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oxidizes resin or dielectric, followed by a neutralization-reduction step The fourth method sulfuric acid solvates or dissolves resin or dielectric All methods remove smear, but the resultant surface of the epoxy affects hole wall pull-away and adhesion 28431 Sulfuric Acid This process has been used extensively for many years because of its ease of operation and reliability of results Disadvantages are lack of control, inability to attack certain resin systems, and the inability to create significant topography resulting in poor hole wall adhesion Operator safety is crucial since concentrated sulfuric must be used 28432 Chromic Acid Chromic acid is a more controllable method that imparts some topography for enhanced hole wall adhesion and has a longer bath life However, insufficient neutralization of the Cr+6 leads to copper voids The line cost of using chromic acid is appealing.

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However, the Restriction of Hazardous Substances (RoHS) and waste treatment regulations of chromic acid add substantial costs that make this method a nonviable option Etchback is possible by double processing 28433 Permanganate Permanganate is the most widely used and preferred method in the industry This easy-to-control process incorporates electrolytic regeneration, which adds to consistency and increases bath lives Permanganate effectively removes drill smear from most materials and imparts some texturing to the resin that increases hole wall adhesion3 (See Fig 282) for an example of hole wall topography after etchback Problems result from lack of chemical control or inconsistent cure of the multilayer package Permanganate is also used as a second step in conjunction with the other methods to enhance hole quality4 28434 Plasma Plasma utilizes electrical current to generate a plasma from fluorocarbon gases.

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This plasma oxidizes the epoxy resin and removes drill smear Longer cycles or double cycling will generate etchback Plasma works on any material and is especially effective when processing polytetrafluoroethylene (PTFE)-based dielectrics This process has few.

TABLE 28.2 Smear Removal and Etchback Processes* Sulfuric acid Rack panels Sulfuric acid, 96% Neutralizer 8 min., 125 F Ammonium bifluoride 3 min., room temperature Unrack panels High-pressure hole cleaning Release to electroless copper/DM Permanganate Solvent conditioner 90 F, 5 min. Alkaline permanganate 170 F, 10 min Neutralizer-120 F, 5 min. Glass etch, 4 min., room temperature High-pressure hole cleaning (optional) Release to electroless copper/DM

Chromic acid Rack panels Chromic acid 20-s dwell, 15-s drain, 3 min., 140 F room temperature Reducer 3 min., room temperature Ammonium bifluoride 3 min., room temperature Unrack panels High-pressure hole cleaning Release to electroless copper/DM Plasma Etch Plasma Oxyget, CF4, 30 min. Glass etch (optional) High-pressure hole cleaning Release to electroless copper/DM

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steps and does not require the use of large quantities of chemicals. Disadvantages of plasma are nonuniformity of the treatment across the batch and across the panel.The texture generated on the epoxy is minimal, and an ash is commonly left behind that leads to poorer hole wall adhesion.A secondary cleanup, such as permanganate, is commonly used after plasma to remove the ash. The cost of the equipment and its maintenance is high. Controls must be provided to prevent air pollution. 28.4.4 Process Outline: Smear Removal and Etchback The four common methods for smear removal and etchback are given in Table 28.2. Combinations of these methods are also in use because of added reliability they offer to both process and product. Polyimide and polyimide-acrylic systems are processed in chromic acid or plasma.Teflon , and R T Duroid materials are treated (before operations) in sodium-naphthalene mixtures to yield void-free, high-bond-strength copper in the PTH. The introduction of lead-free material and halogen-free material has challenged the desmear processes. The new materials are more chemically resistant, and thus more aggressive desmear cycles are required to remove any smear. These more chemically resistant resin systems are more difficult to texture. Alternative solvents, higher temperatures, and cycle optimization may be required to process these newer materials effectively.

ELECTROLESS COPPER 5,6,7,8,9,10

Purpose This second series of chemical steps (after smear removal) is used to make panel side-to-side and innerlayer connections by metallizing with copper. The process steps required include

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