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HDI technology after technologies as ALIVH is considered a second-generation HDI technology. NMBI was pioneered by North Corporation of Japan. 23.3.6.1.1 Structure. Figure 23.33 shows the structure of an NMBI substrate. Also in this figure is an scanning electron microscope (SEM) of the etched-metal bumps that make up NMBI s via interconnects. 23.3.6.1.2 Manufacturing Process. The manufacturing process for NMBI is unusual in that it does not drill the via connections. Instead, a new material is employed that consists of two different coppers (one thicker than the other) that are bonded together. The thicker copper is imaged and etched to form the interconnect vias. This structure is then filled with a film or liquid dielectric. It is bonded to copper foil and both are cured. These copper foils are then imaged and etched to circuitize the layer pair. The layer pairs can be tested and later be stacked with uncured NMBI structures to form the final multilayer. Like the second-generation ALIVH HDI structure, an NMBI structure allows the connection of any layer to any other layer. This manufacturing process is shown in Fig. 23.34. 23.3.7 ToolFoil Technologies Imprinted circuits are an example of a ToolFoil technology. 23.3.7.1 Imprinted Circuits. Imprint pattering is a similar technique used to manufacture compact discs (CDs). No photoresist, registration, or conventional techniques are employed.

Every substrate is a copy of the mold (or ToolFoil, in this case), and each can be done in sequence to make a build-up substrate. The unique characteristic of CDs and DVDs is the millions of 0.5 micron pits or vias. A typical CD includes over 3 km of these. The simple manufacturing process and perfect reproduction of the master tool creates inexpensive and accurate substrates. The patented process is a lab process; actual complexity is still under evaluation. 23.3.7.1.1 Structure. Figure 23.35 shows a diagram of the imprinted circuit structure, whereas Fig. 23.36 shows SEMs of an imprint-patterned circuit. The unique characteristic

180 182 184 190 193 201 203 204 204 206 209 211 214 215 215 215 216 218

FIGURE 23.36 Various views of SEMs of imprinted circuit liquids and traces. (Courtesy of Dimensional Circuits.)

FIGURE 23.37 SEM examples of an imprinted circuit using Dexter LF69702 epoxy and showing how traces and vias are recessed. (Courtesy of Dimensional Circuits.)

of this structure is that all features are embedded in the substrate. The critical dielectric is the part that is imprinted or molded. A long fiber molding compound, such as that used on components overmolding, is best suited for this task. Such a compound can be used with or without an FR-4 backing. The cross section of an imprint circuit shows the features similar to a CD or DVD, that is, the various impressions. All are metallized but the vias are deeper. This allows the vias to contact the next layer of imprinted circuits, as shown in Fig. 23.37. 23.3.7.1.2 Manufacturing Process. A master of the substrate is machined in copper by a UV laser or by photochemical machining. The vias are deep, and the circuits and pads are shallow. Since only one master tool, called a ToolFoil, is required, time can be taken to make sure the master is perfect. With a laser, it is possible to have perfect registration of lands to via holes or even landless vias. This master is electroformed with nickel and back-filled to make a master tool. A sample ToolFoil is shown in Fig. 23.38. For production, the mold is filled with a thermoset or thermoplastic resin and then cured. The substrate is additive or semi-additive metallized, and plated thicker with copper. The recesses are filled with an etch resist, and the surface resist is removed to expose the copper surface by polishing or by using an abrasive agent. The exposed copper is etched away and the etch resist is dissolved. The entire manufacturing process does not employ photoresists, exposure, or registration. Because of this, the yield is expected to be very high. Figure 23.39 shows the process for tool generation and production substrate. The process for metallization is shown in Fig. 23.40.

FIGURE 23.38 Example of a ToolFoil for imprinting. (Courtesy of Dimensional Circuits.)

FIGURE 23.39 The manufacturing process for the ToolFoil and using the tool to make imprinted circuits.

FIGURE 23.40 Methods of metallization using electroless plating, plugging, and etching. (Courtesy of Dimensional Circuits.)

HDI and microvias provide a big boost in density due to miniaturization. These technologies will continue to evolve and become smaller, following integrated circuit cell geometries. So the next revolution will be in optical wiring. Currently, optical networking ties together continents and cities, providing the backbone of modern worldwide networking. The fiercely competitive market is what technology will provide the last mile on connectivity Optical wiring is competing for that market.

Printed Optical Waveguides Although electrical signals can be multiplexed on a single 100 micron wire or trace, many individual laser wavelengths can each carry many multiplexed signals on a single 100 micron waveguide. This results in a 10,000 increase in information handling while not being influenced by magnetic and electrical fields such as electronic signals. These optical fibers can now be mass produced on a printed circuits as polymer optical waveguides, as shown in Fig. 23.41. Much like when the industry transitioned from single-point soldering by individual wires to printed circuits, single-point fiber-optical cabling can now have low-cost printed waveguides. 23.4.1.1 Structures. The optical waveguide structures are shown in Fig. 23.42. The transmitter package provides the multiplexed laser signal sources, through vertical cavity surface