Methods of optical filament scribing of circuit patterns with planar and non-planar portions

Abstract

Methods of forming optical filament circuit patterns with planar and non-planar portions are provided. An optical filament circuit pattern is scribed by moving a filament guide and a substrate relative to one another at a speed between about 110 inches/minute and about 190 inches/minute, and dispensing an optical filament on, or in the vicinity of, a surface of the substrate. The filament or the substrate or both have adhesive surface(s). The adhesive surface is capable of being adhesively actuated by application of energy. Energy is applied simultaneous with, or subsequent to, scribing. Preferably, ultrasound energy is applied having an output power between about 2.0 watts and about 3.5 watts while applying a pressure to the filament between about 1.177 Newtons and about 1.324 Newtons. A portion of the filament circuit pattern is planar and another portion is non-planar. The non-planar portion traverses but does not contact or adhere to a pre-selected area of the substrate. The pre-selected area corresponds with a pad, a contact pattern, a hole, a slot, a raised feature, a part of the previously scribed planar portion of the pattern, and a filament termination point. Alternately, the non-planar portion may be embedded below the surface of the substrate. Another planar portion of the filament circuit traverses the non-planar portion but does not contact or adhere to a pre-selected part of the previously scribed non-planar portion. Optical filament-scribed circuit boards are formed by this method.

Dependencies are inferred from the claim text.