ELECTROLESS PLATING METHOD AND PRODUCT OBTAINED

Abstract

The present invention relates to an electroless plating method, in which electroless plating is performed by contacting a substrate which is patterned with an anti-electroless plating coating with an electroless plating solution, whereby metal is deposited by electroless plating onto portions of the substrate that are not patterned with the anti-electroless plating coating, the anti-electroless plating coating having multiple layers, each of which is obtainable by plasma deposition of a precursor mixture comprising (a) one or more organosilicon compounds, (b) optionally O.sub.2, N.sub.2O, NO.sub.2, H.sub.2, NH.sub.3, N.sub.2, SiF.sup.4 and/or hexafluoropropylene (HFP), and (c) optionally He, Ar and/or Kr.

Claims

1. An electroless plating method, in which electroless plating is performed by contacting a substrate which is patterned with an anti-electroless plating coating with an electroless plating solution, whereby metal is deposited by electroless plating onto portions of the substrate that are not patterned with the anti-electroless plating coating, the anti-electroless plating coating having multiple layers, each of which is obtainable by plasma deposition of a precursor mixture comprising (a) one or more organosilicon compounds, (b) optionally O.sub.2, N.sub.2O, NO.sub.2, H.sub.2, NH.sub.3, N.sub.2, SiF.sub.4 and/or hexafluoropropylene (HFP), and (c) optionally He, Ar and/or Kr.

2. The method according to claim 1, wherein the anti-electroless plating coating has two to ten layers, preferably four to eight layers.

3. The method according to claim 1 or 2, wherein the plasma deposition is plasma enhanced chemical vapour deposition (PECVD).

4. The method according to any one of the preceding claims, wherein the plasma deposition occurs at a pressure of 0.001 to 10 mbar.

5. The method according to any one of the preceding claims, wherein the first/lowest layer of the anti-electroless plating coating, which is in contact with the substrate, is organic.

6. The method according to claim 5, wherein the first/lowest layer of the anti-electroless plating coating is obtainable by plasma deposition of a precursor mixture containing no, or substantially no, O.sub.2, N.sub.2O or NO.sub.2.

7. The method according to claim 6, wherein the first/lowest layer of the anti-electroless plating coating is obtainable by plasma deposition of a precursor mixture containing no, or substantially no, O.sub.2, N.sub.2O, NO.sub.2, fluorine-containing organosilicon compound, SiF.sub.4 or HFP.

8. The method according to any one of the preceding claims, wherein the final/uppermost layer of the anti-electroless plating coating is obtainable by plasma deposition of a precursor mixture containing no, or substantially no, O.sub.2, N.sub.2O or NO.sub.2.

9. The method according to any one of the preceding claims, wherein the final/uppermost layer of the anti-electroless plating coating is obtainable by plasma deposition of a precursor mixture comprising one or more halogen-containing organosilicon compounds, SiF.sub.4 and/or HFP.

10. The method according to any one of the preceding claims, wherein the final/uppermost layer of the multi anti-electroless plating coating is obtainable by plasma deposition of a precursor mixture comprising He, Ar and/or Kr.

11. The method according to any one of the preceding claims, wherein at least one layer of the anti-electroless plating coating is a moisture barrier layer obtainable by plasma deposition of a precursor mixture comprising O.sub.2, N.sub.2O and/or NO.sub.2

12. The method according to any one of the preceding claims, wherein at least one layer of the anti-electroless plating coating is a moisture barrier layer obtainable by plasma deposition of a precursor mixture comprising a nitrogen-containing organosilicon compound, N.sub.2, NO.sub.2, N.sub.2O and/or NH.sub.3.

13. The method assembly according to claim 11 or 12, wherein the precursor mixture from which the at least one moisture barrier layer is obtainable further comprises He, Ar and/or Kr.

14. The method according to any one of claims 11 to 13, wherein the at least one moisture barrier is located between the first/lowest layer and the final/uppermost layer of the anti-electroless plating coating.

15. The method according to any one of the preceding claims, wherein the one or more organosilicon compounds from which each layer of the anti-electroless plating coating is obtainable by plasma deposition is independently selected from hexamethyldisiloxane (HMDSO), tetramethyldisiloxane (TMDSO), 1,3-divinyltetramethyldisiloxane (DVTMDSO), hexavinyldisiloxane (HVDSO) allyltrimethylsilane, allyltrimethoxysilane (ATMOS), tetraethylorthosilicate (TEOS), trimethylsilane (TMS), triisopropylsilane (TiPS), trivinyl-trimethyl-cyclotrisiloxane (V.sub.3D.sub.3), tetravinyl-tetramethyl-cyclotetrasiloxane (V.sub.4D.sub.4), tetramethylcyclotetrasiloxane (TMCS), octamethylcyclotetrasiloxane (OMCTS), hexamethyldisilazane (HMDSN), 2,4,6-trimethyl-2,4,6-trivinylcyclotrisilazane, dimethylamino-trimethylsilane (DMATMS), bis(dimethylamino)dimethylsilane, (BDMADMS), tris(dimethylamino)methylsilane (TDMAMS), trimethyl(trifluoromethyl)silane or 1H,1H,2H,2H-perfluorooctyltriethoxysilane, 3-(Diethylamino)propyl-trimethoxysilane.

16. The method according to any one of the preceding claims, in which the anti-electroless plating coating is removed after electroless plating has been performed.

17. The method according to claim 16, wherein the anti-electroless plating coating is removed by plasma etching.

18. A plated substrate obtainable by the method as defined in any one of claims 1 to 17.

19. A plated substrate, which substrate is patterned with an anti-electroless plating coating as defined in any one of claims 1 to 15, and which substrate is plated with metal in areas of the substrate that are not patterned with the anti-electroless plating coating.

20. A substrate for electroless plating, which substrate is patterned with an anti-electroless plating coating as defined in any one of claims 1 to 15.

21. A method for producing a substrate patterned with an anti-electroless plating coating, which method comprises selectively depositing an anti-electroless plating coating as defined in any one of claims 1 to 15 onto the substrate.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0019] FIGS. 1A to 1C illustrate the selective electroless plating method of the invention.

[0020] FIGS. 2 to 4 show cross sections through preferred examples of anti-electroless plating coatings of the invention.

[0021] FIG. 5 shows the Fourier transform infrared (FTIR) spectrum for the coating prepared in Example 1.

[0022] FIG. 6 shows the FTIR spectrum for the coating prepared in Example 2.

[0023] FIG. 7 shows the results from Example 4, in which combs were coated with various multi-layer coatings and then tested for electrical resistance using a liquid (deionised water) drop test. These results demonstrate the ability of the multi-layers tested to act as effective anti-electroless plating coatings.

DETAILED DESCRIPTION OF THE INVENTION

[0024] The present invention is concerned with an electroless plating method, in which a metal is selectively deposited onto specific areas of a substrate. In particular, the substrate on which electroless plating is performed is patterned with an anti-electroless plating coating. As discussed in further detail below, the anti-electroless plating coating of the invention is typically formed by plasma deposition, preferably plasma enhanced chemical vapour deposition (PECVD). The anti-electroless plating coating material prevents deposition of metal in the areas where it is present on the substrate. Metal is thereby selectively deposited onto portions of the substrate that are not patterned with the anti-electroless plating coating.

[0025] Electroless plating Electroless plating techniques are well known to those of skill in the art, and rely upon a redox reaction to deposit metal onto a substrate. The chemistry involved in electroless plating is well known to those of skill in the art, and is described in, for example, Electroless Plating: Fundamentals and Applications, Editors: G. O. Mallory, J. B. Hajdu, American Electroplaters and Surface Finishers Society, 1990.

[0026] Electroless plating involves contacting the substrate to be coated with an electroless plating solution, which typically contains a complexed metal ion and a reducing agent. A mild reducing agent, such as formaldehyde, is preferably used. The reducing agent reduces the metal ions, thereby to produce the metal which is deposited onto portions of the substrate in contact with the solution.

