Field of the Invention
[0001] The present invention is directed to electroless copper plating compositions and
methods for electroless plating copper on substrates, wherein electroless copper plating
has a high electroless copper plating rate at low temperatures and the electroless
copper plating compositions are stable. More specifically, the present invention is
directed to electroless copper plating compositions and methods for electroless plating
copper on substrates, wherein electroless copper plating has a high electroless copper
plating rate at low temperatures and the electroless copper plating compositions are
stable, wherein the electroless copper plating compositions include pyridinium compounds
or salts thereof.
Background of the Invention
[0002] Electroless copper plating baths are in widespread use in metallization industries
for depositing copper on various types of substrates. In the manufacture of printed
circuit boards, for example, the electroless copper baths are used to deposit copper
on walls of through-holes and circuit paths as a base for subsequent electrolytic
copper plating. Electroless copper plating also is used in the decorative plastics
industry for deposition of copper on nonconductive surfaces as a base for further
plating of copper, nickel, gold, silver and other metals, as required. Electroless
copper baths which are in commercial use today contain water soluble divalent copper
compounds, chelating agents or complexing agents, for example, Rochelle salts and
sodium salts of ethylenediamine tetraacetic acid, for chelating the divalent copper
ions, reducing agents, for example, formaldehyde, and formaldehyde precursors or derivatives,
and various addition agents to make the bath more stable, adjust the plating rate
and brighten the copper deposit.
[0003] It should be understood, however, that every component in the electroless copper
bath has an effect on plating potential, and therefore, must be regulated in concentration
to maintain the most desirable plating potential for particular ingredients and conditions
of operation. Other factors which affect internal plating voltage, deposition quality
and rate include temperature, degree of agitation, type and concentration of basic
ingredients mentioned above.
[0004] In electroless copper plating baths, the components are continuously consumed such
that the baths are in a constant state of change, thus consumed components must be
periodically replenished. Control of the baths to maintain high plating rates with
substantially uniform copper deposits over long periods of time is exceedingly difficult.
In general, electroless copper plating rates of equal to or greater than 0.6 µm/5
min. are highly desirable (preferably desired for current horizontal plating applications)
but rarely achieved, especially at low electroless plating temperatures, such as below
40 °C. Consumption and replenishment of bath components over several metal turnovers
(MTO) can also contribute to bath instability, for example, through the buildup of
side products. Therefore, such baths, and particularly those having a high plating
potential, i.e. highly active baths, tend to become unstable and to spontaneously
decompose with use. Such electroless copper bath instability can result in nonuniform
or discontinuous copper plating along a surface. For example, in the manufacture of
printed circuit boards, it is important to plate electroless copper on the walls of
through-holes such that the copper deposit on the walls is substantially continuous
and uniform with minimal, preferably, no break or gaps in the copper deposit. Such
discontinuity of the copper deposit can ultimately lead to mal-functioning of any
electrical device in which the defective printed circuit board is included.
[0005] To address the foregoing stability issues, various chemical compounds categorized
under the label "stabilizers" have been introduced to electroless copper plating baths.
Examples of stabilizers which have been used in electroless copper plating baths are
sulfur containing compounds, such as disulfides and thiols. However, many stabilizers
lower electroless copper plating rates, and, also, at high concentrations can be catalyst
poisons, thus reducing plating rates or inhibiting plating and compromising the performance
of the plating bath. Low plating rates are detrimental to electroless copper plating
performance. Electroless copper plating rate is also temperature dependent, thus when
high stabilizer concentrations lower the rate, increasing the plating temperature
can increase the rate. However, increasing the operating temperatures can decrease
the stability of the electroless copper bath by increasing the buildup of byproducts
as well as increasing the rate of generation of byproducts by side reactions, thus
negating some of the effects of increasing the stabilizer concentration. As a result,
in most cases the amount of stabilizer used must be a careful compromise between maintaining
a high plating rate and achieving an electroless bath that is stable over a long period
of time.
[0006] Alternatively, an "accelerator" additive can be incorporated into the electroless
bath formulation. Ideally, the accelerator additive does not impact the stability
of the electroless bath, such that higher plating rates can be achieved while keeping
bath stability in check; or such that the same plating rate is now achieved at lower
temperatures which typically also results in a more stable bath. The lower electroless
bath temperatures reduce cost of the electroless bath, for example, by decreasing
the rate of passive consumption of plating chemicals. Furthermore, a more stable formulation,
which is afforded by lowering the working temperature, results in lower maintenance
requirements. Finally, lower plating temperatures can lower the build-up of internal
stress in the electroless deposit, making the metallization process better suited
for high-adhesion applications. Thus, rate acceleration in electroless copper plating
is a key strategy for lowering working temperatures, lowering internal stress of copper
deposits such as on flexible substrates and decreasing overall running costs of metallization.
[0007] Therefore, there is a need for an additive for electroless copper plating baths which
enables a high rate of electroless copper plating at low temperatures to provide bright
and uniform copper deposits on substrates.
Summary of the Invention
[0008] The present invention is directed to an electroless copper plating composition including
one or more sources of copper ions, one or more pyridinium compounds, one or more
complexing agents, one or more reducing agents, and, optionally, one or more pH adjusting
agents, wherein a pH of the electroless copper plating composition is greater than
7.
[0009] The present invention is also directed to a method of electroless copper plating
including:
- a) providing a substrate comprising a dielectric;
- b) applying a catalyst to the substrate comprising the dielectric;
- c) applying an electroless copper plating composition to the substrate comprising
the dielectric, wherein the electroless copper plating composition comprises one or
more sources of copper ions, one or more pyridinium compounds, one or more complexing
agents, one or more reducing agents, and, optionally, one or more pH adjusting agents,
wherein a pH of the electroless copper plating composition is greater than 7; and
- d) electroless plating copper on the substrate comprising the dielectric with the
electroless copper plating composition.
[0010] The pyridinium compounds enable increased electroless copper plating rates at low
plating temperatures of less than or equal to 40 °C. The electroless copper plating
compositions and methods of the present invention further enable good through-hole
wall coverage, even at low plating temperatures. Low plating temperatures reduce consumption
of electroless copper plating composition additives which occur by undesired side
reactions or by decomposition, thus providing a more stable electroless copper plating
composition, and lower the cost of operating the electroless copper plating process.
