Multilayered laminate

Details Multilayered laminate Multilayered laminate

2002-04-11

2003-02-11

Paladini, Albert W. (Department: 2827)

Electricity: conductors and insulators

Conduits, cables or conductors

Preformed panel circuit arrangement

C174S255000, C029S852000

Reexamination Certificate

active

06518516

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to conductive substructures of a multilayered laminate and associated methods of fabrication.
2. Related Art
FIGS. 1
,
2
, and
3
illustrate conductive substructures that may appear in a conventional multilayered laminate.
FIG. 1
illustrates a 0S2P substructure
10
,
FIG. 2
illustrates a 2S0P substructure
20
, and
FIG. 3
illustrates a 1S1P substructure
30
. Definitionally, the substructures in this application are described by an adjective of the form nSmP, wherein n and m are non-negative integers, wherein S stands for “signal plane,” and wherein P stands for “power plane.” Thus, “0S2P” connotes 0 signal planes and 2 power planes (n=0, m=2), “2S0P” connotes 2 signal planes and 0 power planes (n=2, m=0), and “1S1P” connotes 1 signal plane and 1 power plane (n=1, m=1). A conventional multilayered laminate comprises stacked substructures which may include any or all of the 0S2P, 2S0P, and 1S1P substructures.
A power plane is characterized by its inclusion of a continuously conductive layer. For example, the 0S2P substructure
10
in
FIG. 1
comprises a power plane
11
which includes a continuously conductive layer
12
, and a power plane
13
which includes a continuously conductive layer
14
. As another example, the 1S1P substructure
30
in
FIG. 3
comprises a power plane
31
which includes a continuously conductive layer
32
. Although not shown in
FIGS. 1 and 3
, a power plane may include one or more holes within the continuous conductive layer. The continuous conductive layer of a power plane may include copper.
A signal plane is characterized by its inclusion of a layer comprising conductive circuitry. For example, the 2S0P substructure
20
in
FIG. 2
comprises a signal plane
21
which includes a conductive circuitry
22
, and a signal plane
23
which includes a conductive circuitry
24
. As another example, the 1S1P substructure
30
in
FIG. 3
comprises a signal plane
33
which includes a conductive circuitry
34
. The conductive circuitry of a signal plane may include copper.
A substructure may include a via through its thickness, such as a conductively plated via
27
in the 2S0P substructure
20
in FIG.
2
.
In a substructure, a power plane cannot conductively contact another power plane, a power plane cannot conductively contact a signal plane, and a signal plane cannot conductively contact another signal plane. Thus, power planes and signal planes may be insulatively separated by a dielectric layer. As a first example, the 0S2P substructure
10
in
FIG. 1
comprises a dielectric layer
15
that insulatively separates the power plane
11
from the power plane
13
. As a second example, the 2S0P substructure
20
in
FIG. 2
comprises a dielectric layer
25
that insulatively separates the signal plane
21
from the signal plane
23
. As a third example, the 1S1P substructure
30
in
FIG. 3
comprises a dielectric layer
35
that insulatively separates the power plane
31
from the signal plane
33
.
Unfortunately, some or all of the preceding 0S2P, 2S0P, and 1S1P substructures prevent improved wiring density within the substructures, and thus within the overall multilayered laminate that includes the 0S2P, 2S0P, and 1S1P substructures. With the 2S0P substructure of
FIG. 2
, for example, the conductive circuitry
22
may be required to be oriented at about right angles to the conductive circuitry
24
in order to minimize cross-talk (i.e., noise) due to electromagnetic radiative coupling between the conductive circuitry
22
and the conductive circuitry
24
; i.e., if x and y axes represent orthogonal directions within the signal planes
21
and
23
, then the conductive circuitry
22
would be oriented in the x direction if the conductive circuitry
24
were oriented in the y direction, and vice versa. The aforementi ned directional constraints on the conductive circuitry
22
and the conductive circuitry
24
translates into a constraint on wireability (i.e., a constraint on how high the wiring density can be within the signal planes
21
and
23
).
Additionally, with less than optimum wiring density, the geometrical size of the overall multilayered laminate will have to be large enough to accommodate all of the wiring that is physically required for the intended application. The increased size is undesirable, because of at least two reasons. A first reason is that space is likely to be at a premium and a conservation of space is generally strived for in the electronic packaging industry. A second reason is that an increased size is more expensive because of increased material requirements and, more importantly, a requirement to drill longer through holes through the substructures and the overall multilayered laminate.
Moreover, if a highly pliable or flexible dielectric material is used in the substructures, then all three of the 0S2P, 2S0P, and 1S1P substructures will be required to have a thickness that is large enough for the substructures to have sufficient structural rigidity. Note that an organic dielectric material for use in a chip carrier may exemplify a highly pliable or flexible dielectric.
There is a need for conductive substructures for use in multilayered laminates such as chip carriers, wherein the conductive substructures improve wireability, reduce substructure and overall laminate thicknesses, and result in lower fabrication costs.
SUMMARY OF THE INVENTION
A second aspect of the present invention is a method for forming a multilayered laminate, comprising: stacking a plurality of signal/power plane substructures to for a stack of signal/power plane substructures , wherein a dielectric material of an intervening dielectric layer insulatively separates each pair of successive signal/power plane substructures; positioning a first continuously conductive layer on a first dielectric layer, the first dielectric layer stacked on a first side of the stack of signal/power plane substructures; positioning a second continuously conductive layer on a second dielectric layer, the second dielectric layer stacked on a second side of the stack of signal/power plane substructures; and applying heat and/or pressure to the resultant stack of signal/power plane substructures and the first and second dielectric layers and the first and second continuously conductive layers to form the multilayered laminate.
A second aspect of the present invention is an electrical structure, comprising: a multilayered laminate that includes in sequential order: (a) a first intermediate layer having microvias and conductive lands; (b) a plurality of signal/power plane substructures, wherein a dielectric material of an intervening dielectric layer insulatively separates each pair of successive signal/power plane substructures; and (c) a second intermediate layer having microvias and conductive lands.


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