METHOD OF FORMING A METAL LAYER AND METHOD OF MANUFACTURING A SUBSTRATE HAVING SUCH METAL LAYER

Abstract

In a substrate like a printed circuit board comprising an insulator and a copper layer laminated on part of the insulator, the insulator outer surface and the copper layer outer surface are simultaneously subjected to (1) a process including treatment with an alkali metal hydroxide solution, (2) a process including treatment with an alkaline aqueous solution containing an aliphatic amine, (3) a process including treatment with an alkaline aqueous solution having a permanganate concentration of 0.3 to 3.5 wt % and a pH of 8 to 11, (4) a process including treatment with an acidic microemulsion aqueous solution containing a thiophene compound and an alkali metal salt of polystyrenesulphonic acid, and (5) a process including copper electroplating, which are implemented sequentially.

Claims

1. A method of forming a metal layer on an insulator outer surface and on a copper layer outer surface of a substrate comprising an insulator and said copper layer laminated on part of the insulator, characterised in that simultaneously said insulator outer surface and the copper layer outer surface are subjected to (1) a process comprising treatment with an alkali metal hydroxide solution, (2) a process comprising treatment with an alkaline aqueous solution containing an aliphatic amine, (3) a process comprising treatment with an alkaline aqueous solution having a permanganate concentration of 0.3 to 3.5 wt % and a pH of 8 to 11, (4) a process comprising treatment with an acidic microemulsion aqueous solution containing a thiophene compound and an alkali metal salt of polystyrenesulphonic acid, and (5) a process comprising copper electroplating, which (1)-(5) are implemented sequentially.

2. The method of forming a metal layer according to claim 1, characterised in that after the abovementioned (3) process comprising treatment with an alkaline aqueous solution having a permanganate concentration of 0.3 to 3.5 wt % and a pH of 8 to 11, (3) a process comprising treatment with an acidic aqueous solution is performed, and the processes from (4) onward are implemented sequentially.

3. The method of forming a metal layer according to claim 1, characterised in that the insulator is a polyimide resin or an epoxy resin.

4. The method of forming a metal layer according to claim 1, characterised in that the contact angle of the insulator outer surface after the abovementioned (1) treatment with an alkali metal hydroxide solution is 15 to 55.

5. The method of forming a metal layer according to claim 1, characterised in that the pH of the alkaline aqueous solution containing an aliphatic amine in the abovementioned (2) is in the range of 9 to 13.

6. The method of forming a metal layer according to claim 2, characterised in that the pH of the acidic aqueous solution in the abovementioned (3) is in the range of 3.0 to 5.5.

7. The method of forming a metal layer according to claim 1, characterised in that the substrate is an electronic substrate having a metal layer circuitry structure.

8. The method of forming a metal layer according to claim 7 characterised in that the electronic substrate is an IC substrate, a printed circuit board or lead frame.

9. The method of forming a metal layer according to claim 7 characterised in that the electronic substrate is a multilayer printed circuit board.

10. A method of manufacturing a printed circuit board characterised in that a board comprising an insulator sheet and a copper layer laminated onto both sides of said insulator sheet is used, holes penetrating through from the front to the back of said board are provided, an electrically conductive polymer layer is provided on insulator wall surfaces of said through holes by means of processes (1) to (4) of the method of forming a metal layer according to claim 1, after which a patterned mask is formed on the copper layer on the insulator sheet outer surface using a photolithographic method, the copper layer not covered by said patterned mask and the insulator wall surfaces in the through holes are subjected to copper plating by means of the copper electroplating process (5), and after the patterned mask has been removed only the copper layer portion that was not covered by the patterned mask is removed by etching, thereby forming a patterned circuit and forming a layer of copper plating on the through hole wall surfaces.

11. A method of manufacturing a printed circuit board characterised in that a board comprising an insulator sheet and a copper layer laminated onto both sides of said insulator sheet is used, holes penetrating through from the front to the back of said board are provided, an electrically conductive polymer layer is provided on insulator wall surfaces of said through holes by means of processes (1) to (4) of the method of forming a metal layer according to claim 1, the through holes and the copper layer provided with an electrically conductive polymer layer are subjected to copper plating by means of the copper electroplating process (5), after which a patterned mask is formed on the layer of copper plating using a photolithographic method, the portion of the layer of copper plating not covered by the patterned mask is removed by etching and the patterned mask is removed, thereby forming a patterned circuit and forming a layer of copper plating on the through hole wall surfaces.

12. The method of manufacturing a printed circuit board according to claim 10, characterised in that after the patterned circuit has been formed on the copper layer, plating is performed using tin, nickel, palladium, silver, gold, platinum or alloys thereof, individually or in combination.

13. The method of manufacturing a printed circuit board according to claim 11, characterised in that after the patterned circuit has been formed on the copper layer, plating is performed using tin, nickel, palladium, silver, gold, platinum or alloys thereof, individually or in combination.

14. The method of forming a metal layer according to claim 2, characterised in that the contact angle of the insulator outer surface after the abovementioned (1) treatment with an alkali metal hydroxide solution is 15 to 55.

15. The method of forming a metal layer according to claim 2, characterised in that the pH of the alkaline aqueous solution containing an aliphatic amine in the abovementioned (2) is in the range of 9 to 13.

16. The method of forming a metal layer according to claim 4, characterised in that the pH of the alkaline aqueous solution containing an aliphatic amine in the abovementioned (2) is in the range of 9 to 13.

