The present invention relates to a method of fabricating patterned conductive circuit lines on a circuit board, and more particularly to a method of manufacturing a circuit board, on which very fine conductive circuit lines of 0.5 μm˜20 μm in width are formed.
Conventionally, the very fine conductive circuit lines on a flexible circuit board are fabricated through an etching process, which includes the steps of providing a carrier metal foil 10 having a metal oxide layer 11 formed on one surface thereof; plating a seed layer 12 on the metal oxide layer 11; forming a soft organic insulation material layer 13 on the seed layer 12; attaching a flexible backing layer 14 on the soft organic insulation material layer 13; peeling the carrier metal foil 10 off from an interface between the carrier metal foil 10 and the seed layer 12; and finally, forming a patterned circuit 15 on the seed layer 12.
To form the patterned circuit 15, the seed layer 12 is used as a seed to electroplate a circuit line forming metal layer 16; a patterned photoresist 17 is formed on the circuit line forming metal layer 16; the patterned photoresist 17 is used as a mask and the circuit line forming metal layer 16 and the seed layer 12 are etched to form the patterned circuit 15; and finally, the patterned photoresist 17 is removed from the circuit line forming metal layer 16.
The above-described wet etching produces an isotropic etching effect. Since the patterned photoresist 17 is an etch-resistant material, there is a relatively large difference between the etching rates of the etching fluid on the patterned photoresist 17 and on the circuit line forming metal layer 16. As a result, when the etching fluid etches in a vertical direction, a serious side etching will occur on the circuit line forming metal layer 16.
By using wet etching process to fabricate very fine conductive circuit lines, the total etched surface on the circuit line forming metal layer 16 would be too large in proportion to the total area thereof. The circuit line forming metal layer 16 is unevenly etched to result in increased electric impedance thereof. In some worse conditions, the fabricated conductive circuit lines will break locally. Therefore, the produced flexible circuit boards with the very fine conductive circuit lines are not easily controllable in quality and have low yield rate.
A primary object of the present invention is to provide a manufacturing method of circuit board with very fine conductive circuit lines, in which a predetermined circuit pattern containing conductive circuit lines is formed on a conductive motherboard through electroforming, and the circuit pattern can be directly adhered to or indirectly transferred to a substrate for providing a circuit board. Therefore, the whole circuit board manufacturing process is simplified while ensures largely upgraded yield rate of the very fine conductive circuit lines on the circuit board.
Another object of the present invention is to provide a circuit board, on which a plurality of molded conductive electrodes is directly pressed against an adhesive layer, so that the contact areas between the conductive electrodes and the adhesive layer are increased to avoid separation of the conductive electrodes from the substrate in the manufacturing process and accordingly ensure upgraded yield rate.
To achieve the above and other objects, the manufacturing method according to a first embodiment of the present invention is to directly form conductive electrodes on a substrate, and the manufacturing method according to a second embodiment of the present invention is to first form conductive electrodes on a transfer carrier film and then transfer the conductive electrodes from the transfer carrier film to a substrate. The circuit board manufacturing method of the present invention is applied mainly to electronic circuit board production and touch sensing electrode design.
According to the first embodiment of the manufacturing method of the present invention, the following steps are included: providing a conductive motherboard; forming a masking layer on the conductive motherboard, and the masking layer being provided with a plurality of recessed portions that form a predetermined circuit pattern; forming a conductive electrode in each of the recessed portions on the masking layer, and the conductive electrodes together forming a conductive layer; providing a substrate, on one side of which an adhesive layer is provided for sticking to a top of the masking layer and the conductive layer; and separating the substrate, the adhesive layer and the conductive layer from the masking layer and the conductive motherboard to provide a circuit board, in which the conductive electrodes are very fine conductive circuit lines.
According to the second embodiment of the manufacturing method of the present invention, the following steps are included: providing a conductive motherboard; forming a masking layer on the conductive motherboard, and the masking layer being provided with a plurality of recessed portions that form a predetermined circuit pattern; forming a conductive electrode in each of the recessed portions on the masking layer, and the conductive electrodes together forming a conductive layer; providing a transfer carrier film and sticking the transfer carrier film to a top of the conductive layer and the masking layer; separating the transfer carrier film and the conductive layer from the masking layer and the conductive motherboard; providing a substrate, on one side of which an adhesive layer is provided for sticking to a top of the conductive layer; and separating the substrate, the adhesive layer and the conductive layer from the transfer carrier film to provide a circuit board, in which the conductive electrodes are very fine conductive circuit lines.
