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As the fundamental building block for printed circuits, base materials must meet the needs of the printed circuit board (PCB) manufacturer, the circuit assembler, and the original equipment manufacturer (OEM). A balance of properties must be achieved that satisfies each member of the supply chain. In some cases, the desires of one member of the supply chain conflict with another. For example, the need for improved electrical performance by the OEM, or improved thermal performance by the assembler, may necessitate the use of resin systems that require longer multilayer press cycles or less productive drilling processes, or both. Lead-free assembly processes are driving the need for greater thermal reliability. This will be discussed further in Chaps. 10 and 11. Other trends are also driving the need for greater performance. These include:

The density of IC packaging technologies such as ball grid array (BGA) and chip scale packages continues to increase. In turn, this requires greater interconnection density in the printed circuits onto which they are assembled. The need for increased density in the PCB impacts each of the components of the base material as well as the way in which they are manufactured. To achieve high levels of interconnection, component pitch densities result in smaller and more closely spaced plated through holes and circuit features. As the space between these holes and features decreases, the potential for conductive anodic filament (CAF) failures increases substantially. Higher operating frequencies can also impact each of the three main components of base materials. Circuits operating at high frequencies are driving the use of materials with low dielectric constants, low dissipation factors, and tighter thickness tolerances. These performance issues and the impact to the printed circuit manufacturing process are discussed in this chapter.

TABLE 63.12 Key Items for Dimension Control in Flex Circuit Manufacturing Categories Materials Design Manufacturing process Key items for dimension control Base film, copper, coverlay, bonding material Layer constructions, circuit density, circuit balance Wet processes, heat processes, mechanically stressed processes

TABLE 63.13 Critical Processes for Dimensional Control Process NC drilling TH plating Cleaning DF lamination and print Development Etching and stripping of resist Coverlay, film lamination Coverlay, screen printing Coverlay, photoimageable Lamination for multilayer Plasma etching HASL Electro- and electroless plating Baking RTR process Category Mechanical Wet and heat Wet and heat Mechanical Wet and heat Wet Heat and pressure Heat Heat Heat and pressure Heat High heat Wet and heat Heat Mechanical Importance Medium High Medium High High High High High High High Medium High Medium High Medium

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the various dimensional alterations, particularly as additional factors are incorporated into the process. 5. Coverlay processes There are several coverlay processes that have been developed with varying process conditions for different concept materials. Film coverlay undergoes a manufacturing process with a temperature greater than 160 C and a pressure over 20 kg/cm2. Cover coat ink withstands a screen-printing process with a drying temperature higher than 130 C. A newly developed photoimageable coverlay must be baked at over 150 C.The majority of the heat and pressure processes impact dimensional stability significantly. Additional factors, such as press pad heating, make dimensional changes even more complicated. Conditioning should be reviewed in detail for each construction. 6. Lamination pressing for multilayers Like the coverlay process, lamination pressing involves high temperature and pressure. Due to the number of layers, however, dimensional changes are more complicated because each level needs to be considered.