17. The method of forming a metal layer according to claim 4, characterised in that the pH of the acidic aqueous solution in the abovementioned (3) is in the range of 3.0 to 5.5.

18. The method of forming a metal layer according to claim 5, characterised in that the pH of the acidic aqueous solution in the abovementioned (3) is in the range of 3.0 to 5.5.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] [FIG. 1] Schematic diagram of a subtractive process and a semi-additive process according to the present invention

[0021] [FIG. 2] Outline diagram of a test coupon

[0022] [FIG. 3] Schematic diagram of a printed circuit board

[0023] [FIG. 4] Schematic diagram of a printed circuit board having a blind hole.

DETAILED DESCRIPTION

[0024] In order to solve the abovementioned problems, the present invention is characterised in that, in a substrate like a printed circuit board comprising an insulator and a copper layer laminated on part of the insulator, said insulator outer surface and said copper layer outer surface are simultaneously subjected to (1) a process comprising treatment with an alkali metal hydroxide solution, (2) a process comprising treatment with an alkaline aqueous solution containing an aliphatic amine, (3) a process comprising treatment with an alkaline aqueous solution having a permanganate concentration of 0.3 to 3.5 wt % and a pH of 8 to 11, (4) a process comprising treatment with an acidic microemulsion aqueous solution containing a thiophene compound and an alkali metal salt of polystyrenesulphonic acid, and (5) a process comprising copper electroplating, which are implemented sequentially.

[0025] Further, treatment with an acidic aqueous solution is performed after the abovementioned (3) treatment with an alkaline aqueous solution of permanganate, and the treatments from (4) onward are then implemented sequentially.

[0026] Examples of insulators that can be used in the present invention include polyimide resins and epoxy resins. Polyimide resins or those which have been modified by the addition of polysiloxane, polycarbonate, polyester or the like can be used as a polyimide resin. A glass epoxy board comprising a combination of an epoxy resin and glass fibre (heat resistant glass cloth substrate epoxy resin copper-clad laminated board), or the same modified to have a low thermal expansion and a high glass-transition temperature, constituting a high glass-transition temperature glass epoxy board, can for example be used as an epoxy resin. It is also possible to use the same on which a copper layer having a thickness of 0.05 to 35 m has been formed, or those on which copper foil has been bonded by means of a bonding agent, or those on which a copper layer has been formed by means of a dry method or a wet method such as sputtering or vapour deposition followed by copper electroplating, or those comprising a thermoplastic polyimide resin and a copper layer laminated together, or those in which a single or multiple types of polyimide resin have been flow-casting laminated onto a copper layer.

[0027] These may also be used laminated into multiple layers.

[0028] In treatment (1), in which an alkali metal hydroxide solution is used, an alkali metal hydroxide solution such as sodium hydroxide, potassium hydroxide or lithium hydroxide can be used in order to enhance cleaning of the copper layer outer surface and cleaning, activation and hydrophilicity of the exposed insulator outer surface. Further, in the case of a polyimide resin, monoethanolamine, hydrazine or the like may be added to said solution in order to promote ring-opening of the imide ring. The contact angle between water and the resin outer surface after treatment with the alkali metal hydroxide solution is preferably 15 to 55. If the contact angle is 55 or less, many carboxyl groups, hydroxyl groups and the like, which are ionic polar groups, appear on the insulator outer surface, binding of amino groups in the subsequent process (2) increases, and the amount of manganese dioxide formed in process (3) can be adequately increased, the conductive film resistance in process (4) is reduced, and the ability of the copper plating to attach around holes during (5) copper electroplating is satisfactory. Also, a value of 15 or more is preferable in that activation of the resin outer surface does not become excessive, formation of a moderate amount of manganese dioxide and formation of a moderate amount of electrically conductive polymer can be achieved, and an excess of manganese dioxide or manganese hydroxide does not remain on the insulator outer surface, the conductive film does not exhibit a brown colour and adhesive strength is not markedly reduced. In order to obtain the abovementioned contact angle, the alkali metal hydroxide solution preferably has a pH of 12 or more, and the treatment temperature is preferably 55 C. or less. With a pH of 12 or more, if the treatment temperature is 55 C. or less, the insulator is activated, the amount of manganese dioxide formed by process (3) can be controlled optimally, the resistance of the conductive film is reduced, and the adhesive strength can be improved. Further, a non-ionic surfactant such as polyoxyethylene nonylphenyl ether can also be added to increase the cleaning and wetting effects further. In addition, if holes are machined in a polyimide resin or glass epoxy board using a laser, the abovementioned alkali metal hydroxide solution treatment can be implemented after implementation for example of an ultraviolet irradiation treatment or a smear removal treatment using permanganic acid for removing carbides generated by the laser cutting.