In both of the first and the second embodiment of the circuit board manufacturing method of the present invention, the conductive motherboard is subjected to a surface passivation treatment to form an easily separable surface, so as to reduce an adhesive strength between the conductive layer and the conductive motherboard to facilitate subsequent separation of the conductive layer from the conductive motherboard.
In an operable embodiment of the present invention, each of the conductive electrodes includes a conductive portion that fills up the recessed portion corresponding thereto and partially protrudes beyond the recessed portion.
In another operable embodiment of the present invention, each conductive electrode is formed in the recessed portion by sequentially forming a first functional portion, a conductive portion and a second functional portion in the recessed portion from bottom to top.
In a further operable embodiment of the present invention, the conductive motherboard has a plurality of cavities formed at positions corresponding to the recessed portions of the masking layer; and each conductive electrode is formed by first forming a first functional portion on inner wall surfaces of the cavity, then forming a conductive portion in the cavity and the recessed portion, and finally forming a second functional portion in the recessed portion. The first and second functional portions can be formed of a weatherproof material, a dulling material, a welding flux material or a darkening material.
In a still further operable embodiment of the present invention, each conductive electrode is formed by first forming a first functional portion on inner wall surfaces of the cavity, then forming a conductive portion in the cavity, and finally forming a second functional portion in the recessed portion.
To achieve the above and other objects, the circuit board structure according to the present invention includes a substrate, an adhesive layer, and a conductive layer. The adhesive layer is spread over one surface of the substrate. The conductive layer includes a plurality of conductive electrodes which are very fine conductive circuit lines and are arrayed to present a circuit pattern, and the circuit pattern is pressed against a surface of the adhesive layer, so that a part of every conductive electrode in the thickness direction is embedded in the surface of the adhesive layer to enable an increased contact area between the conductive electrode and the adhesive layer.
The adhesive layer is formed of a soft material that is deformable under pressure and will cure to form a rigid material after sticking to the conductive layer. And, the conductive electrodes of the conductive layer respectively have a width ranged between 0.5 μm and 20 μm.
In a preferred embodiment of the circuit board structure of the present invention, the conductive electrode includes a first part that is embedded in the adhesive layer, and a second part that is projected from the adhesive layer. The first part of the conductive electrode has a width larger than that of the second part.
Further, each of the conductive electrodes includes a conductive portion and at least one functional portion provided on a surface of the conductive portion. In an operable embodiment, each of the conductive electrodes includes two functional portions provided on a top and a bottom surface of the conductive portion, respectively. Alternatively, the two functional portions may cover outer surfaces of the conductive portion.
In view that the adhering strength is a very important factor that has influence on the yield rate of the very fine conductive circuit lines formed on the substrate of the circuit board, in the present invention, a circuit pattern containing conductive circuit lines is first formed on the surface of a molding conductive motherboard through an electroforming process, and the conductive motherboard and the patterned conductive circuit lines are directly adhered to a substrate or the patterned conductive circuit lines are transferred from a transfer carrier film to the substrate. By directly pressing the patterned conductive circuit lines against an adhesive layer spread over one surface of the substrate, the contact areas between the conductive electrodes, which are formed of the patterned conductive circuit lines, and the adhesive layer is increased to avoid separation of the conductive electrodes from the substrate in the manufacturing process and accordingly ensure upgraded yield rate. In addition, with the above arrangements, the whole circuit board manufacturing process is simplified while ensures largely upgraded yield rate of the very fine conductive circuit lines on the circuit board.
The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein
The present invention will now be described with some preferred embodiments thereof and by referring to the accompanying drawings. For the purpose of easy to understand, elements that are the same in the preferred embodiments are denoted by the same reference numerals.
