Source: http://www.google.fr/patents/US8003513?hl=fr
Timestamp: 2013-05-18 23:25:50
Document Index: 272642612

Matched Legal Cases: ['Application No. 2009', 'application No. 2006', 'Application No. 03754668', 'application No. 2539280', 'application No. 2004', 'Application No. 2009']

Brevet US8003513 - Multilayer circuit devices and manufacturing methods using electroplated ... - Google�BrevetsRecherche Images Maps Play YouTube Actualit�s Gmail Drive Plus » Recherche avanc�e dans les brevets | Historique Web | Connexion Recherche avanc�e dans les brevets BrevetsA multilayer circuit includes a dielectric base substrate, conductors formed on the base substrate and a vacuum deposited dielectric thin film formed over the conductors and the base substrate. The vacuum deposited dielectric thin film is patterned using sacrificial structures formed by electroplating...http://www.google.fr/patents/US8003513?utm_source=gb-gplus-shareBrevet US8003513 - Multilayer circuit devices and manufacturing methods using electroplated sacrificial structures Num�ro de publicationUS8003513 B2Type de publicationOctroi Num�ro de demande11/086,936 Date de publication23 ao�t 2011 Date de d�p�t22 mars 2005 Date de priorit�27 sept. 2002Autre r�f�rence de publicationUS20050161826 InventeursShaun PendoRajiv Shah Cessionnaire d'origineMedtronic Minimed, Inc. Classification aux �tats-Unis438/622438/624438/623438/618257/758438/637 Classification internationaleH05K3/04H01L21/48H01L21/4763H05K3/40H05K1/16H05K3/46 Classification coop�rativeH05K3/4053H05K3/467H05K2203/308H01L21/4867H05K3/4664H05K2203/1476H05K3/048H05K2203/085H05K2201/0179H05K2203/0278H05K1/162H01L21/4857H05K3/06H05K3/4061 Classification europ�enneH05K3/46C7H05K3/40D2BH05K3/40D2H01L21/48C4DH01L21/48C4SH05K1/16CR�f�rencesCitations de brevets (93)Citations hors brevets (72)Liens externesUSPTO Cession USPTO EspacenetMultilayer circuit devices and manufacturing methods using electroplated sacrificial structuresUS 8003513 B2 R�sum� A multilayer circuit includes a dielectric base substrate, conductors formed on the base substrate and a vacuum deposited dielectric thin film formed over the conductors and the base substrate. The vacuum deposited dielectric thin film is patterned using sacrificial structures formed by electroplating techniques. Substrates formed in this manner enable significant increases in circuit pattern miniaturization, circuit pattern reliability, interconnect density and significant reduction of over-all substrate thickness.
RELATED APPLICATIONS This application is a continuation-in-part application that claims priority under 35 USC �120 from U.S. patent application Ser. No. 10/671,996, filed 26 Sep. 2003, which claims priority under 35 USC �119(e) from U.S. Provisional Application Ser. No. 60/414,289, filed 27 Sep. 2002, entitled �Multilayer Substrate;� and is a continuation-in-part application of U.S. patent application Ser. No. 10/331,186, filed 26 Dec. 2002, entitled �Multilayer Substrate,� the entirety of each of which is incorporated herein by reference and forms a basis for priority.
In addition, this application is related to U.S. patent application Ser. No. 10/038,276, filed 31 Dec. 2001, entitled �Sensor Substrate and Method of Fabricating Same,� the entirety of which is incorporated herein by reference.
Other multilayer substrates are conventionally fabricated by lamination techniques in which metal conductors are formed on individual dielectric layers, and the dielectric layers are then stacked and bonded together. However, various conventional lamination techniques have limitations that restricts their usefulness. For example, high temperature ceramic co-fire (HTCC) lamination techniques form conductors on �green sheets� of dielectric material that are bonded by firing at temperatures in excess of 1500 degrees C. in a reducing atmosphere. The high firing temperature precludes the use of noble metal conductors such as gold and platinum. As a result, substrates formed by high temperature processing are limited to the use of refractory metal conductors such as tungsten and molybdenum, which have very low resistance to corrosion in the presence of moisture and are therefore not appropriate for use in certain environments.
SUMMARY OF THE DISCLOSURE Therefore, embodiments of the invention may be employed to address some or all of the limitations of conventional processes described above, to provide multiple layer electronic devices (such as electronic circuit substrates, portions of electronic circuits or circuit elements), where processes of forming such devices are compatible with a large variety of layer materials and layer thicknesses. Improved processing techniques that employ electroplated sacrifical structures to pattern one or more layers of a multiple layer device, as described herein, may be employed with a many different materials and layer thicknesses. As a result, aspects of the invention can provide a greater number of design options for layer materials, layer thicknesses and layer patterns designed to meet desired electrical, structure and environmental compatability properties.