[0029] Next, by (2) treating with an alkaline aqueous solution containing an aliphatic amine, a robust adhesive strength can be realised between the insulator/electrically conductive polymer/layer of copper plating. Aliphatic primary amines, aliphatic secondary amines, amino alcohol, alicyclic amines and the like can for example be used as the aliphatic amine, which is a nitrogen-containing basic compound. Of these, aliphatic primary amines and aliphatic secondary amines are preferable, more specifically methanol ethanolamine, dimethanolamine, diethanolamine, N-methyl ethanolamine, ethyleneimine, polyallylamine, polyvinylamine and the like are preferable. This is because, for example in the case of a polyimide resin, resistance to organic solvents and acid is excellent, whereas hydrolysis occurs readily with alkalis. It is assumed that the adhesive strength is therefore increased through the appearance of ionic polar groups on the polyimide resin outer surface due to the presence of basic aliphatic amines, in addition to the ionic polar groups which appear due to the presence of the alkali metal hydroxide solution. Preferably the aliphatic amine concentration is 0.1 to 10 wt % and its pH is adjusted to between 9 and 13 using sodium hydroxide or sulphuric acid. With aliphatic amines exhibiting basicity, when the pH is 13 or less bonding between the insulator and the electrically conductive polymer is promoted and a high adhesive strength is readily obtained through interactions with the many ionic polar groups, such as carboxyl groups and hydroxyl groups, which appear on the insulating substrate outer surface as a result of the alkali metal hydroxide solution activation treatment. Further, if the pH is 9 or more, a large number of ionic active groups do not appear on the insulating substrate outer surface, the amount of manganese dioxide that becomes attached is not reduced, and non-adhesion and a reduction in the adhesive strength during copper plating do not occur. Further, by adding a water-soluble organic solvent such as isopropyl alcohol or ethylene glycol to the abovementioned aqueous solution, a more stable adhesion strength can be obtained. A non-ionic surfactant such as polyoxyethylene alkyl ether can also be added in order to remove foreign matter that remains attached to the insulator in (1), and to increase wetting performance.

[0030] Next, (3) the substrate is immersed in an alkaline aqueous solution having a permanganate concentration of 0.3 to 3.5 wt % and a pH of 8 to 11, and a manganese dioxide layer is formed on the insulator outer surface. Sodium permanganate, potassium permanganate and the like can be used as the permanganate solution, and sulphuric acid, sodium hydroxide or the like can be used to adjust the pH. The permanganate concentration must be between 0.3 and 3.5 wt %, and the pH must be in the range of 8 to 11. If the permanganate concentration is less than 0.3 wt % then the amount of electrically conductive polymer film that forms is reduced and the electrical conductivity deteriorates. Thus the ability to attach around holes during copper plating deteriorates, generating portions with no adhered copper, and the board cannot be used as a circuit board. Further, if it is 3.5 wt % or more then a large amount of manganese hydroxide is formed on the insulator outer surface together with the manganese dioxide, and manganese dioxide that is not consumed in forming the electrically conductive polymer film remains, causing the adhesive strength to deteriorate. Also, manganese hydroxide on the copper layer causes copper protuberances to be generated during copper electroplating, and circuit breaks, shorts and the like are generated during circuit pattern formation, causing the yield to deteriorate. Further, the colour tone exhibited by the electrically conductive polymer changes from colourless and transparent to a smut-like dark brown colour. Thus the adhesive strength between the insulator/electrically conductive polymer/copper deteriorates and locational variation thereof increases, and thus the board cannot be used as a printed circuit board. With regard to the pH range, if the pH is less than 8 then the amount of manganese dioxide that forms increases, the adhesive strength deteriorates and copper pattern peeling occurs. If the pH is 12 or more, the amount of manganese dioxide that forms decreases, the adhesive strength consequently deteriorates, and peeling occurs in adhesive tape testing, and thus the board cannot be used as a printed circuit board.

[0031] Further, with regard to the adhesive strength after heat resistance, it was determined that a practical level of adhesive strength after heat resistance can only be obtained if the permanganate concentration and pH are in accordance with the abovementioned optimal conditions and the process is performed as a continuation of the previous processes, namely (1) a process comprising treatment with an alkali metal hydroxide solution, and (2) a process comprising treatment with an alkaline aqueous solution containing an aliphatic amine. With regard to the polyimide resin, a difference was seen in the degree to which copper is diffused to the polyimide resin layer in a sample having a strong adhesive strength after heat resistance and a sample having a weak adhesive strength after heat resistance, the adhesive strength tending to increase as the degree of scattering of the copper to the polyimide resin layer reduces. It is assumed that by performing both processes sequentially the imide rings on the polyimide resin outer surface are hydrophilised by the aqueous alkali metal solution and are ring-opened, the amino groups bond thereto, the manganese dioxide bonds to the amino groups, and further the electrically conductive polymer bonds by means of the oxidising power of the manganese dioxide, and thus the polyimide resin/electrically conductive polymer/copper bonds are strengthened and diffusion of the copper is suppressed.

[0032] It should be noted that if an alkaline aqueous solution of permanganate is used in an environment in which a large amount of liquid is brought into or is taken out from a previous process, a buffering agent such as boric acid or sodium carbonate, and a non-ionic surfactant having a draining effect can be added with the aim of stabilising the pH of the solution.

[0033] Next, the substrate which has been subjected to the abovementioned permanganate treatment is preferably (3) treated with an acidic solution, because it is possible in this way to remove smut-like manganese hydroxide attached to the copper layer outer surface and to improve the smoothness and the surface quality of the plated surface obtained after copper electroplating. Sulphuric acid, hydrochloric acid or the like can be used as the acid employed in the acidic solution, and the pH is preferably 3.0 to 5.5. If the pH is 5.5 or less, the copper layer outer surface is dissolved and smut-like manganese hydroxide attached to said surface can be removed, and a copper plating film having a smooth outer surface can be formed by (5) copper electroplating. Further, a pH of 3.0 or more is preferable in that the copper does not dissolve even if the copper layer is a thin film of 0.1 m or less, exposure of the underlying insulator, causing the electrically conductive polymer layer not to be formed and generating non-adhesion of the copper plating, also does not occur, and there are no occurrences of failures whereby the amount of electrically conductive polymer that forms is reduced due to the dissolution and removal of manganese dioxide that has formed on the insulator, leading to a deterioration in the ability to attach around holes during copper plating and generating portions with no adhered copper.

