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Basically, the brightener increases the current and reduces the suppression. The brightener plays a key role in determining the physical properties of the deposit. It is a grain refiner and, as such, it has a direct enhancing effect on the physical properties of the deposit, such as tensile strength and percent elongation. 29.5.6 Levelers Levelers are used to offset localized high-current-density areas that result from high points or sharp edges in the plating surface. An example would be the dog-bone effect, occasionally seen at the knee of the hole. Levelers are a class of compounds, typically aromatic, that adsorb preferentially at high points in the plating topography due to the increased mass transport possible at these sites. The adsorption of the leveler at these sights creates localized suppression, allowing plating in the lower-current-density areas to catch up with high areas hence, the leveling effect.

Low-Current-Density Plating One way to achieve good distribution is the use of a low-current acid copper-plating system, which is designed specifically to produce a deposit with the required physical properties at reduced current density. Some shops are presently plating HDI boards at 6 to 8 ASF for a period of 4 to 6 hours. This will give excellent plating distribution, due to the increased suppression at these low plating voltages. Low-current-density plating baths or electrolytes are characterized by lower copper concentration and increased sulfuric acid concentrations (refer to Table 29.4). The additive package of carrier and brightener is specifically formulated to operate at these low-current densities.

TABLE 29.4 Operation and Control Operating variable plating Copper Copper sulfate Sulfuric acid Chloride Additives Temperature Cathode CD Anodes Type Composition Bags Hooks Length Anode CD Properties Composition Elongation Tensile strength

Low current density plating 1 2 oz./gal 4 8 oz./gal 25 32 oz./gal 40 80 ppm As required 75 85 F 5 15 ASF Bars or baskets Phosphorized 0.04 0.06% P Closed-napped polypropylene Titanium or Monel 2 in. shorter than rack 25 50% of cathode CD 99.8% (99.5% min., ASTM-E-53) 10 25% (6% min., ASTM-E-8 or ASTM-E-345) 40 50 kpsi (36 kpsi min, ASTM-E-8 or ASTM-E-345)

Conventional CD* plating 2 3 oz./gal 8 12 oz./gal 22 28 oz./gal 40 80 ppm As required 70 85 F 20 40 ASF

These types of products are in use throughout the industry and are tolerated as long as the numbers of HDI boards are a small percentage of the overall production. This practice, however, dramatically reduces the output of the plating line and increases the cost of the part. As the percentage of HDI boards increased, the need for a different answer became apparent. 29.5.8 Chemically Mediated Process Here, the carrier is engineered for maximum chemical suppression, even at a high-current density. This is demonstrated by the shift in the Tafel slope (see Fig. 29.11). These baths are capable of good throwing power and surface distribution while plating at relatively high-current densities. Super-throw baths are capable of 85 percent throw in a 5:1 aspect ratio board while plating at 30 and at 35 ASF. This kind of bath contrasts with the low-current bath and can improve productivity significantly, while still operating under conventional DC plating.

(a) (b) (c) (d) 3.

The system fits readily into existing in-house equipment and in-house know-how. Figure 29.12 shows an example of a blind via that is 5.0 mil in diameter and 3.0 mil deep, plated with this type of bath at 20 ASF for 90 min.

Pulse Plating (Electrically Mediated Process) In this plating system, the bath is engineered to respond to a periodically pulsed reverse current. The required Tafel slope shift is accomplished through rectification (see Fig. 29.13). The rectifier produces a pulsed wave with a forward cathodic current that is perturbed by short anodic pulses. The forward current at 1X (e.g., 30 ASF) is maintained for 10 ms and the reversed at 3X (e.g., 90 ASF) for 0.5 ms, for example. The duty cycle may vary (e.g., 20 ms forward with 1.0 ms reverse).

FIGURE 29.12 Example of a blind via that is 5.0 mil in diameter and 3.0 mil deep, plated with chemically mediated bath.

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There is also room to optimize the forward-to-reverse current ratio; 1:3 is only one example. The shape of the wave is very important here, also. A square wave with minimum rise time gives the best results (see Fig. 29.14).

1000 500 0 -500 -1000 -1500 -2000 -2500

Chemical suppliers have designed specific additive packages that ensure maximum response to the periodic pulse reverse wave. During the reverse cycle, the additive is preferentially desorbed from the high-current-density areas. This results in less plating acceleration due to the additive, and more suppression due to the carrier. Since the low-current-density areas of the panel will also receive a lower reverse pulse, the acceleration is reduced to a lesser degree than in the high-current-density areas. This leads to greatly improved plating thickness distribution.