As new generations of electronic products emerge they often surpass the capability of existing packaging and interconnection technology and the infrastructure needed to support newer technologies. This movement is occurring at all levels: at the IC,at the IC package,at the module,at the hybrid,the PC board which ties all the systems together. Interconnection density and methodology becomes the measure of successfully managing performance. The industry must address the technology gap between printed boards and semiconductor technology and how the semiconductor and IC packaging suppliers can combine resources in furnishing viable solutions. Although the development of fine-line substrates and assembly refinement has narrowed the gap somewhat,minimizing component outline,the array contact
format and reduced contact pitch is proving to be the most practical solution for uncased flip-chip and die-size package
applications.
This paper outlines the basic elements furnished in the newly released IPC-7094 ‘Design and Assembly Process Implementation for Flip-Chip and Die Size Components’ providing a comparison of existing and emerging wafer level and chip-size package methodologies. It will focus on the effect of PCB design and assembly of bare die or die-size components in an uncased or minimally cased format. The PCB design guidelines and assembly process variations furnished will provide useful and practical information to those who are considering the adoption of miniature bare die or die size array components.

Even though ink jet printed circuit has many advantages over typical subtractive PWB technology such as fewer processes,less waste and labor,it has some problems. A major problem is weak adhesion between circuit and substrate. The other problem with ink jetting conductor is poor line and edge quality. One of the most widely adapted solutions is the substrate surface treatments. The various treatment methods have been used to increase the affinity between substrateand ink. However,the resulting circuit quality was still not good enough to be compatible with conventional circuit. Therefore,printed electronics industry is looking for new method.
To meet this demand,a novel primer coating technology is developed. An aromatic primer was spin coated and dried on
either Fr-4 or PI substrate. The contact angle between nano silver ink and the coated surface has been increased more than three times to 50~70 degrees,resulting in quality ink jet printing. The line definition and edge quality of 100um/100um circuit after sintering was as good as those of conventional circuit. Fine pattern up to 25um/25um was possible using 10um nozzle. The adhesion by newly developed peel test method was 1~1.5 kgf/cm2,which is compatible with conventional PWB. The reliability of printed circuit was also good. The details of peel test method and reliability test results will be presented.

For several years,3D-integration approaches have been explored to keep pace with the continuous trends towards electronics
miniaturization and densification. Numerous technologies issued from various chip-,package- or board-level concepts can now be used and combined to achieve highly integrated “smart” systems. PCB embedding of passive and active devices is one of these advanced options with a strong potential : it enables a dramatic functionality increase while maintaining key PCB attributes of component and interconnects carrier. The presented paper will discuss some aspects of the PCB embedding technology developed in the frame of the HERMES project (High density integration by Embedding chips for Reduced size Modules and Electronic Systems). This European funded FP7 3 years research program targets to establish an industrial platform capable of producing PCBs with 2 layers of embedded components including large die sizes. The embedded PCBs manufactured will then be populated with external SMD components on both sides to constitute complex high-end integrated modules able to withstand conventional repair operations and ensuring a high reliability level. The work carried out will support the design and manufacturing of the various HERMES functional demonstrators for security,automotive and power module applications.

Manufacturers of electronic devices are always searching for new technologies that can improve processes,extend capabilities and lower costs. These drivers,along with the needs of new markets like Printed and Plastic Electronics,have brought processes like inkjet printing to the forefront. This paper explores the promise of what inkjet printing can bring to process simplification,cost reduction and improved capabilities. It also takes a critical look at the practical issues and concerns of this new technology.

Miniaturization and higher functionality in electronics packaging require the use of advanced packages and small components. This trend has translated into the use of new package types such as Quad Flat Pack – No Lead (QFP) (also referred to as Leadless Plastic Packages),increased use of chip scale packages as well as increased component density and tighter PCB layouts. Advanced package innovations and new flux types may compromise the validity of the R.O.S.E. cleanliness testing method. This paper researches the effectiveness of the R.O.S.E. cleanliness testing process for dissolving and measuring ionic contaminants from boards soldered with no-clean and lead-free flux technologies. The paper researches quality assurance and process control improvements needed to clean,extract,and measure the resistivity of solvent extract on today’s circuit assemblies.

Electronics manufacturing process engineers are faced with significant challenges when selecting a cleaning system as a
consequence of the wide ranges of cleaning processes and equipment. Currently available cleaning systems include aqueous
processes,semi-aqueous processes,monosolvent vapor degreasing and co-solvent vapor degreasing; while equipment options
include inline,batch,centrifugal and ultrasonic immersion. When matching the right process with the right equipment for a
specific application,many other factors must be considered including performance,capital expense,SHE (safety,health and
environmental) restrictions,throughput,available floor space,chemical compatibility and operating costs and maintenance
costs. An analysis of the total cost of ownership of a cleaning process is an important step in choosing the right process.
This analysis helps identify the lifetime costs of acquiring,maintaining and operating a process. This paper discusses the
factors,advantages and disadvantages that should be considered for each of the commonly used processes in the electronics
cleaning industry to help determine the total cost of ownership.

