PRINTED CIRCUIT SUBSTRATE WITH PHOTOIMAGEABLE
COVERCOAT LAYER
Background The disclosures herein relate generally to flexible circuits and more particularly to flexible circuits with photoimageable covercoat layers.
Flexible circuits generally include a pattern of conductive traces that are supported on a base substrate such as a layer of dielectric material. The conductive traces typically have a copper core plated with a corrosion resistant material such as gold. Polyimide is a common base substrate. U.S. Patent Nos. 4.987.100; 5.227.008; 5.334.487; 5,557.844 and 5,680.701 disclose processes for fabricating printed circuits having a flexible polymeric base substrate such as polyimide. U.S. Patent Nos. 3.660.726: 4.029.845; 4.526.835; and 5.806.177 disclose processes for fabricating printed circuits having a generally rigid base substrate such as a glass reinforced epoxy composite. Electronic packages, medical devices, hard disk drive suspensions and ink jet printer pens are common applications for flexible circuits. Flexible circuits offer attributes such as fine pitch traces, complex circuit designs and flexibility. Depending on the design and specific application, a flexible circuit may have an opening formed in the base substrate. One or more of the conductive traces may include a lead that extends in a cantilevered manner from an edge of the opening. The leads may also be formed in a manner in which they the span across the opening.
In some applications, flexible circuits may be exposed to an aggressive environment. Unprotected conductive traces and the interface between the conductive traces and the base substrate are two areas susceptible to being affected by adverse environmental conditions such as exposure to corrosive fluids. Exposing unprotected conductive traces to adverse environmental conditions typically leads to the traces corroding or delaminating from the base substrate.
The flexible circuit is typically attached to a rigid structure such as a stiffening member or the body of a printer pen. The leads may be interconnected to an electronic device carried by the rigid structure or to an electronic device that is attached directly to the base substrate of the flexible circuit. Typically, the side of the base substrate carrying the conductive traces is attached to the rigid structure. An
encapsulant is typically applied over the leads to provide a degree of protection from adverse environmental conditions.
A covercoat layer is sometimes formed over the conductive traces to prevent the traces from being exposed to adverse environmental conditions. The covercoat layer is often a photoimageable material that is patterned using UV light and a photomask. Due to limitations in conventional methods of forming the covercoat layer, the resulting covercoat layer does not have a uniform and controlled thickness or a well-defined pattern. In some areas, the thickness of the covercoat can be insufficient to provided adequate protection against adverse environmental conditions. This is often the case with circuits having portions of the traces beyond to an edge of the substrate (called leads).
An encapsulant is often applied to protect the leads. Depending on the type of device attached to the leads, the encapsulant may also be used to protect the device (e.g. a bare semiconductor chip). Because of the orientation of the flexible circuit, it is easy to encapsulate the outward facing side of the conductive traces. However, reliably encapsulating the inward facing side of the circuit is difficult. Air pockets formed adjacent to the leads during encapsulation can serve as pathways for contaminants to reach the traces. Over time, traces having an insufficient thickness of covercoat material can be attacked by contaminants, causing the flexible circuit, the attached device, or both, to fail.
Accordingly, a need has arisen for a base substrate having a covercoat formed thereon in which the shortcomings of previous techniques and constructions are overcome.
It has now been discovered that a photoimageable covercoat can be formed which extends beyond the base substrate and onto the lead portion of the conductors. Use of a such a covercoat assists in corrosion protection, and the like, and allows the deposition of the covercoat during an automated assembly process without the need for "batch" type stoppages.
Summary The invention provides a method for coating a base substrate useful for printed circuits having improved resistance to adverse environmental conditions. A printed circuit includes a base substrate having conductors formed thereon. A portion of
some or all of the conductors form traces and a portion form leads extending from an edge of the base substrate. A photoimageable covercoat layer is formed on the base substrate including a lead portion formed on the leads extending beyond the substrate at one or more edges by means of a liner positioned adjacent to the edge. The method includes forming a lead portion of the photoimageable covercoat which is a direct extension of a trace portion of the photoimageable covercoat. i.e.. a continuous coating, and a method for making a completely detached coating. As used herein, these terms have the following meanings:
1. The term "trace" refers to that portion of the conductor(s) which is supported on a base substrate.
2. The term "lead" refers to that portion of the conductor(s) which is unsupported by the base substrate, e.g.. a conductor extending beyond an edge of the polyimide substrate.
3. The term "lead portion" when referring to the photoimageable covercoat refers to the portion of the covercoat which extends beyond an edge of the polyimide substrate. Note: this term is used for the portion of the covercoat extending beyond an edge of the substrate whether or not a conductor lead also extends therefrom.
