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During the qualification of a new material, it is also crucial to run the laminate through the production processes to check whether they are compatible. Table 12.5 summarizes all the steps that are necessary to control. The first process step is innerlayer processing. Here, a change in stiffness of the new laminate material can have a significant impact on the processability in horizontal manufacturing lines. This is especially important for thin cores. A change in the copper quality of the new laminate may impact the adhesion of the innerlayer photoresist and can also affect the copper etch rates. During automatic optical inspection (AOI), it is necessary to verify the contrast between copper circuitry and laminate and adjust the AOI settings if necessary. In case of necessary innerlayer repairs, the settings for the welding process may need adjustment to avoid thermal damage of the laminate and ensure reliable interconnects. The last step during innnerlayer processing is copper blackoxide. Here, it is necessary to verify the compatibility of the employed blackoxide (reduced/nonreduced or alternative) to the base material to obtain a sufficient innerlayer bond strength of the multilayer product. The dimensional stability of the innerlayers must be measured after the multilayer cycle to adjust the innerlayer scaling factors of the new material. The next step after multilayer lamination and edge routing is drilling. A change in the thermomechanical properties of the laminate may impact the quality of the drilled holes, and adjustments to drill speeds or desmear settings may be necessary. After metallization and plating, the adhesion of the copper in the plated through hole as well as reliable contacts to all innerlayers must be verified.

TABLE 12.5 Summary of Production Steps Compatibility with innerlayer (IL) process steps Preclean Resist lamination Exposure Develop, Etch, Strip Punching IL-Automatic optical inspection IL-Repair/outerlayer (OL)-repair Blackoxide/oxide alternatives Compatibility with multilayer process steps IL drying Lay up Press cycle Edge routing Dimensional stability check Compatibility with process steps from drill to electroless copper Drilling Brush/Pumice/Deburr Desmear/Plasma Desmear/Other E less copper or similar process Compatibility with soldermask process step Compatibility with different finish metallization processes Electroless Ni/Au Immersion Sn Immersion Ag Compatibility with routing process

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The adhesion of soldermask may also change as well when a new material is introduced. This is especially critical in combination with any metal finish process steps (such as electroless Ni/immersion Au, immersion Sn, and immersion Ag). In addition to having a negative impact on soldermask adhesion, these processes in combination with new laminates can also lead to nonselective metal plating or skip plating. One of the last manufacturing steps that should be evaluated during the introduction of a new laminate material is board routing and scoring. Here the use of a new base material with changed stiffness or different reinforcement may lead to necessary process adjustments.

film materials Oxide reduction begins to occur spontaneously above this temperature, reducing adhesionThe use of a thin brown oxide, or a reduced oxide, will reduce the risk of this failure mode A second problem with polyimide film is that it is soluble in strong caustics, so if the treatment time in the oxidization process is excessive, significant substrate damage can occur When processing circuits with microfoils having high-density features, the fabricator should reduce processing times because the oxide chemistries can reduce copper thickness The LFAC laminates are compatible with current brown oxides and reduced copper oxide treatmentsThe oxide treatment should be kept thin, not exceeding 04 mg/cm2Alternative oxide treatments, such as peroxysulfuric oxide, are strongly preferred for some HF laminates.

The cores for ML-PWBs that will be subject to LFA should be post-oxide baked to remove moisture generally 120 C for at least 30 minutes for signal layers and 60 minutes for power/ground layers 274102 Silane-Based Adhesion Promotion (Oxide Alternative Treatments) The silane-based process is an alternative to the copper oxide process Silane can be used to bond epoxy to other materials One end of the silane molecule bonds to the epoxy If the other end of the molecule is modified to bond to the secondary material, the silane can serve as a bridge, greatly enhancing adhesion It is commonly used in this mode to enhance the adhesion of epoxy to glass It can be also used to enhance the adhesion of epoxy to copper This silane process attaches a thin silane layer to the copper surface In lamination, the active epoxy molecules bond to the silane.

This causes it to be a binding layer holding the epoxy to the copper The objective is to achieve a stable coupling between the silane and the copper This can be done by precoating the copper with a metal such as tin that reacts with the silane When properly applied, the silane treatment is very stable and is resistant to chemical attack and delamination The silane process has the advantage that it can be conveyorized in an inline process system The major weakness of the process is that silane layers can absorb water and fail in some environments The proper choice of silane chemistry minimizes the risk..