[0011] The electroless copper plating compositions of the present invention are stable over
wide concentration ranges of the pyridinium compounds. A broad operating window for
the pyridinium compounds concentration means that the pyridinium compounds concentrations
do not need to be carefully monitored such that the performance of the electroless
copper plating compositions do not substantially change regardless of how the composition
components are being replenished and consumed.
Detailed Description of the Invention
[0012] As used throughout this specification, the abbreviations given below have the following
meanings, unless the context clearly indicates otherwise: g = gram; mg = milligram;
mL = milliliter; L = liter; cm = centimeter; mm = millimeter; µm = micron; ppm = parts
per million = mg/L; °C = degrees Centigrade; g/L = grams per liter; DI = deionized;
C = the element carbon; Pd = palladium; Pd(II) = palladium ions with a +2 oxidation
state; Pd° = palladium reduced to its metal state vs. its ionic state; wt% = percent
by weight; and T
g = glass transition temperature.
[0013] All amounts are percent by weight, unless otherwise noted. All numerical ranges are
inclusive and combinable in any order except where it is logical that such numerical
ranges are constrained to add up to 100%.
[0014] The terms "plating" and "deposition" are used interchangeably throughout this specification.
The terms "composition" and "bath" are used interchangeably throughout this specification.
The term "alkyl", unless otherwise described in the specification as having substituent
groups, means an organic chemical group composed of only carbon and hydrogen and having
a general formula: C
nH
2n+1. The term "average" is equivalent to the mean value of a sample. All amounts are
percent by weight, unless otherwise noted. All numerical ranges are inclusive and
combinable in any order except where it is logical that such numerical ranges are
constrained to add up to 100%.
[0015] The electroless copper plating compositions of the present invention include one
or more sources of copper ions, one or more pyridinium compounds, one or more complexing
agents; one or more reducing agents; water; and, optionally, one or more pH adjusting
agents, wherein a pH of the electroless copper plating composition is greater than
7.
[0016] Preferably, the one or more pyridinium compounds have a formula:

wherein R
1 is selected from the group consisting of linear or branched, substituted or unsubstituted
(C
1-C
10)alkyl, substituted or unsubstituted (C
6-C
10)aryl, substituted or unsubstituted (C
6-C
10) heterocyclic aromatic groups and substituted or unsubstituted benzyl, wherein substituent
groups are selected from the group consisting of hydroxyl, sulfate, amino, amide,
carbonyl and carboxyl; and R
2 is selected from the group consisting of hydrogen, hydroxyl, sulfate, carbonyl, carboxyl,
vinyl, amino and amide. More preferably, R
1 is selected from the group consisting of linear or branched, substituted and unsubstituted
(C
2-C
4)alkyl and substituted or unsubstituted C
6-heterocyclic aromatic group, wherein the substituent groups are selected from the
group consisting of hydroxyl and sulfate; and, more preferably, R
2 is selected from the group consisting of hydrogen, hydroxyl and sulfate; and, most
preferably, R
1 is selected from the groups consisting of linear, substituted or unsubstituted (C
2-C
4)alkyl, wherein a preferred substituent is sulfate; and, most preferably, R
2 is hydrogen. Preferably, the pyridinium compound of formula (I) includes a counter
anion to neutralize the positive charge of the pyridinium compound.
[0017] Preferably, the foregoing pyridinium compounds are hydroxide salts, sulfate, tetrafluoroborate,
hexafluorophosphate, nitrate, formate, acetate, tartrate or halogen salts, wherein
the halogen is selected from the group consisting of chloride, bromide, fluoride and
iodide. More preferably, the salts are halogens selected from the group consisting
of chloride and bromide, most preferably, the halogen is chloride. Examples of three
preferred pyridinium compounds of the present invention are the salts 1-butylpyridinium
chloride, and 1-(3-sulfopropyl) pyridinium hydroxide inner salt (also known as 1-(3-sulfopropyl)
pyridinium) and 1-(4-pyridyl) pyridinium chloride.
[0018] The pyridinium compounds of the present invention are included in amounts of 0.5
ppm or greater, preferably, from 1 ppm to 50 ppm, more preferably, from 2 ppm to 30
ppm, even more preferably, from 2.5 ppm to 20 ppm, most preferably, from 5 ppm to
20 ppm.
[0019] Sources of copper ions and counter anions include, but are not limited to, water
soluble halides, nitrates, acetates, sulfates and other organic and inorganic salts
of copper. Mixtures of one or more of such copper salts can be used to provide copper
ions. Examples are copper sulfate, such as copper sulfate pentahydrate, copper chloride,
copper nitrate, copper hydroxide and copper sulfamate. Preferably, the one or more
sources of copper ions in the electroless copper plating composition of the present
invention range from 0.5 g/L to 30 g/L, more preferably, from 1 g/L to 25 g/L, even
more preferably, from 5 g/L to 20 g/L, further preferably, from 5 g/L to 15 g/L, and
most preferably, from 10 g/L to 15 g/L.
[0020] Complexing agents include, but are not limited to, sodium potassium tartrate, sodium
tartrate, sodium salicylate, sodium salts of ethylenediamine tetraacetic acid (EDTA),
nitriloacetic acid and its alkali metal salts, gluconic acid, gluconates, triethanolamine,
modified ethylene diamine tetraacetic acids, S,S-ethylene diamine disuccinic acid,
hydantoin and hydantoin derivatives. Hydantoin derivatives include, but are not limited
to, 1-methylhydantoin, 1,3-dimethylhydantoin and 5,5-dimethylhydantoin. Preferably,
the complexing agents are chosen from one or more of sodium potassium tartrate, sodium
tartrate, nitriloacetic acid and its alkali metal salts, such as sodium and potassium
salts of nitirloacetic acid, hydantoin and hydantoin derivatives. Preferably, EDTA
and its salts are excluded from the electroless copper plating compositions of the
present invention. More preferably, the complexing agents are chosen from sodium potassium
tartrate, sodium tartrate, nitriloacetic acid, nitriloacetic acid sodium salt, and
hydantoin derivates. Even more preferably, the complexing agents are chosen from sodium
potassium tartrate, sodium tartrate, 1-methylhydantoin, 1,3-dimethylhydantoin and
5,5-dimethylhydantoin. Further preferably, the complexing agents are chosen from sodium
potassium tartrate and sodium tartrate. Most preferably, the complexing agent is sodium
potassium tartrate (Rochelle salts).
