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LAMINATE TEST STRATEGY
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Laminates contain different reinforcement materials (woven/non-woven glass/organic fibers, expanded PTFE, etc.), resin types (phenolic, epoxy, cyanate ester, polyimide, BT, etc.), resin formulations (blended, functionality, etc.), hardeners (dicyanodiamide [dicy], phenol-novolak, cresol-novolak, p-aminophenol, isocyanurate, etc.), and sometimes filler particles (ceramic or organic). The ratio of all of these individual components can vary widely. To define a test strategy for laminates, it is important to understand the different main components of the materials as well as the conditions during manufacturing, as these will have a large influence on their properties and quality. The evaluation and qualification of a laminate material can be a quite complex task and the new requirements for lead-free processing have specifically increased the focus on the thermal characteristics of laminate materials. A number of different qualification test methods are available to the materials engineer. However, very often not all of them are relevant or necessary for the final product. At the same time, the materials engineer faces pressure to produce quick results driven by shorter development cycles and increasing product and process requirements. The organization of the test methods described in this chapter follows a proposed best-practice guide aimed to help perform full material evaluations efficiently and at the same time address the new requirements of lead-free processing. The sections allow quick decisions, especially when a number of materials are being evaluated at the same time.
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Data Comparison The first step in every material evaluation is data comparison and assessment. This step may already allow the elimination of some material candidates without performing actual tests. The first and most important thing to understand is the state of the material that is being considered. Is it an established material formulation that has a solid history at other manufacturing locations, or is it a newly developed material that has not seen mass production yet
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LAMINATE QUALIFICATION AND TESTING
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New developments often do not come with complete data sheets that allow an early assessment, whereas the laminator can often provide one for established materials. Cost is another important factor. The laminator can provide guidance about volume pricing for the new material. Other considerations are the history of the supplier, in terms of having met previous commitments and whether the material is already in high-volume production. If it is a new material that has not yet been ramped to high volume, if no more than one PWB manufacturer is using it, and if no second source can be identified, then these facts may be a red flag when considering the material for use. 12.3.2 Two-Tier Test Strategy The qualification procedure proposed in this chapter follows a two-tier test strategy that enables quick decisions during a material qualification program. The first set of tests is easy to perform and focuses on key properties that should be evaluated when testing a new laminate material. Failure to pass any of them will likely result in rejection of a material for manufacturing. If multiple materials are being evaluated, the first tests will allow the easy elimination of the least probable candidates. The second set of tests is an expanded set of qualification tests that focuses on all key properties that are commonly evaluated for laminates. However, the final decision about a qualification test plan for a new laminate should always be driven by product-level requirements, which means that additional laminate tests as well as board-level tests may need to be added to the set of tests described in the following section.
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This first set of tests is most commonly performed when starting a material evaluation and qualification project. The tests can be performed easily and give some early indications of whether the material exhibits any major problems.
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Surface and Appearance This test is one of the very first tests to happen as the new material arrives in the shop. The laminate is inspected for its appearance and visual quality. Often the materials engineer will be able to assess the quality of the product without applying specification guidelines. Even packaging and shipping materials should be used to assess the laminator s overall quality control. IPC-TM-650 method 2.1.2 and method 2.1.5 define procedures for how to inspect the surface and appearance of copper-clad laminates. These standards should be applied only to surface areas that are pertinent to the finished board. More than 90 percent of the copper will usually be removed during manufacturing, and a new material should not be discarded solely for cosmetic reasons. On the other hand, for areas that will contain edge card connector pads or very fine-line traces, these surface standards must be applied. The specifications categorize the longest permissible dimensions of any copper pits and dents and define a point value-based rating system (as shown in Table 12.2).
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TABLE 12.2 Longest Permissible Dimensions Longest dimension (mm) 0.13 0.25 0.26 0.50 0.51 0.75 0.76 1.00 Over 1.00
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