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While there are also a variety of reinforcements used in base materials, woven fiberglass cloths are by far the most common. Other materials include paper, glass matte, non-woven aramid fibers, non-woven fiberglass, and a variety of fillers. The advantages of woven glass cloths include a good combination of mechanical and electrical properties, a wide range of types for achieving various laminate thicknesses, and good economics.
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Woven Fiberglass The process of manufacturing woven fiberglass cloth begins with melting the various inorganic components required for a particular grade of glass. The molten components travel through a furnace and ultimately flow through specialized bushings to form the individual fiberglass filaments and yarns. These yarns are then used in a weaving process to manufacture the fiberglass cloth. The relative concentrations of the components used affect the chemical, mechanical, and electrical properties of the fiberglass.The compositions of a few fiberglass types are provided in Table 7.3. Figure 7.15 illustrates the process used to manufacture the fiberglass yarns. The yarns are then woven into fiberglass cloths.
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TABLE 7.3 Fiberglass Compositions in Percentages Component Silicon Dioxide Calcium Oxide Aluminum Oxide Boron Oxide Sodium Oxide and Potassium Oxide Magnesium Oxide Iron Oxide Titanium Oxide Fluorides E-Glass 52 56 16 25 12 16 5 10 0 2 0 5 0.05 0.4 0 0.8 0 1.0 NE-Glass 52 56 0 10 10 15 15 20 0 1 0 5 0 0.3 0.5 5 S-Glass 64 66 0 0.3 24 26 0 0.3 9 11 0 0.3 D-Glass 72 75 0 1 0 1 21 24 0 4 Quartz 99.97
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FIGURE 7.15 Illustration of fiberglass yarn manufacture.
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E-glass is by far the most commonly used fiberglass for printed circuits. It provides an excellent combination of electrical, mechanical, and chemical properties at a reasonable cost. NE-glass is used in limited quantities and offers improved permittivity (Dk) and loss (Df) properties (see Table 7.4). However, NE-glass is more expensive than E-glass. S-glass provides greater strength but is more difficult to process through the mechanical drilling operation. Other glass types are seldom used.
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TABLE 7.4 Comparison of E-Glass and NE-Glass Property CTE, ppm/ C Dielectric constant @ 1 MHz Dissipation factor @ 1 MHz E-Glass 5.5 6.6 0.0012 NE-Glass 3.4 4.4 0.0006
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Several diameters of filaments are available (see Table 7.5), as well as many different yarn types. D, DE, E, and G filaments are the most commonly used. Combining the various yarn
TABLE 7.5 Glass Filament Diameters Filament Designation B C D DE E G H K Nominal Diameter (Microns) 3.5 4.5 5 6 7 9 10 13 Nominal Diameter (Inches) 0.00015 0.00018 0.00021 0.00025 0.00028 0.00037 0.00043 0.00051
PRINTED CIRCUITS HANDBOOK
types in the weaving process leads to many different types of cloth styles. While there are also many different weave types, virtually all cloths for printed circuits use a plain weave (see Fig. 7.16). The plain weave consists of yarns interlaced in an alternating fashion, one over and one under every other yarn. This weave pattern provides good fabric stability. Some of the common plain weave cloth styles used for printed circuits are shown in Table 7.6. The fiberglass cloths are also coated with a finish or coupling agent tailored for improving the bond between the glass filaments and the specific resin coated onto the glass. This coupling agent and the resin-to-glass bond that results are important considerations for CAF resistance, which will be discussed in Chap. 9.
FIGURE 7.16 Plain weave.
Yarn Nomenclature
Because there can be so many types of yarn manufactured from the available grades of glass and filament diameters, special nomenclature systems have been developed. The two systems used are the U.S. System and the TEX/Metric System.
7.5.2.1 The U.S. System. An example of a yarn name in the U.S. system is ECD 450-1/0. This yarn is used in making a 1080 style glass cloth. Each letter and number in the name describes something about the yarn:
First letter This describes the glass composition. Electrical grade, or E-glass, is the most common grade used for manufacturing materials for printed circuits. Second letter C indicates that the yarn is composed of continuous filaments. S would indicate staple filaments, and T indicates texturized continuous filaments. Third letter This letter indicates the individual filament diameter (see Table 7.5).
TABLE 7.6 Common Fiberglass Cloth Styles for Printed Circuit Base Materials Approx. Fiberglass Thickness (In.) 0.0013 0.0014 0.0014 0.0023 0.0026 0.0052 0.0045 0.0028 0.0038 0.0051 0.0040 0.0029 0.0031 0.0033 0.0068 0.0070 0.0080 Count (Ends/In.) 60 52 56 56 69 69 60 47 60 60 49 42 52 52 60 56 60 58 60 35 60 52 60 64 70 70 60 62 44 32 44 34 44 29 Weight (Oz./Yd.2) 0.55 0.73 0.71 1.42 1.55 4.95 4.06 2.31 3.22 4.36 3.55 2.38 2.74 2.40 6.00 6.25 6.90
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