[0021] Complexing agents are included in the electroless copper plating compositions of
the present invention in amounts of 10 g/l to 150 g/L, preferably, from 20 g/L to
150 g/L, more preferably, from 30 g/L to 100 g/L, even more preferably, from 35 g/L
to 80 g/L, and, most preferably, from 35 g/l to 55 g/L.
[0022] Reducing agents include, but are not limited to, aldehydes, such as, formaldehyde,
formaldehyde precursors, formaldehyde derivatives, such as paraformaldehyde, borohydrides,
such sodium borohydride, substituted borohydrides, boranes, such as dimethylamine
borane (DMAB), saccharides, such as grape sugar (glucose), glucose, sorbitol, cellulose,
cane sugar, mannitol and gluconolactone, hypophosphite and salts thereof, such as
sodium hypophosphite, hydroquinone, catechol, resorcinol, quinol, pyrogallol, hydroxyquinol,
phloroglucinol, guaiacol, gallic acid, glyoxylic acid, 3,4-dihydroxybenzoic acid,
phenolsulfonic acid, cresolsulfonic acid, hydroquinonsulfonic acid, catecholsulfonic
acid, tiron and salts of all of the foregoing reducing agents. Preferably, the reducing
agents are chosen from formaldehyde, formaldehyde derivatives, formaldehyde precursors,
borohydrides and hypophosphite and salts thereof, hydroquinone, catechol, resorcinol,
and gallic acid. More preferably, the reducing agents are chosen from formaldehyde,
formaldehyde derivatives, formaldehyde precursors, and sodium hypophosphite. Most
preferably, the reducing agent is formaldehyde.
[0023] Reducing agents are included in the electroless copper plating compositions of the
present invention in amounts of 0.5 g/L to 100 g/L, preferably, from 0.5 g/L to 60
g/L, more preferably, from 1 g/L to 50 g/L, even more preferably, from 1 g/L to 20
g/L, further preferably, from 1 g/L to 10 g/L, most preferably, from 1 g/L to 5 g/L.
[0024] A pH of the electroless copper plating composition of the present invention is greater
than 7. Preferably, the pH of the electroless copper plating compositions of the present
invention is greater than 7.5. More preferably, the pH of the electroless copper plating
compositions range from 8 to 14, even more preferably, from 10 to 14, further preferably,
from 11 to 13, and most preferably, from 12 to 13.
[0025] Optionally, but preferably, one or more pH adjusting agents can be included in the
electroless copper plating compositions of the present invention to adjust the pH
of the electroless copper plating compositions to an alkaline pH. Acids and bases
can be used to adjust the pH, including organic and inorganic acids and bases. Preferably,
inorganic acids or inorganic bases, or mixtures thereof are used to adjust the pH
of the electroless copper plating compositions of the present invention. Inorganic
acids suitable for use of adjusting the pH of the electroless copper plating compositions
include, for example, phosphoric acid, nitric acid, sulfuric acid and hydrochloric
acid. Inorganic bases suitable for use of adjusting the pH of the electroless copper
plating compositions include, for example, ammonium hydroxide, sodium hydroxide, potassium
hydroxide and lithium hyddroxide. Preferably, sodium hydroxide, potassium hydroxide
or mixtures thereof are used to adjust the pH of the electroless copper plating compositions,
most preferably, sodium hydroxide is used to adjust the pH of the electroless copper
plating compositions of the present invention.
[0026] Optionally, but preferably, one or more stabilizers can be included in the electroless
copper plating compositions of the present invention. Stabilizers include, but are
not limited to 2,2'-dipyridyl and derivatives, 4,4'-dipyridyl, phenanthroline and
phenanthroline derivatives, thiomalic acid, 2,2'dithiodisuccinic acid, mercaptosuccinic
acid, cysteine, methionine, thionine, thiourea, benzothiazole, mercaptobenzothiazole,
2,2'-thiodiacetic acid, 3,3'-thiodipropionic acid, 3,3'-dithiodipropionic acid, thiosulfate,
and glycols such as polypropylene glycol and polyethylene glycol.
[0027] Such optional stabilizers are included in the electroless copper plating compositions
of the present invention in amounts of 0.1 ppm to 20 ppm, preferably, from 0.5 ppm
to 10 ppm, more preferably, from 0.5 ppm to 5 ppm, most preferably from 0.5 ppm to
2 ppm.
[0028] Optionally, but preferably, one or more secondary accelerators can be included in
the electroless copper plating compositions of the present invention. Such accelerators
include, but are not limited to, several free nitrogen bases such as guanidine, guanidine
derivatives, such as guanidine hydrochloride, pyridine and pyridine derivatives such
as aminopyridine, di- and trialkylamines, such as trimethylamine and triethylamine,
N,N,N',N'-Tetrakis(2-Hydroxypropyl)ethylenediamine, and ethylenediaminetetraacetic
acid, and nickel(II) salts such as Nickel(II) sulfate. An example of a preferred secondary
accelerator is guanidine hydrochloride.
[0029] Such accelerators can be included in amounts of 0.1 ppm to 500 ppm, preferably, from
0.2 to 15 ppm, more preferably from, 0.3 ppm to 10 ppm, most preferably from 0.3 ppm
to 5 ppm.
[0030] Optionally, one or more surfactants can be included in the electroless copper plating
compositions of the present invention. Such surfactants include ionic, such as cationic
and anionic surfactants, non-ionic and amphoteric surfactants. Mixtures of the surfactants
can be used. Surfactants can be included in the compositions in amounts of 0.001 g/L
to 50 g/L, preferably in amounts of 0.01 g/L to 50 g/L.
[0031] Cationic surfactants include, but are not limited to, tetra-alkylammonium halides,
alkyltrimethylammonium halides, hydroxyethyl alkyl imidazoline, alkyl imidazolium,
alkylbenzalkonium halides, alkylamine acetates, alkylamine oleates and alkylaminoethyl
glycine.
[0032] Anionic surfactants include, but are not limited to, alkylbenzenesulfonates, alkyl
or alkoxy naphthalene sulfonates, alkyldiphenyl ether sulfonates, alkyl ether sulfonates,
alkylsulfuric esters, polyoxyethylene alkyl ether sulfuric esters, polyoxyethylene
alkyl phenol ether sulfuric esters, higher alcohol phosphoric monoesters, polyoxyalkylene
alkyl ether phosphoric acids (phosphates) and alkyl sulfosuccinates.
