Methods and systems for forming electronic modules

A method of manufacturing an electronic module includes providing a conductive strip and a dielectric material. The method includes coating the dielectric material and the conductive strip to form a layered structure having a conductive layer defined by the conductive strip and a dielectric layer defined by the dielectric material. The method includes applying a carrier strip to the layered structure. The method includes processing the conductive layer to form a circuit while the layered structure is on the carrier strip. The method includes removing the carrier strip from the layered structure. The method includes applying the layered structure with the circuit to an electronic module substrate.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to methods and systems for forming electronic modules. Electronic modules are used for many applications, including high power applications, such as solid state lighting.

Currently, within the solid state lighting market, light emitting diodes (LEDs) are mounted on metal clad circuit boards to form electronic modules. The metal clad circuit boards are useful in high power LED solutions for adequate heat spreading or heat sinking of the LEDs. Other electronic components may be mounted to the metal clad circuit boards to define other types of electronic modules.

Metal clad circuit boards typically include a base or substrate, such as an aluminum sheet, that has an electrically insulative, but somewhat thermally conductive layer to isolate the base aluminum from copper traces which are on top of the insulative layer. The metal clad circuit boards are manufactured in a batch process, much like a traditional printed circuit board made from a glass epoxy material, such as an FR4 circuit board, where many electronic modules are formed from one large sheet or product. Many electronic modules are arranged in rows and columns on the sheet.

Circuit boards manufactured by the batch process are not without disadvantages. For instance, every time a new geometry or circuit is required, an etch resist plate needs to be created. This requires time and money investment before the circuit geometry can be made. Additionally, a high amount of scrap or waste material is generated between electronic modules.

A need remains for a circuit board that can be manufactured in a cost effective and reliable manner. A need remains for a circuit board that has effective heat dissipation.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a method of manufacturing an electronic module includes providing a conductive strip and a dielectric material. The method includes laminating the dielectric material and the conductive strip to form a layered structure having a conductive layer defined by the conductive strip and a dielectric layer defined by the dielectric material. The method includes applying a carrier strip to the layered structure. The method includes processing the conductive layer to form a circuit while the layered structure is on the carrier strip. The method includes removing the carrier strip from the layered structure. The method includes applying the layered structure with the circuit to an electronic module substrate.

In another embodiment, an electronic module formation system includes a layered structure that has a conductive layer and a dielectric layer. The layered structure has a first portion and a second portion. The first portion is supported by an unwound segment of a reel to reel carrier strip. The conductive layer of the first portion is processed to form a plurality of circuits. The second portion is supported by an electronic module substrate. The layered structure and electronic module around the circuits are singulated to from individual electronic modules.

In a further embodiment, an electronic module formation system includes a first reel upon which a carrier strip is wound. A second reel upon which the carrier strip pulled off from the first reel is wound up. A laminate application station applies a layered structure to the unwound carrier strip. The layered structure is processed while on the carrier strip to form at least one circuit. The layered structure is removed from the carrier strip after the at least one circuit is formed and prior to the carrier strip being wound on the second reel. A substrate application station applies the layered structure, removed from the carrier strip, to an electronic module substrate. The layered structure and electronic module substrate is progressively pulled through the substrate application mechanism.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates an electronic module100formed in accordance with an exemplary embodiment. The electronic module100includes a circuit board102having one or more electronic components104mounted thereto. In the illustrated embodiment, the electronic module100is configured for a high power application, such as a high power LED application. In an exemplary embodiment, the circuit board102is a metal clad circuit board having a metal base or substrate useful for heat spreading or heat sinking of the electronic components104. In alternative embodiments, the circuit board102may have a base or substrate that is manufactured from a material other than metal.

In an exemplary embodiment, the circuit board102includes a metal substrate that provides heat transfer to cool the electronic components104mounted to the circuit board102. The metal substrate of the circuit board102provides better thermal transfer than other types of circuit boards, such as circuit boards manufactured from glass epoxy or FR4 materials. The metal substrate of the circuit board102provides a mechanically robust substrate that is not as fragile as other types of circuit boards. The circuit board102provides low operating temperatures for the electronic components104and has increased thermal efficiency for dissipating heat from the electronic components104. The circuit board102has high durability and may have a reduced size by eliminating the need for an additional heat sink. In alternative embodiments, the circuit board102may include a non-metal substrate, such as a semi-metal or a non-metal substrate (e.g. a copper graphite substrate). Such substrates may be manufactured from a material that is lighter weight than a metal substrate. Such substrates may still be highly thermally conductive and thus suitable for heat dissipation applications. In some alternative embodiments, the circuit board102may include a plastic or other similar, non-metal substrate. The plastic substrate may be a thermally conductive plastic suitable for heat dissipation applications.

