Selective metallization process and additive method for manufactured printed circuit boards

Claim 2

A process for metallizing a substrate in a pre-selected pattern, comprising the steps of: (a) applying a resist to the substrate surface in a predetermined pattern such that the exposed substrate areas not covered by the resist define the desired substrate pattern to be metallized; (b) thereafter treating the resist-patterned substrate with a conditioning agent effective to increase adsorption of subsequently-applied catalytic species to exposed substrate areas; (c) treating the resist-patterned substrate with an adjuvant material effective to decrease the receptivity of resist surfaces to subsequently-applied catalytic species and flash metal deposit; (d) thereafter treating the resist-patterned substrate with a deactivating agent comprising a solvent for said resist, the conditions of said treatment being such as to decrease the receptivity of resist surfaces to subsequently-applied catalytic species and flash metal deposit without effecting any substantial dissolution of said resist; (e) thereafter providing on the resist-patterned substrate species catalytic to electroless flash deposition of metal; (f) thereafter immersing the resist-patterned substrate in an electroless metal depositing bath to provide on the exposed, catalyzed areas of said substrate a thin flash metal deposit; (g) thereafter stripping the resist from the substrate, leaving a flash metal deposit on the substrate in the preselected desired pattern; and (h) thereafter providing additional metal on the pattern of flash metal deposit.

Claim 3

The process according to claim 1 wherein said application of resist in a predetermined pattern comprises the steps of (i) uniformly coating the substrate surface with a photoresist composition which is developable in aqueous alkaline medium and, after development, strippable in aqueous alkaline medium, (ii) imaging said photoresist composition by exposing it to light through a suitably patterned mask; and (iii) developing said imaged photoresist utilizing aqueous alkaline developing medium so as to remove undesired resist from predetermined areas on said substrate surface and leave behind on said surface a desired predetermined pattern of resist.

Claim 4

The process according to claim 2 wherein said adjuvant is an amine.

Claim 5

The process according to claim 3 wherein said adjuvant is selected from the group consisting of ethylenediamine, 1,2-propanediamine, N,N,N',N'-tetramethyl-1,3-butanediamine, diethylene triamine, and mixtures thereof.

Claim 6

The process according to claim 2 wherein said deactivating agent comprises an aqueous alkaline solution.

Claim 7

The process according to claim 2 wherein said conditioning agent comprises an organosilane.

Claim 8

The process according to claim 2 wherein said electroless metal depositing bath comprises a formaldehyde-free, hypophosphite-reduced electroless copper bath having an operating pH below about 10.

Claim 9

The process according to claim 1 wherein said treating with conditioning agent and adjuvant is effected in a single step.

Claim 10

A process for manufacturing by additive processes a printed circuit board having metallized thru-holes, comprising the steps of: (a) applying a resist to a thru-hole containing printed circuit board substrate surface in a pre-determined pattern such that the thru-holes remain exposed and the exposed substrate surfaces not covered by the resist define the desired circuit pattern; (b) thereafter treating the resist-patterned substrate with a conditioning agent effective to increase adsorption of subsequently-applied catalytic species to exposed substrate surfaces including thru-hole surfaces; (c) treating the resist-patterned substrate with an adjuvant material effective to decrease the receptivity of resist surfaces to subsequently-applied catalytic species and flash metal deposit; (d) thereafter treating the resist-patterned substrate with a deactivating agent comprising a solvent for said resist, the conditions of said treatment being such as to decrease the receptivity of resist surfaces to subsequently-applied catalytic species and flash metal deposit without effecting any substantial dissolution of said resist; (e) thereafter providing on the surfaces of resist-patterned substrate, including thru-hole surfaces, species catalytic to electroless flash deposition of metal; (f) thereafter immersing the resist-patterned substrate in an electroless metal depositing bath to provide on the exposed, catalyzed areas of said substrate, including thru-hole surfaces, an adherent thin flash metal deposit; (g) thereafter stripping the resist from the substrate, leaving a flash metal deposit on the substrate in the preselected desired circuit pattern and on the thru-hole surfaces; and (h) thereafter providing additional metal on the areas of flash metal deposit.

Claim 11

A process for manufacturing by additive processes a printed circuit board having metallized thru-holes, comprising the steps of: (a) applying a resist to a thru-hole containing printed circuit board substrate surface in a pre-determined pattern such that the thru-holes remain exposed and the exposed substrate surfaces not covered by the resist define the desired circuit pattern; (b) thereafter treating the resist-patterned substrate with a conditioning agent effective to increase adsorption of subsequently-applied catalytic species to exposed substrate surfaces including thru-hole surfaces; (c) treating the resist-patterned substrate with an adjuvant material effective to decrease the receptivity of resist surfaces to subsequently-applied catalytic species and flash metal deposit; (d) thereafter treating the resist-patterned substrate with a deactivating agent comprising a solvent for said resist, the conditions of said treatment being such as to decrease the receptivity of resist surfaces to subsequently-applied catalytic species and flash metal deposit without effecting any substantial dissolution of said resist; (e) thereafter providing on the surfaces of resist-patterned substrate, including thru-hole surfaces, species catalytic to electroless flash deposition of metal; (f) thereafter immersing the resist-patterned substrate in an electroless metal depositing bath to provide on the exposed, catalyzed areas of said substrate, including thru-hole surfaces, an adherent thin flash metal deposit; (g) thereafter stripping the resist from the substrate, leaving a flash metal deposit on the substrate in the preselected desired circuit pattern and on the thru-hole surfaces; and (h) thereafter providing additional metal on the areas of flash metal deposit.