[0033] Amphoteric surfactants include, but are not limited to, 2-alkyl-N-carboxymethyl or
ethyl-N-hydroxyethyl or methyl imidazolium betaines, 2-alkyl-N-carboxymethyl or ethyl-N-carboxymethyloxyethyl
imidazolium betaines, dimethylalkyl betains, N-alkyl-β-aminopropionic acids or salts
thereof and fatty acid amidopropyl dimethylaminoacetic acid betaines.
[0034] Preferably, the surfactants are non-ionic. Non-ionic surfactants include, but are
not limited to, alkyl phenoxy polyethoxyethanols, polyoxyethylene polymers having
from 20 to 150 repeating units and random and block copolymers of polyoxyethylene
and polyoxypropylene, and polyamines, such as polyallylamine.
[0035] Optionally, one or more grain refiner can be included in the electroless copper plating
compositions of the present invention. Grain refiners include, but are not limited
to, cyanide and cyanide containing inorganic salts such as potassium hexacyanoferrate,
2-mercaptobenthiazole, 2,2'-bipyridine and 2,2'-bipyridine derivatives, 1,10-phenanthroline
and 1,10-phenanthroline derivatives, vanadium oxides such as sodium Metavanadate,
and nickel salts such as nickel(II) sulfate. Grain refiners are included in amounts
well known to those of ordinary skill in the art.
[0036] Preferably, the electroless copper plating composition of the present invention consists
of one or more sources of copper ions, including corresponding anions, one or more
pyridinium compounds or salts thereof having formula (I), one or more complexing agents,
one or more reducing agents, water, optionally, one or more pH adjusting agents, optionally,
one or more stabilizers, optionally, one or more secondary accelerators, optionally,
one or more surfactants, and optionally, one or more grain refiners, wherein a pH
of the electroless copper plating composition is 10-14.
[0037] More preferably, the electroless copper plating composition of the present invention
consists of one or more sources of copper ions, including corresponding anions, one
or more pyridinium compounds or salts thereof having formula (I), wherein the salts
are selected from the group consisting of hydroxide, chloride and bromide salts, one
or more complexing agents, one or more reducing agents, water, one or more pH adjusting
agents, one or more stabilizers, optionally, one or more secondary accelerators, optionally,
one or more surfactants, and, optionally, one or more grain refiners, wherein a pH
of the electroless copper plating composition is 11-13.
[0038] Most preferably, the electroless copper plating compositions of the present invention
consist of one or more sources of copper ions, including corresponding anions, one
or more pyridinium compounds selected from the group consisting of 1-butyl pyridinium
chloride, 1-(3-sulfopropyl) pyridinium hydroxide and 1-(4-pyridyl) pyridinium chloride,
one or more complexing agents, one or more reducing agents, water, one or more pH
adjusting agents, one or more stabilizers, optionally, one or more secondary accelerators,
optionally, one or more surfactants, and, optionally, one or more grain refiners,
wherein a pH of the electroless copper plating composition is 12-13.
[0039] The electroless copper compositions and methods of the present invention can be used
to electroless plate copper on various substrates such as dielectrics, semiconductors,
metal-clad and unclad substrates such as printed circuit boards. Such metal-clad and
unclad printed circuit boards can include thermosetting resins, thermoplastic resins
and combinations thereof, including fibers, such as fiberglass, impregnated embodiments
of the foregoing. Preferably the substrate is a metal-clad printed circuit or wiring
board with a plurality of through-holes, vias, or combinations thereof. The electroless
copper plating compositions and methods of the present invention can be used in both
horizontal and vertical processes of manufacturing printed circuit boards, preferably,
the electroless copper plating compositions methods of the present invention are used
in horizontal processes.
[0040] Thermoplastic resins include, but are not limited to, acetal resins, acrylics, such
as methyl acrylate, cellulosic resins, such as ethyl acetate, cellulose propionate,
cellulose acetate butyrate and cellulose nitrate, polyethers, nylon, polyethylene,
polystyrene, styrene blends, such as acrylonitrile styrene and copolymers and acrylonitrile-butadiene
styrene copolymers, polycarbonates, polychlorotrifluoroethylene, and vinylpolymers
and copolymers, such as vinyl acetate, vinyl alcohol, vinyl butyral, vinyl chloride,
vinyl chloride-acetate copolymer, vinylidene chloride and vinyl formal.
[0041] Thermosetting resins include, but are not limited to allyl phthalate, furane, melamine-formaldehyde,
phenol-formaldehyde and phenol-furfural copolymers, alone or compounded with butadiene
acrylonitrile copolymers or acrylonitrile-butadiene-styrene copolymers, polyacrylic
esters, silicones, urea formaldehydes, epoxy resins, allyl resins, glyceryl phthalates,
and polyesters.
[0042] The electroless copper plating compositions and methods of the present invention
can be used to electroless copper plate substrates with both low and high T
g resins. Low T
g resins have a T
g below 160° C and high T
g resins have a T
g of 160° C and above. Typically, high T
g resins have a T
g of 160° C to 280° C or such as from 170° C to 240° C. High T
g polymer resins include, but are not limited to, polytetrafluoroethylene (PTFE) and
polytetrafluoroethylene blends. Such blends include, for example, PTFE with polyphenylene
oxides and cyanate esters. Other classes of polymer resins which include resins with
a high T
g include, but are not limited to, epoxy resins, such as difunctional and multifunctional
epoxy resins, bimaleimide/triazine and epoxy resins (BT epoxy), epoxy/polyphenylene
oxide resins, acrylonitrile butadienestyrene, polycarbonates (PC), polyphenylene oxides
(PPO), polypheneylene ethers (PPE), polyphenylene sulfides (PPS), polysulfones (PS),
polyamides, polyesters such as polyethyleneterephthalate (PET) and polybutyleneterephthalate
(PBT), polyetherketones (PEEK), liquid crystal polymers, polyurethanes, polyetherimides,
epoxies and composites thereof.
[0043] In the method of electroless copper plating with the electroless copper compositions
of the present invention, optionally, the substrates are cleaned or degreased, optionally,
roughened or micro-roughened, optionally, the substrates are etched or micro-etched,
optionally, a solvent swell is applied to the substrates, through-holes are desmeared,
and various rinse and anti-tarnish treatments can, optionally, be used.
