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The disadvantage of PPO is that it has a broad Tg with softening beginning well below 150 C This has an adverse effect on the ultimate fatigue life of high-aspect-ratio holes Care should be taken in using this material in applications where the system must operate over a very large number of thermal cycles that include temperatures in excess of 130 C..

27.2.3.4 Materials with Enhanced Electrical Properties. The resin and the reinforcement determine the Dk and tan d of a composite material. Standard FR-4, made up of epoxy resin and woven glass, has a Dk in the range of 4.0 to 4.4 and a tan d of 0.02. This may be reduced somewhat by replacing some or all of the epoxy resin with PPO, cyanate ester, or PTFE. Further reductions require replacing the glass reinforcement, which contributes a Dk of 6.0 to the effective Dk of the system.

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272341 Cyanate Ester Blends Both the tan d and the Dk of the cyanate ester resin system are much lower than those of epoxy The best results are achieved with pure cyanate ester However, as mentioned earlier, this resin is brittle and difficult to drill The BT blend provides an excellent compromise BT has a Dk of 294 and a tan d of 001 This improvement is useful in some applications; however, it is inadequate for many high-performance applications, and the approximately 100 percent cost penalty for BT has prevented its broad acceptance 272342 PPO Blends As with cyanate ester, both the tan d and Dk of the PPO resin are lower than those of epoxy For processibility and cost reasons, a blend of approximately 50 percent PPO and 50 percent epoxy is generally used.

This gives electrical performance similar to that of BT, but with a cost penalty of only 20 to 50 percent above standard epoxy It is likely that PPO will find wide use in those applications such as high-performance workstations that need a small improvement in electrical performance Unfortunately, the characteristics of a PPO-epoxy blend are often inadequate for very high-speed applications such as supercomputers and wireless (RF) applications 272343 PTFE-Based Laminates This resin system is commonly known as Teflon Of all resin systems in common use, the best electrical performance is provided by PTFEThe Dk of PTFE is close to 20 and the tan d is less than 0001 This is a significant improvement over all other materials In addition to offering excellent electrical properties, PTFE has excellent thermal properties.

It is a thermal plastic that can operate at temperatures above 300 C without softening, oxidation, or other forms of degradation PTFE is naturally fire retardant, so it does not need bromine addition to achieve the UL rating of V-0 It has very low moisture absorption For ML-PWB applications, PTFE has three serious disadvantages:.

Poor processibility Because PTFE is a high-temperature thermoplastic, it is generally laminated in a high-temperature lamination cycle not achievable in conventional lamination presses. The fabricator can avoid this poor processibility by using a low-temperature adhesive, but this can lead to serious compromises with electrical and thermal properties of the laminate. The second major difficulty in processing PTFE is the hydrophobic nature of the material. This makes it difficult to clean and metallize the holes. Generally, plating must be immediately preceded by a special fluoride etch, TETRA-ETCH, that activates the hole wall and enhances wetting. As an alternative, some PTFE systems can be activated in plasma etch; however, this does not work with all PTFE materials. High CTE PTFE maintains full strength up to and above solder temperature. When this strength is combined with a high CTE, PTH reliability is a serious concern. This is a particular problem with glass-reinforced PTFE, where the x-y constraint of the glass magnifies the out-of-plane expansion. A second problem attributable to high CTE is excessive warpage whenever Teflon is combined with epoxy based laminate in an unbalanced hybrid structure. Cost PTFE-based laminates are often 100 times more expensive than epoxy-based laminates. This makes it difficult to justify the use of PTFE if any alternative exists. At least three types of laminate systems are available with PTFE resin: