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Flexible circuits have many supplemental constructions other than electrical traces to optimize their capabilities. The stiffener boards are the major one of them. An issue is that it is difficult to apply full automation to the process of making stiffener boards because of the many varieties. Most of the processes are conducted manually and are labor intensive. Sometimes stiffener boards account for a big percentage of the total manufacturing cost. An adhesive film is laminated on a rigid board with a release sheet first. The boards are then routed by punching or by NC router. It is a very simple process if the adhesive material is pressure-sensitive adhesives (PSAs). Each piece of stiffener is placed on the flex circuits with appropriate pressure, mostly by hand.The process is more complicated when a thermo-set type adhesive material is required. A temperature higher than 160 C with a pressure higher than 20 kg/cm2 is required for more than 30 min. A similar heat press used for multilayer circuit boards or film coverlay is necessary. Dummy boards should be prepared to make the pressure uniform. A heat press with a vacuum chamber or autoclave could provide uniform adhesion for irregularly shaped stiffener boards.

Many ideas have been introduced for packaging fragile HDI flex circuits. The packaging should provide easy handling capability, including the processing of the assembling side. A reeled tape modified from TAB technology is a valuable solution for volume production. A sheet carrier is another possible solution for medium- and large-scale production. Reusable cartridge or container designed for each circuit is recommended for volume production. An appropriate packaging design results a lot of benefit for both flex circuit manufacturers and customers. It needs a total design of the circuits including their manufacturing and assembling to optimize the productivities.

Roll-to-roll (RTR) manufacturing is a specialty developed for rolled materials of flex circuits. It can reduce manual handling and defects caused by human errors; therefore, when running effectively, it will increase productivity significantly and reduce manufacturing cost. On the other hand, RTR manufacturing has several serious disadvantages and a lot of applied limitations. It requires a large investment and advanced engineering capabilities. It is not appropriate for small-volume production, and can create a lot of scrap when not set up correctly. Table 63.10 shows advantages and disadvantages of RTR manufacturing systems for flex circuits. Table 63.11 shows available manufacturing processes and typical examples. Most RTR systems are developed for single-sided flex circuits.

Small flexibility for small volume Much scrap caused by small mistakes Large investment cost Limited for quick turnaround Low flexibility for design changes

TABLE 63.11 Availability of RTR Processes Process Surface cleaning Via hole generation Via hole plating Resist coating Pattern generation Developing Etching/strip resist Coverlay Surface treatments Blanking Inspection Stiffener boards Technical difficulty Standard machines available Possible, but difficult Big investment Standard machines available Standard machines available Standard machines available Standard machines available Possible, but difficult Standard machines available Possible, but difficult Possible, but difficult Difficult

RTR Drilling There have been significant technical barriers to applying the RTR system for double-sided flex circuit with through-holes. The NC drilling process is the bottleneck in introduction of the RTR system. A punching process, which is basically a continuous-flow process element, is an alternative technology to NC drilling of the RTR system to be used for double-sided flex circuits. However, it requires an expensive punching die and is not flexible for a design change. An RTR base NC drilling machine has been developed, as shown Fig. 63.34. The machine is capable to generate smaller holes than 100 micron diameters processing multiple rolls in a same time.

FIGURE 63.34 Reel-to-reel base numerical control drilling machine. (Source: Hitachi Via Mechanics.)

We now summarize a few basic algebraic operations that can be carried out with tensors to produce new tensors. These operations basically mirror the types of things you can carry out with vectors. For example, we can add two tensors of the same type to get a new tensor: R ab c = S ab c + T ab c

The new via hole technologies such as laser drilling and chemical etching are an innovative solution for generating small holes in rolled materials. A blind-via hole design is preferred for these RTR manufacturing processes.

RTR Copper Plating Technically, RTR copper plating is possible. But the line will be very long, and it is not easy to have uniform quality for the wide rolls.There is a difficult choice which is better vertical system or horizontal process.

Pattern Generation The pattern generation processes of resist coating, photo-print, development, etching and resist stripping are well established for single-side circuits. There are several key points such as straightness of the whole line, EPC (Edge Position Control), etc. Stability of loader/un-loader could be an example. Appropriate stabilities are required for the one-side holding systems of the rolled materials, especially for the wide materials. There are not many technical difficulties with double-side circuits for we processes such as development or etching. On the other hand, special alignment systems are required between top/bottom and holes/traces.