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For each group, the chart shows average insulation resistance for a set of coupons over time. Clearly, the average insulation resistance varied by group, with group 1 showing the most significant decline in resistance. In addition, evaluating the individual coupons in each group provides additional insight into performance differences. In group 1, 40 percent of the coupons failed by 600 hours, with the first failure occurring at 400 hours. In group 2, 20 percent of the coupons failed at 600 hours. Groups 3 through 5 did not have any failures in this test. So even though the resin system was the same for each group, differences in glass cloth and laminate manufacturing processes clearly can have a significant impact on CAF performance. 9.8.2 Choosing a Base Material for CAF Resistance Some of the key conclusions of these examples and other research on CAF performed in the industry include the following:
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All base materials have some level of CAF resistance, but even materials promoted as CAF-resistant can vary widely in actual performance. The test vehicle design has a significant impact on results. The closer the circuit features, the more likely that CAF failures will occur. In addition, the other attributes of the test vehicle design can impact the fabrication variables that influence CAF for example, the thickness of the PCB and drilled hole sizes can lead to high aspect ratios that can be more challenging to manufacture. As a result of these factors, there is not universal agreement on what constitutes a CAF-resistant material. This can vary by OEM and application. Even one type of base material (resin system type) can vary in performance based on other factors, such as the glass cloth quality and the controls used during laminate and prepreg manufacturing. The specific glass styles can also impact performance. Although 7628 glass was the focus of much attention in CAF testing, 106 and 1080 styles can be challenging as well, in that getting full resin-to-glass wetting can be challenging with these styles. When selecting a material for applications requiring CAF resistance, consider the following:
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It is critical to define appropriately the performance level required and to design a test vehicle and test protocol that reflects the requirements of the application. Failure to do so can result in either underspecifying the material attributes and risking PCB failures or overspecifying the material and paying too much for it. For resistance to CAF growth, the resin system and the bonding of the resin system to the fiberglass cloth are key considerations. Coupling agents, typically silanes, are used to promote adhesion between the fiberglass filaments and the resin system. The molecular structure of the coupling agent includes a portion that bonds well to the fiberglass surface and other portions that bond well to the resin system. Specific coupling agents have been developed for specific resin types. Achieving a good bond between the fiberglass filaments and the resin system with an appropriate coupling agent helps prevent this interface from becoming a path for CAF growth. The use of expanded glass cloths can facilitate full wet-out of the resin to the glass, but such cloths typically cost more. The important point is that each glass style must be able to achieve good wet-out of all of the glass filaments. Low rates of moisture absorption and low levels of ionic contamination within the resin system also aid in resisting CAF growth. Epichlorohydrin is a precursor material used to make epoxy resins. The use of this compound can result in residual hydrolyzable chlorides in the epoxy resin. In the presence of moisture, these hydrolyzable chlorides form ionic species that can promote electromigration. When CAF resistance is a critical consideration, the use of high-purity resins may be required.
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