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laser, however, has higher manufacturing costs than the excimer laser process because of the additional chemical processes required to remove the organic residue left on the copper surface, but it has a lower associated manufacturing cost for larger opening sizes due to faster abrasion speeds.

TAB has been developed as the special wiring material for IC chips and liquid crystal displays (LCDs). Although it was developed separately from standard flexible circuits, they have similar constructions and they use similar materials, and can be categorized as one kind of flexible circuits.

Basic Concepts Basic construction of TAB is the same as that of the flying-lead structure of flex circuits except for the web size used in manufacturing and the sprocket holes made for reel-to-reel conveyor systems which give TAB an appearance similar to that of cinema film. A 35-mm-wide web is the most common standard width for TAB. Webs 70 and 155 mm wide are available for larger circuits, nowadays. Because of the small working areas, TAB is good at producing fine traces with flying leads. The reeled circuits are convenient for automation of circuit manufacturing and termination. A short strip circuit made by standard manufacturing processes for flex circuits is also called a TAB circuit because it has the same functions. (Examples of TAB are shown in Fig. 66.8.)

Manufacturing Processes The basic manufacturing flow of single-sided TAB is the same as that of the traditional prepunch manufacturing process of flying-lead construction. Basically, all manufacturing processes of TAB are designed for automatic reel-to-reel equipment. Actual processing steps are slightly

Plastic film in roll Resist coating Slit to work width Pattern generation Sprocket punching Etching Glue coating Coverlay coating Device hole opening Surface finishing Coppr foil lamination Packing in reel

It was Monday morning, and I was doing a program on presentation skills for a group of fty managers. I arrived an hour early and began to set up. When the projector was connected, the client s laptop couldn t read some of my slides. No problem. I attached my own laptop to the projector. The projector wouldn t recognize my laptop. No problem. I reattached the client s computer while I began to remove the slides that wouldn t work with their system. With ten minutes until my start time, Burt, the tech support manager, arrived and began to adjust the projector. When he got everything connected, the slides came up on the screen upside down. No problem. With only a few minutes left until showtime, I knew I needed to focus on how I would proceed. I let the technical team deal with the computer while I left the room and created a new introduction. I decided how I could make the whole situation an example of how easily things can go wrong. After all, I was teaching a presentation skills course, and the class needed to know about these things. With only two minutes until showtime, Burt managed to get the slides upright, and I went back to my original plan. No problem!

different as shown in Fig. 66.9. The process starts from a plain film, mostly polyimide film. The first parts of the manufacturing are glue coating and punching of the hole generation. Secondary, a copper foil is laminated and the fine traces are generated by photolithography and chemical etching. Thirdly, final finishing such as cover coating and surface finishing is conducted. All of the processing equipment has to have loader and un-loader by reels,. The machines should be free from manual handling to eliminate the mechanical damages on the fragile fine flying leads. The whole process has to be kept in clean rooms to avoid the contamination for the fine lithography processes. Because of the narrower material width, TAB constructions have high capability for fineline generation with good dimensional accuracy. The chemical etching process is also available to generate device holes. The technology can generate 40-mm-pitch traces as the flying leads. The manufacturing process for the double side TAB with fine flying leads and micro via holes is much more complicated. Very few manufacturers are capable to produce the products with high yield.