©2012 iNEMI

Co-Chairs: Valerie St. Cyr (Teradyne)

Greg Monty (UL), Jackie Adams (IBM)

Improving UL Certification of Laminates and

Printed Circuit Boards (Phase 1)

2 ©2012 iNEMI

Improving UL Certification Statement of Work Review

•  Introduction of Project Chairs •  Overview of iNEMI Project Selection Process •  Company participation in Statement of Work (SOW)

development •  Introduction •  Review of SOW •  Summary and next steps •  Q&A

Agenda

Note:  All  phones  will  be  on  mute  un2l  the  end  of  the  presenta2on  

3 ©2012 iNEMI

Improving UL Certification of Laminates and PCBs

Project Chairs •  Jackie Adams ... IBM Senior Technical Staff Member

–  Jackie has been in the plastics industry since 1981. She has been working as an engineer in the electronics industry with including involvement with PCB technology. Her broad commodity knowledge relative to polymer, mechanical attributes and safety/electrical has grown for more than 22 years. Jackie has spent the last 7 years dedicated to removal of hazardous substances, alternative technologies to meet environmental regulations and their comparable test standards. She has developed patent and publications related to alternative materials, testing, sourcing and procurement of various commodities and alternative technology in preparedness for environmental regulatory readiness. Her current responsibilities includes strategy and task force leadership to develop material, supplier strategies and test readiness for new technology forecasting and introduction of new materials.

•  Greg Monty… UL, Corporate Research, and Chair of IEC TC113-Nanotechnology Stds. –  Greg has 30 years experience in semiconductors and research. After receiving a Ph.D. from MIT, he was a

Professor at the Univ. of Michigan, and then was a founder of both Ovonic Imaging Systems and Vitesse Semiconductor Corp. (both successful IPOs). Next Greg worked for Motorola in GaAs technology for wireless applications. After Motorola, Greg transitioned to UL as Director of R&D, and held roles of Director of Quality, Director of Technology, and lastly Director of Business Development.

•  Valerie St. Cyr… Teradyne Inc., Senior Engineer, PCB Technologist –  Valerie has over 35 years in the electronics industry, most recently 10 years with Teradyne, a Semiconductor

Testing Equipment company. She has held senior business and technical roles in Sun Microsystems and Digital Equipment Corp. Her current responsibilities include new technology forecasting and the introduction of new materials and processes for advancing printed circuits function.

©2012 iNEMI

Project Management

Project Selection Process

5 ©2012 iNEMI

STRATEGY

RESOURCE ANALYSIS

& PLANNING

COMPANY COMMITMENT

Resource Skills & Utilization Maps

PROJECTS PROJECTS

ALIGNED TO STRATEGY

PROJECTS REALISTICALLY

POSSIBLE

Filter Filter MARKET

OPPORTUNITIES BUSINESS GROWTH

Project Selection Process

6 ©2012 iNEMI

Questions to Ask: •  VALUE:

–  What is the value?

•  TEAM: –  Does the team have the right leadership? –  Does the team have the right

membership? –  Does the team have the necessary

experience and skills?

•  PRODUCTS / RESULTS: –  What are the essential specifications?

–  Is existing technology usable?

•  STRATEGIC ALIGNMENT: –  Why is the project strategic?

–  Is it identified as a key thrust? –  Why must we do it now?

•  PROJECT SCHEDULE: –  Is the schedule achievable? –  Has a detailed work breakdown structure

been derived? –  How does “time-to-market” compare with

industry benchmarks?

•  RESOURCE REQUIREMENTS: –  Are all resources identified and committed

for the schedule? –  Will all of the skills needed be available

when required?

•  RISK AND ISSUE MANAGEMENT: –  Are all risks regularly identified, monitored

and managed? –  Are the probability and impacts realistic? –  Are clear action plans established for high

risks? –  Are all issues identified promptly and

escalated as appropriate for decisions?

7 ©2012 iNEMI

The Project Process - 5 Steps

SELECTION

DEFINITION

PLANNING

EXECUTION / REVIEW

CLOSURE

1

2

3

4

5 Limited to iNEMI Members

Open for Industry input

------------------- iNEMI Technical Committee (TC) Approval Required for Execution

©2012 iNEMI

Company Participation in

SOW Development

9 ©2012 iNEMI

Statement of Work (SOW) Development Company Participation

©2012 iNEMI

Improving UL Certification of Laminates and

Printed Circuit Boards (Phase 1)

Introduction

11 ©2012 iNEMI

Improving UL Certification of Laminates and PCBs • Problem

–  Technology advancements in PCB materials and densities have progressed at a very rapid rate •  Low Halogen laminates; HDI materials; inks and pastes to embed functions or connect via structures

–  The existing UL certification requirements need to be updated and streamlined to support the rapid TTM requirements of new PCB designs.

