What Are Vias And Why Do You Need Them?

Just as a printed circuit board (PCB) is a means to allow interconnection of different components, vias are means to interconnect different layers on and within the multilayered PCBs. Also, just like there are various types of PCBs, there are multiple types of vias with their own functionality. Simply put, vias are Plated-Through Holes (PTHs) passing through one or more layers in a PCB, connecting traces on its way. IPC defines seven types of vias in IPC-50M, Terms and Definitions for Interconnecting and Packaging Electronic Circuits. These are:
Type I: Tented Vias—vias that have a mask material applied, bridging over them, with no additional material inside the holes.
Type II: Tented and Covered Vias—type I vias with a secondary covering of mask material over and above the tented vias.
Type III: Plugged Vias—vias with material partly penetrating into the via holes.
Type IV: Plugged and Covered Vias—type III vias with a secondary material covering the vias.
Type V: Filled Vias—vias with material fully penetrating and encapsulating the via holes.
Type VI: Filled and Covered—type V vias with a secondary material covering the vias.
Type VII: Filled and Capped—type V vias with a secondary metalized coating covering the vias.
                                                            Fig. 1: Close-up of a Via
Although small and sometimes very small, vias are extremely important parts of the circuit board landscape. In fact, in the world of surface mount components, vias are the only means to interconnect copper traces on different layers on a PCB, where earlier, leads of components would do the job when soldered on both sides of a two-layer PCB. The only difference between plated-through holes and vias is no component lead will ever pass through the hole of a via.
                                                        Fig. 2: Different Types of Vias
Each of the seven types of vias classified above may be further subdivided into three types depending on their functionality—blind or hidden vias, buried vias, and through hole vias. As the name suggests, through hole vias travel through the board, connecting traces on the outermost layers, and if required, on the inner layers as well. Blind vias start on the surface on one side of the board, but do not extend to the other side, finishing on one of the internal layers instead. Buried vias remain completely encapsulated within the board, and none of their ends extend to any of the outer surfaces of the board.
Most vias in high-density boards have very small-diameter holes, and are called micro-vias. Manufacturers use different tools such as ultrasonic beams and lasers to drill these holes. Usually, micro-vias are filled with a conductive material to facilitate connecting with the pad on the other layer. However, this can lead to issues with unequal expansion as explained later.
Tented Vias
                                                                  Fig. 3: Tented Vias
The word “tenting” in the PCB industry originally meant the solder mask would enclose the via fully in the form of a skin or tent over the hole. This was difficult for manufacturers to achieve with liquid photo-imageable (LPI) solder mask, as the success of the process was dependent on the diameter of the hole and surface tension of the LPI. With the introduction of dry film solder mask, manufacturers achieved tenting easily, but the process was more expensive.
With LPI, tenting caused the mask to cover the pad and enter the hole partly. However, this was not consistent, as some vias remained unplugged, and others had the tent broken over the hole, covering only the annular ring or pad. Therefore, as per requirement, manufacturers resorted to plugging vias with conductive or non-conductive materials before tenting with LPI.
Tenting is useful for reducing the number of exposed conductive pads present on the PCB, and helps in reducing the likelihood of shorts from solder bridging during the assembly process. In the case of SMT pads, tenting helps to reduce paste migration away from the pads of SMD components when vias are placed either on the ends of their pads or on the dog-bones meant for BGAs.
Additionally, tenting is helpful whenever vias are placed close to SMT pads, especially in areas within the BGA package, where shorts can easily happen under the component during reflow, making rework difficult and time-consuming. Covering the tented via with a secondary coating of solder mask often helps,
Disadvantages of Incomplete Tenting
                                                             Fig. 4: Incomplete Tenting
Although tenting of vias by primary LPI solder mask is advantageous as it is only a single step process, the process cannot guarantee complete tenting, resulting in long-term reliability issues. Successful tenting by screen coating depends on the size of the hole, surface tension of the liquid mask, and the board thickness. As no surface finish is applied to the via barrel before tenting, incomplete tenting may cause entrapments. Usually, this is chemical entrapment from preclean lines when enhancing surface finish.
Preclean lines subject surface finishes to a micro-etching process, allowing micro-etchants to be trapped in the open vias, where the chemical crystallizes rapidly to generate copper-sulfate crystals. Over time, these crystals etch away the copper in the barrel, causing long-term reliability issues. For instance, the gold of the ENIG finish could form a galvanic cell with the exposed copper near the top of the via in the presence of the micro-etchant chemical, thereby accelerating the process of etching.
Incomplete tenting may also cause solder paste to wick into the via, leaving insufficient paste to complete the actual soldering. In the case of BGAs, localized thermal energy may cause the LPI solder mask to lift between the ball and the via capture pads, as the distance between them is very short, causing solder shorts.
Above issues with incomplete tenting has led to manufacturers plugging vias with solder mask or some other non-conductive or even conductive materials. The plugged via does not require surface finish to be applied to the via barrel, but does ensure that subsequent application of the LPI mask leaves all the vias fully tented.
Vias Plugged with Non-Conductive Fill
 
