Patent ID: 8771805

Claim:
A process for embedding at least one metal trace in a silicone containing polymer, comprising the steps of: applying a first silicone polymer layer having at least one surface area and comprised of a first formulation on a substrate; thermally treating said first silicone polymer layer to cure said first polymer layer; irradiating said at least one surface area of said thermally treated first silicone polymer layer with a light beam emitted by a laser having a frequency suitable to remove silicone, thereby removing a portion of said thermally treated first silicone polymer layer thereby creating cuts, grooves, blind holes, or vias having an inner surface; irradiating said inner surface with a light beam emitted by a laser having a frequency suitable to break silicon carbon bonds, thereby breaking silicon-carbon bonds on said inner surface resulting in an inner surface of partially decomposed silicone; immersing said irradiated first silicone polymer layer in an autocatalytic bath containing ions of at least one metal and metallizing said inner surface of said first silicone polymer layer by forming covalent silicon bonds and at least partially filling said cuts, grooves, blind holes, or vias with metal forming said at least one metal trace; applying a second silicone polymer layer, comprised of a second formulation different from said first formulation, covering said thermally treated immersed first silicone polymer layer; thermally treating said first silicone polymer layer and said second silicone polymer layer to cure said second silicone polymer layer and obtain one polymer layer; forming openings in said one polymer layer to access said at least one metal trace; and plating electrodes in said openings.