• Goals –  Clear and defined recommendations on improvements for the present UL materials and PCB standards. This may include: number of samples;

types of samples; test suites; test methodologies, techniques or procedures based upon scientific evidence.

–  A review of the possibility of newer existing tests or the development of new tests, to complement or replace the existing tests.

–  Potential reduction in the present time to acquire UL certification.

12 ©2012 iNEMI

Outline of Statement of Work (SOW) •  Background/Context •  Scope of Work •  Purpose of Project •  Project IS / IS NOT Analysis •  Business Impact •  Outcome of Project •  Previous Related Work •  Project Plan •  Project Monitoring Plans •  Future Project Plans •  Next Step – Project Sign-up

©2012 iNEMI

Improving UL Certification of Laminates and

Printed Circuit Boards (Phase 1)

Review of Statement of Work

14 ©2012 iNEMI

Background/Context •  The evolution of product functionality, densification, and environmental

consciousness continues. The materials and manufacturing processes for printed circuit boards have met these market and regulatory needs by developing Halogen-reduced or low Halogen laminate materials; High Density Interconnect (HDI) materials; and inks and pastes to embed functions or connect via structures.

•  These new materials and processes may require changes to the Underwriters Laboratories Inc., Standards for Safety which ensure product safety through certification processes. –  UL796, Printed-Wiring Boards –  UL746, Standard for Polymeric Materials – Industrial Laminates .. and

Materials Used in Printed-Wiring Boards.

•  Additionally, with the EU ROHS Recast review by 2014 which has the potential to look further at brominated and chlorinated flame retardant restrictions, there is interest within the PCB supply chain to increase utilization of alternative materials. Hence the interest to streamline any certification procedures, enhancing the ability to bring new board materials and PCBs to market quicker.

15 ©2012 iNEMI

Scope of Work – Phase 1 Phase 1 documents and evaluates the current status of the UL laminate and PCB certification processes

–  A scientific review + Hazards-based assessment of UL746E and UL796. •  Identify known or anticipated hazards evaluated in the present test suites •  Verify if the present test suites are suitable and complete for existing

materials, technologies, and manufacturing processes for PCBs –  Confirm if new materials or combinations of materials, processes,

and other variations anticipated in the future, are being addressed within the certification methodology employed today

–  Deliver documentation attesting to what is working well, what isn’t, and gaps relative to those tests/certification

–  Assess/document the time to market of the existing certification process and recommend possible improvements to the requirements

or methodologies. This will be done by producing and studying process flow charts and identifying clear areas for improvement

16 ©2012 iNEMI

Scope of Work – Phase 2 • The Phase 2 actions are dependent to the Phase 1 outputs. • The Phase 2 actions will be designed to address the identified gaps

and areas for improvement determined in Phase 1. –  These actions will be a science-based attempt to close those gaps by

recommending tests or procedures that can be added, modified, or removed to address those hazards and failures that impact safety.

17 ©2012 iNEMI

Purpose of Project (1/2)

•  It is hoped that most, if not all, hazards and failures that effect safety for rigid laminates and PCBs will be addressed in this project. This will provide the participants with a complete assessment of UL746 and UL796 certification requirements and the foundations and justifications for the included tests.

•  With Respect to EU RoHS ( Restriction of Hazardous Substances) Directive 2002/95/EC, the EU ROHS amendment 2008/34/EC, and the recent EU ROHS Recast Directive 2011/65/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL, published 8 June 2011, an increased potential to restrict the use of brominated and chlorinated flame retardants will be in play. Along with those flame retardants some phthalates found in flexible polyvinyl chloride are also potentially in scope. To meet these directives a reduction or elimination of brominated flame retardants as found in traditional FR4s, and Tetra Bromo Bisphenol A (TBBPA) may be targeted. This project could great reduce the time to industry adoption as alternatives are developed and released.

18 ©2012 iNEMI

Purpose of Project (2/2) •  The iNEMI 2011 Roadmap, Interconnection PCB – Organic, January, states

many Research Needs (p. 48) that would benefit from this project. These needs are forecast as HDI and/or Bromine-free technologies continue to drive innovation in materials and processes. The Roadmap cites these specific needs:

–  High performance laminates that are competitively priced with low dielectric constant and loss

–  Integral materials for resistors/capacitors/inductors and embedded actives –  Self reinforced materials

–  Liquid crystal polymer that can be introduced into a PCB shop manufacturing process

–  Waveguide materials and manufacturing techniques –  Non-solder based interconnects –  Aging and long term effects on newer resins, polymer additives, and flame

retardants

•  As these new materials and their associated manufacturing processes are developed and introduced in the industry, safety tests need to keep apace. These tests and their methodologies need to be efficient, capable and cost effective – the essence of this project.

