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The basic concept of quality assurance for flexible circuits is the same as that for rigid boards, in the sense that any critical defect must be eliminated before shipping.This includes failures due to opens and shorts; dimensional degradation of pad arrays, serious defects on conductors, substrates, coverlay, and so on. These defects need to be inspected for each circuit, whether it is flexible or rigid. Technically, however, there are several differences in quality assurance for flexible circuits because of their additional functions, such as dynamic flexing capability. A common issue is damage incurred during the manufacturing process because of the fragile materials. Even though the fine traces are inspected by a high-resolution automatic optical inspection (AOI) system during processing, it is possible that subsequent processes may cause new damage to the inspected circuits. This is a special issue for flying leads, which have no mechanical support under the traces. Therefore, a final inspection is necessary at the end of the manufacturing process. The basic quality assurance concept for high-density flexible circuits is the same as for other circuit types. However, a difference for high-density flexible circuits is the acceptable defect size, which is one order smaller than that for traditional flexible circuits, necessitating higher inspection capabilities. Furthermore, new high-density flexible circuits contain additional structures such as flying leads and microbump arrays that require additional inspection capabilities for reliable termination. Exact 3-D accuracy and uniform surface conditions are required. Dimensional allowances are smaller than 0.3 percent, and sometimes 2-mm accuracy is required.

This is true for trace pitches, but it is also true for linewidths and spaces. Three-dimensional measurements are required to guarantee the quality of microbump arrays. Usually, it takes time to measure exact dimensions for each circuit, and this is one of the major costs of the circuits when the specification is very tight compared to the process capability. There have been several basic technical issues regarding quality assurance for high-density flex circuits, as listed in Table 67.1. Because of the fine circuits and the severe acceptable level of the defects, low-magnification scopes and low-resolution AOI do not work effectively. Magnification of 20 to 50 is required for visual inspections of fine circuits, and higher resolutions are required for AOI systems. Low contrast between copper and polyimide base creates another difficulty for traditional AOI equipment. It is not easy for common AOI systems to distinguish the copper traces from the circuits on the other side of a double-sided circuit built on adhesiveless substrate, because the base layer is very transparent and the sensor detects both sides of the circuits as one.

TABLE 67.1 Key Inspection Issues for High-Density Flex Circuit Item Finer traces Micro blind via holes Unstable materials Photoimageable coverlay Fragile traces Fragile flying leads Microbump arrays Cosmetic defects Issues Resolution of AOI Low contrast for AOI Resolution of AOI Dimensional accuracy Low contrast for AOI Damage during processes Damage from test probe pins Damage after AOI 3-D constructions Serious failures caused by small defects

At this time, all these methods are defined as being private to this object. Later on we will make them public, and any method in another procedure will be able to call and use them. When we combine all the preceding code into a program, we get the listing in Program 21-7.

AOI is the most valuable inspection equipment for detecting dimensional defects in the traces and spaces of the printed circuits, especially for high-density traces. It s also very useful for the detection of cosmetic defects on the surfaces. Further sensitivities are required for AOI systems to detect small defects on coverlay, flying leads, microbumps, narrow space perimeters, and so on. These small defects have low contrast, different kinds of brightness, and different defect shapes, among other things. Traditional AOI systems are usually not appropriate for inspection in these circumstances. Traditional AOI systems were designed for rigid circuit boards, and they were originally only good for the detection of copper trace qualities. They could work for 50-mm-line/space fine traces, but their inspection speed could be very slow. Therefore, remarkable progress has been made in the resolution and productivity of the newer AOI systems; and as a result, systems can now detect 1.5-mm defects on 15-mm traces. Also, the systems have other capabilities for detecting various defects on polyimide films and coverlay films.A careful review of AOI capabilities, compared to the specified design requirements, should be done prior to committing to a particular equipment.