An optical interconnection technology for multi-layer printed circuit boards is presented. The application of this technology enables onboard data rates of several Gbps whereas at the same time a significant improvement on the electromagnetic compatibility (EMC) can be achieved. After an introduction,the most important properties of electrical interconnects are compared with those of optical interconnects. Moreover,requirements are derived which are essential to be met for an industrial use of optical interconnection technology on the printed circuit board level. The most important one of these requirements is to ensure compatibility with the existing design,manufacturing,and assembly processes. In the second part the current state of the art of this new technology,which takes into account the different demands and requirements,is presented. Technologies for the manufacturing of optical layers,their integration into the printed circuit board,as well as coupling concepts enabling furthermore the pick & place process are presented and discussed. As an efficient employment of this new technology requires also an enhanced and efficient design process,the necessary extensions are introduced. This includes an overview on modeling and simulation techniques for the active and passive components whereas again compatibility with the existing printed circuit board design tools is essential.

The rapid developments of IT equipment are placing increased demands on printed wiring boards (PWBs) in terms of high efficiency,high-density and lightweight. Industry experience has proven that glass fiber base materials are essential for highly reliable PWBs,in particular to obtain such characteristics as heat resistance,dimensional stability,and mechanical strength and insulation reliability. There can be some difficulties in the processing of traditional PWB laminating in terms of accuracy and cost performance applications are focused on fine glass fiber fabric developments. Resin coated copper foil (RCC) is used widely as layer material for build-up (sequential) processing technology as a solution to these accuracy issues. However,in RCCs increasing use,much higher reliability such as no warp and crack and correspondingly improved dimensional stability and high cost performance are being demanded. We are investigating new glass base materials to overcome these deficiencies in both systems by developing improved spinning and binder technology in a novel,non-woven glass fiber fabric (FF sheet). This novel base material for microvias is able to bring high reliability,good processing and also high productivity as an improved
RCC alternative.

The next generation of surface finish coatings to replace HASL are now being installed by various PWB manufacturers and have been implemented by many OEMs. Coating thickness requirements are part of the OEMs’ specification given to the board manufacturer. Clearly from previous and existing final finish coating performances,thickness has shown to have a major impact on the performance of the surface finish during soldering. OEMs have traditionally specified wide thickness specifications,to meet production variations by PWB producers. This paper investigates the current methodologies / alternatives used to determine accurately and consistently the thickness of these new immersion silver & tin coatings,and how this variation may impact solderability performance under various pre-conditioned states.

Dry film photoresist to produce highly integrated and advanced PWBs has been developed to meet more demanding
fine line requirements.
Advantages for volume production of fine features below 50?m with high yield are now available with newly
developed dry film photoresist that is designed to have specific features. In order to develop such a highly reliable
dry film photoresist,Quality Function Deployment (QFD) helped significantly to well interpret 'Voice-Of-the-
Customer' (VOC) into specific requirement of dry film photoresist performance and how it can be achieved by
formulation design. The developed dry film photoresist resulted in L/S resolution and isolated adhesion better than
1:1 aspect ratio to thickness,with very wide exposure range,and with wide developing latitude.

We will present a new positive working dry film resist system that is suitable for high accuracy use. The new positive working dry film resist is composed of base polymers with active hydrogen functionality,and a
multifunctional vinyl ether compound plus a photo acid generator,and makes use of a chemical amplification method to allow imaging at low exposure levels of UV light. At the pre-bake stage,a ketal structure is formed by an additive reaction between the active hydrogen functional
groups and the vinyl ether. Consequently,the base resin is cross-linked and the resist becomes insoluble in an alkaline developer.
At the UV exposure stage,the photo acid generator forms a strong acid and the area of exposure becomes soluble in alkaline developer via an hydrolysis reaction. This new chemistry makes it possible to form a high reliability image with high contrast in comparison with conventional positive- and negative-acting systems. The new positive working dry film resist achieves on the order of 10?m Line/Space patterns plus the ability to tent 5mm diameter through holes with a resist as thin as 10?m.

Prepregs used in the PCB industry possess various properties and need to be handled with care to maintain
identical chemo -rheological properties to yield dimensionally stable laminates. A prepreg is a viscoelastic polymeric material which losses some portion of energy exerted on it. The characteristic viscoelasticity property depends on the chemical reaction and rheological flow path. To heat the prepreg more uniformly,a new method is invented,utilizing a metal separator as an electrical heating medium (Heated Electrical Separator -HES). The HES technology has been tested to demonstrate the improvement in temperature uniformity among the boards in daylight. A mathematical squeeze flow model is used to stress the consequences of different heating histories on the pressed
laminate thickness.

Polyimides have proven their performance in electronic applications demanding high strength,increased durability,
broader temperature ranges and exceptional chemical resistance. They serve as the material of choice for fabricating
flex circuitry due to their excellent properties and demonstrated capabilities. Typical polyimides require the use of
an adhesive to assemble multilayer circuits,which results in additional material thickness for the overall package.
Several concerns related to the adhesives currently used involve CTE mismatch,wrinkling,voids and delamination
of the layers that can ultimately lead to circuit failure. The recent trend is toward adhesiveless materials; reducing
the total package thickness without compromising the performance,capacity or cost of the final product.
One material,which has been investigated in an effort to meet the demands of the electronics industry,is an
advanced polyimide developed by researchers at NASA Langley Research Center. SI (Soluble Imide) is a
thermoplastic that extends the possibilities for polyimides in flex circuits. SI can be used as a substrate material by
laminating or casting directly onto metal foil such as copper or aluminum yet is versatile enough to be used as the
adhesive in fabricating flex circuits thereby producing an ultra-thin adhesiveless,monolithic flex circuit. Eliminating
the adhesive results in a reduction in materials and processing costs,lighter end weight circuits,increased flexibility,
and circuits with smaller z-axis expansion.

??Machine Technology designed for the manufacture of Ultra Fine Line product
??Machine design provides clean production environment
??Latest State of the Art,Horizontal Wet Processing Equipment
??Intelligent Machines with high levels of automation,self cleaning
??Reliable process control and dosing systems that can maintain demanding production tolerances
??Bar-coded panels automatically adjust machines processing parameters
??Reel to Reel production for thin material
??A totally integrated production system
It’s all the numerous single details which when combined,in the end,make a highly capable and effective
production environment.

With the printed circuit board becoming increasingly complex,there is an ever-growing need to implement
manufacturing standards that ensure high productivity at even higher yields. Factors such as operator error and
incorrect data collection make producing such boards an exercise in frustration. If a company is going to be
successful in the future,it must look to implement a total system of Supervisory Control And Data Acquisition as a
means of success. Since this industry is one of the last high-tech industries to embrace SCADA,this paper will give
attendees a better understanding of why such a discipline is a necessity.

A new thermosetting resin system with modified cyanate ester resins having a loose cross-linked structure and
alloyed with polymers was developed to provide low dielectric constant (Dk) and low dissipation factor (Df)
materials for high-frequency PCBs. The laminates with this resin and glass fabrics demonstrated low transmission
losses at high frequencies up to 30 GHz. Those with inorganic filled resin and glass fabrics were almost comparable
in Dk and Df to the conventional PTFE laminates. These new materials have a high Tg,low moisture absorption,
and excellent mechanical performance. They showed the same processability and reliability as the conventional FR-
4 materials. They will be suited to the multilayer PCBs for high-speed communications as well as the low loss
circuit boards for telecommunications.