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63.1 63.2 63.3 63.4 63.5 63.6 63.7 63.8 63.9 63.10 63.11 Introduction / 63.1 Special Issues with HDI Flexible Circuits / 63.1 Basic Process Elements / 63.3 New Processes for Fine Traces / 63.14 Coverlay Processes / 63.24 Surface Treatment / 63.30 Blanking / 63.31 Stiffener Processes / 63.33 Packaging / 63.33 Roll-to-Roll Manufacturing / 63.34 Dimension Control / 63.36

64.1 64.2 64.3 64.4 64.5 64.6 Introduction / 64.1 Selection of Termination Technologies / 64.1 Permanent Connections / 64.4 Semipermanent Connections / 64.11 Nonpermanent Connections / 64.13 High-Density Flexible Circuit Termination / 64.20

65.1 Introduction / 65.1 65.2 Multilayer Rigid/flex / 65.1

400

We need two more pieces of information to characterize the tetrad. The rst is we specify that the two real vectors satisfy l n =1 and nally, the complex vectors satisfy m m = 1 (9.5) (9.4)

temperatures in the range of 290 310 C, while the 140 C Tg FR-4 materials generally have slightly higher Td values. The shaded regions indicate the peak temperature ranges for standard tin-lead assembly and lead-free assembly. A very common question is, if a PCB will be assembled at 260 C, and the material has a decomposition temperature of 310 320 C, then why wouldn t it be compatible with lead-free assembly The answer lies in the level of decomposition in the temperature ranges where assembly will take place. In the tin-lead temperature range, neither material exhibits a significant level of decomposition. However, in the lead-free assembly temperature range, the traditional FR4 begins to exhibit 1.5 3 percent weight loss. This level of decomposition can compromise long-term reliability or result in defects such as delamination during assembly, particularly if multiple assembly cycles or rework cycles are performed.

TYPES OF FR-4

As can be seen in Table 6.2, several materials listed are considered FR-4. This begs the question: What is FR-4 In Table 6.2, it can be seen that each material considered FR-4 is flame-resistant, uses a woven fiberglass reinforcement and is primarily an epoxy-based resin system.

The Many Faces of FR-4 So what can be different about these materials The most obvious difference between the commercially available FR-4 materials is in Tg values. Specification sheet 21 refers to an FR4 with a minimum Tg of 110 C. More common are FR-4 materials with Tg values between 130 C to 140 C and 170 C to 180 C. Therefore, it is obvious that FR-4 materials can consist of different types of epoxy resins. Indeed, there are many types of epoxy resins that will provide differing Tg values, as well as differences in other properties. Specification sheets 92-95 list FR-4 materials with non-halogen-based flame retardants, as well as different Tg ranges. Sheets 92 and 94 indicate the use of a phosphorus-based flame retardant, whereas sheets 93 and 95 show the use of aluminum hydroxide. So FR-4 may include different types of flame retardants. In addition, several FR-4 materials, such as those shown in sheets 99, 101, and 126, show that these materials contain inorganic fillers. These fillers are often used to reduce the amount of Z-axis expansion. Some of these materials also have requirements for Td, Z-axis expansion and time-to-delamination, which historically were not properties included on the specification sheets. The addition of specification sheets with these properties was partly driven by their relevance to compatibility with lead-free assembly processes. Finally, specification sheet 82 covers an FR-4 material catalyzed for an additive copperplating process. A catalyst used for this material is a kaolin clay filler coated with palladium. In short, there are many combinations of resin system, flame retardant and filler that can result in many types of FR-4.

The Longevity of FR-4 FR-4 materials have been the most successful, most commonly used materials in printed circuit manufacturing for many years. Why Well, as we just discussed above, FR-4 actually encompasses a range of material types, even though they share certain properties and are primarily epoxy-based. The result is that there is often an FR-4 material readily available for the most common end-use applications. For relatively simple applications, the 130 C to 140 C Tg FR-4s have become the material of choice. In higher layer count multilayer circuits, in very