Q: What Is Halogen-Free FR-4 Material?

In the previous topics, we have talked about “ How to choose the material of PCB? ”, “ Brief Talk about PCB Materials ”, and “ How to Have PCB Material Ready? ”. Today let’s discuss Halogen-Free FR-4 material. What Is Halogen-Free FR-4 Material? Defined by IPC and IEC, only BR(Bromine) and CL(Chlorine) content is less than 900 PPM, and the total of BR(Bromine) CL(Chlorine) content is less than 1500PPM, can be considered as Halogen-Free FR-4. Meanwhile, all materials used must meet the halogen-free requirements when using Halogen-Free FR-4. Halogen-Free FR-4 vs. Lead-Free FR-4 The grade of Halogen-Free FR-4 is greater than Lead-Free FR-4. Halogen-Free FR-4 basically meets the requirements for lead-free assembly. On the other hand, Lead-Free FR-4 that meets the requirements for lead-free assembly does not necessarily meet the requirements for Halogen-Free. As you might know there’re many types of PCB material. And choosing the suitable material will affect the durability and reliability of end products.

Q: Reliability Test - Accelerated Life Test

Except from E-test and some other Multiple Tests , there is also advanced testing for PCB reliability which is so called Aging Test or Accelerated Life Test. For those application which needs long time working without failure, this kind of testing can help to find out if PCB can withstand abrasion of operation and time. Some certain environment simulation tests can be done to verify the reliability of material by our Programmable Temperature & Humidity Chamber. Here is the test and the testing conditions that we do: High Temperature High Humidity Test Target: To understand influence of moisture absorption to reliability performance of material by environmental simulation. Condition: 85°C / 85% (Temperature / Humidity) Test Time: 168 Hours to 2000 Hours (168 Hours approximately equals 875 Days)

Question 1

Micro-section Inspection of PCB

Accepted Answer

Micro-section Inspection is a key quality analysis method used to evaluate the interlayer connections and conductor shapes of printed circuit boards. This inspection method is usually performed on the finished PCB to ensure that the conductors between each layer comply with the design requirements and production standards, or when a product defect occurs, sampling and analysis can be done at specific location to find cause of the abnormality.

When performing micro-section inspection, a sample of a certain size is first cut from the finished PCB, and then its surface is ground to make the internal structure visible. A microscope is then used to observe and take images of micro-sections, which show the vias, conduct layers and dielectric layers of the PCB.

Through micro-section inspection, PCB manufacturers can evaluate several key factors:

Conductor Integrity and Connections: Check whether the shape, thickness and position of the conductors are consistent with the design to ensure that the circuit connection is reliable.
Quality of interlayer dielectric: Check the dielectric layers are even and free of cracks or air voids to prevent short circuit between conductor layers or insufficient insulation strength.
Copper plating quality of PTH holes: Check whether the copper plating of the through holes is sufficient and evenly distributed to ensure the conductivity and reliability of the product.

Micro-section inspection is an important step in quality control during the PCB manufacturing process. It can detect potential manufacturing defects early and make timely adjustments and improvements. This not only helps improve PCB manufacturing efficiency and product reliability, but also reduces the cost and time investment in subsequent testing and repair.

Question 2

Introduction to CCL

Accepted Answer

CCL is primarily divided into three categories.

The first is high-frequency, the second is high-speed, and the third is standard.
There are three main standards to distinguish this categories:

Df (Dielectric Loss): The loss of electrical signals within the material.
Dk (Dielectric Constant): The delay of electrical signals within the material.
Tg (Glass Transition Temperature): The heat resistance of CCL.

Basic standards are as follows:

Df < 0.005 is high-frequency.
Df between 0.005 and 0.01 is high-speed.
Df > 0.01 is Standard.

The higher the grade of the CCL, the lower the values of Df and Dk, resulting in less signal loss and delay. This means the technical requirements and the added value will be higher, naturally leading to higher profit margins and unit prices. If we want to divide it further, there are a total of six categories. Among them, automotive use is related to safety, so it will be classified as high-frequency CCL with 5G, high-speed CCL is used in servers and switches, and standard CCL is generally used in consumer
electronics.

Major Advantages of High-Frequency CCL

High efficiency
Fast speed
Good control
Strong durability

In the manufacturing process, resin, catalyst, and curing agent are first mixed, then applied to fiberglass cloth. This is bonded with PP and covered with copper foil to form the so-called copper-clad laminate.

