Patent ID: 9101056
Filing Date: 2015-08-04
Classification: H05K

Abstract:
1. A method of making a micro-wire structure, comprising: providing a substrate having an edge area and a central area separate from the edge area; providing a first stamp and a multi-level second stamp; providing a curable bottom layer in relation to the substrate; forming an imprinted bottom-layer micro-channel in the curable bottom layer by at least imprinting the curable bottom layer with the first stamp in at least a portion of the central area and in at least a portion of the edge area and curing the curable bottom layer, the bottom-layer micro-channel extending from the central area into the edge area; locating a curable electrical conductor in the bottom-layer micro-channel and curing the curable electrical conductor to form a bottom-layer micro-wire in the bottom-layer micro-channel, the bottom-layer micro-wire extending from the central area into the edge area; providing a curable multi-layer adjacent to and in contact with the cured bottom layer and the bottom-layer micro-wire, the curable multi-layer including a connecting layer formed over the cured bottom layer and a top layer formed over the connecting layer on a side of the connecting layer opposite the bottom layer; forming an imprinted multi-layer micro-channel in the top layer and the connecting layer of the curable multi-layer over at least a portion of the bottom-layer micro-channel in at least a portion of the edge area and forming an imprinted top-layer micro-channel in the top layer of the curable multi-layer separate from the bottom-layer micro-channel and over at least a portion of the bottom-layer micro-channel in at least a portion of the central area by at least imprinting the curable multi-layer with the multi-level stamp and curing the curable multi-layer so that the bottom-layer micro-channel is beneath the multi-layer micro-channel in the edge area and is also beneath the top-layer micro-channel in the central area; forming a multi-layer micro-wire in the multi-layer micro-channel contacting at least a portion of the bottom-layer micro-wire and forming a top-layer micro-wire in the top-layer micro-channel that is electrically isolated from the multi-layer micro-wire and the bottom-layer micro-wire; and wherein the bottom-layer micro-wire in the central area is electrically connected to the multi-layer micro-wire in the edge area and is electrically isolated from the top-layer micro-wire.