias and contact points from another stack thereby providing communication between the stacks. Vias may extend through combinations of one or more of the substrate, stencil and insulation layers of each stack to provide communication between the reusable traces of the stacks.
Clause 80: A highly sustainable circuit layup or circuit assembly as described above may optionally include an encapsulant covering at least a portion of an electric component, vias, and/or contact points. The encapsulant may be formed from a readily recyclable material that may be like or the same as one or more of the layers of a layup or stack.
Clause 81: The substrate, stencil, and insulation layers may include a flexible material. The layers may include a stretchable material. At least a portion of one of the layers may have an adhesive property. The layers may be joined together by the adhesive property.
Clause 82: At least one electric device may include a surface mount component. At least one electric device may include an integrated circuit in a package. At least one electric device may include a bare integrated circuit die, At least one electric component may be attached to the circuit layup by the adhesive property of one of the layers, or may be attached to one of the layers by an adhesive.
Clause 83: At least one electric component may be attached to the insulation layer. The insulation layer may have an adhesive property sufficient to reliably attach the electric component to the circuit layup. The conductive material may be deformable and have a adhesion characteristic that provides a reliable electrical connection between at least one contact point of the circuit layup and at least one terminal of the electric component without the need for soldering and eliminating the need for substantial energy consumption, producing substantially no waste, and emitting substantially no volatile organic compounds (VOC's).
Clause 84: A method may include providing a substrate layer, forming one or more passages in the substrate layer, depositing a deformable conductive material in at least one of the passages, and stacking an insulation layer on the substrate layer, wherein the insulation layer at least partially encloses the deformable conductive material. Depositing the deformable conductive material in at least one of the passages may include wiping a volume of the conductive material over at least one passage removing excess deformable conductive material from the surrounding substrate surface.
Clause 85: A method may include providing a substrate layer, and optionally forming one or more passages in a substrate layer and depositing a deformable conductive material in at least one of the substrate layer passages, sequentially stacking at least one stencil layer having one or more passages over the substrate layer, after stacking each stencil layer depositing the deformable conductive material in at least one of that stencil layer's passages, and stacking an insulation layer on the last-stacked stencil layer. At least one of the passages in each stencil layer may pass through the entire thickness of that layer. Successively stacked stencil layers may at least partially enclose the deformable conductive material of each a preceding layer. The insulation layer at least partially encloses the deformable conductive material in the at least one passage of the last-stacked stencil layer. Depositing the deformable conductive material may include wiping a volume of the conductive material over at least one passage removing excess deformable conductive material from the surrounding surface of the layer in which the passage is formed.
Clause 86: The substrate surface and at least one stencil layer surfaces may include a release layer. Release layers may be removed after deformable conductive material is deposited on the respective surface layers.
Clause 87: At least one of the passages in the substrate layer or at least one stencil layer may communicate with the at least one passage of another layer. Passages in stencil layers may pass through the layer's entire thickness.
Clause 88: A method may include forming at least one contact point on a circuit layup, the contact point including a deformable conductive material with a adhesion characteristic, and supporting an electric component on the circuit layup, the electric component having at least one terminal, wherein at least one terminal of the electric component contacts at least one of the contact points to form at least one electrical connection between the electric component and the contact point. At least one terminal may include multiple terminals arranged in a pattern, at least one contact point may include multiple contact points including the deformable conductive material and arranged in a pattern corresponding to the pattern of terminals of the electric component, and the multiple terminals of the electric component may contact the multiple contact points, wherein the adhesion characteristic of the deformable conductor provides a reliable electrical connection between the electric component and the contact points.
Clause 89: A method may include heating a circuit assembly to a melting temperature of an encapsulation material, extracting electric components, heating the circuit assembly to the melting temperature one or more of a substrate, stencil and insulation layers, separating a conductive material from the circuit assembly, and purifying the conductive material. The method may further include the steps of re-using the electric components, reprocessing the layer material(s) and the conductive material for re-use.