[0034] Next, the abovementioned treated substrate is (4) immersed in an acidic microemulsion aqueous solution containing a thiophene compound, polystyrenesulphonic acid and an alkali metal salt thereof, and the monomer is oxidised by the manganese dioxide attached to the insulator outer surface and an electrically conductive polymer film is formed. The thiophene compound can be selected from the group comprising 3-heterosubstituted thiophenes and 3,4-diheterosubstituted thiophenes, and can preferably be selected from the group comprising 3,4-ethylenedioxythiophene, 3-methoxy-thiophene, 3-methyl-4-methoxy-thiophene and derivatives of the same. This can be made into a water-based microemulsion solution by adding for example sodium polystyrene sulphonate, which is an alkali metal salt of polystyrenesulphonic acid, and forming a mixture. Next, by adjusting the pH to between 1 and 3 using an alkanesulphonic acid such as methanesulphonic acid or ethanesulphonic acid and making it into an acidic microemulsion solution, an electrically conductive polymer (a conjugate of polyethylenedioxythiophene and polystyrenesulphonic acid) can be formed easily in a single process by immersing the insulator to which the manganese dioxide is attached into said solution. According to the description corresponding to patent literature EP 1 390 568 B1, the microemulsion is aqueous (at least 50% by volume), and can include lower aliphatic alcohols, esters and ethyl esters. Microemulsions are emulsions containing extremely small droplets (diameter 5 to 100 nm). They are thus optically transparent and thermodynamically stable, and do not separate into two visible phases for a long time after manufacture. In this way, by means of a method in which treatment is performed using a conventional polyethylenedioxythiophene film-forming liquid, after which treatment is performed in a separate tank using a polystyrenesulphonic acid film-forming liquid, degradation of the latter liquid by liquid being brought in can be avoided, and a stable electrically conductive polymer layer can be formed. Specifically, the Seleo (direct plating method trademark) CPF1 series chemical liquids sold by Atotech Japan KK can be used. The Seleo CPF1 series treatment processes are performed in the following sequence: etch cleaner process (outer surface cleaning)/conditioner process (regulation, activation of outer surface)/adhesion (?) promoter process (permanganic acid treatment)/polyconductor process (polymer formation by oxidative polymerization of a monomer), and of these only the polyconductor process can be used in the present invention. The polyconductor process can use a single liquid comprising a mixture of two liquids, namely Seleo CP Basic Plus, a solution containing 5 to 10 wt % of 3,4-ethylenedioxythiophene, and Seleo CP Matrix Plus, a solution containing 2.5 to 5 wt % of sodium polystyrene sulphonate. An electrically conductive polymer film can be formed by immersing an insulator substrate that has been subjected to treatments (1), (2) and (3) into this liquid mixture.

[0035] After formation of said film, the next process, namely copper electroplating, may be implemented while in a state in which the substrate is wet with water, but copper electroplating may also be performed after hot-air drying (100 C., 1 hour) or after being allowed to stand at room temperature.

[0036] For the copper electroplating it is preferable to use a copper sulphate bath which can support through holes and blind holes. Copper plating can for example be performed with the addition of copper sulphate, sulphuric acid or chloride ions (added using hydrochloric acid), to which a leveller (smoothing agent) and a brightener (brightening agent) have been added.

[0037] In order to manufacture a substrate like a printed circuit board using the method of forming a metal layer of the present invention, in the case of a semi-additive construction method (FIG. 1), a through hole 3 is opened using a drill or the like in a substrate comprising an insulator 1 on both sides of which copper layers 2 have been formed, and an electrically conductive polymer film 4 is formed on the side wall of the through hole in which the insulator is exposed. Next, a circuit pattern 5 is formed for example by lamination/exposure/development of a photosensitive dry film resist, and copper electroplating 6 is formed on the exposed portions of the copper layer and the electrically conductive polymer film. A printed circuit board 7 can then be formed by peeling off the dry film and removing the copper layer thereunder by etching. Further, when forming a circuit board using a subtractive construction method (FIG. 1), a through hole 3 is opened using a drill or the like in a substrate comprising an insulator 1 on both sides of which copper layers 2 have been formed, and an electrically conductive polymer film 4 is formed on the side wall of the through hole in which the insulator is exposed, after which copper electroplating 8 is performed on all surfaces, and a photosensitive dry film is then laminated/exposed/developed 9, and a printed circuit board 10 can be formed by peeling off the dry film after etching the layer of copper plating and the copper layer. Further, depending on the intended use of the printed circuit board, in both cases tin, nickel, palladium, silver, gold, platinum and alloys thereof can be electrolytically or non-electrolytically coated onto the copper circuit pattern either individually or in combination.

[0038] Also, a printed circuit board having a blind hole can also be manufactured using the method of forming a metal layer of the present invention. To form a blind hole, the copper layer on one surface and the insulator are removed by laser machining or by chemical etching, in the process in FIG. 1 in which a through hole is opened, leaving only the copper layer on the reverse surface. Then, in the case of the semi-additive construction method (FIG. 1) for example, an electrically conductive polymer film 4 is formed on the side wall of the blind hole in which the insulator is exposed, after which implementation can proceed by performing tin plating or the like using the same processes as mentioned hereinabove.

[0039] The method of forming a metal layer of the present invention was evaluated according to the following methods.

