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Manufacturing There are two kinds of manufacturing processes for the micro bump array on flex circuits: 1. The same technology as for ball grid arrays may be used. Solder paste is dispensed on the pads of the circuits with a liquid dispenser or screen printer.The solder paste will form spherical shapes for a refusing process. The process is available for relatively large solder balls. 2. Electroplating processes are used for small solder balls and non-spherical micro bumps. Suitable combinations of different metal plating can provide wide varieties of micro bumps. There are several factors that determine the shape and size of the bumps. The thickness of the dielectric layer and the size of the opening are the major factors in determining the bump shapes. The bump shapes will be more spherical when the aspect ratio of the opening is large. The bump shapes will be like flat discs when the aspect ratio is small. An appropriate plating mask will help to build straight, high bumps. When the micro bumps need to be built through the insulation layers, it requires a suitable hole generation process. Several laser drilling processes are recommended for small sizes but exact dimensions. Plasma etching and chemical etching are recommended for low cost processing with large numbers of the holes.

A thick-film circuit is a type of additive manufacturing process. If an organic resin matrix is used, the conductor can be flexible, and this process has been applied in flexible circuits.

Materials A silver paste conductor with an acrylic resin matrix is the most popular conductor material as the major thick-film conductor material for flexible circuits. It can provide very flexible conductor layers via a simple screen-printing process. Copper-based and carbon-based paste materials have been developed as the low-cost materials, but their conductivity is very low and unstable, and therefore their applicable areas are limited. The screen printing process with conductive paste provide low cost solutions for the large size flexible circuit employing economical plastic films such as PET films.

Applications A silver paste thick-film flexible circuit built on polyester film can provide the lowest-cost solution for large circuits. Unfortunately, the conductivity of the traces is much lower than for copper foil conductors, and this material is not available for power circuits or signal layers of high-speed circuits. Standard soldering is not available because of the acrylicbased matrix. The largest application of thick-film-based flexible circuits is in membrane switches, which need large circuit spaces but do not carry large currents. The majority of membrane switches are covered by silver paste thick-film flexible circuits. Major switching circuits of keyboard switches are also covered by the same constructions. Most of the key board circuits are covered by the silver paste base membrane switches. Most of the touch panel switches designed for micro waves, office appliances and medical equipment also use PET based membrane switches. Several examples are shown in Fig. 66.13.

PET based thick film flexible circuits have been consumed for the touch panel switches of the electronic terminals such as PDA because of their transparency.

Manufacturing Process It is a very simple process to build a thick-film flexible circuit. There are two steps: 1. Screen printing on a flexible film followed by baking. 2. Blanking. This still requires that the process conditions be controlled carefully.The basic properties of these circuits change significantly depending on these conditions. A pre-baking step is recommended for polyester film substrate to eliminate thermal shrinkage during baking for printed conductor paste. It is not difficult to apply the roll-to-roll manufacturing system for large volume because of the simplicity of the processes. The latest technologies of the printers and screens are able to produce 10 to 15 micron line space with low cost. The electrical properties and trace densities are very depend on the conductor paste. A combination with screen printable nano conductive paste will provide fine conductive traces by a simple manufacturing process.

EXAMPLE 3-7 Let Q ab = Q ba be a symmetric tensor and R ab = R ba be an antisymmetric tensor. Show that Q ab Rab = 0 SOLUTION 3-7 Since R ab = R ba , we can write Rab = Therefore, we have Q ab Rab = 1 1 ab Q (Rab Rba ) = Q ab Rab Q ab Rba 2 2 1 1 (Rab + Rab ) = (Rab Rba ) 2 2

When the flexible circuits are used as the cables for the high-speed telecommunications, appropriate shielding systems are required. Generally, the cable will be bent frequently, therefore the shielding layers should also have high flexibilities.

(c) FIGURE 66.14 Shielding of the flexible cables (a): Screen-printing of silver paste (b): Screen-printing of carbon paste (c): Lamination of thin aluminum foil.

Several materials and constructions are available for the shielding of the flexible cables as shown in Fig. 66.14. Screen-printing of silver paste provides both high shielding effect and high flexibility. Screen-printing of carbon paste provides low cost solution. But its shielding effects are limited. Thermal lamination of a thin aluminum foil with thin flexible adhesive provides a reliable solution for both shielding efficiencies and flexibilities.

Various new processes have been developed to build functional elements and devices on the flexible substrates. They have been generating more functions than wiring or assembling board of the discrete components. They are the similar ideas as embedded passive technologies of multilayer boards, but they generate more values with flexible substrates. Table 66.2 shows several material examples and applications.

These disasters can be avoided if you prepare for them ahead of time. Consider these suggestions every time you re conducting a presentation.

TABLE 66.2 Functional materials for flexible circuits Materials NiCr, W Functions Embedded resistors Heater Mechanical sensors Embedded capacitance Transparent electrode Embedded active devices Transistors and diodes Sensor devices Flexible displays