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Cut Tests on Delaminated Bias Circuits

Cut Tests on Delaminated Bias Circuits. NCR #431 – 06 June 2005. Description and reference documentation. Description of nonconformance Delaminations found on bias circuits after the trimming WS Instances Cut Test on delaminated Area Suspected Root cause

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Cut Tests on Delaminated Bias Circuits

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  1. Cut Tests on Delaminated Bias Circuits NCR #431 – 06 June 2005

  2. Description and reference documentation • Description of nonconformance • Delaminations found on bias circuits after the trimming WS • Instances • Cut Test on delaminated Area • Suspected Root cause • Bad bonding of the Kapton to Kapton bonding Interface • Reference NCR List • NCR n°431

  3. CUT TEST PROCEDURE • SET-UP • Place the Bias Circuit on an Aluminum plate • Focus the Area to be cut under a microscope • Use a scalpel with a new blade • Place the template over the bias, using as reference the corner of the bias • TEST • Cut three lines in the free area marked by the template, the area is inside the kapton-kapton bonding • RESULTS • FAILED : cutting the bias, a delamination starts, inserting the scalpel edge, it is easy to separate the two bonded layers • (see the movie) • PASSED: No delamination is detected PASSED Delamination front startup FAILED

  4. Results analysis FAILED PASSED Delamination start FRONT • RESULTS • A bias circuit foil has been tested per each Lot of Production as showed in Status Chart: • Rejected Lots: #6212.00 .1 and #6212.00 .4 • Accepted Lots: #6212.00 .3; #6212.00 .2; #6212.00 .9; #6212.01 .1; #6212.01 .0; #6212.02 .0; #6212.03 .0; #6212.03 .1.01 • #6212.03 .2 • *color inspection in progress

  5. Color Correlation FAILED, Bias Circuit #4768, LOT #6212.00 .1 PASSED FAILED PASSED, Bias Circuit #4951, LOT #6212.02 .0 • Differences in Color • Evident Correlation has been found at the end of the test: • passed bias have an opaque color compared to the failed ones • (different Kapton raw material, different Kapton treatments, absence of an adhesive layer…..? To be investigated in Parlex)

  6. STATUS CHART: 47XX to 50XX series Total number of orange bias: 62 Total number of good (brown) bias tested: 13

  7. Corrective actions and Considerations • Proposal: • To scrap the orange bias and replace them with new bias circuits (~75) • Perform CUT Test on samples of the new circuits and compare the Color of the passed/failed Lots • Perform Complete color inspection per each item stored in italy, in some cases item of the same lot shows different color (#4900 orange; #4901 brown; #4902 orange)

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