Patent ID: 6085414
Filing Date: 2000-07-11
Classification: H05K,Y10T

Abstract:
A process of making a flexible circuit having first and second opposite surfaces and raised pressure contact electrical features protruding outwardly from the surfaces of the flexible circuit comprising:providing a foil having a first and second opposite face, forcing a tool into the first face to provide a first dimple in the first face and a corresponding second bump extending outwardly from the second face of the foil, turning the foil over and forcing the tool into the second face to provide a second dimple in the second face and a corresponding first bump extending outwardly from the first face of the foil,thereafter constructing a first flexible circuit on at least the first face of the foil comprising coating the first face of the foil including the first dimple and the first bump extending outwardly from the first face of the foil with a first electrically conductive material to provide a flash coating so that the flash coating is relatively separable from the foil including the first dimple and the first bump,selectively depositing a second electrically conductive material over the flash coating to form a pattern of circuit traces on the flash coating, at least a portion of one of the traces extending into the first dimple and at least another portion of one of the traces deposited over the first bump extending outwardly from the first face of the foil,selectively laminating a dielectric substrate onto the traces wherein said coating effectively blocks the dielectric substrate from adhering to the foil,removing, the traces, dielectric substrate and the flash coating from the foil, and thereafter removing the flash coating to provide a flexible circuit, the dielectric substrate having the first and second opposite surfaces and the pattern of circuit traces carried by the dielectric substrate including a first raised pressure contact electrical feature extending outwardly from the first surface of the dielectric substrate and a second raised pressure contact electrical feature extending outwardly from the second surface of the dielectric substrate, the first raised pressure contact electrical feature being formed by the second electrically conductive material deposited in the first dimple in the first face of the foil and the second raised pressure contact electrical feature being formed by the second electrically conductive material deposited over the first bump extending outwardly form the first face of the foil.