19 ©2012 iNEMI

Improving UL Certification of Laminates and PCBs IS / IS NOT Analysis

This Project IS: This Project IS NOT: iNEMI Project on UL PCB Certification – Phase 1

Science based assessment, building on learning from prior investigation Repeat of prior industry work

1. Review & Assess current UL laminate and PCB certification standards (UL746 & UL 796) and process flows; document.

PCB technology development

Laminate technology development 2. Review & Assess current UL Laminate and PCB tests, methods, & sampling

in support of meeting UL Safety requirements. Standards development

3. Employ a Hazards based focus to •  Identify the hazards in laminates and PCBs; •  Classify the hazards; •  Understand the modes and causes. •  Are those hazards tested for today? If not how can they be? •  Are there additional tests to consider for potential future hazards?

o  Includes current and future laminate and PCB technologies (materials, processing and interactions; hybrid constructions; chemistries; etc)

To define Durability

Intended to be static, used indefinitely without further review, input and updates from the PCB and Laminate suppliers.

Review of flexible laminate and board standards (UL746f and UL 796f)

4. Report out: •  List the existing tests, methods, & sampling in support of meeting UL Safety

requirements that appear currently valid •  List the gaps in tests, methods & sampling that need to be addressed in

support of meeting UL Safety requirements. •  Provide the input list of tests and tasks for Ph.2

Biased toward specific segments of the supply chain; suppliers; regions of supply; or market segments

Development of an alternate test to replace LTTA

20 ©2012 iNEMI

Improving UL Certification of Laminates and PCBs IS / IS NOT Analysis

This Project IS: This Project IS NOT: iNEMI Project on UL PCB Certification - Phase 2

Science based assessment, building on learning from prior investigation

Repeat of prior industry work

PCB technology development

5. Identify, Assess and/or Develop new appropriate tests, methods, & sampling in support of meeting UL Safety requirements

•  Well defined process that deals with new materials’ classifications, ex: basis of ANSI determination (FTIR scan).

•  Endeavor to reduce time to market: .eg. UL Long Term Thermal Aging (LTTA). LTTA is a scientific and precise method to express thermal aging of the material and so ensure the safety of the end product; it is necessary to research a faster, more convenient new test method, such as oxidation induction time

Intended to be static, used indefinitely without further review, input and updates from the PCB and Laminate suppliers.

Laminate technology development

To define Durability

Review of flexible laminate and board standards (UL746f and UL 796f)

Biased toward specific segments of the supply chain; suppliers; regions of supply; or market segments

6. Report out: Recommendations to UL Standards Development Standards development

Development of an alternate test to replace LTTA

21 ©2012 iNEMI

Business Impact (1/2) •  The industry will benefit from this collaborative and scientific approach

to recommend a complete and non-redundant set of necessary testing procedures for PCB materials and boards, supported by scientific study and evidence. Only the testing necessary to ensure the safety of PCBs will be recommended. The business impact could be substantial.

• Cost of project: –  Numerous iNEMI companies will be contributing to this research project

minimizing the costs to any one company. The main costs would be incurred in Phase 2 and will be assessed at the conclusion of Phase 1.

•  Efficiency: –  Final conclusions and recommendations will be derived in a far shorter time

frame than one company acting alone could achieve. –  The adoption of recommendations by the UL STP should be much faster than

usual as the recommendations will have the full support of iNEMI, the main constituents of the supply chain, and because UL is represented in the project as one of the co-chairs.

22 ©2012 iNEMI

Business Impact (2/2) Return on Investment

•  Potential elimination of unnecessary or redundant testing •  Improvements in time-to-market are expected from the work done to

flow chart the procedures •  Readiness for restriction of brominated flame retardants •  Newer tests or procedures may be developed to close hazard and

safety gaps

23 ©2012 iNEMI

Outcome of Project (Phase 1) •  A thorough evaluation of UL746 and UL796 as they pertain to PCB safety will

be conducted, with a result of a written assessment of the procedures and their applicability to safety.

•  A detailed analysis of failures of PCBs in the field will be documented, and either or both a Fault-tree Analysis or a Hazards-based Safety Engineering evaluation will be conducted with findings documented.

•  A list of tests and procedures will be generated that, based on science, are recommended and needed to ensure safety in PCBs. Additionally, a list of tests or procedures will be generated that, based on science, require additional consideration for inclusion or development to make them appropriate as part of the suite of tests and procedures to insure safety in PCBs.

•  Before Phase 2 begins, there will be a list of tests and procedures that will require additional development. This list will be assessed, with prioritization applied, and will be published. An estimate of the effort (resources) required to further develop specific tests will be documented at that time; this documentation will inform planning for Phase 2.

24 ©2012 iNEMI

Outcome of Project (Phase 2) •  The end of Phase 2 will result in recommendations for new or improved

tests and procedures needed to ensure safety in PCBs. These results will be documented in a report that will be submitted to the UL STP as a recommendation for discussion at future STP meetings, with the intent to consider these as changes to the UL certification process.