[0027] Electroless plating deposits may be either a pure single elemental metal (<1% impurity or additives), or they may be alloys. Electroless plating is typically used to deposit silver, copper, platinum, gold or nickel. The exact composition of the solution which is contacted with the substrate will depend upon the metal that is to be deposited. A skilled person can readily determine a suitable solution for depositing a given metal. For example: [0028] a typical electroless plating solution for depositing silver comprises complexed silver ions and dimethylamine borane (DMAB) as the reducing agent; [0029] a typical electroless plating solution for depositing copper comprises complexed copper ions and formaldehyde as the reducing agent; [0030] a typical electroless plating solution for depositing platinum or gold comprises complexed platinum or gold ions and a borohydride reducing agent; and [0031] a typical electroless plating solution for depositing nickel or platinum comprises complexed nickel or platinum ions and hydrazine as the reducing agent.

[0032] In most cases, electroless plating methods involve acidic and/or basic pre-cleaning steps, along with several subsequent water rinsing steps. Further to that, often post-treatment steps like water rinsing, anti-oxidation or anti-tarnishing and minor backing may also be involved. The electroless plating process as a whole therefore generally involves the substrate being exposed to acidic, neutral and basic chemistries.

[0033] Depending on the thickness and the metal/alloy to be deposited, the duration of the electroless plating process may vary from few minutes to more than 60 minutes, excluding the pre- and post electroless plating steps discussed above.

[0034] According to the method of the present invention, a substrate which is patterned with an anti-electroless plating coating is used. The anti-electroless plating coating prevents deposition of metal when the substrate is contacted with the electroless plating solution, such that metal is selectively deposited on areas of the substrate that are not patterned with the anti-electroless plating coating.

[0035] After electroless plating has been performed and metal has been deposited on areas of the substrate that are not patterned with the anti-electroless plating coating, it is possible either to leave the anti-electroless plating coating in situ or remove it. It is often desirable to leave the anti-electroless plating coating in situ since it can provide the underlying substrate with chemical, electrical and/or physical protection.

[0036] It can, however, alternatively be desirable to remove the anti-electroless plating coating after electroless plating has been performed. Removal of the anti-electroless plating coating can be achieved by any suitable technique, such as plasma etching. Plasma etching uses plasma species of fluorocarbons, O.sub.2, N.sub.2, Ar, He and/or their different admixtures, such as fluorocarbon/O.sub.2/Ar or fluorocarbon/Ar/N.sub.2, to remove the anti-electroless plating coating.

[0037] Preferably, however, the anti-electroless plating coating is left in situ following electroless plating.

The Anti-Electroless Plating Coating

[0038] The anti-electroless plating coating of the invention comprises multiple layers, each of which is obtainable by plasma deposition of organosilicon compounds. The organosilicon compound(s) can be deposited in the presence or absence of reactive gases and/or non-reactive gases. The resulting layers deposited have general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b, wherein the values of x, y, z, a and b depend upon (a) the specific organosilicon compound(s) used, (b) whether or not a reactive gas is present and the identify of that reactive gas, and (c) whether or not a non-reactive gas is present, and the identify of that non-reactive gas. For example, if no fluorine or nitrogen is present in the organosilicon compound(s) and a reactive gas containing fluorine or nitrogen is not used, then the values of a and b will be 0. As will be discussed in further detail below, the values of x, y, z, a and b can be tuned by selecting appropriate organosilicon compound(s) and/or reactive gases, and the properties of each layer and the overall coating controlled accordingly.

[0039] For the avoidance of doubt, it will be appreciated that each layer of the anti-electroless plating coating may have organic or inorganic character, depending upon the exact precursor mixture, despite the organic nature of the precursor mixtures used to form those layers. In an organic layer of general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b, the values of y and z will be greater than zero, whereas in an inorganic layer of general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b the values of y and z will tend towards zero. The organic nature of a layer can easily be determined by a skilled person using routine analytical techniques, such as by detecting the presence of carbon-hydrogen and/or carbon-carbon bonds using spectroscopic techniques well known to those skilled in the art. For example, carbon-hydrogen bonds can be detected using Fourier transform infrared spectroscopy. Similarly, the inorganic nature of a layer can easily be determined by a skilled person using routine analytical techniques, such as by detecting the absence of carbon-hydrogen and/or carbon-carbon bonds using spectroscopic techniques well known to those skilled in the art. For example, the absence of carbon-hydrogen bonds can be assessed using Fourier transform infrared spectroscopy.

Plasma Deposition Process

[0040] The layers present in the anti-electroless plating coatings of the invention are obtainable by plasma deposition, typically plasma enhanced chemical vapour deposition (PECVD) or plasma enhanced physical vapour deposition (PEPVD), preferably PECVD, of a precursor mixture. The plasma deposition process is typically carried out at a reduced pressure, typically 0.001 to 10 mbar, preferably 0.01 to 1 mbar, for example about 0.7 mbar. The deposition reactions occur in situ on the surface of the electrical assembly, or on the surface of layers that have already been deposited.

[0041] Plasma deposition is typically carried out in a reactor that generates plasma which comprises ionized and neutral feed gases/precursors, ions, electrons, atoms, radicals and/or other plasma generated neutral species. A reactor typically comprises a chamber, a vacuum system, and one or more energy sources, although any suitable type of reactor configured to generate plasma may be used. The energy source may include any suitable device configured to convert one or more gases to a plasma. Preferably the energy source comprises a heater, radio frequency (RF) generator, and/or microwave generator.

[0042] Plasma deposition results in a unique class of materials which cannot be prepared using other techniques. Plasma deposited materials have a highly disordered structure and are generally highly cross-linked, contain random branching and retain some reactive sites. These chemical and physical distinctions are well known and are described, for example in Plasma Polymer Films, Hynek Biederman, Imperial College Press 2004 and Principles of Plasma Discharges and Materials Processing, 2.sup.nd Edition, Michael A. Lieberman, Alan J. Lichtenberg, Wiley 2005.

[0043] Typically, the substrate to which the anti-electroless plating coating is to be applied is placed in the chamber of a reactor and a vacuum system is used to pump the chamber down to pressures in the range of 10.sup.3 to 10 mbar. One or more gases is typically then injected (at controlled flow rate) into the chamber and an energy source generates a stable gas plasma. One or more precursor compounds is typically then be introduced, as gases and/or vapours, into the plasma phase in the chamber. Alternatively, the precursor compound may be introduced first, with the stable gas plasma generated second. When introduced into the plasma phase, the precursor compounds are typically decomposed (and/or ionized) to generate a range of active species (i.e. radicals) in the plasma that is deposited onto and forms a layer on the exposed surface of electrical assembly.

[0044] The exact nature and composition of the material deposited typically depends on one or more of the following conditions (i) the plasma gas selected; (ii) the particular precursor compound(s) used; (iii) the amount of precursor compound(s) [which may be determined by the combination of the pressure of precursor compound(s), the flow rate and the manner of gas injection]; (iv) the ratio of precursor compound(s); (v) the sequence of precursor compound(s); (vi) the plasma pressure; (vii) the plasma drive frequency; (viii) the power pulse and the pulse width timing; (ix) the coating time; (x) the plasma power (including the peak and/or average plasma power); (xi) the chamber electrode arrangement; and/or (xii) the preparation of the incoming assembly.

[0045] Typically the plasma drive frequency is 1 kHz to 4 GHz. Typically the plasma power density is 0.001 to 50 W/cm.sup.2, preferably 0.01 W/cm.sup.2 to 0.02 W/cm.sup.2, for example about 0.0175 W/cm.sup.2. Typically the mass flow rate is 5 to 1000 sccm, preferably 5 to 20 sccm, for example about 10 sccm. Typically the operating pressure is 0.001 to 10 mbar, preferably 0.01 to 1 mbar, for example about 0.7 mbar. Typically the coating time is 10 seconds to >60 minutes, for example 10 seconds to 60 minutes.