In the illustrated embodiment, the electronic components104include an LED106and a temperature sensor108. Other types of electronic components104may be used in alternative embodiments. An electrical connector110is coupled to the electronic module100. The electrical connector110provides power and/or data to the electronic module100.

The electronic module100may be used in other applications other than in an LED application. For example, the electronic module100may be used as part of a power device, RF transistors, military electronics, or other applications, including non-power applications. The electronic module100may form part of an electrical connector, such as a wafer, chicklet or contact module having a leadframe or conductors embedded in or on an insulative body.

FIG. 2illustrates a portion of the electronic module100formed in accordance with an exemplary embodiment. The electronic module100includes a first side112and a second side114opposite the first side112. One or more circuits116are arranged on the first side112. The electronic components104(shown inFIG. 1) are configured to be coupled to corresponding circuits116. The circuits116include pads118for terminating the electronic components104and/or the electrical connector110(shown inFIG. 1) to the corresponding circuits116. The circuits116are defined by traces120. The circuits116may include electrical elements, such as resistors, inductors, capacitors, and the like. The circuit116may have any configuration depending on the particular application, the number, type and positioning of the electric components104, and the number, type and positioning of the electrical connector110.

In the illustrated embodiment, the circuit board102is generally circular in shape and includes a flat edge122, where the electrical connector110is coupled to the circuit board102. The circuit board102has a width124measured between the edge122and a point along the exterior of the circuit board102opposite the edge122. The width124may be slightly less than the diameter. The circuit board102may have other shapes in alternative embodiments.

FIG. 3is a cross-sectional view of the circuit board102. The circuit board102includes an electronic module substrate130and a layered structure132deposited on the electronic module substrate130. The electronic module substrate130is a support structure for the layered structure132. In an exemplary embodiment, the layered structure132is deposited directly on the electronic module substrate130.

In an exemplary embodiment, the electronic module substrate130functions to dissipate heat, such as from the electronic components104of the circuit board102. The electronic module substrate130constitutes a heat spreader or heat sink. The electronic module substrate130is fabricated from a material having a high thermal conductivity, such as an aluminum material, a copper material, a thermally conductive plastic and the like. The substrate130efficiently transfers heat from the electronic components104(shown inFIG. 1) mounted to the circuit board102, such as the LED106(shown inFIG. 1). Optionally, a thickness of the substrate130may be at least half the overall thickness of the circuit board102measured between the first and second sides112,114of the circuit board102. Having a thick metal substrate provides rigidity and robustness to the circuit board102. In embodiments that are less concerned with heat dissipation, the substrate130may be manufactured from a material having desired characteristics, such as high strength, light weight, inexpensive, or other characteristics.

The layered structure132includes a dielectric layer134and a conductive layer136. The conductive layer136defines the circuits116(shown inFIG. 2). The dielectric layer134may be comprised of one or more layers of dielectric material. The conductive layer136may be comprised of one or more layers of conductive material. The dielectric layer134is positioned between the conductive layer136and the electronic module substrate130. The dielectric layer134is electrically insulative. The dielectric layer134is thermally conductive to transfer heat from the conductive layer136to the electronic module substrate130.

The dielectric layer134electrically isolates the metal substrate130from the conductive layer136. The dielectric layer134has a low thermal resistance so effective thermal transfer can occur to the substrate130. The thickness of the dielectric layer134as well as the type of material used for the dielectric layer134may affect thermal conductivity or thermal resistivity properties of the dielectric layer134. The dielectric layer134is relatively thin to allow adequate thermal transfer through the dielectric layer134to the substrate130. In an exemplary embodiment, the dielectric layer134is between approximately 0.002″ and 0.003″. Other thicknesses of the dielectric layer134are possible in alternative embodiments.

The dielectric layer134has adequate dielectric properties to maintain electrical isolation between the substrate130and the conductive layer136. For example, the dielectric layer134may need to be rated to withstand a predetermined voltage level. The thickness of the dielectric layer134as well as the type of material used for the dielectric layer134may affect the dielectric properties and effectiveness of the dielectric layer134. Different types of dielectric materials may be used in various embodiments.

