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41 The original foil was etched from thicker commercial foil laminate to the working thickness 34744 Changing the Microchannel Flow As previously explained, the flow in the microchannels surrounding the features is critical in achieving uniform and accurate etching results There is a unique process development using fibers to affect localized fluid mixing in these channels42 This approach requires specific patented equipment and processing methods43 Reported results down to 50-mm (2-mil) lines and spaces in 1-oz (34-mm) copper have been produced with 14-mil (37-mm)-thick resist This is a very unique and important result because conventional foil and resist technology can be used to make features significantly smaller than conventional capability through improved fluid application mechanics 34745 Beyond Fine HDI Impacts High-density interconnect (HDI) technology involves several technology changes to form the circuitry.

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The highlight, as the name implies, is small via structures made in a layer-by-layer methodology with a built-up thin insulator and thin foil structure To achieve the interconnection, thin and precisely controlled traces are required The technologies, such as the two previous items, are becoming available to attack the needs of the products As layer counts increase, the accumulating yield implications are significant, so that each process must produce minimum defects For etching, one of the challenges is to make the resist conform to the surface which forces the structural materials and processes to engage planarity of the end stage process as an issue Etching capability requires improving the precision, stability, and capability of processing The flowchart in Fig 346 graphically illustrates the effects required for etching concerns and approaches to address these44 It is significant that there are no new concerns added to previous discussions..

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Practice in an environment similar to that of the actual presentation. Practice as often as you can in a room the size and shape of the one where you ll formally present. Practice while sitting, standing, or using a lectern. If you need to hold your cards in the formal presentation, it s important to practice while holding them. This lets you feel comfortable with your gestures and practice your eye contact.

FIGURE 34.6 Flowchart for study of resolution of HDI etched product limitations. Profile and uniformity limitations may be studied for process improvement by progressing down the chart for contributing elements.

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34.7.4.6 Stability and Control. It is important to measure and understand sources of variation in order to eliminate them. The gauging tools mentioned previously are very useful for collecting the data for analysis. One important feature is the positional and orientational variation in line geometry. Various conclusions can be taken from feature variation by location across the panel and orientation relative to the direction of motion. Repeating the gauging technique on a regular basis can allow observation of changing conditions within the process (such as plugged nozzles and other defects). Another type of variation can be obtained by examining a series of gauge panels progressively processed with specific time-lag variations. If etching chemical controls are not adequate, the etch rate may vary in the sequence and therefore cause line variation with time. Usually, regeneration equipment can be adjusted or modified to minimize these variations, but the value of such instrument upgrades can be determined easily by data recorded about the type and extent of defects incurred.

Etching equipment for circuit line formation has developed many variations on spray processing equipment. Often, as members of a coordinated automatic immersion plating process line, there are immersion etching tank varieties for microetching and surface preparation. However, for individual panels, conveyorized spray processing is clearly established because of efficient part handling and processing effectiveness.

Spray Equipment Basics 34.8.1.1 Construction. Etching equipment must be made from materials for long life, good dimensional stability, and resistance to chemicals and temperatures (130 F and higher). The basic construction includes rigid plastics (PVC, polypropylene, CPVC, and PVDF), metals (titanium, Hastalloy C), elastomers (vinyl, Viton A, Kel F, ethylene-propylene), specialized composites (epoxy-glass, graphite, and carbon-filled polymers, and other specialized formulations), and glass or clear and translucent polymers for visibility. The challenge is to select proper grades, compositions, and properties for mechanical strength, functionality, and durability. Equipment manufacturers perform these tasks in their design process.

34812 Controls Controls and electronics are significant because the increasing robustness and precision can have a large impact on cost Therefore, the compromise on costeffectiveness/technology trade-off often is made with a market-price primary goal Therefore, cost-benefit analysis must be made by purchasers to evaluate available upgrades in instrumentation The key controls are temperature, pressure, conveyor speed, and safety interlocks Temperature is especially important because the etching reactions are usually exothermic and heat must be removed by cooling water coils to maintain stable rates Conductivity, pH, density, ORP, and other process chemical control instruments may be added to monitor and control the processes These instruments may be integrated into a PLC or computerized control system or may be individual control-panel stand-alone instrumentations The wiring and the control cabinet itself must be suitably fume and hazard protected for water and chemical splashes as well as corrosive fumes.

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