[0040] A. Non-Adhesion of Copper Plating

[0041] This was performed using the test coupon illustrated in FIG. 2. The test coupon was prepared by forming in advance a 12 nm nichrome layer as an adhesion reinforcing layer on one surface of a polyimide resin using a sputtering method, then forming a 0.15 m copper layer, and then laminating a dry film resist, exposing and developing it using a photolithographic method, and removing the copper layer and the adhesion reinforcing layer 14 by etching to expose the resin portion. Resin exposed portions were made in seven steps, from a 1 mm width 15 to an 8 mm width 21, representing long through holes or blind holes in a multilayer board. Non-adhesion of copper plating was evaluated by performing copper electroplating (15 m) on said test coupon at 2A/dm2 under various conditions, and observing visually and under a microscope the presence or absence of non-adhered copper in all positions in the resin exposed portions of width 1 mm to width 8 mm. For pass or fail judgement, if non-adhesion of copper does not occur over the full width of the abovementioned resin exposed portion then this is deemed to be a pass, and if non-adhesion of copper occurs in even one position then this is deemed to be a fail (NG).

[0042] B. Copper Pattern Peeling and Adhesive Strength (Normal Condition, After Heat Resistance)

[0043] With regard to copper pattern peeling, the test coupon in FIG. 2 was subjected to copper electroplating (15 m) using the abovementioned method, and a copper pattern having a pitch of 80 m (line/space: 40 m/40 m) was formed on the 5 mm width to 8 mm width resin exposed portions using a photolithographic method. After formation of the copper pattern the presence or absence of peeling during pattern formation was observed using a microscope and a pass or fail judgement was made. Next, if peeling had not occurred then an adhesive tape test was performed, the presence or absence of peeling of the copper pattern was observed using a microscope for 100 lines, and a pass or fail judgement was performed by defining that if there was no peeling of any of the 100 lines then this was deemed to be a pass, and if there was peeling of even one line then this was deemed to be a fail (NG). In the adhesive tape test, Nichiban Co., Ltd cellophane tape LT-24 was used and was adhered to and peeled from the copper pattern in accordance with JIS K5600 (cross-cut test). The specimen after heat resistance was also subjected to an adhesive tape test performed in the same way as described hereinabove, and a pass or fail judgement was made. For evaluation of the adhesive strength, said test coupon was subjected to copper electroplating (15 m) using the abovementioned method, a 0.8 mm42 mm copper pattern was formed in the vicinity of the centre of each of the resin exposed portions of width 1 mm to width 8 mm using a photolithographic method, and the 90 copper peeling adhesive strength was measured using an Orientec Co., Ltd Tensilon RTC-1150A in accordance with IPC-TM-650, the maximum and minimum values were omitted and an evaluation was made using the average value. Also, with regard to the adhesive strength after heat resistance, measurements were taken using the same method as described hereinabove after said pattern had been subjected to heat treatment in air at 150 C. for 158 hours. For the pass or fail judgement of the adhesive strength, if pattern peeling did not occur during copper pattern formation or in the adhesive tape test prior to the subsequent heat resistance adhesive strength measurement, and if a stable adhesive strength of 3.0 N/cm or more (in both normal condition and after heat resistance) was obtained, with little variation in strength difference during the 90 copper peeling adhesive strength measurement, then this was deemed to be a pass.

[0044] C. Ability to Attach Copper Plating Around Through Hole Portions

[0045] A 12 nm nichrome layer and a 0.15 m copper layer were formed on both surfaces (1010 cm) of an insulator using a sputtering method, after which 100 m through holes were machined using a drill and copper electroplating (15 m) was performed using the same method as described hereinabove. After copper plating, the through holes were subjected to cross-sectional cutting using a microtome and were observed using a microscope, and the presence or absence of copper non-adhesion in the hole portions was observed for 100 holes, and a pass or fail judgement was performed by defining that if there was no non-adhesion in any of the 100 holes then this was deemed to be a pass, and if there was non-adhesion in even one hole then this was deemed to be a fail (NG).

[0046] D. Circuit Pattern Formability

[0047] A circuit pattern was formed by copper electroplating (15 m) using the same method as described hereinabove, using the abovementioned specimen with copper on both surfaces in which through holes had been machined, after which a pattern having a pitch of 80 m (40 m/40 mlength 18 mm) was formed by a photolithographic method, and said pattern was observed using a microscope (for defects such as breaks, shorts, voids, protuberances and the like). Also with regard to line width, voids and protuberances of 40 m30% were deemed to be NG, 1,000 lines were observed, and a pass or fail judgement was performed by defining that if there were none of the abovementioned defects in any of the 1,000 lines then this was deemed to be a pass, and if there were defects in even one line then this was deemed to be a fail (NG).

[0048] E. Aqueous Solution pH

[0049] In accordance with JIS Z8802, a DKK-TOA Corporation pH meter HM-30S was regulated after zero calibration using a phthalate pH standard solution (pH 4.01) and a neutral phosphate pH standard solution (pH 6.86), and measurements were made.

[0050] F. Contact Angle of Insulator Outer Surface After Treatment with Alkali Metal Hydroxide Solution

[0051] In accordance with JIS K6768, pure water was added dropwise onto the outer surface of an insulator, and measurements were made using a Kyowa Interface Science Co., Ltd contact angle meter CA-X.

EXAMPLES

[0052] The effect of the present invention will now be described with reference to examples.