In an exemplary embodiment, the dielectric layer134includes a material that is an electrical insulator, such as polymer base material or resin. Optionally, the dielectric layer134may include fillers, additives or other particles mixed in with the polymers to change properties of the dielectric layer134, such as the thermal efficiency of the dielectric layer134. For example, particles such alumina or boron nitride particles may be added to the polymer base material to make the dielectric layer134more thermally conductive. Other types of fillers may be added to the mixture to change other characteristics of the dielectric layer134.

The dielectric layer134may be applied as a powder, film, epoxy, or come in other forms. The dielectric layer134may be applied to the conductive layer136using different processes. In an exemplary embodiment, the dielectric layer134is an epoxy applied to the conductive layer136. For example, the dielectric layer134may include a liquid suspension having a mixture of polymers, fillers and solvent that is spread either directly onto the conductive layer136or alternatively onto a polyester film, which is then transferred to the conductive layer136. The mixture is then at least partially cured to secure the dielectric layer134to the conductive layer136. The epoxy may be applied to the conductive layer136using a doctor blade coater, a draw down coater, a slot die coater or another application machine. Alternatively, the dielectric layer134is powder coated to the conductive layer136, such as using a spray coater or a fluidized bed. The dielectric layer134includes fine powder particles composed of a mixture of polymers and fillers that may be compression molded onto to the conductive layer136.

FIG. 4illustrates an electronic module formation system150used to form electronic modules, such as the electronic module100. The system150includes a plurality of stations that perform operations or functions on materials to form the electronic modules100. The system150is an in-line system that progressively feeds product, such as strips or reels of material, through the stations to process the materials to form the electronic modules100. For example, the product may be continuously feed to stations for processing. In an exemplary embodiment, the system150is a reel system that winds and/or unwinds material from reels to progressively process the electronic modules100through the system150.

The system150includes a conductive strip152, which is wound up on a conductive strip reel154and continuously unwound and pulled through the system150. The conductive strip152may be a copper foil. The width of the copper foil may be dependent on the width124(shown inFIG. 2) designed for the circuit board102. Optionally, the width of the conductive strip152may be slightly wider than the width124such that one circuit board102may be singulated from the strip pulled through the system150.

The system150includes a coating station156. The coating station156applies dielectric material to the conductive strip152. The strip exiting the coating station156defines the layered structure132(shown inFIG. 3). The dielectric material may be applied in a known manner, such as by coating the conductive strip152, using a doctor blade coater, a draw down coater, a slot die coater or another type of coater. The dielectric material may be applied by processes other than coating. The dielectric material may be coated by laminating the dielectric layer to the conductive strip152. The dielectric material may be applied as an epoxy. Alternatively, the dielectric material may be applied in other forms, such as a powder. The dielectric material may be subjected to heat and/or pressure at the coating station156to secure the dielectric material to the conductive strip152. The dielectric material may be at least partially cured in the coating station156or at a subsequent station downstream of the coating station156. Optionally, the dielectric material may be cured to an intermediate or partial curing stage, such as a B-stage, to allow the dielectric material to be secured to a carrier strip158.

A transfer device157is used to advance the carrier strip158through the system150. Optionally, the transfer device157may be one or more reels upon which the carrier strip158is wound and/or unwound. The transfer device157may be a conveyor, such as a conveyor belt or roll. The carrier strip158may be reusable by winding up the carrier strip158on a reel or continuously conveying the carrier strip158through the system150. Alternatively, the carrier strip158may not be reusable, but rather is a strip that is progressed through the system150and discarded. In other alternative embodiments, the carrier strip158forms part of the final product and is therefore not reusable. In the illustrated embodiment, the transfer device157is a reel system upon which the carrier strip158is unwound and wound, however the subject matter herein is not intended to be limited to such system as other types of devices may be used to transfer the carrier strip158through the system150. The carrier strip158is wound up on a first carrier strip reel160and unwound from the reel160as the carrier strip158is pulled through the system150. The carrier strip158is later wound onto a second carrier strip reel162. The second carrier strip162pulls the carrier strip158through the system150. The carrier strip158is attached to the layered structure132at a carrier strip application station164. The carrier strip158is applied to the dielectric layer134(shown inFIG. 3) of the layered structure132at the carrier strip application station164. The carrier strip158may be applied to the layered structure132(and/or the layered structure132may be applied to the carrier strip158) by pressing the carrier strip158against the dielectric layer134.