Claim 12

The process according to claim 9 wherein said application of resist in a predetermined pattern comprises the steps of (i) coating the substrate with a photoresist composition which is developable in aqueous alkaline medium and, after development, strippable in aqueous alkaline medium; (ii) imaging said photoresist composition by exposing it to light through a suitably patterned mask; and (iii) developing said imaged photoresist utilizing aqueous alkaline developing medium so as to remove undesired resist from predetermined areas on said substrate surface and leave behind on said surface a desired predetermined pattern of resist.

Claim 13

The process according to claim 10 wherein said adjuvant is an amine.

Claim 14

The process according to claim 11 wherein said adjuvant is selected from the group consisting of ethylenediamine, 1,2-propanediamine, N,N,N',N'-tetramethyl-1,3-butanediamine, diethylene triamine, and mixtures thereof.

Claim 15

The process according to claim 10 wherein said deactivating agent comprises an aqueous alkaline solution.

Claim 16

The process according to claim 10 wherein said conditioning agent comprises an organosilane.

Claim 17

The process according to claim 10 wherein said electroless metal depositing bath comprises a formaldehyde-free, hypophosphite-reduced electroless copper bath having an operating pH below about 10.

Claim 18

The process according to claim 9 wherein said treating with conditioning agent and adjuvant is effected in a single step.

Claim 19

A process for manufacturing a printed circuit board containing metallized thru-holes by an additive process, comprising the steps of: (a) applying to a thru-hole-containing printed circuit board substrate a photoresist composition which is developable in aqueous alkaline medium and, after development, is strippable in aqueous alkaline medium; (b) imaging said photoresist composition through a mask in a desired pattern; (c) developing said imaged photoresist composition utilizing aqueous alkaline medium so as to result in a printed circuit board substrate having exposed thru-hole surfaces and having resist in a predetermined pattern on the substrate surface such that the exposed substrate surfaces not covered by said resist define the desired circuit pattern; (d) thereafter treating the resist-patterned substrate with a conditioning agent effective to increase adsorption of subsequently-applied catalytic species to exposed substrate surfaces, including thru-hole surfaces; (e) treating the resist-patterned substrate with an adjuvant material selected from the group consisting of ethylenediamine, 1,2-propanediamine, N,N,N',N'-tetramethyl-1,3-butanediamine, diethylene triamine, and mixtures thereof; (f) treating the resist-patterned substrate with a deactivating agent comprising an aqueous alkaline medium under conditions insufficient to effect any substantial dissolution of said resist; (g) thereafter providing on the surfaces of the resist-patterned substrate, including thru-hole surfaces, species catalytic to electroless flash deposition of metal; (h) thereafter immersing the resist-patterned substrate in an electroless copper depositing bath of a pH of 10 or less to provide on the exposed, catalyzed areas of said substrate, including thru-hole surfaces, a thin, adherent copper flash deposit; (i) thereafter stripping the resist from the substrate using aqueous alkaline medium, leaving a flash metal deposit on the substrate in the desired circuit pattern and on the thru-hole surfaces; and (j) thereafter depositing additional copper metal on the areas of flash copper deposit.

Claim 20

A process for manufacturing a printed circuit board containing metallized thru-holes by an additive process, comprising the steps of: (a) applying to a thru-hole-containing printed circuit board substrate a photoresist composition which is developable in aqueous alkaline medium and, after development, is strippable in aqueous alkaline medium; (b) imaging said photoresist composition through a mask in a desired pattern; (c) developing said imaged photoresist composition utilizing aqueous alkaline medium so as to result in a printed circuit board substrate having exposed thru-hole surfaces and having resist in a predetermined pattern on the substrate surface such that the exposed substrate surfaces not covered by said resist define the desired circuit pattern; (d) thereafter treating the resist-patterned substrate with a conditioning agent effective to increase adsorption of subsequently-applied catalytic species to exposed substrate surfaces, including thru-hole surfaces; (e) treating the resist-patterned substrate with an adjuvant material selected from the group consisting of ethylenediamine, 1,2-propanediamine, N,N,N',N'-tetramethyl-1,3-butanediamine, diethylene triamine, and mixtures thereof; (f) treating the resist-patterned substrate with a deactivating agent comprising an aqueous alkaline medium under conditions insufficient to effect any substantial dissolution of said resist; (g) thereafter providing on the surfaces of the resist-patterned substrate, including thru-hole surfaces, species catalytic to electroless flash deposition of metal; (h) thereafter immersing the resist-patterned substrate in an electroless copper depositing bath of a pH of 10 or less to provide on the exposed, catalyzed areas of said substrate, including thru-hole surfaces, a thin, adherent copper flash deposit; (i) thereafter stripping the resist from the substrate using aqueous alkaline medium, leaving a flash metal deposit on the substrate in the desired circuit pattern and on the thru-hole surfaces; and (j) thereafter depositing additional copper metal on the areas of flash copper deposit.

Claim 21

The process according to claim 17 wherein said treating with conditioning agent and adjuvant is effected in a single step.