Jörg Franke
Three-Dimensional Molded Interconnect Devices (3D-MID)
Materials, Manufacturing, Assembly and Applications for Injection Molded Circuit Carriers
Preface
6
Contents
8
1 MID Technology and Mechatronic Integration Potential
14
1.1
1.1
14
14
1.1.1
1.1.1
14
14
1.1.2
1.1.2
15
15
1.1.3
1.1.3
16
16
1.1.4
1.1.4
18
18
1.1.5
1.1.5
19
19
1.1.6
1.1.6
20
20
1.2
1.2
21
21
1.2.1
1.2.1
22
22
1.2.2
1.2.2
24
24
1.3
1.3
25
25
1.3.1
1.3.1
26
26
1.3.2 MID Focuses by Region
27
1.4 Main Fields of MID Research
29
1.5 Key Factors for Successful Projects
32
1.6
1.6
33
33
2 Materials for 3D-MID
36
2.1
2.1
38
38
2.2 Materials Properties and Determination of Characteristic Values for MID
40
2.2.1
2.2.1
42
42
2.2.2
2.2.2
46
46
2.2.2.1
2.2.2.1
46
46
2.2.2.2
2.2.2.2
48
48
2.2.2.3
2.2.2.3
48
48
2.2.3
2.2.3
50
50
2.3
2.3
52
52
2.3.1
2.3.1
52
52
2.3.1.1 Standard Thermoplastics
53
2.3.1.2
2.3.1.2
54
54
2.3.1.3 High-Performance Thermoplastics
56
2.3.2 Modified Thermoplastics for MID
58
2.3.2.1 Radiation Crosslinked Thermoplastics
59
2.3.2.2 Highly Filled Thermoplastics
62
2.3.2.3 Thermoplastics for Selected Technologies of MID Metallization
66
2.3.3 Thermoset Plastics for MID
71
3 Structuring and Metallization
76
3.1
3.1
76
76
3.1.1
3.1.1
77
77
3.1.1.1
3.1.1.1
77
77
3.1.1.1.1 LPKF-LDS® Process
78
3.1.1.1.2 ADDIMID Technology
83
3.1.1.1.3 Alternative Laser Structuring Processes
84
3.1.1.2 Printing Techniques
87
3.1.1.2.1
3.1.1.2.1
87
87
3.1.1.2.2 Inkjet Printing
90
3.1.1.2.3 Hot Embossing
93
3.1.2 Two-Shot Molding
97
3.1.3 Insert Molding
98
3.1.3.1 Film Insert Molding
98
3.1.3.1.1 Thermoplastic Foam Molding
99
3.1.3.1.2 Injection Compression Molding
99
3.1.3.1.3 Press Insert Molding
100
3.1.3.1.4
3.1.3.1.4
101
101
3.1.4 Alternative Structuring Processes
102
3.1.4.1 Primer Technology
102
3.1.4.2 Tampon Printing
104
3.1.4.3 Plasma Technologies
104
3.1.4.3.1 Flamecon®
104
3.1.4.3.2
3.1.4.3.2
105
105
3.2 Metallization
109
3.2.1 Cleaning the Substrate Surface
109
3.2.2 Metallization
110
3.2.3 Thickness and Roughness of Coatings
115
3.2.4 Current-Carrying Capability
119
4 Assembly Technology for 3D-MID
126
4.1 Process Chain
126
4.2 Assembly-Related Challenges
127
4.2.1 Effect of Structure
127
4.2.2 Component Placement on Three-Dimensional Bodies
128
4.3 Automated Assembly
131
4.3.1 Requirements
131
4.3.2 Application of Connection Medium
131
4.3.3 Placement of Components
136
4.3.4 Reflow Soldering
147
4.3.5 Optical Inspection
148
5 Interconnection Technology
152
5.1 Specifics and Challenges
152
5.2 Connection Mediums
156
5.2.1 Solder Paste
156
5.2.2 Conductive and Nonconductive Adhesives
158
5.2.2.1 Isotropic Conductive Adhesives
158
5.2.2.2 Anisotropic Conductive Adhesives
160
5.2.2.3 Nonconductive Adhesives
160
5.2.3 Press-In Pins
160
5.3 Connection Process
162
5.3.1 Reflow Soldering Techniques
164
5.3.1.1 Infrared Soldering
164
5.3.1.2 Convection Soldering
164
5.3.1.3 Vapor-Phase Soldering
165
5.3.2 Selective Soldering Processes
168
5.3.3 Gluing
170
5.3.4 Press-In Connection Technique
172
5.3.5 Chip Placement
175
5.3.5.1 Wire Bonding
177
5.3.5.2 Flip-Chip Technology
179
5.3.5.3 Glob Top
181
5.4 Interfacing to Periphery
182
5.5 Protecting Connections Against Environmental Influences
183
6 Quality and Reliability
186
6.1 Challenges of Quality Assurance
186
6.2 Simulation-Assisted Quality Validation
188
6.3 Nondestructive Testing Methods
189
6.3.1 Optical Testing and Inspection Methods
190
6.3.2 Automated Optical Inspection
191
6.3.3 X-ray Analysis
192
6.3.4 Computerized Tomography