[0046] Plasma processing can be easily scaled up, by using a larger plasma chamber. However, as a skilled person will appreciate, the preferred conditions will be dependent on the size and geometry of the plasma chamber. Thus, depending on the specific plasma chamber that is being used, it may be beneficial for the skilled person to modify the operating conditions.

Precursor Compounds

[0047] The anti-electroless plating coatings of the invention comprise layers which are obtainable by plasma deposition of a precursor mixture. The precursor mixture comprises one or more organosilicon compounds, and optionally further comprises a reactive gas (such as O.sub.2) and/or a non-reactive gas (such as Ar). The resulting layers deposited have general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b, wherein the values of x, y, z, a and b depend upon (i) the specific organosilicon compound(s) used, and (ii) whether or not a reactive gas is present and the identify of that reactive gas.

[0048] Typically the precursor mixture consists, or consists essentially, of the one or more organosilicon compounds, the optional reactive gas(es) and the optional non-reactive gas(es). As used herein, the term consists essentially of refers to a precursor mixture comprising the components of which it consists essentially as well as other components, provided that the other components do not materially affect the essential characteristics of the resulting layer formed from the precursor mixture. Typically, a precursor mixture consisting essentially of certain components will contain greater than or equal to 95 wt % of those components, preferably greater than or equal to 99 wt % of those components.

[0049] When the one or more organosilicon compounds are plasma deposited in the absence of an excess of oxygen and nitrogen-containing reactive gas (such as NH.sub.3, O.sub.2, N.sub.2O or NO.sub.2), the resulting layer will be organic in nature and will be of general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b. The values of y and z will be greater than 0. The values of x, a and b will be greater than 0 if O, F or N is present in the precursor mixture, either as part of the organosilicon compound(s) or as a reactive gas.

[0050] When the one or more organosilicon compounds are plasma deposited in the presence of oxygen-containing reactive gas (such as O.sub.2 or N.sub.2O or NO.sub.2), the hydrocarbon moieties in the organosilicon precursor react with the oxygen-containing reactive gas to form CO.sub.2 and H.sub.2O. This will increase the inorganic nature of the resulting layer. If sufficient oxygen-containing reactive gas is present, all of the hydrocarbon moieties maybe removed, such that resulting layer is substantially inorganic/ceramic in nature (in which in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b, y, z, a and b will have negligible values tending to zero). The hydrogen content can be reduced further by increasing RF power density and decreasing plasma pressure, thus enhancing the oxidation process and leading to a dense inorganic layer (in which in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b, x is as high as 2 with y, z, a and b will have negligible values tending to zero).

[0051] Typically, the precursor mixture comprises one organosilicon compound, but it may be desirable under some circumstances to use two or more different organosilicon compounds, for example two, three or four different organosilicon compounds.

[0052] Typically, the organosilicon compound is an organosiloxane, an organosilane, a nitrogen-containing organosilicon compound such as a silazane or an aminosilane, or a halogen-containing organosilicon compound such as a halogen-containing organosilane. The organosilicon compound may be linear or cyclic.

[0053] The organosilicon compound may be a compound of formula (I):

##STR00001##

wherein each of R.sub.1 to R.sub.6 independently represents a C.sub.1-C.sub.6 alkyl group, a C.sub.2-C.sub.6 alkenyl group or hydrogen, provided that at least one of R.sub.1 to R.sub.6 does not represent hydrogen. Preferably, each of R.sub.1 to R.sub.6 independently represents a C.sub.1-C.sub.3 alkyl group, a C.sub.2-C.sub.4 alkenyl group or hydrogen, for example methyl, ethyl, vinyl, allyl or hydrogen, provided that at least one of R.sub.1 to R.sub.6 does not represent hydrogen. Preferably at least two or three, for example four, five or six, of R.sub.1 to R.sub.6 do not represent hydrogen. Preferred examples include hexamethyldisiloxane (HMDSO), tetramethyldisiloxane (TMDSO), 1,3-divinyltetramethyldisiloxane (DVTMDSO) and hexavinyldisiloxane (HVDSO). Hexamethyldisiloxane (HMDSO) and tetramethyldisiloxane (TMDSO) are particularly preferred, with hexamethyldisiloxane (HMDSO) most preferred.

[0054] Alternatively, the organosilicon compound may be a compound of formula (II):

##STR00002##

wherein each of R.sub.7 to R.sub.10 independently represents a C.sub.1-C.sub.6 alkyl group, a C.sub.1-C.sub.6 alkoxy group, a C.sub.2-C.sub.6 alkenyl group, hydrogen, or a (CH.sub.2).sub.1-4NRR group in which R and R independently represent a C.sub.1-C.sub.6 alkyl group, provided that at least one of R.sub.7 to R.sub.10 does not represent hydrogen. Preferably each of R.sub.7 to R.sub.10 independently represents a C.sub.1-C.sub.3 alkyl group, C.sub.1-C.sub.3 alkoxy group, a C.sub.2-C.sub.4 alkenyl group, hydrogen or a (CH.sub.2).sub.2-3NRR group in which R and R independently represent a methyl or ethyl group, for example methyl, ethyl, isopropyl, methoxy, ethoxy, vinyl, allyl, hydrogen or CH.sub.2CH.sub.2CH.sub.2N(CH.sub.2CH.sub.3).sub.2, provided that at least one of R.sub.7 to R.sub.10 does not represent hydrogen. Preferably at least two, for example three or four, of R.sub.7 to R.sub.10 do not represent hydrogen. Preferred examples include allyltrimethylsilane, allyltrimethoxysilane (ATMOS), tetraethylorthosilicate (TEOS), 3-(diethylamino) propyl-trimethoxysilane, trimethylsilane (TMS) and triisopropylsilane (TiPS).

[0055] Alternatively, the organosilicon compound may be a cyclic compound of formula (III):

##STR00003##

wherein n represents 3 or 4, and each of R.sub.11 and R.sub.12 each independently represents a C.sub.1-C.sub.6 alkyl group, a C.sub.2-C.sub.6 alkenyl group or hydrogen, provided that at least one of R.sub.11 and R.sub.12 does not represent hydrogen. Preferably, each of R.sub.11 and R.sub.12 independently represents a C.sub.1-C.sub.3 alkyl group, a C.sub.2-C.sub.4 alkenyl group or hydrogen, for example methyl, ethyl, vinyl, allyl or hydrogen, provided that at least one of R.sub.11 and R.sub.12 does not represent hydrogen. Preferred examples include trivinyl-trimethyl-cyclotrisiloxane (V.sub.3D.sub.3), tetravinyl-tetramethyl-cyclotetrasiloxane (V.sub.4D.sub.4), tetramethylcyclotetrasiloxane (TMCS) and octamethylcyclotetrasiloxane (OMCTS).

[0056] Alternatively, the organosilicon compound may be a compound of formula (IV):

##STR00004##

wherein each of X.sub.1 to X.sub.6 independently represents a C.sub.1-C.sub.6 alkyl group, a C.sub.2-C.sub.6 alkenyl group or hydrogen, provided that at least one of X.sub.1 to X.sub.6 does not represent hydrogen. Preferably each of X.sub.1 to X.sub.6 independently represents a C.sub.1-C.sub.3 alkyl group, a C.sub.2-C.sub.4 alkenyl group or hydrogen, for example methyl, ethyl, vinyl, allyl or hydrogen, provided that at least one of X.sub.1 to X.sub.6 does not represent hydrogen. Preferably at least two or three, for example four, five or six, of X.sub.1 to X.sub.6 do not represent hydrogen. A preferred example is hexamethyldisilazane (HMDSN).