[0044] Preferably, the substrates to be electroless copper plated with the electroless copper
plating compositions and methods of the present invention are metal-clad substrates
with dielectric material and a plurality of through-holes such as printed circuit
boards. Optionally, the boards are rinsed with water and cleaned and degreased followed
by desmearing the through-hole walls. Prepping or softening the dielectric or desmearing
of the through-holes can begin with application of a solvent swell. Although, it is
preferred, that the method of electroless copper plating is for plating through-hole
walls, it is envisioned that the method of electroless copper plating can also be
used to electroless copper plate walls of vias.
[0045] Conventional solvent swells can be used. The specific type can vary depending on
the type of dielectric material. Minor experimentation can be done to determine which
solvent swell is suitable for a particular dielectric material. The T
g of the dielectric often determines the type of solvent swell to be used. Solvent
swells include, but are not limited to, glycol ethers and their associated ether acetates.
Conventional amounts of glycol ethers and their associated ether acetates well known
to those of skill in the art can be used. Examples of commercially available solvent
swells are CIRCUPOSIT™ Conditioner 3302A, CIRCUPOSIT™ Hole Prep 3303 and CIRCUPOSIT™
Hole Prep 4120 solutions (available from Dow Electronic Materials).
[0046] After the solvent swell, optionally, a promoter can be applied. Conventional promoters
can be used. Such promoters include sulfuric acid, chromic acid, alkaline permanganate
or plasma etching. Preferably, alkaline permanganate is used as the promoter. Examples
of commercially available promoters are CIRCUPOSIT™ Promoter 4130 and CIRCUPOSIT™
MLB Promoter 3308 solutions (available from Dow Electronic Materials). Optionally,
the substrate and through-holes are rinsed with water.
[0047] If a promoter is used, a neutralizer is then applied to neutralize any residues left
by the promoter. Conventional neutralizers can be used. Preferably, the neutralizer
is an aqueous acidic solution containing one or more amines or a solution of 3wt%
hydrogen peroxide and 3wt% sulfuric acid. An example of a commercially available neutralizer
is CIRCUPOSIT™ MLB Neutralizer 216-5. Optionally, the substrate and through-holes
are rinsed with water and then dried.
[0048] After neutralizing an acid or alkaline conditioner is applied. Conventional conditioners
can be used. Such conditioners can include one or more cationic surfactants, non-ionic
surfactants, complexing agents and pH adjusters or buffers. Examples of commercially
available acid conditioners are CIRCUPOSIT™ Conditioners 3320A and 3327 solutions
(available from Dow Advanced Materials). Suitable alkaline conditioners include, but
are not limited to, aqueous alkaline surfactant solutions containing one or more quaternary
amines and polyamines. Examples of commercially available alkaline surfactants are
CIRCUPOSIT™ Conditioner 231, 3325, 813 and 860 formulations (available from Dow Electronic
Materials). Optionally, the substrate and through-holes are rinsed with water.
[0049] Optionally, conditioning can be followed by micro-etching. Conventional micro-etching
compositions can be used. Micro-etching is designed to clean and provide a micro-roughened
metal surface on exposed metal (e.g. innerlayers and surface etch) to enhance subsequent
adhesion of plated electroless copper and later electroplate. Micro-etches include,
but are not limited to, 60 g/L to 120 g/L sodium persulfate or sodium or potassium
oxymonopersulfate and sulfuric acid (2%) mixture, or generic sulfuric acid/hydrogen
peroxide. Examples of commercially available micro-etching compositions are CIRCUPOSIT™
Microetch 3330 Etch solution and PREPOSIT™ 748 Etch solution (both available from
Dow Electronic Materials). Optionally, the substrate is rinsed with water.
[0050] Optionally, a pre-dip can then be applied to the micro-etched substrate and through-holes.
Examples of pre-dips include, but are not limited to, organic salts such as sodium
potassium tartrate or sodium citrate, 0.5% to 3% sulfuric acid, nitric acid, or an
acidic solution of 25 g/L to 75 g/L sodium chloride. An example of a commercially
available pre-dip is acidic Pre-Dip CIRCUPOSIT™ 6520 solution.
[0051] A catalyst is then applied to the substrate. While it is envisioned that any conventional
catalyst suitable for electroless metal plating which includes a catalytic metal can
be used, preferably, a palladium catalyst is used in the methods of the present invention.
The catalyst can be a non-ionic palladium catalyst, such as a colloidal palladium-tin
catalyst, or the catalyst can be an ionic palladium. If the catalyst is a colloidal
palladium-tin catalyst, an acceleration step is done to strip tin from the catalyst
and to expose the palladium metal for electroless copper plating. If the catalyst
is a colloidal palladium-tin catalyst, an acceleration step is applied after catalyst
adsorption, for example, by using hydrochloric acid, sulfuric acid or tetrafluoroboric
acid as the accelerator at 0.5-10% in water to strip tin from the catalyst and to
expose the palladium metal for electroless copper plating. If the catalyst is an ionic
catalyst, the acceleration step is excluded from the method and, instead, a reducing
agent is applied to the substrate subsequent to application of the ionic catalyst
to reduce the metal ions of the ionic catalyst to their metallic state, such as Pd
(II) ions to Pd° metal. Examples of suitable commercially available colloidal palladium-tin
catalysts are CIRCUPOSIT™ 3340 catalyst and CATAPOSIT™ 44 catalyst (available from
Dow Electronic Materials). An example of a commercially available palladium ionic
catalyst is CIRCUPOSIT™ 6530 Catalyst. The catalyst can be applied by immersing the
substrate in a solution of the catalyst, or by spraying the catalyst solution on the
substrate, or by atomization of the catalyst solution on the substrate using conventional
apparatus. The catalysts can be applied at temperatures from room temperature to 80°
C, preferably, from 30° C to 60° C. The substrate and through-holes are optionally
rinsed with water after application of the catalyst.
[0052] Conventional reducing agents known to reduce metal ions to metal can be used to reduce
the metal ions of the catalysts to their metallic state. Such reducing agents include,
but are not limited to, dimethylamine borane (DMAB), sodium borohydride, ascorbic
acid, iso-ascorbic acid, sodium hypophosphite, hydrazine hydrate, formic acid and
formaldehyde. Reducing agents are included in amounts to reduce substantially all
of the metal ions to metal. Such amounts are well known by those of skill in the art.