For vias plugged with solder mask or similar non-conductive epoxy material, the manufacturer has to ensure the via is completely plugged and sealed, and its annular ring is fully covered. This is a common practice when using BGA SMD pads to prevent solder wicking into the via creating poor or non-existent solder joints.
                                                               Fig. 5: Active Pad
However, with BGA packages becoming tighter, it is becoming increasingly difficult placing vias on standard ‘dog-bone’ land patterns for transferring signals to other layers. This difficulty has led to vias being drilled directly into the pads of the BGA footprint. The process is known as via-in-pad, and allows much simpler routing. Although this requires the via hole to be fully plugged, it also requires the surface of the plugged via to be plated over with copper, and subsequently flattened and planarized to be even with the surrounding copper features. Therefore, with the application of the final finish, there is a solderable surface mount pad, also called an active pad, capable of passing signals to inner layers, eliminating the need to place vias on the surface layer for the purpose.
Vias Plugged with Conductive Fill
Some chips generate a lot of heat, which must be conducted away to prevent the chip from overheating. Placing thermal vias plugged with conductive fill under the chip helps in the process, as the metallic nature of the fill naturally wicks the heat away from the chip to the other side of the board, just as a radiator does. This technique is helpful even in cases where a chip draws high currents, as multiple vias plugged with conductive fill reduce the resistance of the track, thereby lowering the voltage drop between the voltage source and the pins of the chip.
Drawbacks of Conductive Fills
Vias filled with conductive fill generally present a different coefficient of thermal expansion (CTE) between the surrounding laminate and the metallic fill. With heat, metals expand much more rapidly than the surrounding laminate does, leading to a possible fracture between the pads and the hole wall. Therefore, where the purpose of the fill is only to reinforce the copper pad plated over the hole, designers using via-in-pad do not recommend the conductive filling process.
Conclusion
Designers often try to match the CTE of the conductive fill for vias with that of the surrounding material. This is important in the view of the board living out its life in a heating/cooling state, where the expansion and contraction of the materials can lead to stress fractures in vias and possible electrical opens in the worst cases. However, this consideration generally favors the non-conductive epoxies for via filling as their CTE matches that of the laminate more closely, making the PCB a more reliable product.
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RF Design and High Frequency Board Manufacturing

The performance of a product operating at high frequencies depends largely on the electrical characteristics of the Printed Circuit Board (PCB) used for mounting and connecting its circuit components. The magnitude of the impact of the PCB design increases exponentially with increase of the operational frequency. Therefore, designers need to include electrical models of PCB structures when simulating RF circuits. For achieving optimum solutions, the product/PCB designer and the manufacturing engineer must appreciate the requirements of RF design.
Designing for High Frequencies
Designing a board to work at high frequencies requires the designer to be critical of the following areas:
  • Material used for the PCB
  • Placement of traces
  • Placement of planes
  • Component interconnections

Materials Used for RF PCBs

RF PCBs can use a variety of different materials. Although common board materials used for high frequency circuits are FR-4 and derivatives of FR-4, many other base substrates are also used as they offer better electrical performance. These include specialized low-loss RF material such as pure PTFE, ceramic filled PTFE, Hydrocarbon Ceramic, and High-Temperature Thermoplastic/Ceramic.
Although FR-4 has its limitations when used for high-frequency work, the RF designer must understand these limitations and make cost/performance tradeoffs for the design. Typical limitations of FR-4 are:
  • Stability of dielectric constant—Varying from lot to lot and over frequency
  • Loss factor—Depending on surface contamination and the hygroscopic nature of the material
  • Ability to withstand processing temperatures—Lead-free processing temperatures are higher than regular soldering temperatures
  • Thermal conductivity—Even low-power RF circuits can produce a lot of heat

Therefore, selecting a suitable material for making a PCB operating at high frequencies depends on the above factors and the product cost. The choice could range from the low-cost FR-4 material, with its higher loss and not tightly controlled dielectric constant, to FR-4 derivatives with better specifications, or to other specialized low-loss RF material with their well-specified dielectric constant.

