4.1.2 Lifted Conductor Repair, Film Adhesive Method

Procedure to repair lifted conductors and circuits using a dry film epoxy method.

Minimum Skill Level: Intermediate
Conformance Level: High

Outline
This method is used to repair damaged and lifted conductors. Dry film epoxy is used to rebond the lifted conductor.

Caution: This method should not be used to rebond a conductor that has been stretched or damaged.
Minimum Skill Level - Intermediate
Recommended for technicians with skills in basic soldering and component rework, but may be inexperienced in general repair/rework procedures.

Conformance Level - High
This procedure most closely duplicates the physical characteristics of the original, and most probably complies with all the functional, environmental and serviceability factors.

Acceptability References
IPC-A-600 2.0 Externally Observable Characteristics
IPC-A-610 10.0 Laminate Conditions
Procedure References
1.0 Foreword
2.1 Handling Electronic Assemblies
2.2 Cleaning
2.5 Baking And Preheating
IPC7721 4.1.2 Lifted Conductor Repair, Film Adhesive Method
Kits and Systems
Part No. / Item / Description Price Order
201-5231
Circuit Bonding System
System to repair damaged conductors, BGA pads, and SMT pads.
$6,995.00 Each
110-6380
Flex-Rack PCB Holder
Sturdy rack for PCBs used for rework and positioning.
$595.00 Each
201-1400
Land/Pad Repair Kit
Kit to repair circuit board damage including lands and pads.
$495.00 Each
201-2400
Master Repair Kit
Kit to repair circuit board damage including pads, lands, conductors and base material.
$729.00 Each
201-7100
Precision Tool Set
Nine precision-crafted tools for detailed circuit board work.
$106.00 Each
201-2100
Professional Repair Kit
Kit to repair damaged pads, lands, conductors, base material, and plated holes.
$1029.00 Each

Tools and Materials

Additional Items and Supplies
cleaner_link_guides
Cleaner
General purpose cleaner for removing contamination.
- -
microscope_link_guides
Microscope
Precision microscope with stand and lighting for work and inspection.
- -
tweezer_link_guides
Tweezers
Multiple sizes and tip configurations of tweezers for various small parts handling needs.
- -
wipes_link_guides
Wipes
Nonabrasive, low-linting wipes for cleanup.
- -

Images and Figures
4.1.2 Lifted Conductor Repair, Film Adhesive Method
Lifted Conductor
4.1.2 Lifted Conductor Repair, Film Adhesive Method
Figure 1: Cut out a piece of dry film epoxy and place it under the lifted conductor.
4.1.2 Lifted Conductor Repair, Film Adhesive Method
Figure 2: Place Kapton tape over the lifted conductor.

4.1.2 Lifted Conductor Repair, Film Adhesive Method
Figure 3: Bond the lifted conductor using a Bonding Iron.
4.1.2 Lifted Conductor Repair, Film Adhesive Method
Figure 4: Completed repair.
Procedure
Procedure
  1. Clean the area.
  2. Remove any obstructions that prevent the lifted conductor from making contact with the baseboard surface.
    Caution: Be careful while cleaning and removing all obstructions not to stretch or damage the lifted conductor.
  3. Clean the area.
  4. Cut out a piece of dry film epoxy that closely matches the size of the lifted conductor. Be careful not to contaminate the dry film epoxy with materials that could reduce the bond strength. (See Figure 1)
    Note:Dry film epoxy thickness should be selected to meet the requirements of the circuit Board.
  5. Place the dry film epoxy under the lifted conductor. (See Figure 1)
  6. Select a bonding tip with a shape to match the shape of the lifted conductor.
    Note: The bonding tip should be as small as possible but should completely cover the entire surface of the conductor.
  7. Place a piece of High-Temperature Tape over the lifted conductor. (See Figure 2)
  8. Position the circuit board so that it is flat and stable. Gently place the hot bonding tip onto the tape covering the new conductor. Apply pressure as recommended in the manual of the repair system or repair kit for 5 seconds to tack the conductor in place. Carefully peel off the tape.
  9. Gently place the bonding tip directly onto the new conductor. Apply pressure as recommended in the manual of the repair system or repair kit for an additional 30 seconds to fully bond the conductor. The conductor is fully cured. Carefully clean the area and inspect the new conductor.
  10. Replace surface coating to match prior coating as required.
Evaluation
  1. Visual examination and tape test per IPC-TM-650 (ANCI/IPC-FC-250A) test method 2.4.1.
  2. Electrical tests as applicable.
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