193
6.3.5 X-ray Fluorescence Analysis
194
6.4 Destructive Testing Methods
195
6.4.1 Adhesive Strength
195
6.4.1.1 Peel Test
195
6.4.1.2 Pull-Off Test
196
6.4.1.3 Shear Pull Test
197
6.4.1.4 Chisel Test
197
6.4.1.5 Cross-Cut Test (Tape Test)
198
6.4.2 Measurement of Shear Force and Pull Test
200
6.4.3 Analysis of Prepared Sections
201
6.5 Electrical Characterization
202
6.5.1 Resistance
203
6.5.2 Ohmic Heating
204
6.5.3 Insulating Properties
205
6.6 Reliability Analysis
205
6.6.1 MID-Specific Challenges
206
6.6.2 Accelerated Aging
207
6.6.3 Application Example I: High-Temperature MID
209
6.6.4 Application Example II: Press-In Connections
211
7 MID Prototyping
214
7.1 Classification of Samples and Prototypes
214
7.1.1 Visualization Samples
215
7.1.2 Concept Model
215
7.1.3 Fully Functional Sample
216
7.1.4 Prototype
217
7.2 Processes for Producing Plastic Blanks
218
7.2.1 Stereolithography
218
7.2.2 Selective Laser Sintering
219
7.2.3 Fused Deposition Modeling
220
7.2.4 Vacuum Casting in Silicone Molds
221
7.2.5 Milling Thermoplastic Semifinished Products
222
7.2.6 Injection Molding
222
7.3 Samples and Prototypes Produced by the LPKF-LDS® Process
223
7.3.1 ProtoPaint LDS Process
223
7.3.2 LDS Process with FDM Plastic Parts
225
7.3.3 LDS Process with Vacuum Castings
225
7.3.4 LDS Process with Milled Semifinished Products
225
7.3.5 LDS Process with Moldings from Rapid Tooling Injection-Molding Tools
226
7.3.6 LDS Process with Moldings from Steel Tools with Nonhardened Inserts
226
7.4 Samples and Prototypes Produced by Hot Embossing
227
7.5 Samples and Prototypes Produced by Two-Shot Molding
227
7.6 Aerosol-Jet Printing on SLA Parts
227
7.7 Overview of the Various Combinations for MID Prototyping
228
8 Integrative Development of MID
230
8.1 Systematic Approach for the Development of MID
231
8.1.1 VDI Guideline 2206: Design Methodology for Mechatronic Systems
231
8.1.2 Thomas Peitz’ Methodology for Product Optimization of Mechanical Electronic Modules
233
8.1.3 Ingo Kaiser’s Systematic Approach for the Development of Mechatronic Systems
235
8.2 Requirements
238
8.3 Product Conceptualization
240
8.4 Production-Process Conceptualization
242
8.5 Electronics Design
248
8.6 Elaboration of the Production Process
253
8.7 Elaboration of Assembly and Connection Technology
255
8.8 Work Planning
257
8.9 MID-Specific Instruments of Development
259
8.9.1 MID Design Catalogs
259
8.9.2 Properties Cards for MID Processes
261
8.9.3 MID Guidelines
263
8.9.4 MID Features
265
8.10 Computer Assistance
267
8.10.1 MID-Specific Requirements for Development Tools
268
8.10.2 Software Tools for Design and Layout
274
8.10.3 Software Tools for Simulation
278
8.10.4 CAD/CAM Chains
284
9 Case Studies
290
9.1 OLED
291
9.2 Flow Sensor
292
9.3 Multiband Antenna for Smartphones
293
9.4 ACC Position Sensor
295
9.5 Pressure Sensor
296
9.6 MULTI LED
297
9.7 Insulin Pump
299
9.8 Passive UHF RFID Transponder
300
9.9 LED Camera Module
301
9.10 3D Switching Module
303
9.11 Security Caps
305
9.12 Solar Sensor
307
9.13 Microphone Carrier for Hearing Aid
308
9.14 Seat-Adjustment Switch
309
9.15 LED Light
311
10 List of Abbreviations
314
11 Literature
320
12 Authors and Contributors
338
12.1 Editor
338
12.2 Authors
338
12.3 Consulting Experts
343
13 Addresses
344
13.1 Research Association Molded Interconnect Devices (3-D.MID)
344
13.2 Members of the Research Association Molded Interconnect Devices (3-D.MID)
344
Index
364
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