Clause 90: A method for making a circuit layup may include providing a substrate layer, forming one or more passages in the substrate layer, collecting scrap material generated from the substrate layer and passage formation steps, depositing a deformable conductive material in at least one of the passages, providing an insulation layer and stacking the insulation layer on the substrate layer, collecting scrap material generated from the insulation layer providing steps, wherein depositing the deformable conductive material in at least one of the passages may include wiping a volume of the conductive material over at least one passage removing excess deformable conductive material from the surrounding substrate surface, the insulation layer at least partially encloses the deformable conductive material, and the substrate and insulation layer scrap is reprocessed and the excess conductive material is included in making one or more subsequent circuit layups.
Clause 91: A method for manufacturing a circuit assembly including: providing a substrate layer including a substrate material; placing a stencil including a stencil material on a surface of the substrate layer, wherein the stencil has a thickness and a pattern of passages formed therein; depositing a deformable conductive material to at least partially fill the pattern of passages; removing the removable stencil from the surface of the substrate layer to leave a pattern of deformable conductive material formed on the substrate layer, wherein the pattern of deformable conductive material can include at least one gap; covering at least a portion of the pattern of deformable conductive material with a first stacked layer, wherein the first stacked layer is an insulation layer, an encapsulation layer, or a combination thereof; and unitizing the circuit assembly, wherein unitizing the circuit assembly causes the at least one gap to heal.
Clause 92: The method of clause 91, wherein the pattern of passages includes a trace feature having a trace width, a trace flare feature having a trace flare width, a staggered pattern of trace flare features, a tab having a tab width, a via feature having a via diameter, or a combination thereof.
Clause 93: The method of any of clauses 91-92, wherein the deformable conductive material includes a viscosity, and wherein the viscosity is optimized such that the deformable conductive material heals upon the unitization but not such that the deformable conductive material overly deforms and does not achieve an intended pattern.
Clause 94: The method of any of clauses 91-93, wherein an adhesive characteristic and/or a viscosity of the deformable conductive material is optimized such that the deformable conductive material remains on the substrate layer upon removal of the removable stencil and does not adhere to the pattern of passages of the removable stencil thereby lifting the deformable conductive material off of the substrate layer.
Clause 95: The method of any of clauses 91-94, wherein unitizing the circuit assembly comprises heating at least a portion of the circuit assembly.
Clause 96: The method of any of clauses 91-95, wherein unitizing the circuit assembly comprises applying pressure to at least one surface of the circuit assembly.
Clause 97: The method of any of clauses 91-96, wherein the heating and/or applying pressure are optimized such that the deformable conductive material heals upon the unitization but not such that the deformable conductive material overly deforms and does not achieve an intended pattern.
Clause 98: The method of any of clauses 91-97, including providing at least one opening in the first stacked layer, the substrate layer, or a combination thereof.
Clause 99: The method of any of clauses 91-98, wherein the at least one opening is formed prior to unitizing the circuit assembly.
Clause 100: The method of any of clauses 91-99, wherein the at least one opening is formed after unitizing the circuit assembly.
Clause 101: The method of any of clauses 91-100, further including, after covering the at least a portion of the pattern of deformable conductive material with the first stacked layer, placing the removable stencil on the first stacked layer, repeating the steps of depositing the deformable conductive material and removing the removable stencil to form a second pattern of deformable conductive material on the first stacked layer, and covering at least a portion of the second pattern of deformable conductive material with a second stacked layer.
Clause 102: The method of any of clauses 91-101, further including unitizing the circuit assembly including the substrate layer, the first stacked layer, and the second stacked layer, wherein the unitizing causes at least one gap of the second pattern of deformable conductive material formed to heal.
Clause 103: The method of any of clauses 91-102, further including, after covering at least a portion of the second pattern of deformable conductive material with the second stacked layer, placing the removable stencil on the second stacked layer, repeating the steps of depositing the deformable conductive material and removing the removable stencil to form a third pattern of deformable conductive material on the second stacked layer, and covering at least a portion of the third pattern of deformable conductive material with a third stacked layer.
Clause 104: The method of any of clauses 91-103, further including unitizing the circuit assembly including the substrate layer, the first stacked layer, the second stacked layer, and the third stacked layer, wherein the unitizing causes at least one gap of the third pattern of deformable conductive material to heal.