The carrier strip158may be a film, such as polyester film. The carrier strip158is used to advance the layered structure132at least partially through the system150. The carrier strip158is later removed from the layered structure132to allow the layered structure132to be attached to the electronic module substrate130(shown inFIG. 3). The carrier strip application station164non-permanently secures the dielectric layer134of the layered structure132to the carrier strip158such that the dielectric layer134is removable from the carrier strip158without destroying the layered structure132.

In an alternative embodiment, rather than the carrier strip158being a separate component, such as a film, that pulls the layered structure132through the system150, the carrier strip158may form part of the layered structure132that is presented downstream through the system150. In such embodiments, the carrier strip158is not removed from the layered structure132. For example, the carrier strip158may be a strengthening or reinforcing mesh that is embedded in the dielectric layer134or that forms part of the dielectric layer134. Such mesh remains as part of the layered structure132in the final product. In other alternative embodiments, the conductive strip152defines the carrier strip and a separate film or strip does not need to be provided as the conductive strip152is the portion of the layered structure132that is progressively pulled through the system150.

The carrier strip158progresses or transfers the layered structure132through at least one processing station166. The processing station166forms the circuit116(shown inFIG. 2) from the conductive layer136. Because the strip is progressively moved through the system150, a series of circuits116are formed from the conductive layer136as the conductive strip152is progressed through the system150.

The processing station166is used to transform the conductive layer136into the circuits116. Multiple processes may be performed in the processing station166and/or multiple processing stations166may be provided in the system150.

In an exemplary embodiment, an etch resist layer is applied to the conductive layer136. The etch resist layer may be printed onto the conductive layer136. For example, the etch resist layer may be an ink that is pad printed, ink jet printed or silk screen printed onto the conductive layer136. The ink may be UV cured onto the conductive layer136.

The portion of the conductive layer136, that is not covered with the etch resist layer, is then etched away. For example, the product may pass through an aqueous etch bath to remove the copper of the conductive layer136that is not covered with the etch resist layer.

After the etching process, the etch resist layer is removed, such as by stripping the etch resist layer in a bath or by another process. Once the etch resist layer is removed, the conductive layer136is exposed, with portions of the conductive layer136removed to define the circuits116.

Optionally, the remaining portions of the conductive layer136may be plated, such as with a tin plating. Other processes may be performed at the processing station166to form the circuits116.

The strip is progressively passed through the processing station166to form a series of the circuits116on the strip. In an exemplary embodiment, the carrier strip158remains largely unaffected by the processes performed in the processing station166. The carrier strip158does not need to be protected, for example covered with an etch resist layer, as the carrier strip158is manufactured from a polyester material or another material unaffected by the etching process. Additionally, the carrier strip158does not form part of the final product as it is removed at a later stage, so damage to the carrier strip158is irrelevant for the final product. Not having to protect the carrier strip158allows the electronic module formation to occur more quickly and inexpensively, such as compared to a system where the substrate130passes through the processing station166.

After the product passes through the processing station166, the product moves to a carrier strip removal station where the carrier strip158is removed from the layered structure132. In an exemplary embodiment, the carrier strip158is wound onto the second carrier strip reel162. The carrier strip158is peeled away from the layered structure132(and/or the layered structure132is peeled away from the conductive strip152) as the carrier strip158is wound on the second carrier strip reel162. The layered structure132continues on beyond the second carrier strip reel162. The carrier strip158is removed from the dielectric layer134without damaging the dielectric layer134. The dielectric layer134remains attach to the conductive layer136. As noted above, the carrier strip158need not be wound on a reel, but rather other types of transfer devices may be used, such as a conveyor belt or rollers. Additionally, in some embodiments, the carrier strip158is not removed but rather forms part of the layered structure132that is passed through the system. In such embodiments, the system150does not include a carrier strip removal station.

The layered structure132is progressively pulled through a substrate application station170. The electronic module substrate130is provided on a substrate reel171. The substrate130is unwound from the reel and progressively presented to the substrate application station170for attaching the substrate130to the layered structure132. The electronic module substrate130may be advanced by a device other than a reel in alternative embodiments. Once the layered structure132is attached to the substrate130, the layered structure132may be advanced through the system150on the substrate130.

At the substrate application station170, the layered structure132is applied to the electronic module substrate130. The layered structure132may be applied to the substrate130by pressing the dielectric layer134against the substrate130. In an exemplary embodiment, a pair of rollers are provided and the layered structure132and substrate130are progressively passed through the rollers to press the dielectric layer134into the substrate130. The layered structure132and substrate130may undergo a lamination process, such as a roll laminating process, to attach the dielectric layer134to the substrate130. Other processes may be performed to secure the layered structure132to the substrate130.