Examples 1 to 4

[0053] A 10 cm10 cm substrate (Metaloyal: manufactured by Toray Advanced Film Co., Ltd) comprising a polyimide film (Kapton 150EN-A38 m: manufactured by Du Pont-Toray Co., Ltd) on both surfaces of which a 12 nm nichrome layer and a 0.15 m copper layer had been formed by a sputtering method and through which 100 m through holes had been machined using a drill, and the test coupon in FIG. 2, manufactured by the method discussed hereinabove, were used. Each of these was immersed in an alkali metal aqueous hydroxide solution (sodium hydroxide 20 g/l the pH of which had been adjusted to 13.7 by the addition of polyoxyethylene nonylphenyl ether 0.1 g/l) at 40 C. for 1 minute, and was washed in water (water contact angle 30), after which each was immersed in an alkaline aqueous solution containing an aliphatic amine (polyethylenimine 10 g/l, ethylene glycol 5 ml/l, to which polyoxyethylene polyoxypropylene glycol 0.05 ml/l had been added and the pH adjusted to 11.5 using sodium hydroxide) at 50 C. for 1 minute, and was washed in water. Each was next immersed for 3 minutes in a liquid (60 C.) comprising a 0.3 wt % sodium permanganate solution the pH of which had been adjusted to 8, 9, 10, 11 using sodium hydroxide. Embodiments 1, 2, 3, 4 correspond respectively to the substrates prepared using the solutions having each of the abovementioned pH values. After being washed with water, they were soaked for 1 minute in pH 4.0 diluted sulphuric acid (room temperature) and were then immersed for 1 minute in a solution (20 C.) comprising a mixture of 60 ml/l of Seleo CPF1 Series polyconductor process aqueous solution Seleo CP Matrix Plus manufactured by Atotech Japan KK and 20 ml/l of Seleo CP Basic Plus, the pH of which had been adjusted to 2.0, forming an electrically conductive polymer film. They were then washed with water and hot-air dried at 100 C. for 3 minutes. They were next subjected to copper electroplating (15 m) at 2A/dcm2 using a copper sulphate plating solution (copper sulphate 150 g/l, sulphuric acid 120 g/l, chloride ions (added using hydrochloric acid) 50 mg/l, leveller (Basic Leveller Cupracid HL: trademark) 30 ml/l, brightener (Correction Cupracid GS: trademark) 0.05 ml/l). The hole portions of the copper plated items machined with through-holes were subjected to cross-sectional cutting using a microtome and were observed using a microscope. The results showed that the ability to attach around the hole portions was satisfactory in all 100 holes, and defects such as non-adhesion of copper plating or peeling were not observed. Further, a circuit pattern having a pitch of 80 m (line/space: 40 m/40 mlength 18 mm) was formed on said copper plating outer surface and was observed using a microscope, and the results showed that a satisfactory outer surface condition had been obtained, without any defects such as pattern breaks or shorts being observed in any of the 1,000 lines. Next, the copper plating outer surface in the 1 mm wide to 8 mm wide resin exposed portions in the test coupons in FIG. 2 was observed visually and using a microscope, but abnormalities such as non-adhesion of copper plating could not be found. In addition, a pattern have a pitch of 80 m (line/space: 40 m/40 m) was formed on the copper plating outer surface in the 5 mm wide to 8 mm wide resin exposed portions of said test coupons, and after confirming by microscopic observation that there was no pattern peeling an adhesive tape test was performed, and the result of microscopic observations showed that copper pattern peeling could not be found in any of the 100 lines. Further, an adhesion test pattern having a width of 0.8 mm was formed on the abovementioned 1 mm wide to 8 mm wide resin exposed portions, and the normal condition adhesive strength was measured in accordance with IPC-TM-650, the results being as shown in Table 1. Under each of the conditions an adhesive strength of 4.0 N/cm or more was obtained, a high adhesive strength of 6.5 N/cm being obtained with a pH of 10. In addition, high values of 3.0 N/m or more were obtained under each of the conditions for the adhesive strength after heat resistance for the same specimens. From these results it can be seen that metal layers having satisfactory surface quality and high adhesive strength (normal condition, after heat resistance) were obtained.

Comparative Examples 1 to 4

[0054] In embodiment 1, the pH of the sodium permanganate having a concentration of 0.3 wt % was modified to 4, 6, 7, 12 using sodium hydroxide and sulphuric acid, and copper electroplating (15 m) was performed with all the other conditions remaining unchanged. Comparative examples 1, 2, 3, 4 correspond respectively to the substrates prepared using the solutions having each of the abovementioned pH values. The evaluation results are shown in Table 1. According to Table 1, a normal condition adhesive strength of 1.9 N/cm was obtained with pH values of 7 and 12, but in each of the 80 m pitch pattern adhesive tape tests, peeling was observed in 7 of the 100 lines, and they therefore failed. With pH values of 4 and 6 the normal condition adhesive strength was 1.5 N/cm or less, locational variation was large and pattern peeling during copper pattern formation was confirmed, and these therefore failed.

Examples 5 to 8

[0055] In embodiment 1, the pH of sodium permanganate having a concentration of 3.5 wt % was varied to 8, 9, 10, 11 using sodium hydroxide, and copper electroplating (15 m) was performed with all the other conditions remaining unchanged. Embodiments 5, 6, 7, 8 correspond respectively to the substrates prepared using the solutions having each of the abovementioned pH values. The evaluation results are shown in Table 1. According to Table 1, under each of the conditions an adhesive strength of 4.0 N/cm or more was obtained without the occurrence of non-adhesion of copper or copper pattern peeling, a value of 6.5 N/cm being obtained with a pH of 10. Further, high values of 3.0 N/m or more were obtained under each of the conditions for the adhesive strength after heat resistance for the same specimens. Other evaluations also yielded similar results to embodiment 1, and metal layers having satisfactory copper surface quality and high adhesive strength (normal condition, after heat resistance) were obtained.