[0057] Alternatively, the organosilicon compound may be a cyclic compound of formula (V):

##STR00005##

wherein m represents 3 or 4, and each of X.sub.7 and X.sub.8 independently represents a C.sub.1-C.sub.6 alkyl group, a C.sub.2-C.sub.6 alkenyl group or hydrogen, provided that at least one of X.sub.7 and Xs does not represent hydrogen. Preferably, each of X.sub.7 and X.sub.8 independently represents a C.sub.1-C.sub.3 alkyl group, a C.sub.2-C.sub.4 alkenyl group or hydrogen, for example methyl, ethyl, vinyl, allyl or hydrogen, provided that at least one of X.sub.7 and X.sub.8 does not represent hydrogen. A preferred example is 2,4,6-trimethyl-2,4,6-trivinylcyclotrisilazane.

[0058] Alternatively, the organosilicon compound may be a compound of formula (VI):

H.sub.a(X.sup.9).sub.bSi(N(X.sup.10).sub.2).sub.4-a-b (VI)

wherein X.sup.9 and X.sup.10 independently represent C.sub.1-C.sub.6 alkyl groups, a represents 0, 1 or 2, b represents 1, 2 or 3, and the sum of a and b is 1, 2 or 3. Typically, X.sup.9 and X.sup.10 represent a C.sub.1-C.sub.3 alkyl group, for example methyl or ethyl. Preferred examples are dimethylamino-trimethylsilane (DMATMS), bis(dimethylamino)dimethylsilane (BDMADMS) and tris(dimethylamino)methylsilane (TDMAMS).

[0059] Alternatively, the organosilicon compound may be a compound of formula (VII):

##STR00006##

wherein each of Y.sub.1 to Y.sub.4 independently represents a C.sub.1-C.sub.8 haloalkyl group, a C.sub.1-C.sub.6 alkyl group, C.sub.1-C.sub.6 alkoxy group, or a C.sub.2-C.sub.6 alkenyl group or hydrogen, provided that at least one of Y.sub.1 to Y.sub.4 represents a C.sub.1-C.sub.8 haloalkyl group. Preferably, each of Y.sub.1 to Y.sub.4 independently represents a C.sub.1-C.sub.3 alkyl group, C.sub.1-C.sub.3 alkoxy group, a C.sub.2-C.sub.4 alkenyl group or a C.sub.1-C.sub.8 haloalkyl group, for example methyl, ethyl, methoxy, ethoxy, vinyl, allyl, trifluoromethyl or 1H,1H,2H,2H-perfluorooctyl, provided that at least one of Y.sub.1 to Y.sub.4 represents a haloalkyl group. Preferred examples are trimethyl(trifluoromethyl)silane and 1H,1H,2H,2H-perfluorooctyltriethoxysilane.

[0060] Preferably the organosilicon compound is hexamethyldisiloxane (HMDSO), tetramethyldisiloxane (TMDSO), 1,3-divinyltetramethyldisiloxane (DVTMDSO), hexavinyldisiloxane (HVDSO allyltrimethylsilane, allyltrimethoxysilane (ATMOS), tetraethylorthosilicate (TEOS), 3-(diethylamino)propyl-trimethoxysilane, trimethylsilane (TMS), triisopropylsilane (TiPS), trivinyl-trimethyl-cyclotrisiloxane (V.sub.3D.sub.3), tetravinyl-tetramethyl-cyclotetrasiloxane (V.sub.4D.sub.4), tetramethylcyclotetrasiloxane (TN/ICS), octamethylcyclotetrasiloxane (OMCTS), hexamethyldisilazane (HMDSN), 2,4,6-trimethyl-2,4,6-trivinylcyclotrisilazane, dimethylamino-trimethylsilane (DMATMS), bis(dimethylamino)dimethylsilane, (BDMADMS), tris(dimethylamino)methylsilane (TDMAMS), trimethyl(trifluoromethyl)silane or 1H,1H,2H,2H-perfluorooctyltriethoxysilane. Hexamethyldisiloxane (HMDSO) and tetramethyldisiloxane (TMDSO) are particularly preferred, with hexamethyldisiloxane (HMDSO) most preferred.

[0061] As used herein, the term C.sub.1-C.sub.6 alkyl embraces a linear or branched hydrocarbon groups having 1 to 6, preferably 1 to 3 carbon atoms. Examples include methyl, ethyl, n-propyl and i-propyl, butyl, pentyl and hexyl.

[0062] As used herein, the term C.sub.2-C.sub.6 alkenyl embraces a linear or branched hydrocarbon groups having 2 or 6 carbon atoms, preferably 2 to 4 carbon atoms, and a carbon-carbon double bond. Preferred examples include vinyl and allyl.

[0063] As used herein, a halogen is typically chlorine, fluorine, bromine or iodine and is preferably chlorine, bromine or fluorine, most preferably fluorine.

[0064] As used herein, the term C.sub.1-C.sub.6 haloalkyl embraces a said C.sub.1-C.sub.6 alkyl substituted by one or more said halogen atoms. Typically, it is substituted by 1, 2 or 3 said halogen atoms. Particularly preferred haloalkyl groups are CF.sub.3 and CCl.sub.3.

[0065] As used herein, the term C.sub.1-C.sub.6 alkoxy group is a said alkyl group which is attached to an oxygen atom. Preferred examples include methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, tert-butoxy, pentoxy and hexoxy.

[0066] The precursor mixture optionally further comprises a reactive gas. The reactive gas is selected from O.sub.2, N.sub.2O, NO.sub.2, H.sub.2, NH.sub.3, N.sub.2, SiF.sub.4 and/or hexafluoropropylene (HFP). These reactive gases are generally involved chemically in the plasma deposition mechanism, and so can be considered to be co-precursors. O.sub.2, N.sub.2O and NO.sub.2 are oxygen-containing co-precursors, and are typically added in order to increase the inorganic character of the resulting layer deposited. This process is discussed above. N.sub.2O and NO.sub.2 are also nitrogen-containing co-precursors, and are typically added in order to increase additionally the nitrogen content of the resulting layer deposited (and consequently the value of b in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b is increased).

[0067] H.sub.2 is a reducing co-precursor, and is typically added in order to reduce the oxygen content (and consequently the value of x in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b) of the resulting layer deposited. Under such reducing conditions, the carbon and hydrogen are also generally removed from the resulting layer deposited (and consequently the values of y and z in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b are also reduced). Addition of H.sub.2 as a co-precursor increases the level of cross-linking in the resulting layer deposited.

[0068] N.sub.2 is a nitrogen-containing co-precursor, and is typically added in order to increase the nitrogen content of the resulting layer deposited (and consequently the value of b in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b is increased).

[0069] NH.sub.3 is also a nitrogen-containing co-precursor, and so is typically added in order to increase the nitrogen content of the resulting layer deposited (and consequently the value of b in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b is increased). However, NH.sub.3 additionally has reducing properties. As with the addition of H.sub.2, this means that when NH.sub.3 is used as a co-precursor, oxygen, carbon and hydrogen are generally removed from the resulting layer deposited (and consequently the values of x, y and z in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b are reduced). Addition of NH.sub.3 as a co-precursor increases the level of cross-linking in the resulting layer deposited. The resulting layer tends towards a silicon nitride structure.

[0070] SiF.sub.4 and hexafluoropropylene (HFP) are fluorine-containing co-precursors, and typically added in order to increase the fluorine content of the resulting layer deposited (and consequently the value of a in the general formula SiO.sub.xH.sub.yC.sub.zF.sub.aN.sub.b is increased).

[0071] A skilled person can easily adjust the ratio of reactive gas to organosilicon compound(s) at any applied power density, in order to achieve the desired modification of the resulting layer deposited.

