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Process Flowcharts Attempting to visualize the process flow of the manufacture of multilayer printed wiring products can be overwhelming. One way to help picture the multiple paths a board travels is through the use of flowcharts. The flowchart in Fig. 27.31a is a typical process flow for the beginning innerlayer process identified as 1 through 4. Figure 27.31b is a typical finish board flow process after lamination and drill. Three additional diagrams are provided in Fig. 27.32 that represent possible sequential flows for HDI products. They are identified as processes 5, 6, and 7, referring to how the different HDI types might flow. It should be noted that alternative flows and methods are possible in HDI. This discussion is limited to mostly conventional processing. Major aspects of these processes are discussed in detail in the following sections.

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Innerlayer Materials The multilayer process begins with the accumulation of the innerlayer clad dielectric laminate. 27.4.2.1 Documentation and Specifications. The ML-PWB design documentation should specify the specific material system to be used in the fabrication. Typically materials are identified

FIGURE 27.31 Process flowcharts: (a) A typical process flow for the beginning innerlayer processes identified as 1 through 4; (b) a typical finished board flow process after lamination and drill.

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by IPC-4101 callout or slash sheet designation, for example, IPC-4101/24. Copper weights as well will be specified within the drawing documentation.The specification IPC-4562, Metal Foil for Printed Wiring Applications, provides reference to the various weights of copper foils along with an applications use guide.The common terminology refers to foils less than oz./ft.2 as a metric thickness of micrometers. The most commonly used foil is STD-Type E electrodeposited (IPC-4562/1) with a weight of 1 oz./ft.2 and a nominal thickness of 1.35 mil. (35.5 mm). 27.4.2.2 Copper Foil. High-current applications use heavier (thicker) copper of 2 oz. or above. With copper weights above 3 oz., processing difficulty is increased. High-density circuit designs that have low voltage and that are mainly concerned with passing signals may use thinner copper weight foils, such as 18 mm or less. When sequentially processing clads as buried via pairs, the fabricator must use thin starting foil to promote line definition and image integrity and, where necessary, impedance-controlled tracks.

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Copper foil is fabricated in an electroplating process on a rotating drum that produces a coarse-grained columnar copper.The economy of the foil process always yields copper at the minimum thickness tolerance. Due to the speed of the foil process, often a course grain structure can yield poor elongation. Elongation is a property of major importance in reducing trace fracturing. Standard copper foils typically fail at elongations around 3 percent. IPC-4562/3 high-temperature elongation (HTE) provides a slight, but important, improvement in elongation from 5 to 8 percent. High-ductility electrodeposited foil, called HD-Type E (IPC-4562/2), is specified to withstand an elongation of 10 percent minimum. Foil vendors also sell special finegrain-structure, annealed, or wrought foils. The foils with higher elongation are advertised to have superior etch performance for fine-line densities. Standard foils have a rough surface called tooth on one side (drum side out) and a smooth or shiny surface on the opposite side (drum side). The rough side, treated with an adhesion promoter, is laminated against the C-stage dielectric to ensure good adhesion. Since the shiny side of the copper has poor adhesion characteristics, the ML-PWB fabricator must include adhesion promotion steps prior to resist lamination and prior to final board lamination. Double-treated copper foil has an adhesion promoter applied to both sides and is attractive in high-volume applications. Although double-treated foil requires no further adhesion promoting treatments, it has several process disadvantages to overcome:

Cleanliness and material handling sensiFIGURE 27.31 (b) (Continued ) tivity is more critical. The cost often offsets the savings from the eliminated processes. It is somewhat fragile, so it is difficult to rework. Complete resist development is difficult, leading to a high incidence of shorts. It is not compatible with the plating processes used to make buried and blind vias.

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Another foil type offered by laminate suppliers, reverse-treated foil (RTF), offers an advantage for producing fine lines. The RTF copper has adhesion promoter applied to both sides and is classified by 4562 as code R (reverse-treated bond enhancement [cathode side] stain-proofing on both sides). This approach provides advantages to imaging fine lines. When the copper tooth is reversed, the fabricator can improve line definition by allowing the etch chemistry process to stop at the surface of the laminate.

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