The product is passed to a curing station172where the dielectric layer134undergoes a secondary curing. The secondary curing may fully cure the dielectric layer134. The secondary curing process of the dielectric layer134tends to permanently secure the dielectric layer134to the conductive layer136and/or the substrate130. The secondary curing may be performed at the substrate application station170, such as by using a hot roll laminating process to both apply and cure the layered structure132to the substrate130.

The product is progressively transferred to a singulation station174where the electronic modules100are singulated from the strip. The singulation station174may singulate the electronic modules100by cutting or punching the electronic modules100from the strip of the layered structure132and substrate130. The electronic modules100may be tightly packaged on the strip in a line along the strip, such that there is little scrap or product waste. The progressive formation process allows a higher volume of electronic modules100to be produced as compared to batch processes.

FIG. 5illustrates a method of manufacturing electronic modules, such as the electronic module100(shown inFIG. 1) in accordance with an exemplary embodiment. The method includes forming200a layered structure. The layered structure may be formed by coating a dielectric material on a conductive strip. The layered structure may be the layered structure132(shown inFIG. 3). The layered structure may be formed by depositing dielectric material on a conductive strip. The dielectric material may be an epoxy that is coated onto a conductive strip or conductive foil, such as a copper foil. Optionally, the layered structure may be progressively formed by pulling the conductive strip through a forming station where the dielectric material is progressively applied to the conductive strip. Optionally, the layered structure may be at least partially cured, such as by curing the dielectric material to an intermediate or B stage. Optionally, the dielectric material may be coated by using a doctor blade coater, a draw down coater, a slot die coater, or another coating machine. Alternatively, the dielectric material may be deposited on the conductive strip by other processes in alternative embodiments.

The method includes applying202a carrier strip to the layered structure and progressing the carrier strip and the layered structure through the forming system. In an exemplary embodiment, the carrier strip is used to progress the layered structure through the forming system. For example, a transfer device may be used to progress the carrier strip, which in turn progresses the layered structure which is supported by the carrier strip. The carrier strip may be similar to the carrier strip158(shown inFIG. 4). The carrier strip may be a polyester film. Other types of carrier strips may be used in alternative embodiments. In an exemplary embodiment, the carrier strip is applied to the dielectric layer of the layered structure. The carrier strip may be applied by pressing the carrier strip and/or layered structure into one another. Rollers may be used to press the carrier strip and layered structure into one another. The carrier strip may be applied by other means or processes in alternative embodiments, such as by embedding the carrier strip in the dielectric layer. In an exemplary embodiment, the carrier strip is removably applied to the layered structure such that the carrier strip may be later removed without damaging the layered structure. In other alternative embodiments, the carrier strip is integrated into the layered structure, such as by incorporating a reinforcing mesh in the dielectric layer, such that the carrier strip is not later removed from the layered structure.

The method includes forming204a circuit. The circuit may be formed by etching the conductive strip or conductive layer. Optionally, an etch resist layer may be applied to the conductive layer, exposing portions of the conductive layer. The exposed portions of the conductive layer are etched away, such as in an aqueous etching bath. The etch resist layer may be stripped or removed after the conductive layer is etched away. In an exemplary embodiment, portions of the conductive layer may be plated, such as with a tin plating, to form the circuits. In an exemplary embodiment, the product is progressively formed by progressively moving the product through different stations or processes.

The method includes removing206the carrier strip from the layered structure. The carrier strip may be removed by winding the carrier strip up on a reel. The carrier strip is pulled off the layered structure without damaging the layered structure. The layered structure continues on for further processing after the carrier strip is removed. In alternative embodiments, the method does not include the removing step, but rather the carrier strip is integrated into the final product and the carrier strip is progressed downstream to form the final product.

The method includes applying208the layered structure to an electronic module substrate. The substrate may be similar to the electronic module substrate130(shown inFIG. 3). The layered structure may be applied to the electronic module substrate by pressing the layered structure into the substrate. A roll laminating process may be used to apply the layered structure to the substrate. The dielectric layer of the layered structure may be applied directly to the substrate. Optionally, the dielectric layer may be cured once applied to the substrate to permanently attach the layered structure thereto. In an exemplary embodiment, the product, including the substrate and layered structure, moves through the system to progressively apply the layered structure to the substrate.