Lead-free flux technology for electronic industry is mainly driven by high soldering temperature,high alloy surface tension, miniaturization,air soldering due to low cost consideration,and environmental concern. Accordingly,the flux features desired included high thermal stability,high resistance against burn-off,high oxidation resistance,high oxygen barrier capability,low surface tension,high fluxing capacity,slow wetting,low moisture pickup,high hot viscosity,and halogen-free. For each of the feature listed above,corresponding desired chemical structures can be deduced,and the impact of those structure on flux residue cleanability can be speculated. Overall,lead-free flux technology results in a greater difficulty in cleaning. Cleaner with a better matching solvency for the residue as well as a higher cleaning
temperature or agitation are needed. Alkaline and polar cleaner are often needed to deal with the larger quantity of fluxing products. Reactive cleaner is also desired to address the side reaction products such as crosslinked residue.

With the miniaturization of electronic devices1,the need for more versatile materials to make these devices increases. Coupled with the gradual removal of lead-based solders2,thermal stability of modern electronics materials is necessary to withstand high rework temperatures. Alternative non-lead solders such as the tin-silver-copper (SAC) solder increase rework temperatures by about 30-40°. New chemistries that increase the glass transition (Tg) and thermal decomposition temperatures (Td) have been developed to maintain the reliability of devices such as printed circuit boards (PCBs) and interconnect (IC) substrates during downstream assembly and rework processes. By increasing the crosslink density of a thermosetting material,higher Tgs are attained. The higher crosslink densities are achieved by increasing the functionality of
the resins and hardeners. High crosslink densities are achieved at the expense of brittleness for these materials. During part
fabrication of PCBs and ICs,circuitry is completed by copper-plated drill-holes between the different layers of the laminates. Currently,these drill-holes are predominantly mechanically drilled into the laminate. Drilling of brittle laminates is problematic because of problems associated with cracking,delamination,and drill-bit wear and breakage. Although the drilling equipment,drill bits,and drilling parameters can be optimized to minimize such issues,additional efforts are desirable to improve the drillability of the PCBs and ICs. Toughening materials are being incorporated into the resin formulations to improve drillability.
In this work we report results from a study on incorporating pre-formed toughening materials into high crosslink density
phenolic cured resin formulations and the effect of the toughener on thermomechanical properties,toughness and drillability
of the electrical laminates. The objective of the current work is to provide a toolbox that will help correlate the thermomechanical properties of the resin formulations to the drillability performance of the corresponding PCBs. Such a correlation is presently absent. These correlations will speed the new materials evaluation process relative to the drillability performance without the expensive and time-consuming process of performing extensive drilling studies.

An overview of previous work regarding light enegine development is provided,proceeded by an in-depth overview of new technology available for solder mask imaging.

Reel to reel production of flexible circuits where the substrate consists of a continuous roll is a technique commonly used in mass production. This method is an obvious solution for efficient Handling of the very flexible and sensitive materials used. This paper presents the latest innovations for production of flexible circuits in a continuous horizontal production system incorporating desmear and electroless copper metallisation followed by Electrolytic copper reinforcement with reverse pulse plating.
The special requirements of flexible material handling in particular in combination with thin copper foil are discussed together with the options available for metallisation and electrolytic copper plating equipment. This demand for thin copper foil is becoming more common for flexible applications to enable tighter line and space specifications. The copper plating system uses a special clamp on one side of the substrate with large contact area which ensure good electrical contact with the thin material also at high applied current densities and under reverse pulse plating.
The advantages of horizontal plating systems for this application are shown,in particular the use of insoluble anodes for copper plating to maintain surface plated copper uniformity and quality. In the system shown the use of segmented insoluble anodes is critical to ensure the best possible surface distribution at the high current densities used. The importance of uniform electrolyte agitation is discussed and methods to achieve this with varying substrate thickness are shown. The metallisation and also electrolytic copper plating utilises frequency controlled pumps and also a special active level control system to maintain optimum working conditions irrespective of the material being processed and the pump flooding set up.
This combination of features in the equipment allows the use of high production current densities even with thin flexible base
materials with thin conductive layers.
Results are shown from production systems being used to produce material with various material types and thicknesses. One
example has laser drilled glass reinforced substrate with through vias which are metallised and subsequently through hole
copper plated in a complete reel to reel production system.