Comparative Examples 5 to 8

[0056] In embodiment 1, the pH of sodium permanganate having a concentration of 3.5 wt % was varied to 4, 6, 7, 12 using sodium hydroxide, and copper electroplating (15 m) was performed with all the other conditions remaining unchanged. Comparative examples 5, 6, 7, 8 correspond respectively to the substrates prepared using the solutions having each of the abovementioned pH values. The evaluation results are shown in Table 1. According to Table 1, copper plating non-adhesion was not found under any of the conditions, but with pH values of 4 and 6 peeling occurred during pattern formation, and these therefore failed. Peeling was not observed during pattern formation with pH values of 7 and 12, but in each of the 80 m pitch pattern adhesive tape tests, peeling was observed in 8 of the 100 lines, and they therefore failed. Further, the normal condition adhesive strength was low with pH values of 7 and 12, at 1.9 N/cm and 1.8 N/cm, and the adhesive strength was even lower with pH values of 4 and 6, at 1.5 N/cm or less, and moreover locational variation was observed, and these therefore failed.

Comparative Examples 9 to 12

[0057] In embodiment 1, the pH of sodium permanganate having a concentration of 0.2 wt % was varied to 4, 6, 9, 11 using sodium hydroxide, and copper electroplating (15 m) was performed with all the other conditions remaining unchanged. Comparative examples 9, 10, 11, 12 correspond respectively to the substrates prepared using the solutions having each of the abovementioned pH values. The evaluation results are shown in Table 1. According to Table 1, in relation to copper plating onto the test coupons, non-adhesion of copper plating was observed for the abovementioned pH values over the full range of 4 mm wide to 8 mm wide resin exposed portions, and they therefore failed. Further, the normal condition adhesive strength in said coupons had a value of 1.0 N/cm or less for each pH value, locational variation was large and pattern peeling during copper pattern formation was confirmed, and these therefore failed. Also with regard to the through hole portions, non-adhesion of copper was observed over the full range, and these therefore failed.

Comparative Examples 13 to 21

[0058] In embodiment 1, the pH of sodium permanganate having a concentration of 4.0 wt % was varied to 4, 5, 6, 7, 8, 9, 10, 11, 12 using sodium hydroxide, and copper electroplating (15 m) was performed with all the other conditions remaining unchanged. Comparative examples 13, 14, 15, 16, 17, 18, 19, 20, 21 correspond respectively to the substrates prepared using the solutions having each of the abovementioned pH values. The evaluation results are shown in Table 1. According to Table 1, non-adhesion of copper plating was not observed, but peeling was confirmed during copper pattern formation with pH values of 4, 5, 7, 8, 9, 11, 12, and in the 80 m pitch pattern adhesive tape tests, peeling was observed in 6 of the 100 lines with pH values of 6 and 10, and they therefore failed. Normal condition adhesive strengths having values of 1.8 N/cm and 1.9 N/cm were obtained with pH values of 6 and 10, but of 1.5 N/cm or less under all other conditions, locational variation was large and pattern peeling during copper pattern formation was confirmed, and these therefore failed. Further, the ability to attach around the through-hole portions was satisfactory, but when circuit pattern formability was evaluated with pH values of 6 and 10, breaks, shorts and the like, assumed to have been caused by copper protuberances, were observed in both cases in 10 or more of the 1,000 lines, and they therefore failed.

Comparative Example 22

[0059] Copper electroplating (15 m) was performed under the same conditions as in embodiment 1, except that treatment with an aqueous alkali metal solution and treatment with an alkaline aqueous solution containing an aliphatic amine were both omitted, this being comparative example 22. The evaluation results are shown in Table 1. According to Table 1, the ability to attach around the through-hole portions was satisfactory, circuit pattern formability was satisfactory, and non-adhesion of copper plating and copper pattern peeling under normal conditions were not found, in addition to which normal condition adhesive strength was stable at 3.5 N/cm, thereby passing the test, but the adhesive strength after heat resistance was low at 0.3 N/cm and also pattern peeling of the 80 m pitch copper pattern occurred after heat resistance, and this therefore failed. (Comparative example 23)

[0060] Copper electroplating (15 m) was performed under the same conditions as in embodiment 1, except that treatment with an alkaline aqueous solution containing an aliphatic amine was omitted, this being comparative example 23. The evaluation results are shown in Table 1. According to Table 1, the ability to attach around the through-hole portions was satisfactory, circuit pattern formability was satisfactory, and non-adhesion of copper plating and copper pattern peeling under normal conditions were not found, in addition to which normal condition adhesive strength was stable at 4.0 N/cm, but the adhesive strength after heat resistance was low at 0.7 N/cm and also pattern peeling of the 80 m pitch copper pattern occurred after heat resistance, and this therefore failed.

Comparative Example 24

[0061] Copper electroplating (15 m) was performed under the same conditions as in embodiment 1, except that treatment with an aqueous alkali metal solution was omitted. The substrate in which the abovementioned aqueous alkali metal solution treatment was omitted was comparative example 24. The evaluation results are shown in Table 1. According to Table 1, the ability to attach around the through-hole portions was satisfactory, circuit pattern formability was satisfactory, and non-adhesion of copper plating and copper pattern peeling under normal conditions were not found, in addition to which normal condition adhesive strength was stable at 4.0 N/cm, but the adhesive strength after heat resistance was low at 1.2 N/cm and also peeling of the 80 m pitch copper pattern after heat resistance was found in the adhesive tape test in 5 of the 100 lines, and this therefore failed.