[0072] The precursor mixture also optionally further comprises a non-reactive gas. The non-reactive gas is He, Ar or Kr. The non-reactive gas is not involved chemically in the plasma deposition mechanism, but does generally influence the physical properties of the resulting material. For example, addition of He, Ar or Kr will generally increase the density of the resulting layer, and thus its hardness. Addition of He, Ar or Kr also increases cross-linking of the resulting deposited material.

Structure and Properties of the Anti-Electroless Plating Coating

[0073] The anti-electroless plating coating of the invention comprises at least two layers. The first, or lowest layer, in the anti-electroless plating coating is in contact with the surface of the substrate. The final, or uppermost layer, in the anti-electroless plating coating is in contact with the environment. When the anti-electroless plating coating comprises more than two layers, then those additional layers will be located between the first/lowest and final/uppermost layers.

[0074] Typically, the anti-electroless plating coating comprises from two to ten layers. Thus, the multilayer coating may have two, three, four, five, six, seven, eight, nine or ten layers. Preferably, the anti-electroless plating coating has from two to eight layers, for example from two to six layers, or from three to seven layers, or from four to eight layers.

[0075] The boundary between each layer may be discrete or graded. In an anti-electroless plating coating that has more than two layers, each boundary between layers may be either discrete or graded. Thus, all of the boundaries may be discrete, or all of the boundaries may be graded, or there may be both discrete and graded boundaries with the coating.

[0076] A graded boundary between two layers can be achieved by switching gradually over time during the plasma deposition process from the precursor mixture required to form the first of the two layers to the precursor mixture required to form the second of the two layers. The thickness of the graded region between the two layers can be adjusted by altering the time period over which the switch from the first precursor mixture to the second precursor mixture occurs. Under some circumstances graded boundaries can be advantageous, as the adhesion between layers is generally increased by a graded boundary.

[0077] A discrete boundary between two layers can be achieved by switching immediately during the plasma deposition process from the precursor mixture required to form the first of the two layers to the precursor mixture required to form the second of the two layers.

[0078] Different layers are deposited by varying the precursor mixture and/or the plasma deposition conditions in order to obtain layers which have the desired properties. The properties of each individual layer are selected such that the resulting multi-layer coating has the desired properties.

[0079] For the avoidance of doubt, all layers of the anti-electroless plating coating of the invention are obtainable by plasma deposition of precursor mixtures as herein defined which contain one or more organosilicon compounds. Thus, the anti-electroless plating coatings of the invention do not contain other layers which are not obtainable from precursor mixtures as herein defined, such as metallic or metal oxide layers.

Properties of First/Lowest Layer

[0080] It is generally desirable for the anti-electroless plating coating to show good adhesion, both to the surface of the substrate and between layers within the coating. This is desirable so that the anti-electroless plating coating is robust during use. Adhesion can be tested using tests known to those skilled in the art, such as a Scotch tape test or a scratch adhesion test.

[0081] It is preferable, therefore, that the first/lowest layer of the anti-electroless plating coating, which is in contact with the substrate, is formed from a precursor mixture that results in a layer that adheres well to that substrate. The exact precursor mixture that is required will depend upon the specific material(s) from which the substrate is made, and a skilled person will be able to adjust the precursor mixture accordingly. However, layers which are organic in character typically adhere best to the surface of the substrate. Layers which contain no, or substantially no, fluorine also typically adhere best to the surface of the substrate.

[0082] Typically, therefore, the first/lowest layer of the anti-electroless plating coating is organic. A layer with organic character can be achieved by using a precursor mixture that contains no, or substantially no, oxygen-containing reactive gas (i.e. no, or substantially no, or O.sub.2, N.sub.2O or NO.sub.2). It is thus preferable that the first/lowest layer of the anti-electroless plating coating is deposited using a precursor mixture that contains no, or substantially no, O.sub.2, N.sub.2O or NO.sub.2.

[0083] As used herein, the reference to a precursor mixture containing substantially no specified component(s) refers to a precursor mixture that may contain trace amounts of the specified component(s), provided that the specified component(s) do not materially affect the essential characteristics of the resulting layer formed from the precursor mixture. Typically, therefore a precursor mixture that contains substantially no specified component(s) contains less than 5 wt % of the specified component(s), preferably less than 1 wt % of the specified component(s), most preferably less than 0.1 wt % of the specified component(s).

[0084] A layer which contains no, or substantially no, fluorine can be achieved by using a precursor mixture that contains no, or substantially no, fluorine-containing organosilicon compound and no, or substantially no, fluorine-containing reactive gas (ie. no, or substantially no, SiF.sub.4 or HFP). It is thus preferable that the first/lowest layer of the anti-electroless plating coating is deposited using a precursor mixture that contains no, or substantially no, fluorine-containing organosilicon compound, SiF.sub.4 or HFP.

[0085] Accordingly, it is particularly preferred that the first/lowest layer of the anti-electroless plating coating is deposited using a precursor mixture that contains no, or substantially no, O.sub.2, N.sub.2O, NO.sub.2, fluorine-containing organosilicon compound, SiF.sub.4 or HFP. The resulting coating will be organic in character and contain no fluorine, and so will adhere well to the surface of the substrate.

[0086] It is also generally desirable for the first/lowest layer of the anti-electroless plating coating to be capable of absorbing any residual moisture present on the substrate prior to deposition of the coating. The first/lowest layer will then generally retain the residual moisture within the coating, and thereby reduce the nucleation of corrosion and erosion sites on the substrate.

Properties of the Final/Uppermost Layer

[0087] It is generally desirable for the final/uppermost layer of the anti-electroless plating coating, that is to say the layer that is exposed to the environment, to be anti-corrosive and chemically stable, and thus resistant to immersion in acidic or basic solutions, or solvents such as acetone, ethanol, methanol or isopropyl alcohol (IPA). These are the conditions to which a substrate is exposed during a typical electroless plating process. It is thus preferred that the final/uppermost layer of the anti-electroless plating coating has high chemical resistance.

[0088] The chemical resistance of a layer or coating can be readily determined by a skilled person. For example, the techniques described below in the Examples can be used, in which the layer/coating is wiped with the test solution/solvent and then immersed in the test solution/solvent, which inspection of the integrity of the layer/coating after each step. Suitable test solutions/solvents include acidic and basic solutions at different pH, typically an electroless plating solution with or without the complex metal ions present. Integrity of the layer/coating can be checked by any suitable means, such as via inspection under microscope, FT-IR analysis or thickness reduction after immersion in solutions. Alternatively or additionally, the effectiveness of a layer/coating can be checked by inspecting (typically via optical methods such as microscopy) whether metal was deposited in areas coated by the anti-electroless plating coating following electroless plating.

[0089] For the Si-based material in the present invention, a layer with organic character will typically show high levels of chemical resistance coupled with hydrophobicity. Organic character can be achieved by using a precursor mixture that contains no, or substantially no, oxygen-containing reactive gas (i.e. no, or substantially no, or O.sub.2, N.sub.2O or NO.sub.2). Typically, therefore, the final/uppermost layer of the anti-electroless plating coating is organic. It is thus preferable that the final/uppermost layer of the anti-electroless plating coating is deposited using a precursor mixture that contains no, or substantially no, O.sub.2, N.sub.2O or NO.sub.2. The pre-cursor mixture may optionally contain a halogen-containing organosilicon compound, SiF.sub.4 and/or HFP, thereby increasing the fluorine-content of the layer, which typically further increases chemical resistance.

[0090] It is also generally desirable for the final/uppermost layer of the anti-electroless plating coating to be hydrophobic. Hydrophobicity can be determined by measuring the water contact angle (WCA) using standard techniques. Typically, the WCA of the final/uppermost layer of the multi-layer coating is >90, preferably from 95 to 115, more preferably from 100 to 110.

