The present invention comprises methods for making three-dimensional (3-D)
liquid crystalline polymer (LCP) interconnect structures using a high temperature singe sided
liquid crystalline polymer, and low temperature single sided
liquid crystalline polymer, whereas both the high temperature LCP and the low temperature LCP are drilled using a
laser or mechanical
drill or mechanically punch to form a z-axis connection. The single sided Conductive layer is used as a
bus layer to form z axis conductive stud conductive stud within the high temperature and low temperature LCP, followed by deposition of a metallic capping layer of the stud that serves as the bonding
metal between the conductive interconnects to form the z-axis
electrical connection. High temperature and low temperature LCP circuit
layers are etched or built up to form circuit patterns and subsequently bonded together to form final 3-D multilayer circuit pattern whereas the low temperature LCP melts to form both
dielectric to
dielectric bond to high temperature LCP circuit layer, and
dielectric to conductive bond, whereas,
metal to
metal bonding occurs with high temperature metal capping layer bonding to conductive metal layer. The
resultant structure is then packaged using two metallized organic cores that are laminated onto either side of the device using a low temperature
adhesive with similar electrical properties and subsequently metallized to form the
input output terminals and EM shielding.