If the catalyst is an ionic catalyst, the reducing agents are applied subsequent to
the catalyst being applied to the substrate and prior to metallization.
[0053] The substrate and walls of the through-holes are then plated with copper using an
electroless copper plating composition of the present invention. Methods of electroless
copper plating of the present invention can be done at temperatures of 40 °C or less.
Preferably, methods of electroless copper plating of the present invention are done
at temperatures from room temperature to 40 °C, more preferably, electroless copper
plating is done from room temperature to 35 °C, even more preferably, from 30 °C to
35 °C, most preferably, from 30 °C to 34 °C. The substrate can be immersed in the
electroless copper plating composition of the present invention or the electroless
copper plating composition can be sprayed on the substrate. Methods of electroless
copper plating of the present invention using electroless copper plating compositions
of the present invention are done in an alkaline environment of pH greater than 7.
Preferably, methods of electroless copper plating of the present invention are done
at a pH of greater than 7.5, more preferably, electroless copper plating is done at
a pH of 8 to 14, even more preferably, from 10 to 14, further preferably, from 11
to 13, and most preferably, from 12 to 13.
[0054] Preferably, the electroless copper plating rates of the present invention are equal
to or greater than 0.6 µm/5 min. at temperatures of less than or equal to 40 °C, more
preferably, the electroless copper plating rates of the present invention are equal
to or greater than 0.65 µm/5 min., such as from 0.65 µm/5 min. to 1 µm/5 min., even
more preferably, equal to or greater than 0.7 µm/5 min., such as from 0.75 µm/5 min.
to 1 µm/5 min., or such as from 0.75 µm/5 min. to 0.8 µm/5 min., at temperatures of
less than or equal to 35 °C, most preferably, electroless plating is done at temperatures
from 30 °C to 34 °C.
[0055] The methods of electroless copper plating using the electroless copper plating compositions
of the present invention enable good average backlight values for electroless copper
plating of through-holes of printed circuit boards. Such average backlight values
are preferably greater than or equal to 4.5, more preferably from 4.6 to 5, even more
preferably from 4.7 to 5, most preferably from 4.8 to 5. Such high average backlight
values enable the methods of electroless copper plating of the present invention using
the electroless copper plating compositions of the present invention to be used for
commercial electroless copper plating, wherein the printed circuit board industry
substantially requires backlight values of 4.5 and greater. The electroless copper
metal plating compositions and methods of the present invention enable uniform, bright
copper deposits over broad concentration ranges of pyridinium compounds or salts thereof,
even at high plating rates.
[0056] The following examples are not intended to limit the scope of the invention but to
further illustrate the invention.
Example 1
Electroless Copper Plating Rates of an Electroless Copper Plating Baths Containing
Pyridinium Compounds
[0057] Ten (10) electroless copper plating baths are prepared. All ten baths include the
following components:
- 1. 10 g/L Copper sulfate pentahydrate
- 2. 40 g/L Rochelle salts
- 3. 8 g/L Sodium hydroxide
- 4. 4 g/L Formaldehyde
- 5. 0.5 ppm 2,2'-dithiodisuccinic acid
- 6. Water (balance)
The pH of each bath is 13. To nine (9) of the electroless plating compositions one
of the following pyridinium compounds is added in the amount specified in Table 1.
Bath 10 is a control where no pyridinium compounded is added.
Table 1
Bath |
1-butylpyridinium chloride |
1-(3-sulfopropyl) pyridinium hydroxide |
1-(4-pyridyl) pyridinium chloride |
1 |
2.5 ppm |
----------- |
----------- |
2 |
10 ppm |
----------- |
----------- |
3 |
20 ppm |
----------- |
----------- |
4 |
----------- |
2.5 ppm |
----------- |
5 |
----------- |
10 ppm |
----------- |
6 |
----------- |
20 ppm |
----------- |
7 |
----------- |
----------- |
2.5 ppm |
8 |
----------- |
----------- |
10 ppm |
9 |
----------- |
----------- |
20 ppm |
Each bath is used to plate copper on bare epoxy substrates of NP140 material (Nanya,
Taiwan). Each epoxy substrate is first treated according to the following process
prior to electroless copper plating:
- (1) Conditioner 231 applied for 1.5 min. at 40 °C;
- (2) Rinse with DI water for 2 min. at room temperature;
- (3) Nitric acid pre-dip, pH = 2, for 0.5 min. at room temperature;
- (4) Rinse with DI water for 2 min. at room temperature;
- (5) 100 ppm of CIRCUPOSIT™ 6530 Catalyst for 1 min. at 40 °C;
- (6) Rinse with DI water for 1 min. at room temperature;
- (7) 5 g/L boric acid and 0.6 g/L dimethylamine borane aqueous solution for 1 min.
at 32 °C; and,
- (8) Rinse with DI water for 1 min. at room temperature.
Electroless copper plating is done at 34 °C for 5 minutes. The plating rate is determined
by weighing each substrate using a conventional laboratory analytical balance prior
to electroless copper plating and then weighing each substrate subsequent to plating.
The difference in the weight of each substrate is then used to calculate the deposit
thickness using the laminate surface area, which is 25 cm
2 and the density of the copper deposit, 8.92 g/cm
3 and the value is converted to plating rate by dividing over the plating time length.
The plating rate for each bath is shown in Table 2.
Table 2
Bath |
Plating Rate |
1 |
0.72 µm/5 min. |
2 |
0.77 µm/5 min. |
3 |
0.74 µm/5 min. |
4 |
0.75 µm/5 min. |
5 |
0.67 µm/5 min. |
6 |
0.61 µm/5 min. |
7 |
0.69 µm/5 min. |
8 |
0.59 µm/5 min. |
9 |
0.61 µm/5 min. |
10 (Control) |
0.49 µm/5 min. |
Including 1-butylpyridinium chloride, l-(3-sulfopropyl) pyridinium hydroxide or 1-(4-pyridyl)
pyridinium chloride in the electroless copper plating bath increases plating rate.
