Method of making a supported foam circuit laminate

1. A method of making a supported foam circuit laminate, comprising:

fitting a dielectric foam substrate having a shape defined by edges to a support frame having a thickness, an inner rim and an outer rim, wherein

the edges of the dielectric foam substrate are flush with the inner rim of the support frame, and

the dielectric foam substrate has a thickness that is greater than the thickness of the support frame;

disposing an electrically conductive layer onto a side of the dielectric foam substrate and the support frame, wherein the edges of the electrically conductive layer overlap the inner rim of the support frame;

co-laminating the electrically conductive layer to the dielectric foam substrate and the overlapped frame under heat and pressure to provide a supported foam circuit laminate; and

forming a circuit in the electrically conductive layer.

2. The method of claim 1 , further comprising disposing an adhesive layer between the surface of the dielectric foam substrate and the electrically conductive layer.

3. The method of claim 2 , wherein the adhesive layer has a thickness of less than or equal to about 0.1 millimeters.

4. The method of claim 1 , further comprising pre-coating the electrically conductive layer with an adhesive prior to disposing the electrically conductive layer onto the dielectric foam substrate and the support frame.

5. The method of claim 1 , further comprising disposing a second conductive layer onto a side of the dielectric foam substrate and the support frame on a side opposite the first layer, wherein the edges of the second electrically conductive layer overlap the inner rim of the support frame.

6. The method of claim 5 , further comprising disposing an adhesive layer between the surface of the dielectric foam substrate and the second electrically conductive layer.

7. The method of claim 6 , wherein the adhesive layer has a thickness of less than or equal to about 0.1 millimeters.

8. The method of claim 5 , further comprising pre-coating the electrically conductive layer with an adhesive prior to disposing the electrically conductive layer onto the dielectric foam substrate and the support frame.

9. The method of claim 1 , wherein forming the circuit comprises etching the electrically conductive layer.

10. The method of claim 1 , further comprising excising the foam circuit from the support frame.

11. The method of claim 1 , further comprising forming plated through-holes in the supported foam circuit laminate.

12. The method of claim 1 , wherein the dielectric foam substrate is about 0.025 to about 0.175 millimeters thicker than the support frame.

13. The method of claim 1 , wherein the dielectric foam substrate comprises an open cell foam material.

14. The method of claim 1 , wherein the support frame is formed from a copper sheet.

15. A method of making a supported foam circuit laminate, comprising:

fitting a dielectric foam substrate having a shape defined by edges to a support frame having a thickness, an inner rim and an outer rim, wherein

the edges of the dielectric foam substrate are flush with the inner rim of the support frame, and

the dielectric foam substrate is about 0.025 to about 0.175 millimeters thicker than the support frame;

disposing an electrically conductive layer onto a side of the dielectric foam substrate and the support frame, wherein the edges of the electrically conductive layer overlap the inner rim of the support frame; and

co-laminating the electrically conductive layer to the dielectric foam substrate and the overlapped frame under heat and pressure to provide a supported foam circuit laminate.