25 ©2012 iNEMI

Previous Related Work • The project team will continue to identify any related research or

development within the industry and academic communities. –  Appropriate internal UL research documents

–  The Center for Advanced Life Cycle Engineering (CALCE) at the University of Maryland has done significant work on laminate properties, separately or in conjunction with printed circuit board failures

–  IPC has an extensive suite of tests in IPC-TM-650, Test Methods Manual and some IPC standards’ development committees are currently engaged in new test development

–  Prior iNEMI project work that relates to PCBs, for example the recently concluded project to characterize Halogen-free and Halogenated laminates and PCBs.

26 ©2012 iNEMI

Project Schedule & Tasks • The Timetable for this project is 1.5 to 2.25 years

–  Phase 1 is 8 -10 months to completion –  Phase 2 is an additional 12-18 months to complete (Dependency is on

Phase 1 outcome)

27 ©2012 iNEMI

Project Monitoring Plans •  Ensure open lines of communication among participants •  Project participants will meet a minimum bi-weekly to review various aspects of

the project and make plans for next phases of the project •  Meeting minutes provided through e-mail •  Follow-up with individuals on an as-needed basis •  Project team will identify specific monitoring or communications plans to

accommodate project team member locations, e.g., multiple project meetings to cover multiple regions (EMEA, Asia, Americas)

•  Workshops and face-to-face meetings as determined by the project team •  Progress reports will be provided upon request for presentation at regularly

scheduled iNEMI meetings (e.g. a short series of PowerPoint slides showing the work in progress at member council meetings)

•  Track and document approximate man-months per quarter per team member (this will require the active members of the team to provide estimates)

•  Track and document approximate number of people on the project per quarter (this can be tracked through iNEMI's WebEx account)

28 ©2012 iNEMI

Future Project Plans (1/2) •  The scope of this project (see: IS / IS Not table) was limited such that the

project could be completed in less than 2 years. This decision to bound the time meant the known exclusion of some promising opportunities that would make ideal standalone projects. These areas of aligned work are outside the scope of this project, for purposes of effective resource deployment, i.e,: time and number of tasks to complete:

–  Flexible standards project: UL 746F and UL 796F, the standards for flexible materials and flexible PCBs are not part of the present project. However, there may be some decisions made in the present project that might inform improvements in the procedures surrounding the flexible UL standards. There may be a future project to work specifically on UL 746F and UL 796F with similar phases to those in this project.

29 ©2012 iNEMI

Future Project Plans (2/2) •  Outside the scope is Long-Term Thermal Aging (LTTA) which is expected to

be discussed during this project, but because of the complexity of finding an improved method to the existing procedures, and the length of time to complete one cycle of the test, would need to be a stand alone project. The LTTA test currently tends to run for over 1 year for a meaningful data set on one material. Any test which might replace or augment LTTA would need to establish results analogous to LTTA, which means at least a year per validation run. Given the time this test requires, a stand alone multiyear project needs to be established to study any alternatives.

•  Embedded optical waveguide materials and processes are outside the scope because

1)  These standards do not currently encompass this technology subset and so there is as yet no foundation established to work from;

2)  These materials and processes might necessitate a separate set of knowledge and participants. Safety requirements of/for “Optical” PCBs would seem to be in need of a discovery group.

30 ©2012 iNEMI

Summary and Next Steps •  Project has been approved by the iNEMI Technical Committee •  Open Enrollment for Project Sign-up will continue until April 27, 2012 •  More information can be found at

http://www.inemi.org/project-page/improving-ul-certification-laminates-and-pcbs

•  Steps for Joining the Project –  Please note: iNEMI membership is required to participate in the iNEMI Improving

UL Certification of Laminates and PCBs. The period for becoming a founding member of this project will close on April 27, 2012. Steps for joining the project are outlined below. •  For iNEMI members:

–  Complete and sign the project statement –  Fax the completed statement to +1 (703) 834-2735 or scan + email to infohelp@inemi.org

•  For non-members: –  Discuss annual membership fees with Bill Bader in North America

(bill.bader@inemi.org), Haley Fu in Asia (haley.fu@inemi.org), or Grace O'Malley in Europe (gomalley@inemi.org).

–  Complete the iNEMI membership application. (www.inemi.org) –  Fax the completed documents to +1 (703) 834-2735 or scan + email: infohelp@inemi.org. –  Complete and sign the Project Statement –  Fax the completed statement to +1 (703) 834-2735or scan + email to infohelp@inemi.org.

31 ©2012 iNEMI

Q&A

©2012 iNEMI

www.inemi.org Email contacts:

Mark  Mark  Schaffer  marks@inemi.org    

Haley  Fu  haley.fu@inemi.org