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Keypad Contacts There are several different constructions for keypads on flexible circuits. Thick-film circuits on polyester film called membrane switch could be a low-cost solution with many millions of reliable contacts. The basic mechanism of the switching is illustrated in Fig. 64.25. Generally, the membrane switches are connected through FFC connectors to the main circuit board. Polyimide-based circuits are necessary with soldering of components.

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The membrane switches built on polyester film are widely used as the standard keyboard circuits of personal computers. They are also used as the switching components of touch panel boards for home appliances such as microwave ovens and office machines such as copy machines. They are also used with the touch screens of display devices.

No perfect termination technology can satisfy all requirements, especially for high-density connections with high pin counts. On the other hand, higher performances are required for the new portable electronics to complete reliable terminations in limited spaces. Accordingly, many new termination technologies with flexible circuits have been developed to satisfy many requirements. Nevertheless, it is still difficult to use one termination technology to satisfy

TABLE 64.12 New Termination Technologies for High-Density Flexible Circuits Termination density (mm pitch) 300 150 150 50 200 60 300 200

Termination technology Lead-free reflow Lead-free hot bar reflow Wire bonding Direct bonding High-density BGA for flip-chip Anisotropic conductive materials Small-pitch ZIF connectors Contact probe array

Requirement for flex circuits Higher heat resistance (260 C for 30 sec.) High heat resistance (400 C for 10 sec.) High dimensional accuracy ( 0.02%) High heat resistance (450 C for 3 sec.) Flying-lead construction (50 mm pitch) Microbump array (200 mm pitch) High dimensional accuracy ( 0.01%) High dimensional accuracy ( 0.05%) uniform tin plating Microbump array hard gold plating on nickel

all requirements. Therefore, suitable combinations are recommended to complete all terminations in an electronic product or module. Table 64.12 shows several examples of the major termination technologies used for high-density flexible circuits.

Originally, the basic design concepts and manufacturing processes for the multilayer rigid/flex had been developed for aerospace equipment because of the need to manage reliable wiring in limited space. More than 30 conductor layers were built on a rigid/flex for complicated applications,. On the other hand, consumer portable products such as cellular phones and digital cameras have long been demanding high-density, low-cost wiring technologies and new design concepts and new manufacturing processes have been developed for this task. A combination of rigid and flexible circuits can be called rigid/flex, flex/rigid, or rigid/flexible. However, they are called multilayer flex when flexible materials are used instead of glass/epoxy. The term rigid/flex is used throughout this chapter.

Multilayer rigid/flex is basically a combination of rigid multilayer and flexible circuit processes. However, the successful accomplishment of this combination requires a high level of skill in both areas, and it is important to have a clear understanding of the abilities and limitations of the chosen fabricator before designing this type of circuit for a product.

Now consider the opposite. When a lowered index in a tensor matches a raised index in the Kronecker delta, set that index to the value of the lowered index of the Kronkecker delta:

65.2.1 Basic Constructions There are many different concepts in the construction design of multilayer rigid/flexible circuits. Figure 65.1 shows the basic construction of a multilayer rigid/flex, both from a plane view and in cross section. Figure 65.2 shows an example of this construction with air gaps between the flexible layers, in order to have high flexibility. More than 30 layers are built in extreme cases, such as for aerospace applications. Because of the requirement for high-reliability, fine pattern designs with micro via holes cannot be used. In addition, leaded components are

specified instead of SMT components. The design usually calls for relatively large lines/spaces and large-diameter through-holes with thick copper plating. There are several types, designated the folding type (Fig. 65.3), the flying tail type (Fig. 65.4), the bookbinder type, and so on, according to their shapes. 65.2.2 Materials

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