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FIGURE 63.24 Twenty micron pitch traces made by advanced screenprinting process. (Source: Micro Tech.)

Via Diameter (micron)

Semi-Additive with laminate Semi-Additive with sputtering 50 100 200 Circuit Density (micron pitch)

(a) Before concluding the meeting, the chair will review any assignments and announce the time of the next meeting. (b) Finally, the chair will call the meeting to a formal close.

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Semi-additive process with thin copper laminates will provide reliable solutions to produce the fine line generation down to 20 micron pitches with 40 microns via holes for both single and double-side circuits. Technical hurdles are relatively low other than the control of the copper plating. The copper thickness of the original laminate is the key to producing finer traces. Semi-additive process with sputtered seed layers is able to generate the finest traces, all the way down to 5 micron pitches with 10 micron via holes, on a thinner polyimide layers than 10 microns.A well conditioned sputtering is the key to have reliable bond strength for the fine traces.Additionally, a photolithography process with photo-sensitive polyimide resin provides the multi-layer capability with micro-size via holes for the ultra-fine flexible circuits.

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It needs some more technical improvement to make the full-additive process with chemical deposition practical. Another full-additive process with high resolution screen printing will be a low cost solution for the 20 micron pitch single-side circuits when appropriate conductor materials are ready to apply. Combinations with the other technologies will create double-side and multi-layer capabilities.

The coverlay construction of flexible circuits demands another special process. It is very different from the solder mask used for rigid circuit boards. Furthermore, recent high-density flexible circuits need new coverlay technologies.Table 63.7 summarizes the comparison of traditional coverlay technologies and new technologies. Traditional film coverlay has an excellent balance of physical properties and can provide high reliability, especially for long dynamic flexible endurance.

TABLE 63.7 Coverlay Process Options Accuracy (minimum opening) Traditional film coverlay Film coverlay + laser drilling Screen print liquid ink Photoimageable, dry film type Photoimageable, liquid type Low (800 mm) High (50 mm) Low (600 mm) High (80 mm) Reliability (flexing endurance) High (long) High (long) Acceptable (short) Acceptable (short) Acceptable (short) Material selection PI, PET PI, PET Epoxy, PI Epoxy, PI, acrylic Epoxy, PI Equipment/ tooling NC drill, heat press Heat press, laser Technical hurdles Need long experience Low

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High (80 mm)

Unfortunately, it requires very complicated, labor-intensive processes, and it is difficult to introduce automatic manufacturing systems.Another big issue is that the standard film coverlay process cannot make small openings with high dimensional accuracy because of the manual handling of thin film materials. Fine openings smaller than 200 mm in diameter with high dimensional accuracy and better than 100 mm positioning have been required for flexible circuits that need high-density interconnect (HDI). Examples include SMT of CSP or chip type passive components. Screen printing of flexible ink can provide a low-cost solution for volume production. However, it cannot provide a better solution for small openings with high dimensional accuracy. The technology of photo-imageable coverlay could be the right solution to the problem of having fine openings with high dimensional accuracy along with keeping the cost down by automation. A suitable photo-sensitive material has been in demand to satisfy all of the requirements. 63.5.1 Film Coverlay A typical coverlay manufacturing process is shown in Fig. 63.26. Generally the same film materials are chosen for the base film and the coverlay film. A B-stage adhesive such as epoxy

or acrylic resin is coated on one side of the film covered with a release sheet The epoxy-based coverlay films have a short shelf life in the room temperature and must be kept in a refrigerator Openings for access windows are made by NC drilling or punching with a release sheet The surface of traces must be cleaned before coverlay lamination takes place It is difficult to introduce an automation system for the lamination process because the materials are very unstable after window openings are made Manual alignment is the solution for this process unless the circuit needs an accurate registration higher than +/ 05 mm After the coverlay film is temporarily fixed on the circuit, the adhesive layer is cured in a heat press or autoclave similar as multi-layer rigid boards A suitable curing condition should be chosen carefully based on the circuit design and material conditions.

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