In terms of cost proportion, CCL as a whole accounts for about 67% of the overall proportion of PCB, and the cost proportion is relatively high.

Question 3

What Is Halogen-Free FR-4 Material?

Accepted Answer

In the previous topics, we have talked about “How to choose the material of PCB?”, “Brief Talk about PCB Materials”, and “How to Have PCB Material Ready?”. Today let’s discuss Halogen-Free FR-4 material.

What Is Halogen-Free FR-4 Material?
Defined by IPC and IEC, only BR(Bromine) and CL(Chlorine) content is less than 900 PPM, and the total of BR(Bromine) CL(Chlorine) content is less than 1500PPM, can be considered as Halogen-Free FR-4. Meanwhile, all materials used must meet the halogen-free requirements when using Halogen-Free FR-4.

Halogen-Free FR-4 vs. Lead-Free FR-4
The grade of Halogen-Free FR-4 is greater than Lead-Free FR-4. Halogen-Free FR-4 basically meets the requirements for lead-free assembly. On the other hand, Lead-Free FR-4 that meets the requirements for lead-free assembly does not necessarily meet the requirements for Halogen-Free.

As you might know there’re many types of PCB material. And choosing the suitable material will affect the durability and reliability of end products.

Question 4

PTH Killer – Some Common Plating Void Factors

Accepted Answer

PTH Killer – Some Common Plating Void Factors

You may know that the most serious problem of PTH is void at where copper should be plated on. But do you know why this is happening? The common factors could be on material, drilling process, or plating process.

1) Material: The CTE of material is not suitable for the plating process. Compare to leaded process in the old times, the recent lead free process is having higher CTE requirement of material. If the material was still suitable for only leaded process, it might lead to void when it applies to lead free process.

2) Drilling Process: After drilling process there will be remaining dust on the material. When the vacuuming machine doesn’t function well that dust is still in the hole, there might be having high chance of leading to void after plating process.

3) Plating Process: When the board enters the plating liquid, bubbles will occur in the hole. Although the plating machine will vibrate to shake off the bubbles, the bubbles may still exist due to not precise parameter or some other reasons. And the bubbles, of course, will lead to void after plating process just the same idea as drilling dust remaining.

Question 5

PCB Vias with epoxy filling before plating.

Accepted Answer

You may have heard of the PCB plugging process. Why use epoxy resin to block PCB vias? What are its pros and cons?

Improved Thermal Conductivity:
Epoxy filling enhances the thermal conductivity of the via, allowing for better heat dissipation within the PCB. This is particularly beneficial for high-power applications or designs with components that generate significant heat.
Enhanced Signal Integrity:
Epoxy filling helps to reduce signal loss and electromagnetic interference (EMI) by improving the integrity of high-speed signal transmission. It minimizes signal reflections and crosstalk, leading to improved overall signal quality.

Improved Electrical Isolation:
Epoxy filling helps to enhance electrical isolation between adjacent layers of the PCB, reducing the risk of short circuits and ensuring proper isolation between different signal or power domains.

It's worth noting that while epoxy-filled vias offer these benefits, they also introduce some challenges. For example, they can be more expensive to manufacture compared to non-filled vias, and the process may require additional steps and specialized equipment. Additionally, if rework or repair is necessary, epoxy-filled vias can be more difficult to modify. Therefore, the decision to use epoxy-filled vias should consider the specific requirements and constraints of the PCB design and application.

Question 6

Why are PCBs designed stack-up?

Accepted Answer

PCB stack-up design is a process of arranging the layer configuration of a multi-layer printed circuit board (PCB). This design considers various factors including electrical performance, signal integrity, EMI (electromagnetic interference), and thermal management. The primary purpose of stack-up design is to maximize the performance and reliability of the PCB.

PCB stack-ups are necessary for several reasons:

Electrical Performance: In high-speed and high-frequency applications, stack-up design ensures stability and consistency in signal transmission. By controlling the distances and arrangements between signal layers, ground planes, and power planes, signal transmission losses and crosstalk can be reduced, thereby enhancing electrical performance.

Signal Integrity: In multi-layer PCBs, couplings and interactions exist between signal layers. Proper stack-up design can mitigate interference between signal layers, improve signal integrity, and reduce signal distortion and jitter.