Example 9

[0062] Copper electroplating (15 m) was performed under the same conditions as in embodiment 1, except that soaking for 1 minute in pH 4.0 diluted sulphuric acid (room temperature) was omitted, this being embodiment 9. The evaluation results are shown in Table 1. According to Table 1, copper plating non-adhesion and copper pattern peeling were not observed. Adhesive strength was also high, clearing 3.0 N/cm, being 6.4 N/cm under normal conditions and 4.0 N/cm after heat resistance. Further, the through-hole portions were subjected to cross-sectional cutting using a microtome and were observed using a microscope, and no non-adhesion of copper or abnormalities at the hole portions were observed in any of the 100 lines, and this was thus satisfactory. Next, an 80 m pitch circuit pattern was formed and was observed using a microscope, and the results showed that defects thought to have been caused by manganese hydroxide were observed in 3 lines, but all were within 15% of the line width, and the result was therefore 0/1,000, which was a pass. From these results it can be seen that metal layers having satisfactory surface quality and high adhesive strength (normal condition, after heat resistance) were obtained.

Example 10

[0063] A specimen comprising the substrate with copper on both surfaces, of embodiment 1, in which 50 m through holes had been machined using a press was treated using the same method as in embodiment 1, forming an electrically conductive polymer film. Next a negative type photosensitive dry film resist manufactured by DuPont (Riston JSF120: film thickness 20 m) was laminated, and on one surface (the signal surface) a 50 m pitch (line/space: 25 m/25 m) semi-additive circuit pattern was formed by exposure/development, and on the reverse surface (the ground surface) a 150 m pitch (line/space: 75 m/75 m) semi-additive circuit pattern was formed by exposure/ development. This was next subjected to copper electroplating (15 m) at 2A/dcm2 using a copper sulphate plating solution (copper sulphate 150 g/l, sulphuric acid 120 g/l, chloride ions 50 mg/l, Basic Leveller Cupracid HL 30 ml/l, Correction Cupracid GS 0.05 ml/l). The dry film was then peeled off using a 1 wt % sodium hydroxide aqueous solution, and the copper layer under the dry film and the nichrome layer, which is an adhesive strength reinforcing layer, were dissolved using a ferric chloride etching solution, and a circuit pattern was formed. The copper circuit pattern portion was then subjected to 0.5 m non-electrolytic tin plating, and a circuit board for mounting an IC (FIG. 3) was prepared. The through holes were subjected to cross-sectional cutting using a microtome and were observed using a microscope, the result showing that the ability to attach around the hole portions was satisfactory. Further, defects such as breaks, shorts, voids and protuberances were not seen in the circuit patterns on either surface. A satisfactory printed circuit board having an adhesive strength or 6.0 N/cm under normal conditions and 3.8 N/cm after heat resistance on both surfaces was thus obtained.

Example 11

[0064] Negative-type photosensitive dry film resists (Riston JSF120: film thickness 20 m) were laminated onto both surfaces of a substrate with copper on both surfaces onto which a 12 nm nichrome layer and a 2 m copper layer had been formed using the sputtering method of embodiment 1, after which a pattern in which the copper layer was exposed to a diameter of 50 m was formed on only one surface (the signal surface) of the dry film resist using a photolithographic method. The copper layer and the nichrome layer were then dissolved using a ferric chloride etching solution, after which the polyimide resin was etched using a polyimide etching liquid (TPE300 manufactured by Toray Engineering), and with the copper layer on the reverse surface (the ground surface) remaining in place, the dry film resist was peeled off using a 1 wt % sodium hydroxide aqueous solution, forming a blind hole with a copper layer on both surfaces. Said specimen was treated under the same conditions as in embodiment 1 to form an electrically conductive polymer film. Next, using the same method as in embodiment 10, a 50 m pitch (line/space: 25 m/25 m) circuit pattern was formed on the signal surface and a 150 m pitch (line/space: 75 m/75 m) circuit pattern was formed on the ground surface, the copper circuit pattern portion was then subjected to 0.5 m non-electrolytic tin plating, and a circuit board (FIG. 4) was prepared. The blind holes were subjected to cross-sectional cutting using a microtome and were observed using a microscope, the result showing that the ability to attach around the hole portions was satisfactory. Further, defects such as breaks, shorts, voids and protuberances were not seen in the circuit patterns on either surface. A satisfactory printed circuit board having an adhesive strength of 5.8 N/cm under normal conditions and 3.5 N/cm after heat resistance on both surfaces was thus obtained.

EXPLANATION OF THE REFERENCE NUMBERS

[0065] 1 insulator, 2 copper layer, 3 through hole, 4 electrically conductive polymer, 5, 9 dry film resist, 6, 8 electroplated copper layer, 7, 10 printed circuit board, 11 semi-additive process, 12 subtractive process, 13 non-electrolytic tin plating, 14 copper layer and adhesive strength reinforcing layer, 15 resin exposed portion (1 mm42 mm), 16 resin exposed portion (2 mm42 mm), 17 resin exposed portion (3 mm42 mm), 18 resin exposed portion (4 mm42 mm), 19 resin exposed portion (5 mm42 mm), 20 resin exposed portion (6 mm42 mm), 21 resin exposed portion (8 mm42 mm), 22 blind hole