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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

Several supplemental materials are necessary for building a multilayer rigid/flex, as shown in Table 65.1. It should be noted that there has been significant technical progress in the development of these high-performance materials.

TABLE 65.1 Materials for Multilayer Rigid/Flexible Circuits Materials required Flexible substrates Copper-clad laminates (double-sided) Coverlay Bonding sheets Traditional materials Traditional polyimide films (Kapton H , Apical AV ) Polyimide film substrate Acrylic adhesive (epoxy adhesive) Traditional polyimide films coated with acrylic or epoxy adhesives Acrylic resin films Epoxy resin films Polyimide films coated with acrylic adhesives on both sides Glass/epoxy boards High-performance materials New polyimide films (Kapton E , Apical HP , Upilex S ) Polyimide film substrate Adhesiveless laminate (cast materials or laminated materials) New polyimide films coated with hot-melt polyimide adhesives New polyimide films coated with hot-melt poyimide resin on both sides

The materials must have high heat resistance and high dimensional stability to survive during several high-temperature processes. Thicker polyimide films (50 mm thick or thicker) are recommended because the basic dielectric materials are required to have good stability in the manufacturing processes.An acrylic adhesive system in copper-clad laminates, as well as coverlay film and bonding sheets that have higher heat resistance than epoxy systems, are also recommended for use in manufacturing. Adhesiveless, copper-clad laminates, made by casting or lamination processes, usually perform better in high-temperature processes.They are also valuable because they reduce the total thickness of the finished board. Hot, melt-type, polyimide adhesive systems, including coverlay films and bonding sheets, have been developed to have very high reliability and smaller thicknesses.They can reduce smear level in drilled holes significantly. But they must be processed at temperatures higher than 300 C, and therefore require special facilities and conditioning. 65.2.3 Manufacturing Process Flow There are many varieties of manufacturing processes for multilayer rigid/flexible circuits because of their complicated structures. Figures 65.5 shows a typical layer construction using

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the standard manufacturing process for multilayer rigid/flexible circuits shown in Fig. 65.6. As seen in Fig. 65.6, the process starts with flexible, double-sided copper-clad laminates. The conductive patterns are generated by the traditional etching process without through holes. All traces are covered with plain coverlay films, which have no openings. The multiple covered flexible circuits are bonded with bonding sheets, which are already routed to make openings for nonbonding flexible areas. Caps (the outside layers of rigid parts) are made with rigid double-sided copper-clad laminates. Traces are printed and etched only on the inside surfaces of the laminates as the first process. Flexible parts of the boards are removed through NC routing or punching. Both flexible layers and caps are bonded with bonding sheets that have been routed for flexible parts. Appropriate dummy boards are prepared for the flexible part during the bonding process. A vacuum press is preferred for good bonding quality. An autoclave system is recommended for complicated circuit constructions, because the autoclave can create uniform pressure on the entire circuit. Suitable baking should be done prior to lamination or bonding processes. As the laminated board can be handled in the same way as multilayer rigid boards, the same through-hole processes are available, except desmearing, which is dependent on the combination of materials used (see later).The drilling process is conducted after enough baking in basically the same way as for rigid boards. A plasma etching process should be applied to remove smears of acrylic resins in the holes. The etchback conditions should be determined carefully. The same through-hole plating process is available; however, detailed conditions must be determined based on reliability test data.

FIGURE 65.7 Example of typical multilayer rigid/flexible circuit with via holes. (Source: Toshiba.)

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