[0091] The hydrophobicity of a layer can be modified by adjusting the precursor mixture. For example, a layer which has organic character will generally be hydrophobic. As noted above, a layer with organic character can be achieved, for example, by using a precursor mixture that contains no, or substantially no, oxygen-containing reactive gas (i.e. no, or substantially no, or O.sub.2, N.sub.2O or NO.sub.2). As discussed above, if an oxygen-containing gas is present a significant amount in the precursor mixture, the organic character and thus hydrophobicity of the resulting layer will be reduced. It is thus preferable that the final/uppermost layer of the anti-electroless plating coating is deposited using a precursor mixture that contains no, or substantially no, O.sub.2, N.sub.2O or NO.sub.2.

[0092] The hydrophobicity of a layer can also be increased by using a halogen-containing organosilicon compound, such as the compounds of formula VII defined above. With such a precursor, the resulting layer will contain halogen atoms and will generally be hydrophobic. Halogen atoms can also be introduced by including SiF.sub.4 or HFP as a reactive gas in the precursor mixture, which will result in the inclusion of fluorine in the resulting layer. It is thus preferable that the final/uppermost layer of the anti-electroless plating coating is deposited using a precursor mixture that comprises a halogen-containing organosilicon compound, SiF.sub.4 and/or HFP, typically in addition to the components discussed above for achieving organic character.

[0093] It is also generally desirable for the final/uppermost layer of the anti-electroless plating coating to be oleophobic. Generally, a layer that is hydrophobic will also be oleophobic. This is particularly the case for fluorine-containing coatings. Thus, if the water contact angle (WCA) of the final/uppermost layer of the anti-electroless plating coating is greater than 100, then the coating will be oleophobic. A WCA of greater than 105 is preferred for increased oleophobic properties.

[0094] It is also generally desirable for the final/uppermost layer of the anti-electroless plating coating to have a hardness of at least 0.5 GPa, preferably at least 1 GPa, more preferably at least 2 GPa, most preferably at least 4 GPa. The hardness is typically no greater than 11 GPa. Hardness can be measured by nanohardness tester techniques known to those skilled in the art. The hardness of a layer can be modified by adjusting the precursor mixture, for example to include a non-reactive gas such as He, Ar and/or Kr. This results in a layer which is denser and thus harder. It is thus preferably that the final/uppermost layer of the anti-electroless plating coating is deposited using a precursor mixture that comprises He, Ar and/or Kr.

[0095] It is also possible to adjust the hardness by modifying the plasma deposition conditions. Thus, reducing the pressure at which deposition occurs generally results in a layer which is denser and thus harder. Increasing the RF power generally results in a layer which is denser and thus harder. These conditions and/or the precursor mixture can be readily adjusted to achieve a desired hardness as set out above.

[0096] It will be appreciated from the above discussion that it is generally preferred that the final/uppermost layer of the anti-electroless plating coating is not inorganic, since the properties of such coatings are generally less favourable than coatings in which the final/uppermost layer is organic. When the anti-electroless plating coating has two or three layers, it is particularly preferred that the final/uppermost layer is not inorganic (ie. the final/uppermost layer is organic). However, when the anti-electroless plating coating contains four or more layers, the differences in properties between coatings with an inorganic final/uppermost layer and coatings with an organic final/uppermost layer are generally less significant, and indeed it can be desirable to have a final/uppermost layer that is not organic under those circumstances to provide increased hardness.

Moisture Barrier Properties

[0097] It is desirable for the anti-electroless plating coating to act as a moisture barrier, so that electroless plating solution cannot breach the coating and damage the underlying substrate. The moisture barrier properties of the anti-electroless plating coating can be assessed by measuring the water vapour transmission rate (WVTR) using standard techniques, such as a MOCON test. Typically, the WVTR of the anti-electroless plating coating is from 10 g/m.sup.2/day down to 0.001 g/m.sup.2/day.

[0098] Typically, the moisture barrier properties of the anti-electroless plating coating may be enhanced by inclusion of at least one layer which has a WVTR of from 0.5 g/m.sup.2/day down to 0.1 g/m.sup.2/day. This moisture barrier layer is typically not the first/lowest or final/uppermost layer of the anti-electroless plating coating. Several moisture barrier layers may be present in the anti-electroless plating coating, each of which may have the same or different composition.

[0099] Generally, layers which are substantially inorganic in character and contain very little carbon are the most effective moisture barriers. Such layers can be obtained by, for example, plasma deposition of a precursor mixture that comprises an organosilicon compound and an oxygen-containing reactive gas (ie. O.sub.2, N.sub.2O or NO.sub.2). Addition of a non-reactive gases such as He, Ar or Kr, use of a high RF power density and/or reducing the plasma pressure will also assist in forming a layer with good moisture barrier properties.

[0100] It is therefore preferred that at least one layer of the anti-electroless plating coating is obtainable by plasma deposition of a precursor mixture comprising an organosilicon compound and O.sub.2, N.sub.2O and/or NO.sub.2, and preferably also He, Ar and/or Kr. Preferably the precursor mixture consists, or consists essentially, of these components.

[0101] A layer containing nitrogen atoms will also typically have desirable moisture barrier properties. Such a layer can be obtained by using a nitrogen-containing organosilicon compound, typically a silazane or aminosilane precursor, such as the compounds of formula (IV) to (VI) defined above. Nitrogen atoms can also be introduced by including N.sub.2, NO.sub.2, N.sub.2O or NH.sub.3 as a reactive gas in the precursor mixture. Preferably the precursor mixture consists, or consists essentially, of these components.

[0102] It is therefore also preferred that at least one layer of the anti-electroless plating coating is obtainable by plasma deposition of a precursor mixture comprising a nitrogen-containing organosilicon compound, N.sub.2, NO.sub.2, N.sub.2O and/or NH.sub.3. Preferably the precursor mixture consists, or consists essentially, of these components.

Other Properties

[0103] The thickness of the anti-electroless plating coating of the present invention will depend upon the number of layers that are deposited, and the thickness of each layer deposited.

[0104] Typically, the first/lowest layer and the final/uppermost layer have a thickness of from 0.05 m to 5 m. Typically, any layers present between the first/lowest layer and the final/uppermost layer have a thickness of from 0.1 m to 5 m.

[0105] The overall thickness of the anti-electroless plating coating is of course dependent on the number of layers, but is typically from 0.1 m to 20 m, preferably from 0.1 m to 5 m.

[0106] The thickness of each layer can be easily controlled by a skilled person. Plasma processes deposit a material at a uniform rate for a given set of conditions, and thus the thickness of a layer is proportional to the deposition time. Accordingly, once the rate of deposition has been determined, a layer with a specific thickness can be deposited by controlling the duration of deposition.

[0107] The thickness of the anti-electroless plating coating and each constituent layer may be substantially uniform or may vary from point to point, but is preferably substantially uniform.

[0108] Thickness may be measured using techniques known to those skilled in the art, such as a profilometry, reflectometry or spectroscopic ellipsometry.

[0109] Adhesion between layers of the anti-electroless plating coating can be improved, where necessary, by introducing a graded boundary between layers, as discussed above. Graded boundaries are particularly preferred for layers which contain fluorine, since these tend to exhibit poor adhesion. Thus, if a given layer contains fluorine, it preferably has a graded boundary with the adjacent layer(s).

[0110] Alternatively, where necessary, discrete layers within the anti-electroless plating coating can be chosen such that they adhere well to the adjacent layers within the coating.

The Substrate and Patterning Thereof with the Anti-Electroless Plating Coating

[0111] The substrate can be part of any object, or the whole of any object, onto which it is desirable to deposit metal by electroless plating.

[0112] Electroless plating has been used for many decades to provide a hard, corrosion resistant surface finish to engineering components. Its application has been extended to the electronics industry for the production of solderable surfaces on printed circuit boards, where the use of flip-chip technology has required the development of low-cost methods for solder bumping of semiconductor wafers. Recently, electroless plating has also been utilized in the creation of microelectronics, such as microelectromechanical systems. The substrate used in the electroless plating technique of the invention may therefore be metal or plastic, for example as part of a printed circuit board, or a MEMS device or electronic chip.

