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Common Problems 27611 Voids and Moisture Substrate voids are a serious problem in many lamination processes One source of these problems is moisture B stage is very hygroscopic and must be stored in a low-humidity environment to preclude serious void problems C-stage components also have a tendency to absorb water, and many fabricators use a bake to dry layers prior to lamination However, for a fast innerlayer line with a good dryer in the oxide line, an innerlayer bake may not be necessary Voids generally cluster in the low-pressure regions near the edge of the panel This effect is minimized by the use of vacuum lamination Increasing the lamination pressure can also reduce voids However, the use of high pressures with high-flow materials can result in excessive flow, which leads to other substrate flaws such as resin starvation 27612 Blisters and Delamination.

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Blisters and delamination are also caused by trapped volatiles that collect in the low-pressure regions associated with print-through If a board has wide copper borders on every layer, blisters are often found in the lower-pressure circuit areas adjacent to the borders The best solution to this problem is to avoid areas of heavy copper adjacent to low-density circuit areas by replacing solid borders with a dot or stripe pattern Also, the glass style and resin content of the prepreg should be matched to the weight of copper thickness adjacent to the prepreg 27613 Under Cure The requirement of full cure is relatively easy to obtain if proper cure time and temperature are used One measure of the cure level is Tg Periodic measurements of Tg are an excellent check for material and process consistency.

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Another way to check cure is to make two consecutive measurements of Tg: If the epoxy is only partially cured, it will continue to cure during the first measurement and a higher Tg will be detected on the second measurement A shift in Tg of more than 5 C is an indication of under cure This measurement is typically performed on a TMA Figure 2739 shows an example of an epoxy TMA run; note that the second TMA run has a delta of 3 C 27514 Post-Lamination Bake Many fabricators bake the ML-PWB at 150 C for up to four hours after lamination One purpose of this baking is to ensure a complete cure..

FIGURE 27.39 TMA analysis of epoxy with woven fiberglass. (Courtesy of Microtek Labs, Anaheim, CA.)

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Although a bake will advance the cure, it is unnecessary if a proper lamination cycle is used (although polyimide is an exception; check the recommended processing guidelines). As discussed earlier, this can be verified by Tg measurements. However, additional baking beyond full cure degrades the material and reduces Tg. A second purpose of the bake is to reduce the warpage often seen in the outer boards of a stack-up. Although a post-lamination bake will flatten the boards, it is more of a repair than a root solution. If the panels are cured in the press in a way that ensures they go through Tg in an isothermal stress-free state, warpage should not occur. The warpage seen in the outer boards of a stack is generally a symptom of nonuniform cooling. The third purpose of a bake is to relax internal stress and improve registration. Internal stresses are a symptom of an overdetermined tooling system. If such a system is used, a bake may improve registration. If the more popular four-pin system is used, a bake is unnecessary. Always confirm the need of a post cure with the recommendations of the material supplier.

2762 Special Consideration for Non-Dicy, Non-Bromine, and LFAC Laminates For decades, the majority of PCBs have been built with epoxy resins, dicy-cured, and with bromine flame retardantThe industry has developed around this paradigm Drills and drilling, chemistry, lamination, and circuit card assembly are all well understood with reference to standard FR-4 Although there are fabricators with processes developed to manufacture PCBs using laminates other than standard FR-4, this knowledgebase is not distributed industrywide Especially problematic is the intersection of requirements for HF and/or LFAC with high thermal resistance and improved electrical characteristics, such as low attenuation in the material Many laminators recognized that the heart of their product line would need to be revamped from the entry-level cost-conscious material all the way through to the highest performance material.

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