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27551 B-Stage Melt During the melt cycle, the B stage is solid and the pressure should be low Excessive pressure during this portion of the cycle will damage the glass cloth and exaggerate problems with image print-through, also known as telegraphing Most press cycles start with a low pressure known as a kiss pressure The kiss pressure is high enough to ensure good thermal contact without damaging the ML-PWBThe length of the kiss cycle depends on the heating rates and the cure kinetics of the B stage In a hot press cycle, the ML-PWB stack is loaded into a preheated press, and the heating rate may approach 20 C/min In a hot press, the kiss cycle should be limited to a few minutes, or the B stage will begin to cure before flow is complete.

At the opposite extreme, the press is loaded cold, and the heating rate is determined by the heating ramp of the press For a slow heating rate of 5 C/min, a kiss cycle of 15 min is appropriate Some LFAC laminates, however, have process guidelines where a best practice is to have a kiss cycle with 0 psi with a slow heat rise on the order of not more than 15 C/min until approximately a 90 C internal temperature This step is held for 30 40 min to drive out moisture before pressure is applied and the flow stage initiates 27552 B-Stage Flow The second portion of the cycle begins when the B stage liquefies, but before its viscosity begins to rise due to curing In this region of the cycle, the liquid Bstage flows and encapsulates the circuitry.

As long as the internal features are surrounded by liquid B stage, print-through is not an issue The key to good results is to select a pressure that will allow reproducible resin flow but that does not squeeze out all available resin before the progressing cure stops the flow Once again, the exact pressure depends on the temperature cycle, the B-stage viscosity characteristics, and the B-stage cure kinetics For a fast-curing B stage and a fast temperature ramp, pressures as high as 600 psi may be needed to ensure complete circuit encapsulation On the other hand, with a slow ramp and a long B-stage working time, high pressures give excessive flow and best results are obtained at 200 psi Improper melt staging can result in footballing, a term used to describe a panel whose center is significantly thicker than its outside.

To determine proper melt, it is recommended to install a thermocouple in the center stack edge to chart the actual heat rise through the flow A typical dicy-cured FR-4 multifunctional epoxy has a flow range, called the critical range, at the temperatures between 70 130 C HF and LFAC laminates have a critical range typically between 80 140 C During the critical range, the heat rate input and pressure are critical variables A typical dicy-cured FR-4 press recipe would be 4 8 C/min rise at 200 to 300 psi pressure HF and LFAC laminates recipes are usually lower in the rate of rise and higher in pressure, such as 2 4 C /min and 225 360 psi pressure Table 275 shows some press recipes from the processing guidelines posted on the laminators web pages.

This table is intended to illustrate that moving from standard FR-4 to other HF or LFAC laminates will require the development of new press recipes..

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TABLE 27.5 Press Recipes for Selected Materials Tg C (DSC) Standard DicyCured FR-4 Non-Dicy FR-4 Laminate HF Laminate LFAC Laminate A LFAC Laminate B LFAC Laminate C LFAC Laminate D LFAC Laminate E Polyimide 175 155 160 185 190 210 190 215 250 Rise ( C/min.) 4 7 2 4 2.3 5.6 4.4 7 2.3 5.6 2 4 2 4.5 2 2 4 Critical range ( C) 70 130 80 140 >100 70 130 83 139 80 140 80 135 80 135 80 138 Pressure (psi) 200 300 275 360 380 200 300 225 325 275 360 200 300 300 225 275 Cure time (min.)/Temp ( C) 60/182 90/193 90/200 75/185 75/193 90/193 120/200 120/200 200/218

27553 B-Stage Cure In the third part of the cycle, flow has stopped and the resin cure is proceeding The temperature is held at its maximum value to minimize the time to obtain full cure For a typical epoxy system, this usually is approximately 180 C for 60 min LFAC laminates, however, tend to require longer and hotter cure stages: up to 200 C internal temperature for 120 min, and longer for thicker boards Some materials, such as polyimide, require a significantly higher cure temperature for even longer 27554 Cooldown The last part of the cycle is the cooldown cycle In Fig 2737, it is suggested that the pressure is released after some cooling has occurred, but before the stack reaches room temperature In many modern systems, the ML-PWB stack is transferred hot to a low-pressure cooling press.