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TABLE 61.8 Properties of Traditional Polyimide Films and New Polyimide Films Kapton H Manufacturer Thickness (mm) Tensile strength (kg/mm2) Elongation (%) Tensile modulus (kg/mm2) CTE (ppm) (100 200 C) CHE (ppm) (50 C, 35 75% RH) Heat (%) shrinkage (200 C, 2 h) Water absorption (23 C, 24 h) Alkaline resistance Chemical etching MD TD MD TD MD TD MD TD MD TD MD TD DuPont 12.5, 25, 50, 75, 125 25.2 22.3 85 83 336.1 321.4 27 31 15 16 0.18 0.20 2.8 17.4 Possible Apical AV Kaneka 12.5, 25, 50, 75, 125 25.0 27.0 119 114 305.9 312.2 35 31 16 15 0.08 0.03 2.9 25.9 Possible Kapton E DuPont 12.5, 25, 50, 75 28.3 25.4 16 32 785.5 622.4 3 12 5 8 0.03 0.02 2.2 5.5 Possible Apical NP Kaneka 12.5, 25, 50, 75 30.0 32.0 82 73 407.9 428.3 17 13 13 12 0.06 0.02 2.5 22.9 Possible Apical HP Kaneka 12.5, 25, 50, 75 28.6 29.0 40 38 654.0 661.0 12 11 8 6 0.06 0.02 1.1 4.2 Possible Upilex S Ube 12.5, 25, 50, 75, 125 39.4 40.2 22 21 897.3 912.1 14 15 9 10 0.07 0.10 1.9

material of the flexible circuits High moisture levels in the films cause a lot of supplemental problems, mostly in increased temperature processes Higher-performance polyimide films are required as the substrate material of HDI flexible circuits The primary materials used in industry to optimize cost and performance have been 50 micron thick polyimide film, used for industrial and avionics applications, and 25 micron thick films, used for consumer applications However, since late 1990s, films as thin as 125 micron have been specified to reduce thickness and increase flexibility 61522 High-Performance Polyimide Film Various manufacturers have made several aggressive measures to commercialize high-performance polyimide films Upilex S by Ube Industry has excellent chemical stability, and it is a barrier for chemical processes such as adhesion with the other materials or chemical etching Strong chemicals, such as hidrasine, are required to do the chemical etching.

Upilex-S could be the major material as the substrate of TAB, which requires very high dimensional stability at high heat resistance Newly developed polyimide films such as Kapton E, EN, and Kaneka s Apical NP and FP have higher dimensional stability and lower moisture absorption rates It is possible to etch these films using mild alkaline chemistry Basic properties of the materials are summarized in Table 618 Hot-melt-type (thermoplastic) polyimide films have been developed as high-heat-resistant adhesive materials Mitsui Chemical s TPI, DuPont s Kapton KJ, Ube s Upicel, and Kaneka s Pixeo are typical examples These are coated on dimensionally stable polyimide films to ensure good physical performance 61523 Liquid Polyimide Resin (Photoimageable) Many new HDI applications require special capabilities and properties on the substrates that are not provided by commercial polyimide films In these cases, circuit manufacturers initiate production by manufacturing polyimide substrates.

Sometimes manufacturers have to start from the synthesis of polyimide resins Several liquid polyimide resins have been developed as the base materials of high-density flexible circuits Some of these liquid polyimide resins can be photoimaged, and have been used in high volume as the dielectric layer and coverlay in the wireless suspension of hard disk drives These liquid polyimide resins could be the major dielectric materials of special high-density flexible circuits that demand extremely high density, down to 5 micron pitches with 10 micron via holes The cost of these materials is higher than that of polyimide film However, they have broader capability for meeting nonstandard requirements such as ultrathin substrates with microvia holes The properties are very dependent on the manufacturer..

Polyester Film PET film (polyester film or polyethylene telephthalate) has been produced as a common film for general use, for the following reasons:

It can provide a low-cost solution. It has excellent mechanical performance at room temperature. It has low moisture absorption and its dimensional stability is excellent.

Unfortunately, PET film cannot keep its high performance at higher temperatures than 70 C, and it is available for only nonsoldering applications. (Several soldering technologies have been developed for PET-based flexible circuits, but they are very specialized.) Also, PET films are flammable and it is difficult to achieve UL flame class certification. Not many available PET films can satisfy the flammability requirements of UL-94. Typical properties are shown in Table 61.9.

TABLE 61.9 Basic Properties of PET Films (Nonflammable Grade) Properties Test Items Tensile strength (kgf/mm2) Elongation Edge tear resistance (kgf/mm) Folding endurance Heat shrinkage CTE CHE Water absorption Volume resistivity Dielectric constant Dielectric loss Breakdown voltage Light transmission Chemical resistance Flammability

16 16 110% 100% 51 58 37,000 times 39,000 times 1.4% 0.2% 30 ppm 10 ppm 0.7% 4 exp 15 *cm 3.0 for 1 MHz 0.03 for 1 MHz 13.6 kV 46% Stable in weak acid and alkaline solution Stable in organic solvent UL-94-VTM-0

Other Materials Used for Flexible Circuits Thin glass-epoxy sheets less than 200 mm thick can be flexible and can be used as a base substrate of low-cost flexible circuits. Their physical properties are basically the same as those of rigid circuit boards, and standard manufacturing processes and assembling processes for rigid circuit boards are available for these materials. Standard soldering processes are applicable. But glass-epoxy sheets do not have high flexibility, and they are not available for repeated flexing use. The basic properties of these materials are listed in Table 61.10.