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It provides a high productivity for the prototype or middle volume productions On the other hand, it is not very capable for traces finer than 25 microns lines and spaces Lower throughput compared to traditional exposure machines, especially for double-side imaging, is the barrier for the volume productions..

Etching Ferric chloride or cupric chloride solution is recommended for use as the etching chemicals for flexible circuits, especially for high-density circuits. An alkaline solution has a higher process speed, but is not good on fine circuits because of unstable etching rates. As an alkaline solution makes some chemical attacks on polyimide surfaces, it should not be used for fine line requirements. There are appropriate correction factors for the etching rates of each combination. Between conductors, patterns, thickness, and etching, solutions should be introduced for the photo masks, based on the actual trials, especially for the multiple parallel fine lines very common to high density flexible circuits. Usually, there are remarkable differences in etching factors between middle conductors and edge conductors, as shown in Fig. 63.13. A set of dummy conductor patterns helps to minimize the difference of the etching factors.

The generation of fine lines is the most basic process in building high-density flexible circuits. Three basic manufacturing concepts have been developed: 1. Advanced subtractive 2. Semi-additive 3. Full-additive

These methods have many variations to cover different construction concepts and specifications. Innovative technologies have been developed for each unit process, such as the collimated light source exposure machine and the laser direct imaging system.

Advanced Subtractive Process The subtractive (etching) process is the most common technology for generating copper-based circuitry on flexible film substrates. It is basically the same method used for rigid boards, but there are several differences in the process. An example is that it may be automated for use with a roll-to-roll process. Subtractive technology with traditional equipment and materials cannot produce highdensity traces with pitches smaller than 150 mm. However, many new technologies have been introduced for each key item, as shown in Table 63.6. The most advanced subtractive process with adhesiveless laminates can generate 30-mm-pitch traces on 9-mm copper foil for the single-side circuits using roll-to-roll manufacturing systems. A 50 micron pitch trace circuit is shown in Fig. 63.14 .

TABLE 63.6 New Technologies Needed to Generate Fine-Line Traces on Flexible Substrates Processes Surface treatment Resist coating New technologies New soft etching chemicals (organic) Sputtering of seed layer High-resolution liquid etching resist and plating resist (spray coater, dipping coater, etc.) Thin dry film ( 15 mm) High-sensitivity dry film with high resolution (10 mJ/cm2) Wet laminator Collimated light source with glass mask ( 15-mm line/space) Autoalignment system for double-sided circuits (with accurate dimension compensation system, 5 mm) Roll-to-roll conveyor system with low tension Laser direct imaging system (30 40 mm line/space) High-resolution etchant (cupric chloride, ferric chloride)

It is possible to produce 20-mm-pitch traces by subtractive process (as shown in Fig. 63.15), but the process will have relatively low yields.. The advanced subtractive process can produce 60-mm-pitch traces on double-sided flexible circuits with thin copper foil plated to 20-mm-thick. Processes New technologies Surface treatment New soft etching chemicals (organic) Sputtering of seed layer Resist coating High-resolution liquid etching resist and plating resist (spray coater, dipping coater, etc.) Thin dry film (~15 mm) High-sensitivity dry film with high resolution (10 mJ/cm2) Wet laminator Exposure Collimated light source with glass mask (~15-mm line/space) Autoalignment system for double-sided circuits (with accurate dimension compensation system, ~5 mm) Roll-to-roll conveyor system with low tension Laser direct imaging system (30 40 mm line/space) Etching High-resolution etchant (cupric chloride, ferric chloride)

FIGURE 63.14 Fifty micron pitch trace produced by advanced subtractive process. (DKN Research.)

FIGURE 63.15 Twenty micron pitch traces made by advanced subtractive process. (DKN Research.)

3. Call for committee or individual reports. (a) The details are reviewed at this time. This is the typically the longest part of the meeting. (b) It is the chair s responsibility to keep the meeting on track and on time. (c) The chair also directs and elds questions. 4. Lead open discussion of any old business. If any items were carried over from the last meeting, this is the time to discuss them. 5. Ask for new business. (a) The chair begins by asking, Are there new topics to be introduced (b) The chair must keep discussions focused.

Semi-Additive Processes The first candidate to produce fine traces instead of subtractive process could be the semi-additive process. Several kinds of semi-additive processes including thin copper laminates and sputtering were developed to generate fine-line traces on specific polyimide substrate materials. An advantage of these processes is that the conductor layers can have