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An NCP connection looks similar to the flip-chip connection described in Section 64.3.7. The NCP connections do not need such severe conditions for both temperature and pressure. The nonconductive paste filled between the bare chip and flexible substrate works as an adhesive resin (see Fig. 64.12). It Bare Chip Micro Bump has good bond strength for both the bare chip and the substrate.The adhesive resin shrinks under a thermal treatment and generates negative pressure between the chip and flexible substrate. The negative pressure is remarkably strong at the contact points of the microbumps, so the metal-to-metal bonding is made between the microbumps and the pads of the flexible substrates (see Fig. 64.12.). A smaller contact of the microbump is recommended to generate a higher presFlexible Substrate NCP sure at the bonding points. The gold bumps or soft goldFIGURE 64.12 NCP bare chip packaging. plated copper bumps and tin-plated copper pads usually are

FIGURE 64.13 Cross section of NCP packaging, (a) Stud bump made by wire bonding machine. (b) Flat bump made by platting process.

used for this bonding. Stud bumps made by the similar machines as gold wirebonding provide needle shapes at the top of the bumps to make good bonding (see Fig. 66.13). NCP connection provides a higher reliability than ACM connections with a pitch smaller than 100 micron. The density of an NCP connection looks lower than that of an ACM connection, but it covers more pin counts in a small space, utilizing the area connection capability. 64.3.11 Automatic Equipment for the Permanent Connections Many kinds of equipment have been developed for the high-density permanent terminations of flexible circuits. However, the basic process and equipment look similar. A mounting machine places the devices on the reeled flexible circuit with accurate alignment by CCD cameras. The bonding head adds pressure and heat from the top of the electronic devices. An ultrasonic vibration of the bonding head could help to increase the reliability of the connections.

During each phase of thermal modeling, the solids of the components, PCB, and system enclosure must be defined to the code These solids are meshed by the code, a process through which the objects are broken into tens of thousands of discrete nodal points The computer calculates thermal parameters such as temperature and heat flow at each of these nodal points as a function of neighboring nodal points rather than trying to solve analytical equations for the thermal fields If the meshing is fine enough, the calculated solution will be very accurate If the meshing is too coarse, errors will creep into the model There is a trade-off between accuracy and run time in computer simulations; models with coarser meshes usually run much faster than models with fine meshes.

It is best for users to become familiar with the mesh sensitivity of their chosen modeling tool to optimize run time versus accuracy before running critical analyses When performing a CFD system-level analysis to determine temperatures on a PCB, it is important to include all airflow obstructions that might change the convection on the PCB and its components Common airflow obstructions include cables, RF shields, daughter cards, brackets, air filters, capacitors, transformers, memory single in-line modules (SIMs), power regulators, and hard drives Failure to include these air blockages in the modeling process can result in systems that run too hot or that suffer from thermal shutdown External blockages should be accounted for as well Cabinet vents should not be located where a user might carelessly toss a magazine or CD cover.

The impact of accumulated dust over the lifetime of the system should also be considered, as the dust can substantially reduce convection From a PCB layout standpoint, the highest velocity air stream on the board may well occur between two tall components if they block the airflow path The blockage causes the air to be channeled through the gap, resulting in higher air velocities High-power electronic components can sometimes be more effectively cooled by placing them in this channeled air stream Locations to avoid for high-power components are the leeward side of air blockages, immediately downstream of high-power components, or on the bottom center of a natural convectioncooled PCB..