Example embodiments of the invention employ vacuum deposition methods for depositing dielectric materials. Vacuum deposited dielectric layers may be formed significantly thinner than the dielectric layers used in conventional lamination techniques, allowing for the formation of multilayer circuit devices that have overall thicknesses significantly thinner than those formed by conventional lamination techniques. Because vacuum deposited dielectrics are deposited in an �as-fired� state that undergoes essentially no shrinkage during subsequent processing, yield reduction due to misalignment may be significantly reduced or eliminated. In addition, vacuum deposition techniques do not impose limitations on the types of conductors or dielectric materials that may be employed, enabling the use of a wide variety of materials with highly tunable properties. Vacuum deposition techniques also produce hermetic layers that facilitate the production of highly reliable substrates.
DESCRIPTION OF THE DRAWINGS FIGS. 1 a, 1 b, 1 c, 1 d, 1 e and 1 f show structures formed during fabrication of a general multilayer circuit device in accordance with an embodiment of the invention;
FIG. 4 shows an example of a medical sensor device made in accordance with the structures of FIGS. 2 a-2 k. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Embodiments of the invention relate to multilayer electronic devices and methods for fabrication of multi-layer electronic devices. Particular embodiments of the invention relate to highly stable multilayer electronic devices and methods of fabrication thereof, for use in caustic or sensitive environments, such as medical and implant environments. In such embodiments, the material used for a patterned dielectric or other patterned materials in the multilayer electronic device are selected, in part, for suitable environmental compatibility.
FIG. 1 e shows the structure of FIG. 1 d after forming a dielectric thin film 40 over the base substrate, the conductors and the sacrificial structures. In an example embodiment the dielectric material is alumina and is vacuum deposited by a method such as sputtering or evaporation, producing a highly hermetic dielectric material in an �as fired� form, that is, in a form that will not undergo significant structural changes such as shrinkage during subsequent processing. To enhance the density, adhesion and hermeticity of the dielectric thin film 40, ion beam assisted deposition (IBAD) may be employed, wherein the deposited dielectric material is bombarded with low energy ions during deposition to provide improved adhesion and coating density. Formation of dielectric thin films by vacuum deposition can produce layers having thicknesses in the range of 100 angstroms to 20 microns (0.00004-0.0008 inches), compared to the conventional minimum green sheet thickness of 0.006 inches or approximately 150 microns. Accordingly, the use of vacuum deposited dielectric thin films rather than conventional sheet dielectrics allows the production of significantly thinner multilayer substrates or the production of multilayer substrates having significantly more layers than those formed by conventional lamination methods. In addition, vacuum deposited layers are highly hermetic and provide significant protection of underlying materials against the outside environment.
FIG. 2 e shows the structure of FIG. 2 d after vacuum deposition of a dielectric thin film 40 over the base substrate, the conductors and the sacrificial structures. In an example embodiment the dielectric material is alumina and is vacuum deposited by a method such as sputtering or evaporation, producing a highly hermetic dielectric material in an �as fired� form, as described above. To enhance the density, adhesion and hermeticity of the dielectric thin film 40, ion beam assisted deposition (IBAD) may be employed, also as described above.
Accordingly, embodiments of the invention also provide great freedom of choice with respect to the deposited dielectric material. In some embodiments, the dielectric layer should be capable of formation by a vacuum deposition technique that provides good adhesion to underlying materials and good process control for producing very thin layers. As a general matter any dielectric material that can be obtained in a substantially pure form may be evaporated and vacuum deposited as a thin film on a substrate. A variety of deposited dielectric materials may be used including alumina, aluminum nitride, silicon oxide, silicon nitride, silicon oxynitride, titanium nitride and the like. Vacuum deposited dielectric thin films provide a number of desirable properties, including highly controllable thickness, high hermeticity, dimensional stability, thermal and chemical stability, and tunable dielectric and thermal conductance properties. For purposes of this disclosure, the term �deposited dielectric� is therefore used not only to describe the processing by which the dielectric is formed, but also the resulting structural features of the deposited dielectric that distinguish it from conventional laminated dielectrics, including its conformality and hermeticity with respect to the materials on which it is formed, its high density and adhesion, and its dimensional, thermal and chemical stability.
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