The copper deposits from the baths containing 1-butylpyridinium chloride and 1-(3-sulfopropyl)
pyridinium hydroxide appear bright and uniform over substantially all of the epoxy
substrates over the concentrations of 2.5 ppm, 10 ppm and 20 ppm. The copper deposits
plated from the baths containing 1-(4-pyridyl) pyridinium chloride show bright and
uniform areas with minor patches of rough deposits. The copper deposit plated from
the control bath shows large areas of irregular, rough and dark deposits with minor
regions of bright deposits.
Example 2 (Comparative)
Electroless Copper Plating Rates of an Electroless Copper Plating Baths Containing
Pyridine (Free Nitrogen Base)
[0058] Three (3) electroless copper plating baths are prepared. All three baths include
the following components:
- 1. 10 g/L Copper sulfate pentahydrate
- 2. 40 g/L Rochelle salts
- 3. 8 g/L Sodium hydroxide
- 4. 4 g/L Formaldehyde
- 5. 0.5 ppm 2,2'-dithiodisuccinic acid
- 6. Water (balance)
The pH of each bath is 13. Pyridine is added to the baths in amounts of 2.5 ppm (Comparative
Bath 1), 10 ppm (Comparative Bath 2) or 20 ppm (Comparative Bath 3).
[0059] Each bath is used to plate copper on epoxy substrates. The epoxy substrates are treated
as described in Example 1 in preparation for electroless copper plating. Electroless
copper plating is done at 34 °C for 5 minutes. The plating rate is then determined
as described in Example 1. The plating rate for each bath is shown in Table 3.
Table 3
Comparative Bath |
Plating Rate |
1 |
0.65 µm/5 min. |
2 |
0.48 µm/5 min. |
3 |
0.42 µm/5 min. |
Although the plating rate of pyridine at 2.5 ppm is higher than in the Control in
Example 1, at higher concentrations of 10 ppm and 20 ppm the plating rates decline
to below the plating rate of the control. The plating rate of pyridine is less than
the Control electroless copper bath in Example 1. The copper deposits have a mixture
of bright and uniform areas and rough and dull areas.
Example 3
Electroless Copper Plating Rates of an Electroless Copper Plating Baths Containing
Pyridinium Compounds and Guanidine Hydrochloride
[0060] Fourteen (14) electroless copper plating baths are prepared. All fourteen baths include
the following components:
- 1. 10 g/L Copper sulfate pentahydrate
- 2. 40 g/L Rochelle salts
- 3. 8 g/L Sodium hydroxide
- 4. 4 g/L Formaldehyde
- 5. 0.5 ppm 2,2'-dithiodisuccinic acid
- 6. 0.36 ppm Guanidine Hydrochloride
- 7. Water (balance)
The pH of each bath is 13. To thirteen (13) of the electroless plating compositions
one of the following pyridinium compounds is added in the amount specified in Table
4. Bath 24 is a control where no pyridinium compounded is added.
Table 4
Bath |
1-butylpyridinium chloride |
1-(3-sulfopropyl) pyridinium hydroxide |
1-(4-pyridyl) pyridinium chloride |
11 |
2.5 ppm |
----------- |
----------- |
12 |
5 ppm |
----------- |
----------- |
13 |
10 ppm |
----------- |
----------- |
14 |
15 ppm |
----------- |
----------- |
15 |
20 ppm |
----------- |
----------- |
16 |
----------- |
2.5 ppm |
----------- |
17 |
----------- |
5 ppm |
----------- |
18 |
----------- |
10 ppm |
----------- |
19 |
----------- |
15 ppm |
----------- |
20 |
----------- |
20 ppm |
----------- |
21 |
----------- |
----------- |
2.5 ppm |
22 |
----------- |
----------- |
5 ppm |
23 |
----------- |
----------- |
10 ppm |
Each bath is used to plate copper on bare epoxy substrates. Each epoxy substrate is
treated prior to electro less copper plating as described in Example 1. Electroless
copper plating is done at 34 °C for 5 minutes. The plating rate is determined as described
above in Example 1. The plating rate for each bath is shown in Table 5.
Table 5
Bath |
Plating Rate |
11 |
0.46 µm/5 min. |
12 |
0.75 µm/5 min. |
13 |
0.78 µm/5 min. |
14 |
0.74 µm/5 min. |
15 |
0.83 µm/5 min. |
16 |
0.69 µm/5 min. |
17 |
0.65 µm/5 min. |
18 |
0.74 µm/5 min. |
19 |
0.78 µm/5 min. |
20 |
0.66 µm/5 min. |
21 |
0.98 µm/5 min. |
22 |
0.67 µm/5 min. |
23 |
0.81 µm/5 min. |
24 (Control) |
0.5 µm/5 min. |
Including 1-butylpyridinium chloride, l-(3-sulfopropyl) pyridinium hydroxide or 1-(4-pyridyl)
pyridinium chloride in the electroless copper plating bath increases plating rate
over the control which included guanidine hydrochloride. The copper deposits from
the baths containing 1-butylpyridinium chloride and 1-(3-sulfopropyl) pyridinium hydroxide
appear bright and uniform over substantially all of the epoxy substrates. The copper
deposits plated from the baths containing 1-(4-pyridyl) pyridinium chloride show bright
and uniform areas with minor patches of rough deposits. The copper deposit plated
from the control bath shows minor regions of bright deposits intermingled with large
areas of irregular and rough deposits.
Example 4 (Comparative)
Electroless Copper Plating Rates of an Electroless Copper Plating Baths Containing
Pyridine (Free Nitrogen Base) and Guanidine Hydrochloride
[0061] Five (5) electroless copper plating baths are prepared. All five baths include the
following components:
- 1. 10 g/L Copper sulfate pentahydrate
- 2. 40 g/L Rochelle salts
- 3. 8 g/L Sodium hydroxide
- 4. 4 g/L Formaldehyde
- 5. 0.5 ppm 2,2'-dithiodisuccinic acid
- 6. 0.36 ppm Guanidine hydrochloride
- 7. Water (balance)
The pH of each bath is 13. Pyridine is added to the baths in amounts of 2.5 ppm (Comparative
Bath 4), 5 ppm (Comparative Bath 5), 10 ppm (Comparative Bath 6), 15 ppm (Comparative
Bath 7) or 20 ppm (Comparative Bath 8).
