Method for manufacturing rigid-flexible printed circuit board

Patent metadata

Field	Value
Publication number	US-9743533-B2
Application number	US-201414512556-A
Country	US
Kind code	B2
Filing date	Oct 13, 2014
Priority date	Oct 12, 2013
Publication date	Aug 22, 2017
Grant date	Aug 22, 2017

Abstract

A rigid-flexible printed circuit board (PCB) a method for manufacturing the rigid-flexible PCB, and a PCB module having the rigid-flexible PCB are provided. The rigid-flexible printed circuit board (PCB) defines a first area, a second area, and a third area connected in the described order. The rigid-flexible PCB includes a first flexible PCB, a second flexible PCB adhered with the first flexible PCB through a bonding sheet in the third area, and, a first conductive layer and a second conductive layer formed on opposite side of the rigid-flexible PCB in the first area and the third area. The first flexible PCB is apart from the second flexible PCB in the first area and the second area.

First claim

What is claimed is:

1. A method for manufacturing a rigid-flexible printed circuit board (PCB), comprising:
providing a first flexible PCB and a second flexible PCB, the first flexible PCB having a first surface and a second surface opposite to, and substantially parallel to, the first surface, the second flexible PCB having a first surface and a second surface opposite to, and substantially parallel to, the first surface, the first flexible PCB defining a first portion, a second portion, and a third portion connected in described order, the second flexible PCB defining a fourth portion, a fifth portion, and a sixth portion connected in described order;
providing a bonding sheet having a first surface and a second surface opposite to, and substantially parallel to, the first surface;
adhering the first surface of the third portion to the first surface of the bonding sheet, and adhering the first surface of the sixth portion to the second surface of the bonding sheet, the fourth, fifth, and sixth portion of the second flexible PCB being respectively aligned with the first, second, and third portion of the first flexible PCB; and
forming a first prepreg sheet and a first conductive layer on the second surface of the first and third portion, and forming a second prepreg sheet and a second conductive layer on the second surface of the fourth and sixth portion, the first prepreg sheet being adhered with the second surface of the first and third portion, the second prepreg sheet being adhered with the second surface of the fourth and sixth portion, the first conductive layers being adhered with a surface of the first prepreg sheet away from the first flexible PCB, the second conductive layers being adhered with a surface of the second prepreg sheet away from the second flexible PCB, thereby, obtaining a rigid-flexible PCB;
wherein the first and second portion of the first flexible PCB are separated from the fourth and fifth portion of the second flexible PCB.

2. The method of claim 1 , wherein a method for forming the prepreg sheets and conductive layers comprises:
providing the first prepreg sheet and the second prepreg sheet, the first prepreg sheet defining an opening aligned with the second portion, and the second prepreg sheet defining an opening aligned with the fifth portion;
positioning the first prepreg sheet on the second surface of the first and the third portion, positioning the second prepreg sheet on the second surface of the fourth and sixth portion;
providing a first copper foil and a second copper foil, positioning the first copper foil on a side of the first prepreg sheet away from the second surface of the first flexible PCB, positioning the second copper foil on a side of the second prepreg sheet away from the second surface of the second flexible PCB;
laminating the first copper foil, the first prepreg sheet, the first flexible PCB, the bonding sheet, the second flexible PCB, the second prepreg sheet and the second copper foil together; and
selectively etching the first copper foil to form the first conductive layer, selectively etching the second copper foil to form the second conductive layer, and a portion of the first copper foil aligned with the second portion and a portion of the second copper foil aligned with the fifth portion being removed by the etching process.

3. The method of claim 1 , wherein a method for forming the prepreg sheets and conductive layers comprises:
providing a first release film and a second release film, positioning the first release film on the second surface of the second portion, positioning the second release film on the second surface of the fifth portion;
providing a first prepreg sheet and a second prepreg sheet, positioning the first prepreg sheet on the second surface side of the first flexible PCB, the first prepreg sheet covering the second surface of the first and third portion, and a surface of the first release film away from the first flexible PCB, positioning the second prepreg sheet on the second surface side of the second flexible PCB, the second prepreg sheet covering the second surface of the fourth and sixth portion, and a surface of the second release film away from the second flexible PCB;
providing a first copper foil and a second copper foil, positioning the first copper foil on a surface of the first prepreg sheet away from the second surface of the first flexible PCB, positioning the second copper foil on a surface of the second prepreg sheet away from the second surface of the second flexible PCB;
laminating the first copper foil, the first prepreg sheet, the first flexible PCB, the bonding sheet, the second flexible PCB, the second prepreg sheet and the second copper foil together;
selectively etching the first copper foil to form the first conductive layer, and selectively etching the second copper foil to form the second conductive layer, a portion of the first copper foil aligned with the second portion and a portion fo the second copper foil aligned with the fifth portion being removed by the etching process;
a portion of the first prepreg sheet aligned with the second portion being removed to expose the first flexible PCBs, and a portion of the second prepreg sheet aligned with the fifth portion being removed to expose the second flexible PCBs; and
the first release film and the second release film being removed.

4. The method of claim 3 , wherein the first prepreg sheet is removed by laser cutting the first prepreg sheet along a boundary of the first portion and the second portion and a boundary of the second portion and the third portion, the second prepreg sheet is removed by laser cutting the first prepreg sheet along a boundary of the fourth portion and the fifth portion and a boundary of the fifth portion and the sixth portion.

5. The method of claim 4 , wherein the first prepreg sheet defines two first grooves, the first grooves pass through the first prepreg sheet, the second prepreg sheet defines two second groove, the second grooves pass through the second prepreg sheet, the two first grooves are respectively corresponding to the boundary of the first portion and the second portion, and the boundary of the second portion and the third portion, and the two second grooves are respectively corresponding to the boundary of the fourth portion and the fifth portion, and the boundary of the fifth portion and the sixth portion; the first groove are partly filled by the first prepreg sheet, and the second groove are partly filled by the second prepreg sheet in the laminating process, therefore, a thickness of the first prepreg sheet in each of the first groove is less than that of other portions of the first prepreg sheet, and a thickness of the second prepreg sheet in each of the second groove is less than that of other portions of the second prepreg sheet.

6. The method of claim 1 , further comprising respectively forming protective layers on surfaces of the conductive layers.

7. The method of claim 6 , wherein at least one opening is defined in each of the protective layers, and portions of the conductive layers exposed from the openings are contact pads, the contact pads are configured to electrically connect PCBs, or electronic components.

Assignees

• Garuda Tech Co Ltd
• Garuda Tech Co Ltd

Inventors

• Tsai Hsien-Ming

Classifications

• H05K3/4691 Primary

  Rigid-flexible multilayer circuits comprising rigid and flexible layers, e.g. having in the bending regions only flexible layers · CPC title

• H05K1/147

  at least one of the printed circuits being bent or folded, e.g. by using a flexible printed circuit (H05K1/148 takes precedence) · CPC title

• Y10T156/10

  Methods of surface bonding and/or assembly therefor · CPC title