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7.6.1.1 Bonding Treatments or Nodularization. This treatment increases the surface area of the foil by plating copper or copper-oxide nodules to the surface of the foil. The increased surface area results in increased foil to resin bond strengths. The thickness of this treatment is relatively small, but can be tailored for adhesion to high-performance resin systems such as polyimides, cyanate esters, and BT. The matte side images in Figs. 7.23 and 7.24 include these nodules. 7.6.1.2 Thermal Barriers. A coating of zinc, nickel, or brass is usually applied over the nodules. This coating can prevent thermal or chemical degradation of the foil to resin bond during manufacture of the laminate, the printed circuit, and the circuit assembly. These coatings typically measure several hundred angstroms in thickness and vary in color due to the specific metal-alloy used, although most treatments are brown, gray, or a yellow mustard color. 7.6.1.3 Passivation and Antioxidant Coatings. In contrast to the other coatings, these treatments are virtually always applied to both sides of the foil. Although many of these treatments are chromium-based, organic coatings can also be utilized. The primary purpose of these treatments is to prevent oxidation of the copper foil during storage and lamination. These coatings are usually less than 100 angstroms thick and are typically removed by the cleaning, etching, or scrubbing processes normally used at the start of printed circuit manufacturing processes. 7.6.1.4 Coupling Agents. The use of coupling agents, primarily silanes such as those used to promote fiberglass to resin adhesion, can also be used on copper foils. These coupling agents can improve the chemical bond between the foil and the resin system and can also be used to help prevent oxidation or contamination.

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Drum Side Treated Foils (DSTF) or Reverse Treated Foils (RTF) Drum side treated (DSTFoil ) or reverse treated foil (RTF) is also an electrodeposited copper foil, but the treatments are coated onto the smooth drum side of the foil rather than the matte side, as with conventional electrodeposited foil (see Figs. 7.25 and 7.26). This results in a verylow-profile surface bonded to the laminate, with the rough matte side facing out. The low

FIGURE 57.23 PTH reliability test coupon. This coupon contains three sets of 1000 PTHs interconnected in series on four layers. Each set is a different hole size. The pad size is also varied. Similar designs are available from the IPC.

57.6.2.2 Mechanical. Printed circuit boards are rarely subjected to mechanical tests that could cause electrical failures; however, adhesion of both Cu and solder mask to the laminate is critical and is often tested. Loss of solder mask adhesion can provide a place for corrodants and moisture to accumulate, which can be the cause of electrical failures when the board is exposed to temperature and humidity. Adhesion is commonly tested using the peel test described in IPC-TM-650, Method 2.4.28. The simplest version of this test is conducted by scribing the adherent and dividing it into small squares. If the Cu or solder mask pulls off with a piece of tape with strong adhesive, the adhesion is inadequate. More quantitative tests that measure the actual peel strength are performed primarily by laminate and solder mask suppliers. 57.6.2.3 Temperature, Humidity, Bias. These tests are designed to promote corrosion on the PCB surface and conductive anodic filament growth, either of which can cause insulation resistance failures. Surface insulation tests utilize two interleaved Cu combs with an imposed dc bias across the combs. These combs may be designed into existing boards or a coupon such as the IPC-B25 test board shown in Fig. 57.24 may be used.The measured resistance (ohms) from the comb pattern can be converted to surface resistivity (ohms per square) by multiplying the measured

FIGURE 57.24 Test coupons used to check moisture, insulation, and metal migration resistance: (a) the IPC-B-25 test board, used to qualify the process; (b) The Y coupon, designed to be incorporated into production boards for statistical process control. From IPC-SM-840.