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circuits are required for switching circuits and test probe circuits. Flat-panel switches and electrical test probe fixtures for microcircuits are typical examples. As flex circuits have high-density cabling capabilities other than the mounting capabilities of electronic components, there have been serious requirements for high-density nonpermanent termination. There have been two kinds of approaches to realizing high-density nonpermanent flex circuits. The first is improvement in connection densities of traditional termination technologies. Crimp tabs, pressure contacts, key contacts, and FFC connectors could be categorized in this group. Another approach is a new concept. Anisotropic conductive rubber, dimple contacts, and bump contacts are typical examples.The technologies are compared in Tables 64.9 through 64.11.

TABLE 64.9 Nonpermanent Interconnects with Flexible Circuits Objectives Crimp tabs Key pad contacts FFC connectors Area array connectors Dimple contacts Microbump arrays Flex-flex Flex internal Flex-flex or rigid boards Flex-rigid boards Flex-rigid parts (flex-flex) Flex-rigid boards and parts Application examples Tach panel switches Keyboards Computer peripherals Industrial equipment Inkjet printers Board testers

TABLE 64.10 Performance of Nonpermanent Technologies Connection density Crimp tabs Keypad contacts FFC connectors Area array connectors Dimple contacts Microbump arrays 1.27 mm pitch 10 in 1 cm2 0.3 mm pitch 100 contacts per cm2 20 contacts per cm2 400 contacts per cm2 Repeatability 100 10 million 100 500 1000 1 million Trace density of flex circuits 1.27 mm pitch 200 mm pitch 150 mm pitch 100 mm pitch 0.5 mm pitch (150 mm pitch) 60 mm pitch

TABLE 64.11 Items to Be Considered for Nonpermanent Termination Technologies Supplemental parts Crimp tabs Keypad contacts FFC connectors Area array connectors Dimple contacts Microbump arrays Tab and housing Conductive keypads or a sheet ZIF connectors Male and female connectors (Housing) (Housing) Applicators Applicator No SMT soldering Special soldering Simple tooling Special fixtures Remarks Low connection density. Density depends on mechanical key sizes. Soldering on the other circuit. High-density traces are required on flex circuits. Suitable forming process shall be developed. Suitable processes to build microbumps must be developed.

General Connectors Most of the general connectors designed for other wiring technologies are applicable without serious changes. (Figure 64.16 shows a set of alternative designs.) 64.5.1.1 Card-Edge Connectors. All kinds of connectors designed for rigid circuit boards are available for flexible circuits. They can be mounted and soldered on flexible circuits supported with stiffener boards of suitable thickness. Card-edge connectors designed for rigid circuit boards are also available. A flexible circuit with a suitable stiffener board on the bottom can be inserted into the connector. However, the newest FFC connectors designed specifically for flexible circuits have a much higher density in a smaller housing and should be replaced by FFC connectors for large volume.

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64.5.1.2 Area Array Connectors. Density higher than 150 mm pitch on double-sided flexible circuits with through holes is required for high-pin-count connections. All kinds of connectors designed for rigid printed circuit boards are available for flexible circuits with some modification on flexible construction. A newly designed array connector for high-density flexible circuits can make 300 connections in a 10 15 mm area (see Fig. 64.17). Special constructions are not necessary, other than 0.5 mm pitch array soldering. However, traces with pitches smaller than 150 mm are required for high pin counts.They can survive 1,000 repeated contacts. 64.5.1.3 Crimp Tabs. Crimp tabs were originally developed for connections of flat conductor cables; however, they are also applied for flexible circuits because of the similar construction. An applicator firmly staples female tabs mechanically through dielectric layers (see Fig. 64.18). Male tabs are stapled on the other cable. Both are covered with plastic housings. Because there is no soldering process, polyester-based materials are available. For a long