4. The term "trace portion", when referring to the photoimageable covercoat refers to the portion of the covercoat which coats a trace portion of the conductor on the base substrate.
5. The term "UV" means ultraviolet and refers to radiation from a source having wavelengths of from about 100 to about 4500 Angstroms.
Brief Description of the Drawing Figures Fig. 1 is a perspective view illustrating an embodiment of a base substrate with a photoimageable covercoat layer formed in an opening in the base substrate.
Figs. 2A-2C are cross sectional views illustrating an embodiment of a method of forming a photoimageable covercoat layer.
Fig. 3 is a flow chart illustrating an embodiment of a method of forming a photoimageable covercoat layer.
Fig. 4 is a perspective view illustrating an embodiment of a printed circuit having a photoimageable covercoat layer formed thereon.
Detailed Description A base substrate 10, Fig. 1, includes a photoimageable covercoat layer 12 (hereinafter referred to as the covercoat layer 12) formed in an opening 14. The base substrate 10 may be a flexible dielectric substrate such as polyimide. a rigid dielectric substrate such as a glass reinforced epoxy composite material, a conductive material such as aluminum or other suitable types of substrates for an intended application.
Many materials that are used as photoimageable covercoat layers are formulated to be crosslinked in the presence of UV light to facilitate patterning and cured in the presence of heat to achieve enhanced resistance to adverse environmental conditions, such as corrosive fluids or gases, biological contaminants, etc. Suitable covercoat materials include photoimageable epoxy acrylates. polyimides, and the like. Commercially available materials include the product sold under the trademark "Imageflex" by Coates Circuit Products under the part number XV601T; "PSR- 4000/AUS5" sold by Taiyo America; "NPR-80/ID431 " sold by Nippon Polytech Corporation; the product sold by Olin-Arch under the trademark "Probimide". under the series number 7500 and the product sold under the trademark "Carapace-A" by Electra Polymers and Chemicals America under the part number EMP1 10.
A method of forming the covercoat layer 12 on the base substrate 10 is illustrated in Figs. 2A to 2C. This method is also depicted in the flow chart of Fig. 3. The opening 14 is formed in the base substrate 10. The base substrate 10 has a first side 18 and a second side 20. A first side 21 of a liner 22. Fig. 2B, is positioned next to the second side 20 of the base substrate 10.
The covercoat layer 12, Fig. 2C, is then formed over the first side 18 of the base substrate 10 and into the cavity 1 1 , Fig. 2B, defined by the opening 14 and the liner 22. The covercoat layer may be formed by applying a layer of a liquid covercoat material using a coating method such as knife coating, extrusion die coating, curtain rod coating, screen printing, spray coating or other suitable known methods of forming a layer of covercoat material. The covercoat layer is then exposed. The covercoat layer 12 is then dried at ambient temperature or in a suitable drying apparatus such as an air convection oven. Other methods of forming a covercoat layer such as laminating a dry film layer to the substrate are also contemplated within the scope of the present disclosure.
As shown in Fig. 2C, the covercoat layer 12 includes a trace portion 13 and a lead portion 15. The trace portion 13 of the covercoat layer 12 is that portion formed on the base substrate 10. The lead portion 15 of the covercoat layer 12 is that portion of the covercoat layer 12 formed on the liner 22. The lead portion of the covercoat layer 12 may be formed adjacent to an exterior edge 17, an interior edge 19 or both edges. Next, the covercoat layer 12 is photoimaged. The photoimaging step includes exposing and developing the covercoat layer 12. The exposure step includes exposing the covercoat layer 12 to a light source 23 such as a UV lamp. The depth to which the material is crosslinked relative to the overall thickness of the covercoat layer 12 is generally a function of the applied exposure energy. Generally speaking, the thickness of the crosslinked material increases with increasing exposure energy.
Following the covercoat layer 12 being exposed, it is subjected to a developing solution. When a negative-acting photoimageable material is used, the portions not exposed to the UV light will be removed during the developing step. When a positive-acting photoimageable material is used, the portions exposed to the UV light will be removed by the developing solution. After the covercoat layer 12 is developed, it is cured by conventional methods, e.g., thermally cured at an elevated temperature in an air convection oven, cured using infrared radiation, or simply dried at ambient temperature although this is less preferred in manufacturing due to time constraints.
The liner prevents covercoat material applied adjacent to openings in the base substrate and adjacent to the edges of the base substrate from contaminating the process equipment. However, the liner is not physically attached to the base substrate, and is somewhat susceptible to shifting relative to the base substrate during processing, and assists in placement of the covercoat. To prevent the liner from shifting, the liner is removed prior to the covercoat layer being dried.
This method of manufacturing presented herein is economical to implement, and does not disrupt a continuous manufacturing process.