Abstract: Apparatus and methods for flattening thin substrate surfaces by stretching thin flexible substrates to which ICs can be bonded. Various embodiments beneficially maintain the substrate flatness during the assembly process through singulation. According to one embodiment, the use of a window frame type component carrier allows processing of thin laminates and flex films through various manufacturing processes. The flexible substrate is bonded to a rigid carrier. The carrier is placed into a specialized fixture comprising a bottom plate and a top plate. The bottom plate with raised regions is created that allows the windowed region of the flex film to be pressed flat. After aligning the top plate, the bottom plate, and the middle structure, the plates are pressed together causing the raised regions to push the flex film substrate upward and around the carrier.

Abstract: This document discusses, among other things, a flexible circuit or other laminate comprising a first conductive layer and a second conductive layer disposed over the first conductive layer. An insulator is disposed between the first and second conductive layers. A conductive via extends through the insulator and electrically connects the first and second conductive layers. The laminate includes a channel in the insulator. In one option, the channel extends at least part way around the via. In another option, the channel extends at least part way between the first and second conductive layers. In another example, a method comprises providing a laminate including at least first and second conductive layers and an insulator disposed therebetween. A via is formed through the insulator. A channel is formed in the insulator at least part way around the via. The channel extends between the first and second conductive layers.

Abstract: A contact pad for a circuit board includes a central portion; and a plurality of spokes extending from the central portion. A circuit board includes a nonconductive substrate; a plurality of electrically conductive contact pads, each of the contact pads having a central portion; and a plurality of spokes extending from the central portion; and an electrically conductive trace interconnecting the contact pads.

Abstract: A component package having a substrate. The substrate has a component or chip section and a separate assembly section. An array of component pads are disposed on the component section and are adapted to be electrically connected to a component. An array of assembly contact pads are disposed on the assembly section and are adapted to be connected to a next level assembly, such as a printed circuit board. The component contact pads are electrically connected to the assembly contact pads by electrical conductors affixed to the substrate. At least a portion of the substrate between the component section and the assembly section is flexible. The assembly section of the substrate can be secured to a rigid carrier and a casing (or overmolded top) can be mounted to the rigid carrier so as to protect a component enclosed in the package.