Methods and devices for manufacturing of electrical components and laminated structures

A device for manufacturing of electrical components on at least one of a continuous web and discrete sheets of dielectric material from at least one of a supply roll of a laminated web and a supply of sheets including at least one layer of conducting material laminated on a flexible backing layer of dielectrical material, said device comprising:

• a patterned cylinder;
• a cooperating cylinder forming a nip into which at least one of said web and discrete sheets is fed to shape said conducting layer into a repeated pattern of conducting material having ridges and valleys;
• and
• a device to remove, by mechanical machining, conducting material from at least one of the ridges the valleys of said thus shaped metal layer, said cooperating cylinder being configured as a milling cutter cylinder, to remove conducting material from said conducting layer simultaneously as the conducting layer is forced against the patterned cylinder to shape said repeated pattern.

A method for patterning at least one of a continuous web and discrete sheets, the method comprising:

• feeding said at least one of continuous web and discrete sheets from at least one of a supply roll of continuous web and a supply of discrete sheets,
• the at least one of continuous web and discrete sheets including a first layer of a first material, and a second layer of a second material,
• said first layer being laminated on said second layer,
• at least one of said continuous web and discrete sheets being fed to a nip between a patterned cylinder and a cooperating cylinder to shape said first layer into a repeated pattern of said first material having ridges and valleys;
• and
• removing, by mechanical machining, said first material from said thus shaped first layer, the removing being performed simultaneously with the feeding to shape the first layer and by way of said cooperating cylinder, designed as a milling cutter cylinder.

A device for patterning at least one of a continuous web and discrete sheets, the device comprising:

• means for feeding said at least one of continuous web and discrete sheets from a supply roll of at least one of continuous web and a supply of discrete sheets,
• the at least one of continuous web and discrete sheets comprising a first layer of a first material, and a second layer of a second material,
• said first layer being laminated on said second layer;
• means for feeding at least one of said continuous web and discrete sheets to a nip, between a patterned cylinder and a cooperating cylinder, to shape said first layer into a repeated pattern of said first material having ridges and valleys;
• and
• means for removing, by mechanical machining, said first material from said thus shaped first layer, said cooperating cylinder being designed as a milling cutter cylinder, arranged to remove said first material from said first layer simultaneously with the shaping of the first layer.

At least one of continuous web and discrete sheet, comprising:

• a first layer of a first material;
• and
• a second layer of a second material,
• said first layer being laminated on said second layer,
• a portion of said first layer being removed so as to expose a surface portion of said second layer,
• such that a border portion is formed at the transition between an unremoved portion of the first layer and an exposed portion of the second layer,
• at said border portion,
• as seen in a plane that is substantially perpendicular to the main plane of the laminated sheet,
• the thickness of the first layer being continuously tapering from a point where the first layer is substantially unremoved to a point where the second layer, is exposed.