Clause 105: The method of any of clauses 91-104, further including, after covering at least a portion of the third pattern of deformable conductive material with the third stacked layer, repeating the steps of placing the removable stencil, depositing the deformable conductive material, removing the removable stencil, and covering at least a portion of the resulting pattern of deformable conductive material until a desired number of layers has been achieved.
Clause 106: The method of any of clauses 91-107, further including unitizing the circuit assembly including the desired number of layers.
Clause 107: The method of any of clauses 91-106, including attaching an electrical component to the substrate layer and/or a stacked layer.
Clause 108: The method of any of clauses 91-107, wherein the electrical component includes a polyimide flex circuit, a resistor, a capacitor, a processer, a chip, a contact, a pin out, or a connector.
Clause 109: The method of any of clauses 91-108, including attaching a lockout and/or stiffener layer to the circuit assembly.
Clause 110: The method of any of clauses 91-109, wherein attaching the lockout and/or stiffener includes placing the lockout and/or stiffener between two of the layers of the circuit assembly.
Clause 111: The method of any of clauses 91-110, wherein attaching the lockout and/or stiffener includes placing the lockout and/or stiffener on an outer layer of the circuit assembly.
All patents, patent applications, publications, or other disclosure material mentioned herein, are hereby incorporated by reference in their entirety as if each individual reference was expressly incorporated by reference respectively. All references, and any material, or portion thereof, that are said to be incorporated by reference herein are incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as set forth herein supersedes any conflicting material incorporated herein by reference and the disclosure expressly set forth in the present application controls.
The present invention has been described with reference to various exemplary and illustrative aspects. The aspects described herein are understood as providing illustrative features of varying detail of various aspects of the disclosed invention; and therefore, unless otherwise specified, it is to be understood that, to the extent possible, one or more features, elements, components, constituents, ingredients, structures, modules, and/or aspects of the disclosed aspects may be combined, separated, interchanged, and/or rearranged with or relative to one or more other features, elements, components, constituents, ingredients, structures, modules, and/or aspects of the disclosed aspects without departing from the scope of the disclosed invention. Accordingly, it will be recognized by persons having ordinary skill in the art that various substitutions, modifications or combinations of any of the exemplary aspects may be made without departing from the scope of the invention. In addition, persons skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the various aspects of the invention described herein upon review of this specification. Thus, the invention is not limited by the description of the various aspects, but rather by the claims.
Those skilled in the art will recognize that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”), the same holds true for the use of definite articles used to introduce claim recitations.
In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”
With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although claim recitations are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are described, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.
It is worthy to note that any reference to “one aspect,” “an aspect,” “an exemplification,” “one exemplification,” and the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, appearances of the phrases “in one aspect,” “in an aspect,” “in an exemplification,” and “in one exemplification” in various places throughout the specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more aspects.
As used herein, the singular form of “a”, an”, and “the” include the plural references unless the context clearly dictates otherwise.
Directional phrases used herein, such as, for example and without limitation, top, bottom, left, right, lower, upper, front, back, and variations thereof, shall relate to the orientation of the elements shown in the accompanying drawing and are not limiting upon the claims unless otherwise expressly stated.
The terms “about” or “approximately” as used in the present disclosure, unless otherwise specified, means an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain aspects, the term “about” or “approximately” means within 1, 2, 3, or 4 standard deviations. In certain aspects, the term “about” or “approximately” means within 50%, 200%, 105%, 100%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.
In this specification, unless otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term “about,” in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
Any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of “1 to 100” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 100, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 100. Also, all ranges recited herein are inclusive of the end points of the recited ranges. For example, a range of “1 to 100” includes the end points 1 and 100. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.
Any patent application, patent, non-patent publication, or other disclosure material referred to in this specification and/or listed in any Application Data Sheet is incorporated by reference herein, to the extent that the incorporated materials is not inconsistent herewith. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.
The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a system that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US22/70853 | 2/25/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63154665 | Feb 2021 | US |
