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6 result in consistent thermal profiles from laminate to laminate and can use low lamination pressures Optimizing these parameters can lead to improved consistency in dimensional stability Other process controls in the laminate manufacturing process are also important for dimensional stability Control of the raw materials, especially the glass cloth, can contribute to dimensional stability The tension applied to the cloth during the treating process, the heat rise, temperature, and pressure profiles during lamination, as well as laminate stack-up techniques during lamination can all affect dimensional stability Consistency in these parameters will generally improve the consistency observed during the printed circuit manufacturing process 9632 Impact of Reverse-Treated Foils (RTF) RTF copper foils typically allow the elimination of surface-roughening processes in the innerlayer circuit imaging process These surface-roughening processes are normally mechanical scrubbing processes that can stretch or distort thin laminates.

Much of the distortion induced by these processes is elastic in that the laminates tend to move back toward their original dimensions This movement takes time, however So laminates imaged one length of time after scrubbing can potentially move a different amount if imaged after a different length of time after scrubbing If the laminates are imaged before they have a chance to fully relax after mechanical scrubbing, some movement may occur after imaging, which then distorts the image placed on the laminate In addition, variation in the mechanical scrubbing process over time can introduce lot-to-lot variation, which adversely impacts registration capabilities RTF foil, which facilitates the removal of these scrubbing processes because of the improved photoresist adhesion to the matte side of the foil, can therefore result in improvements in registration capability 9633 Fiberglass Cloths and Resin-to-Glass Ratios.

Each fiberglass cloth style used in laminates and prepregs has a resin content range that results in sufficient wet-out of the glass cloth, is relatively easy to control, and therefore results in more uniform thickness and more consistent dimensional stability The specification of laminates and prepregs with resin contents in the desired ranges can result in improvements in dimensional stability and therefore registration capabilities As a result, having a range of fiberglass cloth styles available is important to be able to achieve a wide range of dielectric thicknesses 9634 Non-Woven Reinforcements Because of the woven, serpentine geometry of the yarns in fiberglass cloths, they can behave like springs when used as the reinforcement of base materials During the resin treating process and the laminate pressing operation, the fiberglass cloth is subjected to stresses that can be stored in the laminate as the resin is cured.

These stresses can then be released during the circuit manufacturing process, causing dimensional changes Non-woven materials can avoid these stresses In one non-woven material type, short, randomly oriented fibers are treated with the resin system In a second type, linear strands of fiberglass are layed down in a balanced, cross-plied orientation which resists subsequent stresses 9635 Multilayer Press Cycle Optimization Most of the dimensional changes in the laminate occur during the multilayer press cycle when the temperature exceeds the Tg of the.

resin in the laminate. Above the Tg, the resin system in the laminate softens and allows any stored stress in the reinforcement to be released and allows the laminate to be affected by the adjacent materials and the pressure of the lamination cycle. Understanding the rheology of the resin in the prepreg is important when designing the multilayer lamination cycle. The point at which the resin begins to melt, the point at which it begins to cure, and the relationship between the heat rise and the viscosity profile of the resin are all important. With respect to viscosity, not only is the minimum viscosity achieved important, but the length of time that the resin is below a certain viscosity, allowing the resin to flow and fill the internal circuit features, is also important. With an understanding of these parameters, it is possible to design kiss cycles, or soak cycles, where pressure and temperature profiles, respectively, are designed to improve performance, including dimensional stability. In addition, although seldom done in practice, using a resin system in the prepreg materials that can be cured below the Tg of the resin system in the laminate can avoid the softening of the laminate resin system and therefore prevent much of the movement that takes place. The resistance to the use of this technique is usually driven by a desire to keep the resin system same throughout the multilayer PCB.

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