Importance

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Abstract

In a rigid/flex circuit board and fabricating process, patterns of electrical traces are formed by etching conductive layers on outer surfaces of a flexible multi-layer circuit structure. A protective barrier material is deposited on the etched traces using an 'electroless' process, such as immersion of the flexible circuit board in an aqueous solution containing ionic tin. The protective barrier material adheres to and encapsulates the copper traces. An outer circuit structure including a bondfilm of epoxy-impregnated fiberglass ('prepreg' bondfilm) and a copper foil layer is laminated onto the flexible circuit structure. The prepreg bondfilm has a window area removed by routing or an equivalent process prior to being laminated to the flexible structure. The window area defines a flex area of the rigid/flex circuit board that will be relatively flexible. The portion of the outer copper foil above the window area of the prepreg bondfilm is then removed using a chemical etchant to which the previously-applied protective barrier material is immune, such as an ammoniacal etching solution. After the copper foil is etched, the protective barrier material in the flex area of the flexible circuit is stripped away. A flexible sealing coating is then applied to the circuit board to cover the edges of the outer laminated circuit structure.

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First Claim