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TABLE 9.2 Common Laminate Constructions Laminate Thickness (in.) 0.0020 0.0025 0.0030 0.0035 0.0040 0.0040 0.0040 0.0040 0.0040 0.0040 0.0045 0.0045 0.0050 0.0050 0.0050 0.0050 0.0050 0.0060 0.0062 0.0062 0.0080 0.0080 0.0080 0.0090 0.0100 0.0100 0.0120 0.0120 0.0140 0.0210 Fiberglass Cloth(s) 1-106 1-1080 1-2113 1-2113 1-2113 1-3070 1-2116 1-106/1-1080 2-106 2-1080 1-2116 2-1080 1-2116 1-2165 1-1652 2-1080 1-2313/1-106 2-2113 1-2157 1-1080/1-2313 1-7628 1-2116/1-2313 2-2116 2-2116 2-1652 2-2165 2-2157 2-1080/1-7628 2-7628 3-7628 Approx. Resin (%) 71 72 53 54 46 47 52 53 53 54 49 50 43 44 59 60 68 69 50 51 50 51 55 56 52 53 47 48 42 43 56 57 52 53 46 47 49 50 53 54 44 45 49 50 45 46 50 51 42 43 47 48 47 48 47 48 40 41 40 41
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there are both single-ply and multiple-ply options. Above 0.0080 in., multiple plies of cloth are typically required to achieve the desired thickness. Within each range, there are often multiple cloth and resin content combinations that can achieve the desired dielectric thickness. The choice of laminate construction can significantly impact both cost and performance. The choice of single-ply versus multiple-ply construction, when the option is available, is no exception. As should be expected, a single-ply construction will typically represent a cost savings compared to a multiple-ply construction. The magnitude of this savings will depend on the specific glass styles involved and a host of other parameters. Performance can also be affected and should be considered when specifying the constructions to be used. First, single-ply constructions are often lower in resin content, as can be observed in Table 9.2. Resin content issues are discussed in the following section. The other main benefit of single-ply constructions is dielectric thickness control, beyond resin content considerations. Other things being equal, as with resin contents, tighter thickness tolerances can be achieved using a single-ply construction than
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a multiple-ply construction since the variation in thickness control with one ply of prepreg will statistically be less than with multiple plies. 9.4.2 Resin Contents As Table 9.2 illustrates, the same dielectric thickness can be achieved with multiple fiberglass cloth and resin content combinations. Constructions with relatively lower resin contents are often preferred since they result in less z-axis expansion and can therefore improve reliability in many applications. In addition, lower resin contents can also improve dimensional stability, resistance to warpage, and dielectric thickness control. On the other hand, constructions with higher resin contents result in lower dielectric constant values, which are sometimes preferred for electrical performance, which is discussed further in Section 9.8. In addition, a certain minimum resin content is required to ensure adequate resin-to-glass wet-out and to prevent voids from occurring within the laminate. The ability to wet out the glass filaments fully with resin is also important for CAF resistance. In summary, for each glass style, there is an optimal resin content range that balances the various performance requirements. 9.4.3 Laminate Flatness and Flexural Strength When manufacturing the innerlayer circuit patterns, the flatness and flexural strength of the base material is important for successfully transporting these circuit layers through conveyorized equipment. This is particularly important for very thin laminates. If the laminate is curled, it can become caught or damaged inside this equipment. If the thin laminate with the circuit image sags on the conveyors, similar damage can occur. For these reasons, it is sometimes preferred to use constructions with relatively high glass contents and use the thickest cloths possible, as this will result in greater flexural strengths, bearing in mind the performance requirements just discussed in Section 9.4.2. In addition, balanced constructions, or those that use a symmetrical construction, are normally preferred to avoid curling. Asymmetrical constructions are more prone to curling and causing problems in conveyorized equipment. Consider a 0.0080-in. laminate as an example. Table 9.2 shows three constructions for this thickness, 1-7628, 1-2313/1-2116, and 2-2116. The asymmetrical 1-2313/1-2116 construction will be more prone to curling than the other constructions. One word of caution is warranted, however: Curling is but one property that must be considered. Dimensional stability, thickness control, and other properties must also be considered when choosing a construction.
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