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In this laser direct drilling method, copper foil is etched down to about 5 m and its surface goes through oxide treatments such as black oxide or other methods, typically as alternatives to oxide treatment, which is normally an etching process The copper thickness is further reduced by 1 m, and the surface color becomes dark, allowing the CO2 beam to penetrate Alternatively, ultrathin copper RCC may be used Carrier foil, usually copper foil of 70-mm thickness (2 oz), is coated with a very thin layer (10 to 20 mm) of current conductive release film, and a thin foil of 3 to 5 m is plated After such RCC is laminated to the core, the carrier film is peeled off and the surface condition is the same as etched-down copper.

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Drilling speed in this direct CO2 laser drilling method is degraded by 30 to 40 percent compared to that of straight resin drilling, but the registration to the capture pad is ensured 22633 Yag/CO2 This combination is particularly useful for a copper/prepreg structure The Yag laser offers good position accuracy and cuts through copper, but it tends to leave glass fibers sticking out in the hole after prepreg drilling And as mentioned before, it is sensitive to dielectric thickness variation The CO2 laser beam cuts through glass fiber more cleanly than the Yag In this combination laser drilling, the power of the Yag laser beam is adjusted to cut through copper and remove a portion of glass fiber and leaves the finishing to the CO2 laser.

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The speed of drilling is governed by the speed of the Yag laser and is therefore slower than a pure CO2 laser However, this is the preferred laser-drilling machine for fabricating infrastructure types of PWBs, such as ones used for servers, network routers, and base stations that typically have copper/prepreg surface structures The size of the panels used to fabricate such boards is usually large; therefore, the positioning accuracy of the Yag laser is preferred Microvia hole boards used by the automotive industry also have this copper/ prepreg structure The speed of drilling by a Yag/CO2 machine is much slower than that of a CO2 laser However, the number of microvia holes to be drilled for infrastructure boards is normally one magnitude less than that seen in cell phone applications, in which the number of microvia holes can reach as many as 650,000 to 700,000 per m.

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2 Furthermore, the price of infrastructure boards is much more than that of mass-produced cellular phone motherboards Therefore, slower speed of drilling, which means higher drilling cost, does not affect the total cost of manufacturing Residual glass fibers in the hole that can affect reliability may be removed chemically or mechanically Mechanical removal is preferred Blasting with aluminum oxide (about 20 m diameter particles) is commonly used to remove glass fibers and smears as well An excimer laser is also used to remove smears in the hole by a sweeping motion through the copper opening In both cases, it takes about 30 sec to desmear one side of the panel..

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22.6.4 Dry Metallization (Conductive Inks, Conductive Paste, and Insulation Displacement) Three types of dry metallization are covered: conductive ink, conductive paste, and insulation displacement. Conductive ink describes a single-layer dielectric with microvias formed by photoimaging, laser, or insulation displacement.A conductive paste is used to fill the microvias and act as the conductive path between layers. Surface metallization may be accomplished either by laminating copper foil onto the dielectric surface or by chemical deposition. This process is shown in Fig. 22.18d. Insulation displacement is a unique process in that the silver conductive paste is screened on copper foil and cured. The conductive paste forms a pointed via that penetrates conventional prepregs during lamination and adheres to the copper foil on the reverse side, forming a via. Figure 22.18e shows this via formation process. Standard activities concentrate on the use of photoimaging and screen printing while overcoming the limitations and expense associated with processes such as plating and etching. The concept is built on the use of a photoimageable dielectric to produce both vias and circuit

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