[0113] The substrate is contacted with the electroless plating solution during the electroless plating method. Thus, part of the object, or the whole of the object, onto which it is desirable to deposit metal by electroless plating is contacted with the electroless plating solution during the electroless plating method.

[0114] Prior to conducting the electroless plating technique of the invention, it is necessary to first deposit the anti-electroless plating coating onto the substrate. The substrate is patterned with the anti-electroless plating coating, such that the areas of the substrate where it is desired for metal to be deposited remain uncoated, whilst areas of the substrate where deposition of metal is undesirable and/or unnecessary are coated.

[0115] A substrate patterned with the anti-electroless plating coating of the invention can be prepared in a number of different ways. For example, a mask can be applied to the substrate prior to plasma deposition of the anti-electroless plating coating. The masks that are used in a gas-based plasma deposition technique are much easier to apply than the masks that are required in a traditional liquid-based deposition technique. The mask can then be removed after plasma deposition is complete, leaving the substrate patterned with the anti-electroless plating coating. Alternatively, the anti-electroless plating coating could be applied unselectively to the entire substrate, and then selectively removed, leaving the substrate patterned with the anti-electroless plating coating. Selective removal can be achieved by any suitable technique, such as plasma etching.

DETAILED DESCRIPTION OF THE FIGURES

[0116] Aspects of the invention will now be described with reference to the embodiment shown in FIGS. 1 to 4, in which like reference numerals refer to the same or similar components.

[0117] FIGS. 1A to 1C illustrate the selective electroless plating method of the invention. FIG. 1A depicts a substrate 1 for electroless plating, which substrate is patterned with anti-electroless plating coating 2. Portions 3 of the substrate are not patterned with the anti-electroless plating coating. The patterned substrate is then contacted with an electroless plating solution, and the resulting plated substrate is depicted in FIG. 1B. In FIG. 1B metal 4 is deposited by electroless plating onto portions 3 of the substrate 1 that are not patterned with the anti-electroless plating coating 2. FIG. 1B thus depicts a plated substrate, which substrate 1 is patterned with an anti-electroless plating coating 2, and which substrate is plated with metal 4 in areas 3 of the substrate 1 that are not patterned with the anti-electroless plating coating 2. Although anti-electroless plating coating 2 is generally left in situ following electroless plating, since it provides protection to the underlying substrate, it is also possible to remove anti-electroless plating coating 2 after electroless plating has been performed. FIG. 1C depicts the resulting plated substrate, in which the metal 4 remains plating the substrate, whilst anti-electroless plating coating 2 is absent following its removal.

[0118] FIG. 2 shows a cross section through a preferred example of the anti-electroless plating coating 2 in FIG. 1. The anti-electroless plating coating 2 has a first/lowest layer 5 which is in contact with substrate 1, and a final/uppermost layer 6. This anti-electroless plating coating 2 has two layers 5 and 6, and the boundary between the layers 5 and 6 is discrete.

[0119] FIG. 3 shows a cross section through another preferred example of the anti-electroless plating coating 2 in FIG. 1. The anti-electroless plating coating 2 has a first/lowest layer 5 which is in contact with substrate 1, and a final/uppermost layer 6. Between layers 5 and 6 are two further layers 7 and 8. This anti-electroless plating coating 2 has four layers 5, 6, 7, and 8, and the boundary between the layers 5, 6, 7, and 8 is discrete.

[0120] FIG. 4 shows a cross section through another preferred example of the anti-electroless plating coating 2 in FIG. 1. The anti-electroless plating coating 2 has a first/lowest layer 5 which is in contact with the substrate 1, and a final/uppermost layer 6. This anti-electroless plating coating 2 has two layers 5 and 6, and the boundary 9 between layers 5 and 6 is graded.

EXAMPLES

[0121] Aspects of the invention will now be described with reference to the Examples below.

Example 1Deposition of a Single SiO.SUB.x.C.SUB.y.H.SUB.z .Layer

[0122] A substrate was placed into a plasma-enhanced chemical vapour deposition (PECVD) deposition chamber, and the pressure was then brought to <10.sup.3 mbar. He was injected at a flow rate resulting in a chamber pressure of 0.480 mbar, then it was increased (by means of a throttle valve) to 0.50 mbar. Plasma was ignited at RF power density of 0.573 W cm.sup.2 for 3-5 seconds. Next, HMDSO was injected into the chamber at a flow rate of 6 sccm and RF power density was at 0.225, 0.382, 0.573 or 0.637 Wcm.sup.2 for 20 minutes. Pressure was kept (through a throttle valve) at 0.5 mbar during the deposition process.

[0123] Polymeric organosilicon SiO.sub.xC.sub.yH.sub.z layers were obtained on the substrate. The FT-IR transmission spectra for the layer obtained using an RF power density of 0.637 Wcm.sup.2 is shown in FIG. 5.

[0124] The SiO.sub.xC.sub.yH.sub.z layers showed hydrophobic character with a WCA (water contact angle) of 100.

[0125] Layers deposited at 0.637 Wcm.sup.2 as described were tested for chemical resistance against organic solvents (namely isopropyl alcohol [IPA] and acetone) and aqueous acid and basic solutions. The acid solutions were aqueous HCl solutions with the following pHs: 6; 5; 4; 3; 2; and 1. The basic solutions were aqueous NaOH with the following pHs: 8; 9; 10; 11; 12; and 13.

[0126] The layers were wiped first with the above-mentioned solvents and solutions by rubbing a cotton bud (wet with the solvents/solutions) on the surface of the layer. The layers were secondly immersed in the above-mentioned solvents and solutions. In both tests, the layers did not show any signs of delamination, scratching or damage.

[0127] Electrical assemblies have been also coated with the above described layers in order to test their electric resistance/H.sub.2O barrier properties. The coated substrates (combs and pads) were immersed into deionized (DI) water and 5 V were applied into the circuit. The results are set out in Table 1 below.

TABLE-US-00001 TABLE 1 RF Thickness Electrical feature power of Comb A Comb A Comb B Comb B Pads Pads density coating R () at R () at R () at R () at R () at R () at (Wcm.sup.2) (nm) 1 1 1 1 1 1 0.225 550 5.56E+08 3.00E+08 1.72E+08 7.63E+07 6.98E+10 1.25E+10 0.382 680 1.61E+07 4.56E+07 1.93E+07 4.05E+07 9.00E+09 2.93E+12 0.573 1170 1.61E+07 4.56E+07 1.93E+07 4.05E+07 9.00E+09 2.93E+12 0.637 1260 1.56E+08 1.02E+08 1.16E+08 6.99E+07 3.53E+10 3.37E+12

Example 2Deposition of Single SiO.SUB.x.H.SUB.z .Layer

[0128] A substrate was placed into a PECVD deposition chamber, and the pressure was then brought to <10.sup.3 mbar. Against this base pressure, O.sub.2 was inject up to 0.250 mbar of chamber pressure. After that, He was injected in order to reach a chamber pressure of 0.280 mbar. Finally, HMDSO was injected at a flow rate of 2.5 sccm and pressure was increased (by means of throttle valve) to 0.300 mbar. Plasma was then ignited with a power density of 0.892 Wcm.sup.2 and the process was continued until the desired thickness of approximate 750 nm was achieved. A SiO.sub.xH.sub.z layer was obtained with FT-IR transmission spectrum as shown in FIG. 6. The SiO.sub.xH.sub.z layer showed hydrophilic character with a WCA 50.

[0129] The SiO.sub.xH.sub.z layers were tested for chemical resistance as described in Example 1, and again passed both tests.

