Patent ID: 7690103

Claim:
A method of forming a circuit board comprising: (a) providing an electrically conductive sheet having top and bottom surfaces and an edge; (b) conformally coating the top and bottom surfaces and the edge of the electrically conductive sheet with an insulating material; (c) exposing the conformally coated insulating material to an elevated temperature such that the insulating material at least partially melts and flows around the edge of the electrically conductive sheet whereupon, upon removal of the elevated temperature, the insulating material around the edge of the electrically conductive sheet has an arcuate or rounded shape or outline; and (d) following step (c), forming a first conductor on the insulating material with at least a portion of the first conductor on the insulating material around the edge of the electrically conductive sheet, whereupon said portion of the first conductor has an arcuate or rounded shape or outline.