A New Film Technology to Generate Phototools with sub 5 µm Lines and Spaces. EPC 2004 Cologne Germany 5 th 7 th September 2004

Transcription

1 A New Film Technology to Generate Phototools with sub 5 µm Lines and Spaces EPC 2004 Cologne Germany 5 th 7 th September 2004

2 PCB Catch phrase Lighter Smaller Thinner Lower energy consumption Faster Cheaper Eric Janssens Sept. 04 slide 2

3 PCB Catch phrase Lighter Smaller Thinner Lower energy consumption Faster Cheaper Not phototool related Eric Janssens Sept. 04 slide 3

4 PCB Catch phrase Lighter Smaller Thinner Lower energy consumption Faster Cheaper Phototool related Solution: HiRes Eric Janssens Sept. 04 slide 4

5 PCB Catch phrase Lighter Smaller Thinner Lower energy consumption Faster Cheaper Phototool related Solution? Eric Janssens Sept. 04 slide 5

6 The WW PCB industry in mio sqm finished boards 350 mio sqm dry film resist 100 mio sqm liquid resist 13,7 mio kg solder mask Eric Janssens Sept. 04 slide 6

7 The WW PCB industry in ,8 mio sqm phototooling film 2,0 2,1 2,1 5,6 Eric Janssens Sept. 04 slide 7

8 Phototooling film: production Raw material Emulsion QC Coating Finishing Base mat. QC QC QC Granulate QC Raw material Eric Janssens Sept. 04 slide 8

9 Phototooling film: production Raw material Emulsion Base mat. QC Granulate QC QC Coating QC Finishing QC Raw material Eric Janssens Sept. 04 slide 9

10 Phototooling film: improvements Granulate and base material New catalyst avoid black points Improved extrusion process avoid fish eyes Laminar flow avoid black points and fish eyes Eric Janssens Sept. 04 slide 10

11 Phototooling film: improvements Emulsion preparation 1 st day: Preparation: - Combine and mixing of base ingredients 2 e day: Riping - Grow crystals to the right size and shape 3 e day Finalisation - Fine tune energetic and spectral sensitivity, finalise for coatability, control viscosity,. Eric Janssens Sept. 04 slide 11

12 Phototooling film: improvements Emulsion preparation: Riping AgX crystal size: Determines sensitivity and resolution AgX crystal shape: Determines line sharpness and line wide control Parameters that influence size and shape: Temperature and temperature change over time Additives and timing of addition Mixing speed, flow pattern. Eric Janssens Sept. 04 slide 12

13 Phototooling film: improvements HiRes AgX crystals Vivaldi 2 HiRes Eric Janssens Sept. 04 slide 13

14 Phototooling film: improvements Coating Antihalo under emulsion improve line sharpness New combined LIEC improve line sharpness Narrower production tolerances Eric Janssens Sept. 04 slide 14

15 Phototooling film: improvements Finishing Improved clean room conditions New packaging Eric Janssens Sept. 04 slide 15

16 Phototooling film: improvements Finishing Improved clean room conditions New packaging Eric Janssens Sept. 04 slide 16

17 Phototooling film: structure Vivaldi 2 HiRes Eric Janssens Sept. 04 slide 17

18 Phototooling film: structure Vivaldi 2 HiRes 1 No matt on image side 2 Thinner emulsion layer 3 Smaller AgX crystals 4 New combined LIEC 5 Purer base 6 No back layer 7 Smaller Matt on back Eric Janssens Sept. 04 slide 18

19 Phototooling film: layer functions Layer Anti stress 1 Anti stress 2 Emulsion Under layer Substrate 1 Substrate 2 Base Substrate 3 Matt Function Protection image Protection image Image formation Antihalo Bounding under layer to substrate 2 Bounding substrate 1 to base Mechanical support, dimensional stability Bounding matt to base Control transport and vacuum behaviour Eric Janssens Sept. 04 slide 19

20 HiRes Phototooling film: characteristics Fine line capability: down to 3 µm and better (plotter depending)? Line sharpness: improved vs Vivaldi 2 Line width control: improved vs Vivaldi 2 Processing: identical cfr Vivaldi 2 (Vdev and Vfix) Dimensional stab: improved vs Vivaldi 2 (thinner layers, lesser gelatines) Scratch resistance: comparable to Vivaldi 2 Eric Janssens Sept. 04 slide 20

21 HiRes Phototooling film: characteristics Fine line capability: down to 3 µm and better (plotter depending)? Line sharpness: improved vs Vivaldi 2 Line width control: improved vs Vivaldi 2 Processing: identical cfr Vivaldi 2 (Vdev and Vfix) Dimensional stab: improved vs Vivaldi 2 (thinner layers, lesser gelatines) R&D projects in progress Scratch resistance: comparable to Vivaldi 2 Eric Janssens Sept. 04 slide 21

22 Phototooling in praxis Phototool Is the sum of: Design + Plotter + Film + Chemistry + Processor + Plotter room + Operator Plotter: more light output, smaller spot size, higher addressability, higher accuracy and repeatability better controlled spot overlap, faster switching, better overall stability, more powerful computer. Eric Janssens Sept. 04 slide 22

23 Plotters: Red Success fully tested: First EIE: RP 525 ManiaBarco: Eagle, Phoenix Orbotech: LP 9008 Tests in execution or planned: First EIE: RP 300 ManiaBarco: SW 800 and SW 8000 series Orbotech: LP 7008 Screen: RG 8000, RG 8500 Eric Janssens Sept. 04 slide 23

24 HiRes on First EIE 5 µm Eric Janssens Sept. 04 slide 24

25 HiRes on ManiaBarco 10 µm 5 µm Eric Janssens Sept. 04 slide 25

26 HiRes on ManiaBarco 10 µm 5 µm Eric Janssens Sept. 04 slide 26

27 HiRes on Orbotech 10 µm 10 µm Eric Janssens Sept. 04 slide 27

28 Plotters: green, blue, violet, white HiRes film not yet available Interest from: Heidelberg Mivatec Pentax Screen Eric Janssens Sept. 04 slide 28

29 Conclusions On HiRes some plotters can generate designs with: fine lines and spaces, good line width control good line sharpness Capabilities: printers, resists, development, etching? There is room for further evolution Eric Janssens Sept. 04 slide 29

30 Thank you Eric Janssens Sept. 04 slide 30