Method of forming three-dimensional circuitry

A method for forming three-dimensional electrical circuitry having conductors and at least one projecting feature projecting from said conductors to provide a contact button configured and arranged to be pressed against another electrical circuit comprising:

• forming an electrically conductive mandrel substrate having a working surface;
• forming a pattern of electrically non-conductive material on said substrate, said material having a non-conductive material surface that divides said substrate working surface into an electrically conductive pattern, said step of forming a pattern of electrically non-conductive material comprises:
• forming a pattern of grooves on said mandrel surface, and
• filling the groves with an electrically non-conductive material;
• forming an electrically conductive mandrel feature on said mandrel projecting from said working surface;
• electroforming a pattern of conductors and a contact button on the conductive pattern of said working surface and upon said mandrel feature;
• laminating a dielectric material upon said mandrel, upon said pattern of conductors and upon said contact button to position said dielectric material over said conductors and contact button, whereby said conductors are bonded to said dielectric material and whereby said contact button projects from said conductors;
• and
• separating said dielectric material with said electroformed conductors and projecting contact button from said mandrel substrate and its non-conductive material to provide a laminate of dielectric material having conductors thereon and a contact button projecting from said conductors.

A method of forming three-dimensional electrical circuitry having conductors and at least one projecting feature projecting from said conductors to provide a contact button configured and arranged to be pressed against another electrical circuit comprising:

• forming an electrically conductive mandrel substrate having a working surface;
• forming a pattern of electrically nonconductive material on said substrate, said material having a nonconductive material surface that divides said substrate working surface into an electrically conductive pattern;
• forming an electrically conductive mandrel feature on said mandrel projecting from said working surface;
• electroforming a pattern of conductors and a contact button on the conductive pattern of said working surface and upon said mandrel feature;
• laminating a dielectric material upon said mandrel, upon said pattern of conductors and upon said contact button to position said dielectric material over said conductors and contact button, whereby said conductors are bonded to said dielectric material and whereby said contact button projects from said conductors, wherein said step of laminating comprises:
• forming a laminate of a dielectric coated with adhesive,
• applying said laminate to said mandrel with said adhesive in contact with the mandrel and conductors and projecting feature, and
• causing said adhesive to flow over and around said conductors and projecting feature;
• and
• separating said dielectric material with said electroformed conductors and projecting contact button from said mandrel substrate and its nonconductive material to provide a laminate of dielectric material having conductors thereon and a contact button projecting from said conductors.

A method of forming three-dimensional electrical circuitry having conductors and at least one projecting feature projecting from said conductors to provide a contact button configured and arranged to be pressed against another electrical circuit comprising:

• forming an electrically conductive mandrel substrate having a working surface;
• forming a pattern of electrically nonconductive material on said substrate, said material having a nonconductive material surface that divides said substrate working surface into an electrically conductive pattern;
• forming an electrically conductive mandrel feature on said mandrel projecting from said working surface;
• electroforming a pattern of conductors and a contact button on the conductive pattern of said working surface and upon said mandrel feature;
• processing said conductors upon said mandrel;
• laminating a dielectric material upon said mandrel, upon said pattern of conductors and upon said contact button to position said dielectric material over said conductors and contact button, whereby said conductors are bonded to said dielectric material and whereby said contact button projects from said conductors;
• and
• separating said dielectric material with said electroformed conductors and projecting contact button from said mandrel substrate and its nonconductive material to provide a laminate of dielectric material having conductors thereon and a contact button projecting from said conductors.

A method of forming three-dimensional electrical circuitry having conductors and at least one projecting feature projecting from said conductors to provide a contact button configured and arranged to be pressed against another electrical circuit comprising:

• forming an electrically conductive mandrel substrate having a working surface;
• forming a pattern of electrically nonconductive material on said substrate, said material having a nonconductive material surface that divides said substrate working surface into an electrically conductive pattern;
• forming a first electrically conductive mandrel feature on said mandrel projecting from said working surface wherein said first mandrel feature comprises a depression formed in said mandrel, and forming a second mandrel feature projecting outwardly of said mandrel working surface;
• electroforming a pattern of conductors an a contact button on the conductive pattern of said working surface and upon said mandrel feature;
• laminating a dielectric material upon said mandrel, upon said pattern of conductors and upon said contact button to position said dielectric material over said conductors and contact button, whereby said conductors are bonded to said dielectric material and whereby said contact button projects from said conductors;
• and
• separating said dielectric material with said electroformed conductors and projecting contact button from said mandrel substrate and its nonconductive material to provide a laminate of dielectric material having conductors thereon and a contact button projecting from said conductors.

A method of additively forming three-dimensional electrical circuitry having raised contact buttons without employing circuit etching processes, said method comprising the steps of:

• providing a mandrel having an electrically conductive pattern on a surface thereof that defines a configuration of an electrical circuit, and having at least one electrically conductive mandrel feature projecting inwardly from said mandrel surface;
• electrodepositing circuit traces on said pattern and feature to define a three-dimensional electrically conductive circuit configured in said pattern and having a contact button projecting therefrom, wherein said contact button has a back side depression therein;
• back filling said back side depression with a rigid material;
• laminating a dielectric substrate upon said mandrel and said circuit traces, said substrate covering said back filled depression of said contact button;
• and
• separating said substrate and said circuit traces from said mandrel to provide a dielectric substrate having a pattern of circuit races thereon, including a rigid projecting conductive contact button configured and arranged to be pressed against contacts of another electrical circuit.

A method of forming three-dimensional electrical circuitry having conductors and at least one projecting feature projecting from said conductors to provide a contact button configured and arranged to be pressed against another electrical circuit comprising:

• forming an electrically conductive mandrel substrate having a working surface;
• forming a pattern of electrically nonconductive material on said substrate, said material having a nonconductive material surface that divides said substrate working surface into an electrically conductive pattern;
• forming an electrically conductive material feature on said mandrel projecting from said working surface;
• electroforming a pattern of conductors and a contact button on the conductive pattern of said working surface and upon said mandrel feature to define a projecting contact button having a back side depression therein;
• back filling said back side depression with a rigid material;
• laminating a dielectric material upon said mandrel, upon said pattern of conductors and upon said contact button and filled depression to position said dielectric material over said conductors and contact button, whereby said conductors are bonded to said dielectric material and whereby said contact button projects from said conductors;
• and
• separating said dielectric material with said electroformed conductors and projecting contact button from said mandrel substrate and its nonconductive material to provide a laminate of dielectric material having conductors thereon and a contact button projecting from said conductors.

A method of additively forming three-dimensional electrical circuitry having raised contact buttons without employing circuit etching processes, said method comprising the steps of:

• providing a mandrel having an electrically conductive pattern on a surface thereof that defines a configuration of an electrical circuit, and having at least one electrically conductive mandrel feature projecting from said surface;
• electrodepositing circuit traces on said pattern and feature to define a three-dimensional electrically conductive circuit configured in said pattern and having a contact button projecting therefrom;
• laminating a dielectric substrate upon said mandrel and said circuit traces;
• separating said substrate and said circuit traces from said mandrel to provide a dielectric substrate having a pattern of circuit traces thereon, including a rigid projecting conductive contact button configured and arranged to be pressed against contacts of another electrical circuit;
• and
• rigidifying said projecting conductive contact button.