Example 3Deposition of SiO.SUB.x.C.SUB.y.H.SUB.z./SiO.SUB.x.H.SUB.z .Multilayer

[0130] The experimental conditions leading to the PECVD deposition of the SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z multilayers on substrates were basically the same as described in Examples 1 and 2. Briefly, SiO.sub.xC.sub.yH.sub.z was deposited with the same procedure explained in Example 1 (RF power density used for this experiment was 0.637 Wcm.sup.2), then chamber was brought to vacuum (<10.sup.3 mbar) and the deposition of SiO.sub.xH.sub.z, on top of the SiO.sub.xC.sub.yH.sub.z layer, was performed according to the procedure explained in Example 2. Then, a second SiO.sub.xC.sub.yH.sub.z layer was deposited on top of the SiO.sub.xH.sub.z layer. The thickness of the second SiO.sub.xC.sub.yH.sub.z layer was half that of the first SiO.sub.xC.sub.yH.sub.z layer. This was achieved by halving the deposition time. These steps resulted in multilayer coating with the structure: SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/SiO.sub.xC.sub.yH.sub.z.

[0131] The process was then repeated on some substrates in order to add a second pair of SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z layer, thereby giving the structure: SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/SiO.sub.xC.sub.yH.sub.z.

[0132] Both multilayers were tested for chemical resistance as described in Example 1, and again passed both tests.

[0133] Substrates coated with these two multilayers were tested for electrical resistance while immersed into DI water by applying 5 V into the circuit. The results are listed in Table 2 below.

TABLE-US-00002 TABLE 2 Electrical feature Comb A Comb A Comb B Comb B Pads Pads Multilayer R () at R () at R () at R () at R () at R () at structure 1 1 1 1 1 1 SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/ 6.48E+08 2.03E+08 2.39E+10 1.71E+09 8.66E+11 1.55E+12 SiO.sub.xC.sub.yH.sub.z SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/ 2.57E+10 6.64E+10 5.24E+09 8.15E+09 1.78E+12 1.43E+12 SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/ SiO.sub.xC.sub.yH.sub.z

[0134] The performances of the multilayers were tested also the following way. A 5V potential was applied across the coated electrical assemblies, which were immersed in a sweat solution. A failure was recorded when the current leakage across the coating reached 50 A. The results are set out below in Table 3

TABLE-US-00003 TABLE 3 Electrical feature Comb A Comb B Pads Pads Time to Time to Time to Time to Multilayer failure failure failure failure structure (min) (min) (min) (min) SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/ 6.9 19.9 6.9 6.95 SiO.sub.xC.sub.yH.sub.z SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/ 65.7 32.9 291.4 327.1 SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.z/ SiO.sub.xC.sub.yH.sub.z

Example 4Assessment of Properties of Coatings

[0135] Conformal coatings were deposited onto combs under the conditions set out below.

1. Deposition Conditions for SiO.SUB.x .Coating

[0136] Against a base pressure of 10.sup.3 mbar, O.sub.2 was inject up to 0.250 mbar of chamber pressure. After that, He was injected in order to reach a chamber pressure of 0.280 mbar. HMDSO was added at flow rate of 2.5 sccm. Pressure was set to 0.280 mbar. Plasma was ignited at a power density of 0.892 Wcm.sup.2.

2. Deposition Conditions for SiO.sub.xC.sub.yH.sub.z Coating

[0137] Against a base pressure of 10.sup.3 mbar, He was injected at a flow rate resulting in a chamber pressure of 0.480 mbar, then the pressure was increased (by means of a throttle valve) to 0.50 mbar. Plasma was ignited at RF power density of 0.573 Wcm.sup.2 for 3-5 seconds. Next, HMDSO was injected into the chamber at a flow rate of 6 sccm together and RF power density of 0.637 Wcm.sup.2.

3. Deposition Conditions for SiO.sub.xC.sub.yH.sub.z/SiO.sub.x Coating

[0138] An SiO.sub.xC.sub.yH.sub.z layer was deposited as described in paragraph 2 above. Then the deposition chamber was evacuated and the SiO.sub.x layer was deposited on top of the SiO.sub.xC.sub.yH.sub.z layer as described in paragraph 1 above.

4. Deposition Conditions for SiO.sub.xC.sub.yH.sub.z/SiO.sub.x/SiO.sub.xC.sub.yH.sub.z Coating

[0139] An SiO.sub.xC.sub.yH.sub.z layer was deposited as described in paragraph 2 above. Then the deposition chamber was evacuated and the SiO.sub.x coating was deposited on top of the SiO.sub.xC.sub.yH.sub.z layer with the same conditions as described in paragraph 1 above (except for the fact that HMDSO and He mixture was injected and RF plasma was ignited directly at a power density of 0.637 Wcm.sup.2). Finally, the deposition chamber was evacuated and a second SiO.sub.xC.sub.yH.sub.z layer was deposited on top of the SiO.sub.x layer with the conditions described in paragraph 2 above.

5. Deposition of SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.yC.sub.zN.sub.b/SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.yC.sub.zN.sub.b/SiO.sub.xC.sub.yH.sub.z Coating

[0140] The SiO.sub.xC.sub.yH.sub.z layers were deposited by mixing 17.5 sccm of HMDSO with 20 sccm of Ar at a RF power density of 0.057 Wcm.sup.2, while the SiO.sub.xH.sub.yC.sub.zN.sub.b layers were deposited by mixing 17.5 sccm of HMDSO with 15 sccm of N.sub.2O at a RF power density of 0.057 Wcm.sup.2.

6. Deposition Conditions for SiO.sub.xH.sub.yC.sub.zF.sub.a Layer

[0141] A SiO.sub.xC.sub.yH.sub.zF.sub.a layer was deposited by mixing 17.5 sccm of HMDSO with 20 sccm of HPF at a RF power density of 0.057 Wcm.sup.2.

[0142] The coated combs were then tested as follows. Water was placed on the coated combs and power was then applied across the poles of the coated combs. Electrical resistance was measured over time, with a high resistance indicating that the coating was intact and that no current was following. As soon as the coating started leaking water, current started to pass between the poles of the component and resistance decreased. Coating failure was deemed to have occurred when resistance fell below 10.sup.8.

[0143] The results of this test are depicted in FIG. 7. The SiO.sub.xC.sub.yH.sub.z/SiO.sub.x/SiO.sub.xC.sub.yH.sub.z coating performed well (see the black circles), with a high resistance throughout the duration of the test. The SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.yC.sub.zN.sub.b/SiO.sub.xC.sub.yH.sub.z/SiO.sub.xH.sub.yC.sub.zN.sub.b/SiO.sub.xC.sub.yH.sub.z also performed well (see the black stars), with an even higher resistance throughout the duration of the test. The three single layer coatings (SiO.sub.x [black squares], SiO.sub.xC.sub.yH.sub.z [unshaded triangles] and SiO.sub.xH.sub.yC.sub.zF.sub.a [diamonds]) failed, with resistance either starting below 10.sup.8 (for the SiO.sub.x layer) or decreasing to under 10.sup.8 during the duration of the test (for the SiO.sub.xC.sub.yH.sub.z and SiO.sub.xH.sub.yC.sub.zF.sub.a layers).

[0144] The SiO.sub.xC.sub.yH.sub.z/SiO.sub.x two layers coating (unshaded squares) also failed in this test, performing less well than the SiO.sub.xC.sub.yH.sub.z single layer coating. It was notable that addition of a further SiO.sub.xC.sub.yH.sub.z layer on top of the SiO.sub.xC.sub.yH.sub.z/SiO.sub.x coating greatly improved its performance as discussed above. It is believed that whilst a SiO.sub.x layer as the top layer of the coating may result in reduced performance under some conditions for coatings with low numbers of layers (such as SiO.sub.xC.sub.yH.sub.z/SiO.sub.x), such a reduction in performance is unlikely to be observed when there are higher number of layers in the coating.