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Imaging 27.4.7.1 Surface Preparation. The first step in the imaging operation is surface preparation to enhance photoresist adhesion. Double-treated foils (DTFs) and foils laminated with the tooth side up (RTFs) require minimum surface preparation. Generally, a process through a tacky roller machine to remove dust and foreign material is adequate. For cores with standard foil with the shiny side up (non-tooth or drum side), a more aggressive treatment is needed. Common options include a conveyorized chemical cleaning and/or an abrasive

cleaningAutomated equipment is available to perform this function with pumice or aluminum oxide slurry Scrubbing the layer by hand is acceptable but labor-intensive, and can provide inconsistent results However, acidic 4F grit pumice is required for single-step cleaning Standard copper foils are coated with a chromate conversion to eliminate formation of heavy copper oxidation during storage This coating, and any oxides, must be removed to provide a microroughening of the surface When using any of the mechanical cleaning methods, care must be taken to avoid mechanical deformation (stretching) of the thin laminates Stresses induced will be relieved after etching of the image, causing positional movement 27472 Photoresist Photoresist is supplied in both dry-film and liquid forms Dry films are a popular choice because of the simplicity of application For buried via innerlayers, dry films are preferred because liquids are difficult to use with through holes.

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Fig 542: The linear motor method for high-speed feed [19]

The major weakness of dry-film resists is sensitivity to surface flaws and a tendency to lift on poorly prepared surfaces 27473 Dry Film Resist film is typically 15 to 20 mil thick Both thinner and thicker resist is available as a specialty product Dry-film resist is applied with a hot roll laminator To aid in production of fine lines and spaces, the use of a wet nip applicator aids in filling surface imperfections Precision flatness and uniform temperature are equally important as well Popular resists for high-density applications include films formulated with high-speed sensitivity for laser technology 27474 Liquid Photoresist Liquid resists work well in a print-and-etch process They have excellent adhesion and a tolerance for surface flaws and are relatively low in cost The disadvantage of a liquid photoresist is the need to produce a perfect coating.

Foreign material, skips, thin spots, and dewetting all cause serious image problems The use of a wet coating can also cause problems due to resist contamination of the transport system 274741 Roller Coating The least expensive and most popular way to coat liquid resists is with a pair of roller coaters consisting of pinch rollers in which one or both rollers is used for coating The coating roller has a closely spaced, precisely cut spiral grove Liquid is metered onto this roller and then transferred to the panel A good roller coater produces an extremely uniform coating By carefully selecting coater parameters, it is possible to achieve a coating thickness control of 01 mil Some roller coaters use the top roller as a coating roller, allowing the panel to be transported on a clean conveyor system.

In these systems, the resist can be dried or the panel can be printed wet Other roller coaters use both the top and bottom rollers for coating These roller coaters require a handling system that holds the panel by its edge until the resist is dry The coating roller is the weak link in a roller coating Alignment problems result in nonuniform coatings Flaws produce repeating defects in the coating Worn or improperly cut grooves result in a low-quality coating 274742 Curtain Coating The curtain coater operates by pumping a waterfall of liquid through a narrow slot By carefully controlling the slot width, pumping pressure, and viscosity, the fabricator can create a well-controlled curtain of liquid When a panel moves through the curtain, a thin coating is applied to one side.

Curtain coaters produce a good-quality coating, but not all photoresists have the proper viscosity for curtain coating 274743 Electrodeposition With electrodeposition, a polymer is deposited on a biased metal surface submerged in a liquid medium by a process that is analogous to plating It gives a well-controlled, high-quality coating Both curtain coating and electrodeposition are expensive and are not widely used for innerlayer processing 27475 Photo Print Exposure The third step in imaging is photo printing The three types of photo-printing machines are flood, collimation, and direct image Most flood printers consist of high-UV (5,000 W) light sources housed within large reflectors to distribute the light uniformly across the imaged surface Hard contact by means of a vacuum is required between the film and the innerlayer The silver emulsion side of the polyester film tool makes direct contact with the resist.

Fig 543: The high-lead ball screw method for high-speed feed [19]

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