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The rest of the processes are very similar to those used for multilayer rigid boards. Outer layer etching, coverlay (solder mask), and surface treatment are conducted in the same way. When the dummy boards are removed after routing, the circuit becomes a rigid/flexible circuit. 65.2.4 Through-Hole Process When inner via holes are required in flexible layers, the same through-hole process should be conducted prior to etching of inner-layers as for rigid board inner-layers. Figure 65.7 shows an example of inner via holes in flexible parts of a multilayer rigid/flex, and Fig. 65.8 shows a cross section of a multilayer rigid/flex plated through-hole. The through hole drilling can be accomplished by the same machine as used for rigid multilayer boards. However, the drilling conditions should be determined carefully for each material s construction. Baking conditions prior to drilling could be critical in creating reliable through-holes. Desmearing of the rigid/flex is different from that of standard rigid multilayer boards. The acrylic adhesive materials will undergo serious swelling during standard FIGURE 65.8 Cross section of a through-hole in a permanganate desmearing processes, lower- multilayer rigid/flexible circuit. ing through-hole reliability. A plasma etching process is recommended to remove the smears of acrylic adhesive materials in the drilled holes. Use of a polyimide adhesive system can reduce the smear level significantly, but this also requires a high-temperature process in special press equipment.

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Aerospace and industrial equipment require a higher reliability for the through holes than consumer electronic products Copper plating thicker than 25 microns is recommended Several adhesive resins, especially acrylic-based adhesives developed for flexible circuits are not stable with the permanganate solution that is common for rigid multilayer boards, which means that a very narrow window is allowed for the desmearing of the rigid/flex process If the materials are dipped too long in the solution, the adhesive layers swell and the reliability of the through holed will be damaged A plasma etching process has been introduced to remove the smear inside of the drilled holes as a substitute for using potassium permanganate solution for the polyimide base multilayer rigid/flex The plasma gas removes the smear in the holes effectively without chemical damages on the adhesive resins.

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The use of supplemental plasma etching, called the Etch Back Process, is recommended to achieve high reliability of throughhole multilayer rigid/flexible circuits The plasma gas provides further etching on both of polyimide films and adhesive layer in the drilled holes The plasma gas does not etch metal materials and it FIGURE 659 Etchback of through-hole clears the surface of the copper foils for reliable copper plating as in multilayer flexible circuit shown in Fig 659 6526 Bookbinder Construction A multilayer rigid/flex that has multiple conductor layers in its flexible (parts fixed by rigid caps at both sides) will not bend effectively if all the layers are of the same length Special designs are not required while the flex areas have long distance and they use thin films and copper foils They are sometimes called Air Gap Construction.

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We also need to be able to send the LCD certain nonprinting instructions, and this is done with the send command instruction mentioned in the preceding list. Let s first build up the methods that control the LCD; they use the Register Select line, the Read/Write line, and the Enable line. We set the LCD up for initial use by sending it some special instructions that specify the number of bits, number of lines, font size, cursor condition, and other factors. These instructions and their proper uses are described in the Hitachi manual.

The Bookbinder Construction is recommended for the reliable interconnects of the multiple flexible layers in a rigid/flex with a short distance A longer length of the flexible layer should be provided at the outer side of the flexible area When they are bent, the flexible layers have uniform gaps between the flexible layers as shown in Fig 6510 Special tooling and equipment are required to build the bookbinder construction, and the productivity is comparatively extremely low As a result, this process is not used for consumer or other applications that require low cost..

There are basically three ways to increase printed circuit density:

Decrease conductor line widths and the spacings between them Increase the number of circuit layers in the PCB Reduce via and pad sizes.