Please refer to
In a fourth step, use a selected material to make a substrate 25, on one side of which an adhesive layer 26 is provided for directly sticking to a top of the masking layer 21 and the conductive layer 24 on the conductive motherboard 20. The adhesive layer 26 is formed of a soft material that is deformable under pressure and will cure to form a rigid material after sticking to the masking layer 21 and the conductive layer 24. Finally, in a fifth step, separate the substrate 25, the adhesive layer 26 and the conductive electrodes 23 from the conductive motherboard 20 and the masking layer 21 to provide a circuit board having a patterned circuit formed thereon.
The conductive motherboard 20 may be first subjected to a surface passivation treatment to thereby have an easily separable surface to reduce its adhesive strength to the conductive layer 24 and enable ease of separation of the conductive motherboard 20 from the conductive layer 24 in the fifth step. Further, the conductive motherboard 20 may have a plurality of cavities 27 formed at positions corresponding to the aforesaid recessed portions 22 of the masking layer 21, as that shown in
The masking layer 21 is formed by way of printing or photolithography or a combination thereof. The conductive layer 24 can be formed by electroplating of gold, copper, silver, nickel, tin or any alloy thereof on the masking layer 21.
The substrate 25 can be formed of a soft material, a rigid material, a glass sheet, a polymeric material, or a ceramic material. The soft material for forming the substrate 25 can be polyethylene terephthalate (PET), poly(methyl methacrylate) (PMMA), polycarbonate (PC), poly(phenylene sulfone) (PPSU), polyethylenimine (PEI) or polyimide (PI).
After being separated from the conductive layer 24, the substrate 25 and the adhesive layer 26, the conductive motherboard 20 and the masking layer 21 are repeatedly usable for forming another conductive layer 24 thereon. Then, another piece of substrate 25 is attached to the conductive layer 24 via an adhesive layer 26. Finally, separate the conductive motherboard 20 and the masking layer 21 from the conductive layer 24. In this way, the circuit board manufacturing method is largely simplified to facilitate the production of circuit boards.
Thereafter, a transfer carrier film 28, which is a transitional structure in the manufacturing method of the present invention, is adhered to a top of the conductive layer 24 and the masking layer 21. Then, separate the transfer carrier film 28 and the conductive layer 24 from the surfaces of the masking layer 21 and the conductive motherboard 20. Then, provide a substrate 25 having an adhesive layer 26 provided on one side thereof for sticking to one side of the conductive layer 24 opposite to the transfer carrier film 28. Finally, separate the substrate 25, the adhesive layer 26 and the conductive layer 24 from the transfer carrier film 28 to provide a circuit board. That is, in the second embodiment, the final circuit board is not obtained by directly separating it from the conductive motherboard 20, but is obtained by separating it from the transitional structure of the transfer carrier film 28.
In either of the above two embodiments of the circuit board manufacturing method according to the present invention, the conductive electrodes 23 can be differently formed according to actual needs in use. First, as shown in
Please refer to
The above second, third and fourth types of conductive electrodes 23 all have a multilayer complex structure, in which the first and second functional portions 23b, 23c can be formed of a weatherproof material, a dulling material, a welding flux material or a darkening material, depending on actual need in use. Further, the first and second functional portions 23b, 23c respectively have a thickness ranged between 1 nanometer (nm) and 1000 nm.
The present invention also provides a circuit board structure.
The adhesive layer 26 is formed of a soft material that is deformable under pressure and will cure to form a rigid material after sticking to the conductive layer 24. The conductive electrodes 23 of the conductive layer 24 respectively have a width ranged between 0.5 μm and 20 μm. The part of the conductive electrode 23 embedded in the adhesive layer 26 is defined as a first part 23d, and another part of the conductive electrode 23 projected from the adhesive layer 26 is defined as a second part 23e. In a preferred embodiment of the present invention, the first part 23d of the conductive electrode 23 has a width larger than that of the second part 23e.
The individual conductive electrode 23 shown in
According to another operable embodiment of the present invention, the conductive electrode 23 can include a conductive portion 23a and at least a second functional portion 23c that is located at a top of the conductive portion 23a.
Please refer to
The present invention has been described with some preferred embodiments thereof and it is understood that many changes and modifications in the described embodiments can be carried out without departing from the scope and the spirit of the invention that is intended to be limited only by the appended claims.