[0062] Each bath is used to plate copper on epoxy substrates. The epoxy substrates are treated
as described in Example 1 prior to electroless copper plating. Electroless copper
plating is done at 34 °C for 5 minutes. The plating rate is determined as described
above in Example 1. The plating rate for each bath is shown in Table 6.
Table 6
Comparative Bath |
Plating Rate |
4 |
0.61 µm/5 min. |
5 |
0.62 µm/5 min. |
6 |
0.57 µm/5 min. |
7 |
0.52 µm/5 min. |
8 |
0.48 µm/5 min. |
Even in combination with the accelerator guanidine hydrochloride, the highest plating
rates for the electroless copper baths containing the base pyridine are just above
0.60 µm/5 min. In general, increasing the concentration of pyridine in the electroless
bath shows a tendency toward a decrease in electroless copper plating rate. The copper
deposits have bright and uniform areas intermixed with rough and dull areas.
Example 5
Backlight Experiment with Aqueous Alkaline Electroless Cooper Compositions of the
Present Invention Containing Pyridinium Compounds
[0063] The following aqueous alkaline electroless copper compositions of the invention are
prepared having the components and amounts disclosed in Table 7 below.
Table 7
Component |
Bath 25 |
Bath 26 |
Copper sulfate pentahydrate |
10 g/L |
10 g/L |
Rochelle salts |
40 g/L |
40 g/L |
Sodium hydroxide |
8 g/L |
8 g/L |
Formaldehyde |
4 g/L |
4 g/L |
2,2'-Dithiosuccinic acid |
0.5 ppm |
0.5 ppm |
Guanidine hydrochloride |
0.36 ppm |
0.36 ppm |
1-butylpyridinium chloride |
10 ppm |
----------- |
1-(3-sulfopropyl) pyridinium hydroxide |
----------- |
10 ppm |
Water |
To one liter |
To one liter |
The pH of the aqueous alkaline electroless copper compositions have a pH = 13 at room
temperature as measured using a conventional pH meter available from Fisher Scientific.
[0064] Six (6) different FR/4 glass epoxy panels with a plurality of through-holes are provided:
TUC-662, SY-1141, IT-180, 370HR, EM825 and NPGN. The panels are eight-layer copper-clad
panels. TUC-662 is obtained from Taiwan Union Technology, and SY-1141 is obtained
from Shengyi. IT-180 is obtained from ITEQ Corp., NPGN is obtained from NanYa and
370HR from Isola and EM825 are obtained from Elite Materials Corporation. The T
g values of the panels range from 140° C to 180° C. Each panel is 5cm x 10cm.
The through-holes of each panel are treated as follows:
- 1. The through-holes of each panel are desmeared with CIRCUPOSIT™ Hole Prep 3303 solution
for 6 min. at 80° C;
- 2. The through-holes of each panel are then rinsed with flowing tap water for 2 min.;
- 3. The through-holes are then treated with CIRCUPOSIT™ MLB Promoter 3308 aqueous permanganate
solution at 80° C for 8 min.;
- 4. The through-holes are then rinsed for 4 min. in flowing tap water;
- 5. The through-holes are then treated with a 3wt% sulfuric acid/3wt% hydrogen peroxide
neutralizer at room temperature for 2 min.;
- 6. The through-holes of each panel are then rinsed with flowing tap water for 2 min.;
- 7. The through-holes of each panel are then treated with CIRCUPOSIT™ Conditioner 231
alkaline solution for 1.5 min. at 60° C;
- 8. The through-holes are then rinsed with flowing tap water for 2 min.;
- 9. The through-holes are then treated with a sodium persulfate/sulfuric acid etch
solution for 1 min. at room temperature;
- 10. The through-holes of each panel are then rinsed with flowing DI water for 1 min.;
- 11. The panels are then immersed into acidic Pre-Dip CIRCUPOSIT™ 6520 for 0.5 min.
at room temperature and then immersed into CIRCUPOSIT™ 6530 Catalyst which is an ionic
aqueous alkaline palladium catalyst concentrate (available from Dow Electronic Materials)
for 1 min. at 40 °C, wherein the catalyst is buffered with sufficient amounts of sodium
carbonate, sodium hydroxide or nitric acid to achieve a catalyst pH of 9-9.5;
- 12. The through-holes of each panel are then rinsed with flowing DI water for 1 min.
at room temperature;
- 13. The panels are then immersed into a 0.6 g/L dimethylamine borane and 5 g/L boric
acid solution at 32 °C for 1 min. to reduce the palladium ions to palladium metal;
- 14. The through-holes of each panel are then rinsed with flowing DI water for 1 min.;
- 15. The panels are then immersed in the electroless copper plating composition of
Table 7 and copper is plated at 34 °C, at a pH of 13 and copper is deposited on the
walls of the through-holes for 5 min.;
- 16. The copper plated panels are then rinsed with flowing tap water for 4 min.;
- 17. Each copper plated panel is then dried with compressed air; and
- 18. The walls of the through-holes of the panels are examined for copper plating coverage
using the backlight process described below.
[0065] Each panel is cross-sectioned nearest to the centers of the through-holes as possible
to expose the copper plated walls. The cross-sections, no more than 3 mm thick from
the center of the through-holes, are taken from each panel are placed under a conventional
optical microscope of 50X magnification with a light source behind the samples. The
quality of the copper deposits are determined by the amount of light visible under
the microscope that is transmitted through the sample. Inside the plated through-holes,
transmitted light is only visible in areas where there is incomplete electroless coverage.
If no light is transmitted and the section appears completely black, it is rated a
5 on the backlight scale indicating complete copper coverage of the through-hole wall.
If light passes through the entire section without any dark areas, this indicates
that there is very little to no copper metal deposition on the walls of the through-holes
and the section is rated 0. If sections have some dark regions as well as light regions,
they are rated between 0 and 5. A minimum of ten through-holes are inspected and rated
for each board. Backlight values of 4.5 and greater are indicative of commercially
acceptable catalysts in the plating industry.
[0066] The average backlight value for each type of FR/4 glass epoxy panel is disclosed
in the table below.
Table 8
Panel |
Bath 25 |
Bath 26 |
370HR |
4.8 |
4.4 |
EM825 |
4.8 |
4.6 |
IT-180 |
4.8 |
4.7 |
NPGN |
4.7 |
4.8 |
SY-1141 |
4.4 |
4.4 |
TU-662 |
4.6 |
4.7 |
Overall both baths show very good backlight values.