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Applications Due to usage and assembly technologies, many applications require increased performance for high-density flexible circuits. The manufacturing processes for these circuits must adapt to new requirements imposed by additional process conditions.Table 61.4 lists major applications and the associated advantages of using high-density flexible circuits for a given purpose.

TABLE 61.4 Major Applications of High-Density Flexible Circuits Applications Wireless suspension of disk drives Reasons to use high-density flexible circuits High-density wiring in a small space Flexible, thin, light, 3-D wiring Direct connection to magnetic heads High-density wiring in a small space Flexible, thin, light, 3-D wiring Repeated reparability High-density wiring in a small space Thin, light, 3-D wiring High-density wiring in a small space Flexible, thin, light, 3-D wiring Chip-on-flex capability High-density connection High-density wiring in a small space Flexible, thin, light, 3-D wiring Direct connection to ultrasound device High-density wiring in a small space Flexible, thin, light, 3-D wiring surface-mount technology (SMT) and COF capability High-density wiring in a small space Flexible, thin, 3-D wiring Direct connection to printer head device

Describe the transformation matrix that maps cartesian coordinates to polar coordinates, and write down the polar coordinate basis vectors in terms of the basis vectors of cartesian coordinates.

Without high-density flexible circuits, these applications could not achieve miniaturization or support valuable new functions. For example, specially developed high-density flexible circuits can provide highly reliable connections at a low cost for new tiny magnetic heads of hard disk drives with a vertical recording system. Chip-scale package (CSP) technologies can be developed with high-density flexible circuits. Driver integrated circuits (ICs) for flat panel displays in personal computers and large flat panel TVs are assembled with a set of chip-on-flex (COF) substrates. Due to the limited space within the camera bodies, small liquid crystal display (LCD) monitors for video cameras and digital cameras are assembled using long-tailed high-density flexible circuits. The wiring of the next generation of portable electronics cannot be completed without high-density flexible circuits.

The basic difference between flexible circuits and rigid circuit boards is the thin and flexible materials used in the substrates of flexible circuits. Furthermore, because the flexible circuits have complicated constructions, supplemental materials other than copper-clad materials have been required to build a whole circuit.

Traditional Flexible Circuit Materials Table 61.5 shows traditional major materials and typical examples of flexible circuits. A broad variety of the materials are employed to build traditional flexible circuits. Film materials, such as polyimide (PI) films and polyester (PET) films are the specially adapted for use in flexible circuits. For greater flexibility, rolled annealed (RA) copper foil is used as the major conductor material. Coverlays and stiffeners are typical examples of the special components needed to build flexible circuits. Many types of materials have been introduced to accommodate the designs of the end applications.

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TABLE 61.5 Traditional Major Materials Used to Build Flexible Circuits Application Base substrates Conductors Copper-clad laminates Coverlay Adhesive layer Stiffener Typical materials Polyimide film (PI), polyester film (PET), polyester telephthalate Thin glass-epoxy, fluorinated ethylene propylene (FEP), resin-coated paper Electrodeposited (ED) copper foil, RA copper foil, stainless steel foil, aluminum foil, etc. Epoxy-based, acrylic-based, phenol-based (adhesive-based) PI film, PET film, flexible solder mask Acrylic resin, epoxy resin, phenol resin, pressure-sensitive adhesives (PSAs) PI film, PET film, glass-epoxy, metal boards, etc.

HDI-Oriented Flexible Circuit Materials Since 1990, many new materials for flexible circuits have been developed in conjunction with design and manufacturing processes to satisfy new requirements in HDI applications. These include:

High-performance films Adhesiveless laminates Direct cast processes of liquid polyimide resins Photoimageable coverlay

TABLE 61.6 Materials for High-Density Flexible Circuits Application areas Base dielectrics Conductor materials Copper-clad laminates Coverlay Adhesive sheets New materials for high-density flexible circuits Polyimide films (Kapton K, E, EN, KJ; Apical NP, FP; Upilex S) Liquid polyimide resin, PEN film, LCP films Ultra-thin copper foils, sputtered copper, copper alloys, stainless steel foil Adhesiveless laminates (cast type, sputtered/plated type, laminated type) Photoimageable coverlay (PIC) (dry film type, liquid ink type) Hot-melt polyimide film