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62.3.8 Micro Bumps and Dimples Many kinds of micro bump arrays and dimple arrays have been developed for high-density terminations of flexible circuits other than solder ball grid arrays. Recent technologies allow for a wide variety of shapes, materials, sizes, and pitches; down to 50 microns. The solder ball arrays are built by similar processes of the rigid BGA substrates. The combinations of the electrical and electroless-plating process provide a lot of choice for the shapes and sizes of the micro bump arrays on flexible circuits. The double-access capabilities of flexible circuits provide more choices for the locations of the micro bumps, as shown in Fig. 62.12, other than through coverlay. The micro bumps can be built on the bottom side of the conductors through base layers. They can be also built on both sides of the flying leads. An appropriate design should be chosen according to the requirements of the terminations.Whether it s a permanent connection or non-permanent connection is one of the key points needed for designing the basic constructions of the micro bumps. Bump density and reliability are other factors needed to design the micro bump structures. Details of the manufacturing processes are described in Chaps. 64 and 67.

Dimple structure of flexible circuits is a low cost solution for the non-permanent termination. Multiple dimple arrays can be formed on the polyimide base or PET base flexible circuits by simple pressing processes. (Details are shown in Fig. 62. 13) A typical example of the dimple termination is the connection of the disposable cartridges of ink jet printers. Over 60 dimples with hard gold plating are formed at the end of flexible circuit for the connection with the ink cartridge. The dimple arrays can make reliable connections over one thousand times.

Dimple structures (Ink jet printer).

One of the major features of flexible circuits is their long flexing endurance. A suitable layer construction and materials survives over billion times of flexing with a small radius. A basic idea of the mechanical stress during the bending is illustrated in Fig. 62.14(a). To have the longest flexing life, the conductor layer should be the center of the layer construction. It should have symmetrical layer constructions for both sides of the conductor layer. The flexing life will be remarkably shorter when the conductor layer is out side of the bending center as shown in Fig. 62.14(b). A rolled annealed copper foil should be used instead of ED copper foil for a longer flexing life. But there is no exact relation between roll direction and flexing

You are already somewhat familiar with the notion of a metric if you ve studied calculus In that kind of context, the quantity ds 2 is often called a line element Let s quickly review some familiar line elements The most familiar is.

Tension Coverlay film Adhesive layer Conductor layer Center line Compression (a) Adhesive layer Base film

Coverlay film Adhesive layer Adhesive layer Base film Conductor (a) Coverlay film Adhesive layer Adhesive layer Base film Conductor (b) Coverlay film Conductor Base film (c)

There are two things that are more dif cult than making an after-dinner speech: climbing a wall which is leaning toward you and kissing a girl who is leaning away from you.

FIGURE 62.15 Layer construction for dynamic flexing, (a) Standard layer construction, (b) Dynamic flexing construction with thin adhesive layers, (c) Dynamic flexing construction without adhesive layer.

endurance; the exact performance should be evaluated for each material. Generally, 35 microns thick RA copper is more expensive than the same thick ED copper foil. The cost difference between RA copper foil and ED copper foil will be larger at thinner thickness. A high ductility ED copper foil could be alternative choice for middle class dynamic flexing. Its flexing life is shorter than RA copper foil, but it is less expensive and it can survive one million flexing instances with an appropriate layer construction and flexing radius. Another principle is that for dynamic flexing, the thinner the layer, the better.An 18-mm-thick copper foil has a longer flexing life than a 35-mm-thick copper foil. A 12.5-mm-thick polyimide film provides a longer flexing life than a 25-mm-thick polyimide film (Fig. 62.15). Adhesive layers should be as thin as possible for dynamic flexing. But thin adhesive layers do not have good bond strength and good encapsulation for traces, and therefore a suitable thickness should be determined based on experimental data. Generally, polyimide films have a longer life than polyester films. The combination of a thin, adhesiveless, polyimide base laminate and a thin coverlay of liquid polyimide resin could be the best solution to have the longest flexing life. Many kinds of bending modes on flexible circuits could be practical, but in IPC-TM-650 it is recommended to evaluate the flexing life using the movement shown in Fig. 62.16.