The method includes singulating210the electronic modules. For example, the electronic modules may be cut or punched from the product strip as the product strip is pulled through the system. The product strip may be sized relative to the electronic module such that there is little waste after the electronic modules are singulated. For example, the product strip may be approximately as wide as the electronic modules such that when the electronic modules are singulated, substantially all of the material of the product strip is used as part of the electronic module.

FIG. 6illustrates a portion of the electronic module formation system150in accordance with an exemplary embodiment. The system150uses the conductive strip152to form the electronic module. The conductive strip152is presented to a coating station156. At the coating station156, the layered structure132is formed. The layered structure132is formed by applying dielectric material to the conductive strip152to define both the dielectric layer134and the conductive layer136. The layered structure132is progressively passed from the coating station156to the carrier strip application station164. At the carrier strip application station164, the layered structure132is applied to the carrier strip158. The carrier strip158is used to pull the layered structure132through one or more processing stations166. In an exemplary embodiment, the dielectric layer134is non-permanently secured to the carrier strip158such that the carrier strip158may later be removed from the layered structure132. At the processing station166, the conductive layer136is processed to form one or more circuits116(shown inFIG. 2).

FIG. 7illustrates a method of processing the conductive layer136to form at least one circuit116. The method includes applying220an etch resist layer to the conductive layer. The etch resist layer may be a UV curable ink or other type of ink that is printed onto the conductive layer. The etch resist layer may be applied to the conductive layer by other means in alternative embodiments. The etch resist layer exposes portions of the conductive layer.

The method includes etching222the conductive layer. Only the exposed portions of the conductive layer are removed during the etching process. The etch resist layer protects other parts of the conductive layer. The etching may be sprayed with etchant or otherwise exposed to etchant. The etching may occur by immersing or submerging the product into an aqueous etching bath where the exposed portions of the conductive layer are exposed to an etching solution that removes the material from the product.

The method includes removing224the etch resist layer. The etch resist layer may be removed by submersing the product into a stripping bath that strips the etch resist material from the product. Other processes may be used to strip the etch resist material from the product.

The method includes plating226the remaining portion of the conductive layer. Optionally, the conductive layer may be tin plated. The remaining portion of the conductive layer defines one or more circuits defining one or more electronic modules. Other processing steps may be performed in alternative embodiments to form one or more circuits for the electronic modules.

FIG. 8illustrates a portion of the electronic module formation system150showing the carrier strip removal station168and the substrate application station170. The carrier strip removal station168includes the second carrier strip reel162. The carrier strip158pulls the layered structure132through the system150to the carrier strip removal station168. The carrier strip158is removed from the layered structure132by winding the carrier strip158onto the carrier strip reel162. During removal, the carrier strip158is pulled away from the dielectric layer134without damaging the dielectric layer134.

The layered structure132continues from the carrier strip removal station168to the substrate application station170. The substrate130is applied to the layered structure132at the substrate application station170. The substrate130pulls the layered structure132from the substrate application station170and through the downstream stations.

In an exemplary embodiment, the substrate application station170includes a pair of rollers. The substrate130and layered structure132are passed between the rollers, which press the layered structure132against the substrate130to secure the dielectric layer134to the substrate130. In an exemplary embodiment, the dielectric layer134is secondarily cured after the dielectric layer134is applied to the substrate130. The curing process permanently secures the dielectric layer134to the substrate130.

The layered structure132includes a first portion240, a second portion242and a third portion244between the first and second portions240,242. The first portion240is supported by the unwound segment246of the reel-to-reel carrier strip158. The conductive layer136of the first portion240is processed to form at least one circuit116. The first portion240is generally defined between the carrier strip application station164(shown inFIG. 4) and the carrier strip removal station168.

The second portion242is supported by the electronic module substrate130. The second portion242is generally the portion of the layered structure132downstream of the substrate application station170and is the portion of the layered structure132that passes through the curing station172and singulation station174(both shown inFIG. 4). Sections of the second portion242are singulated at the singulation station174to form individual electronic modules. For example, sections of the second portion242and corresponding substrate130below the second portion242are punched by a machine to singulate the electronic module100from the surrounding product strip that is progressively pulled through the system150.

The third portion244is unsupported by either the carrier strip158or the electronic module substrate130. The third portion244generally extends between the carrier strip removal station168and the substrate application station170. The third portion244is pulled through the system150by the second portion242. Each of the portions240,242,244are progressively pulled through the system150to progressively form circuits and electronic modules. The layered structure132is progressively transitioned from the first portion240to the third portion244and from the third portion244to the second portion242.