EMI Suppression: Rational PCB stack-up design can reduce electromagnetic radiation and external interference (EMI) of the PCB. Proper spacing between layers and distribution of copper foils between layers can enhance PCB's EMI suppression capability.

Thermal Management: In high-power applications, stack-up design can aid heat conduction and dissipation. By adding thermal heat spreaders or copper foils at appropriate locations, PCB heat dissipation can be facilitated, preventing overheating and damage.

In summary, stack-up design aims to ensure high performance, reliability, and stability of the PCB while meeting specific requirements of diverse applications. The reasonable stack-up design optimizes PCB's design and performance to the fullest extent.

Question 7

How do PCB Manufacturer Trace Each Production?

Accepted Answer

When client complaint happens, the PCB manufacturer needs to find out the root cause of the problem and prevent it from happening again. However, how to distinguish the defect board from specific production will be essential.
In order to trace each production, the PCB manufacturer will put Date Code and its LOGO on the PCB board. Date code will show when the PCB board is produced. And the manufacturer’s logo will show which PCB manufacturer produces the PCB board. For example, Date code 2316 means the PCB board is produced on the 16th weeks of year 2023. And below “EP AB 94V-0” is the manufacturer’s logo. Once the PCB manufacturer sees its logo and Date code, they could trace the PCB board and start the root cause analysis.

Question 8

Reliability Test - Accelerated Life Test

Accepted Answer

Except from E-test and some other Multiple Tests, there is also advanced testing for PCB reliability which is so called Aging Test or Accelerated Life Test.
For those application which needs long time working without failure, this kind of testing can help to find out if PCB can withstand abrasion of operation and time.
Some certain environment simulation tests can be done to verify the reliability of material by our Programmable Temperature & Humidity Chamber.

Here is the test and the testing conditions that we do:
High Temperature High Humidity Test
Target: To understand influence of moisture absorption to reliability performance of material by environmental simulation.
Condition: 85°C / 85% (Temperature / Humidity)
Test Time: 168 Hours to 2000 Hours (168 Hours approximately equals 875 Days)

Question 9

Why do we not recommend using the PCB which exceeds the shelf life?

Accepted Answer

Why do we not recommend using the PCB which exceeds the shelf life?

Due to the high risk of oxidation and components dropping

Each surface finish has a recommended assembly time and specific storage condition, boards that exceed the storage period will cause oxidation of the surface finish and also the high risk of dropping the components during the high temperature of assembly.

The recommended rework

According to the recommended storage conditions, the manufacturer cannot guarantee their quality if the PCBs have exceeded the storage time. Once the boards exceed the storage time, rework is recommended, such as baking before assembly or reapplying the surface finish, you can check our previous article for more information:
https://www.explus.com.tw/faq/why-does-long-stored-pcb-need-to-be-baked.html

However, not every material is suitable for rework, the binding force of PP between layers will decrease over time. When doing the rework process in the oven, one can run a high risk as those boards past their shelf life can cause delamination and blistering issues.

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Question 10

The packaging methods for Flying Lead, TAB and COF

Accepted Answer

Flex PCB: Also known as a flexible printed circuit board (FPC).

In a previous article, we introduced rolled-annealed copper (RA) and electro-deposited copper (ED).
Today, let's talk about the Flying Lead packaging method.

Flying Lead is a packaging method for flexible boards/high-density flexible boards, which refers to the design and manufacturing method of a connector used to connect PCBs with other devices or systems. It is not specific to a particular type of PCB or packaging method. Therefore, Flying Lead can be applied to various types of PCBs, including rigid PCBs, soft boards, and high-density flexible boards.

There are two common methods for Flying Lead in soft boards (FPC), namely TAB and COF.

TAB (Tape Automated Bonding) is a method that uses a plastic substrate to transfer the conductive circuit onto another substrate and connects the conductive circuit to the chip pins through gold plating. This method requires a longer

The COF (Chip on Film) method involves directly connecting chips to the FPC, requiring shorter flying leads and enabling implementation in smaller spaces. This method requires higher technical requirements and costs, but can achieve higher conductivity and reliability.

Both manufacturing methods have their advantages and disadvantages, so it is crucial to choose the appropriate method based on customer requirements and project needs.

Knowledge