Fabrication Issues with Special Materials
 
All laminates mentioned above involve individual fabrication issues. For achieving the proper quality and reliability, the manufacturer must follow these individual fabrication notes for each substrate material for storing, handling, preparing the inner layer, surface preparation for photoresist application, bonding, drilling, deburring, and plating.
Manufacturers require setting up special processes for fabricating PCBs with low-loss RF materials to work at high frequencies. For instance, plated-through hole preparation is very critical for PTFE substrates—it needs an etch-back process requiring Plasma etch setup to prepare the PTFE hole surface and make it capable of accepting electroless copper plating. Therefore, apart from proper selection of material, following the proper fabrication methods is equally important for achieving a good quality PCB working reliably at high frequencies.
Placement of Traces
For matching the impedance, designers effectively manage the spacing of traces, ground planes, and the dielectric material to form a controlled impedance transmission line. They do this in several ways—in the form of a microstrip, stripline, co-planar waveguides, and differential pairs. The width of the trace, the dielectric thickness, dielectric constant of the used dielectric material and copper thickness determine the impedance. As high frequency signals are very sensitive to noise, ringing, and reflections, they must be designed with great care towards impedance. Mostly preferred impedance is 50 ohms for single ended and 100 ohms for differential, with control limits of ±10%.
                                                               Fig.1: Microstrip
                                                         Fig.2: Centered Stripline
                                                               Fig.3: Off-Center
Microstrip: This is a circuit trace carrying the RF signals routed on an outside layer of the PCB with a reference plane below it. The reference plane may be power or ground plane.
Stripline: This is a circuit trace carrying the RF signals routed on an inside layer of the PCB with two low-voltage reference planes above and below it. The reference planes may be power and or ground plane. The stripline can be equidistant from the two reference planes, in which case it is called the centered stripline, or it can be an off-center stripline, where it is closer to one of the reference planes.
                                                               Fig.4: Coplanar
                                              Fig.5: Coplanar Waveguide with Ground
Co-planar Waveguide: This is a circuit trace carrying the RF signals embedded within a ground reference plane on the same layer of the PCB. Co-planar waveguides (CPW) offer lower loss tangent than microstrips do, but have a higher skin effect loss, as fields concentrate on the edges of the trace and ground. Another form of co-planar waveguide is the co-planar waveguide with ground (CPWG), where a ground plane is placed just below the waveguide layer.
                                                    Fig.6: Coplanar Differential Pair
                                                  Fig.7: Coplanar Differential Pair with
 
Co-planar Differential Pairs: These are two traces carrying the RF signals embedded within a ground reference plane on the same layer of the PCB. This arrangement is also called the CP Differential Pair or Edge-Coupled CPW. This gives an extra degree of signal-to-noise isolation over the standard CPW. An added ground plane just below the layer offers even better field containment over the coupled CPW, and is called the Edge Coupled CPWG.
Placement of Planes
Most RF products use multilayer PCBs. These comprise a number of laminates of the substrate material separately etched, drilled, and bonded. The chief advantage of this is to allow the use of more than two conductor layers, thereby reducing the required board space, but at increased cost.
Setting up the laminates is a major part of the design for a multilayer RF board. The stack defines the number of layers the board will ultimately possess. At this stage, it is important to define the layers carrying specific high-speed tracks, and the placement of the ground and power layers with respect to those layers. Enclosing tracks carrying high frequency signals within the ground and power layers serves to define two significant factors related to high speed multilayer design—minimizing cross-talk, and maintaining a check on the impedance on the board. However, the cost of the board increases proportional to the number of layers it has, and therefore, the number of layers is usually a compromise of the board’s functionality and its cost.
RF products typically use a four or six layer FR-4 multilayer construction. Drilled and plated through holes or vias link tracks on one layer to tracks on other layers or all layers. Complex structures use blind or buried vias, with blind vias connecting the outermost layers to one or more inner ones, while buried vias connect only the inner layers and do not appear on the outermost layers. The third type of via is the through via, going through all the layers of the board. To create the connections, it is necessary to drill and then plate-through all vias. Via structures have a major effect on the fabrication processes of the PCB and contribute to the cost of the finished board.
Component Interconnections
Parasitic elements of a PCB refer to its physical attributes that affect the performance of the circuit. For instance, at high frequencies, a long thin track will usually be inductive, while a large pad over a ground plane will behave like a capacitor. In addition, when modeling in real circuits for, say a series capacitor, the designer must also include the impedance of the connections between the ground plane and circuit components.
A plated through via hole also adds significant inductance. RF designers can use good circuit simulation packages that include models to allow their addition. For instance, the typical inductance of a 0.2 mm diameter, 1.6 mm long hole can be as much as 0.75 nH. Although this may seem to be small, it can exert significant influence at high frequencies.
Components mounted on the PCB also contribute with their non-ideal characteristics. The use of Surface Mount Device (SMD) components helps to reduce the effect largely because of their reduced lead lengths and small construction, but the effect is still prominent at higher frequencies.
Designers use different ground plane strategies for their RF PCB design, and there is no unique solution as the best strategy. While most designers advocate breaking up the ground plane over the analog, digital, radio, and audio parts of the circuit, providing an individual ground plane of low impedance for all parts of the circuit is usually a good point to start.
Designers need to consider the flow of currents carefully throughout the product to minimize interferences between the audio and radio circuits. This assumes even greater significance if the design uses Digital Signal Processing (DSP) and microprocessors.
RF PCB Layout Strategies and Techniques
  • Separate all RF, low-level analog,  and digital sections.
  • Divide the RF section into circuit groups (amps, LO, VCO, etc.).
  • Place all the high-frequency components early in the layout, as this helps to minimize the length of the RF routes (in RF PCBs, functional orientation is more important compared to DFM).
  • Place the components carrying the highest frequency next to the connectors.
  • Never place unrelated inputs and outputs next to each other. For instance, multi-stage windings should never be placed adjacent.
  • When long input or output to RF amplifiers is unavoidable, choose to make the output longer.
  • As the trace impedance is a critical factor when trying to control reflections, always match the impedance between the driver and the load, except where the trace is shorter than 1/20th of the wavelength.
  • When using pull-up inductors or resistors at the outputs of open-collector devices, always place the pull-up component next to the output pin it is pulling up.
  • In addition to decoupling the main power pins of the IC, decouple the pull-up also.
  • Inductors usually have large magnetic fields around them-
    • Never placed them close together, when in parallel (unless the intention is to couple their magnetic fields)
    • Separate all inductors by 1x times the body height (minimum) OR
    • Place inductors perpendicular to one another
  • Confine “ALL” routes to the section or stage to which they are assigned –
    • Digital traces in the digital section
    • Low-level analog traces in the low-level analog section
    • RF traces in the RF section
    • Routing traces into adjoining sections is not recommended
  • Route all short RF traces on the component side of the PCB, rout them to eliminate vias
  • Place a ground layer below the RF traces.
  • Minimize the vias in the RF path, as this reduces the breaks in the ground plane(s) and –
    • Minimizes inductance
    • Helps contain stray magnetic and electric fields.
  • Long controls lines are acceptable, but take care to route them away from RF inputs.
  • Keep RF lines away from one another by a minimum distance to avoid unintended coupling & crosstalk.
  • Minimum spacing is a function of the acceptable level of coupling, and is good for crosstalk, directional couplers, crosstalk, differential lines coupled in even or odd modes.
Summary
Finally, the design of a PCB and its fabrication for high frequency use is a complex process requiring intimate communication between the designer and the fabricator, with each understanding the issues related to high-speed design.
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FRAMELESS STENCILS – Production & Benefits

