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In a difunctional system, the epoxide molecule has two cross-linking sites, and the cured epoxy contains long linear molecular chains Pure difunctional laminates have excellent physical properties, and for many years were the mainstay of the industry They have a Tg of 120 C, which is adequate for most use environments, but is low for some applications and too low for LFA The epoxide molecule of a tetrafunctional epoxy has more than two cross-linking sites This allows a high cross-link density and a high Tg A pure tetrafunctional system is expensive and difficult to work with To meet the need for a Tg, above 120 C, laminators blend difunctional and tetrafunctional resins, producing a mixture referred to as multifunctional Around 1985, some laminators began to sell a multifunctional epoxy blend with a Tg between 130 and 145 C.

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This blend was called tetrafunctional, even though it actually contained both difunctional and tetrafunctional epoxies This blend is available at little or no price premium over a difunctional laminate Laminates with a higher fraction of tetrafunctional resin are available These systems, which are called multifunctional, have Tg values in excess of 170 C and are sold at a price premium of approximately 10 percent over difunctional systems Multifunctional blends often have lower moisture absorption and higher thermal degradation temperature than difunctional systems However, in some multifunctional systems, these properties are not improved Care must be taken in selecting a multifunctional system to ensure that all properties of importance are enhanced Modern ML-PWBs often operate at elevated temperatures due to the heat output from semiconductor devices As boards become thicker and holes smaller, these thermal cycles result in an increasing threat to the reliability of plated holes.

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For example, plated holes have been shown to fail when subjected to multiple thermal cycles up to temperatures near the Tg of the base material These cycles can easily occur when a high-power device is turned on and off One solution to this problem is to use materials with a higher Tg..

In general, internal guideways are chosen when the sliding velocity is high, and it is essential to provide a good retention of the lubricant at the interface On the other hand, when the sliding velocity is not that high and it is necessary to prevent chip accumulation and to ensure its easy removal, the external guideway is preferred In ultra-precision machines, it is common to use bellows for protection against chips and dirt

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ML-PWBs often have surface-mount devices on both sides of the board, and they receive three or more solder operations during the assembly of connectors and devices In addition, because of the value of a completed assembly, the board must be able to withstand additional soldering operations needed for occasional removal and replacement of defective devices Boards made with difunctional GF epoxy can suffer from lifted lands, cracked PTH barrels, or substrate blisters during these multiple soldering operations The solution is to use materials with low moisture absorption and high thermal degradation temperature 272312 RoHS-Compliant Epoxies (Non-Dicy Cure Agent) Conventional epoxy resin systems have commonly used dicyandiamide (dicy) as the curing agent Experiments reported in the industry have concluded that dicy-cured FR-4 PWBs even with high Tg and optimized PWB fabrication do not withstand the thermal stress of lead-free assembly conditions.

Phenolic-cured (novolac) epoxies had demonstrated better thermal stability than the dicy-cured systems Many of the new RoHS-compliant LFAC laminates use a phenolic curing agent Many of the new laminates, in addition to changing the curing agent, also incorporate some percentage of inorganic fillers to restrain the z-axis expansion of the system4 These changes fundamentally impact the fabrication of the base materials into ML-PWBs especially in the lamination, drilling, and hole-preparation processes The process impacts will be discussed in later sections 27232 Halogen-Free Halogen-free laminates are a response to the European Union direction to require original equipment manufacturers (OEMs) to reclaim electronics to remove hazardous substances from the waste stream (leaving aside the discussion of which substances are hazardous and how hazardous those substances are considered to be) Waste management of PCBs containing halogens will be costly.

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Halogen-free (HF) technology is sometimes used to refer to laminates that have no tetrabromobisphenol A (TBBPA), which is the primary flame retardant used in FR-4 laminate TBBPA is an organic molecule whose composition includes approximately 59 percent bromine There is no legislation or regulation calling for the removal of TBBPA; however, the driver for halogen-free technology is the ecofriendly consumer market For this reason, these laminates are also sometimes called green laminates HF laminates can be identified by a non-bromine flame retardant in the composition The main chemical families used for nonhalogenated flame retardants are phosphorous compounds, nitrogen compounds, inorganic fillers, and compounds containing aluminum, magnesium, or red phosphorous Curing agents are available that improve cross-linking with epoxy systems, completely curing the resin.

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