Frameless Stencils which are loose foil not with rigis Frames have the advantage of being extremely economical and save tremendous amount of space as well. For Limited Production runs and where budgets are a factor, these are very useful.

1. Patterned border
2. Basic outline border.

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Frameless Stencils are laser sliced weld glue stencils intended to work with stencil tensioning frameworks otherwise called Reusable Stencil Frames. Frameless Stencils are noteworthy more affordable than Framed Stencils and lessen storage room necessities.

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Online PCB Specialist – pcbpower

PCBPOWER (Subsidiary of Circuit Systems India Ltd) has come a long way ever since it began to manufacture PCBs in 1996 to become one of India’s leading PCB manufacturers today. The company’s high quality and cost effective printed circuit boards with its unmatched consistency and customer-centricity has earned it respect and appreciation on a global level. PCBPOWER has a long-established reputation in providing its customers prototype and small volume through an efficient usage of the state of the art production facility.

One of our major contributions also includes for the development of Electronics Industry through support of:

  • Individual Users
  • Hobbyists
  • Students
  • Educational Institutes

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With the rapid technological and economical changes, only a flexible organisation can withstand the turbulent circumstances. Flexibility has been our forte. We believe in providing solutions that meet the requirement of our customers and are revolutionary at the same time. Among our ground breaking solutions are a wide range of New Advancements in High Frequency-RF PCBs in Metal Clad PCB’s, RT Duroid and Higher Layer counts with lean manufacturing and SPC. We are a UL certified facility.

Our customers are invaluable to us; their time, money and efforts matter a great deal. We, therefore, strive single-mindedly to minimize the cost, time and efforts of our valued customers, providing them complete solutions concerning PCB fabrication, PCB Layout-Design, Stencil Fabrication through our online ordering & tracking system.

We strive to deliver quality products and services and have a team of creative, experienced and technically competent engineers, designers and staff at PCB POWER and CSIL actively serving the following industries:

  • Research & Developments
  • Students/ Hobbyist
  • Automotive
  • Railways
  • Medical
  • Aerospace & Defence
  • Educational Institutes
  • Industrial Electronics
  • Metering
  • Test & Measurement

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