Patent Application
20170051411
The present invention relates generally to an electroless silver plating composition that is both stable and prevents extraneous plating. The invention uses heavy metal based stabilizers which are both measurable and controllable in solution. The process of plating on a substrate using the invention described herein substantially prevents plating in areas other than the metal surface where plating is desired. This invention provides for an autocatalytic reaction, opposed to the galvanic reaction that typically occurs between silver and the metal to be plated upon
There are several well-known methods for the plating of metals, such as electroplating, immersion plating and autocatalytic electroless plating. Among all the plating methods, autocatalytic electroless plating has the capability to plate a substantially uniform metallic coating onto a substrate having an irregular shape. Electroless coatings are also virtually nonporous, which allows for greater corrosion resistance than electroplated plated or immersion plated substrates. Thus, electroless plating methods are widely used in the printed circuit board (PCB), integrated circuit (IC), and light emitting diode (LED) industries. Most common plating methods involve electroless nickel plating, electroless copper plating, and electroless gold plating.
Plating a copper or copper alloy surface with electroless nickel followed by immersion gold (ENIG) is an industry standard that typically produces a reliable deposit that is useful in various applications. While ENIG has proven to be very reliable, it is not without issues. The gold plating step can be excessively corrosive to the nickel deposit causing deterioration of the nickel at the grain boundaries which compromises the integrity of the deposit. The gold plating step is additionally very expensive in comparison to other plating steps. Electroless silver plating has become a desirable alternative to plating immersion gold over nickel plated surfaces due to cost restraints and a desire to reduce potential corrosion at the grain boundaries found on the nickel surface. Black line nickel is a well-known issue within the industry when the traditional coating of ENIG is employed. Not only is silver an economically responsible choice over gold but a silver bath formulation that plates completely by an electroless mechanism (not by immersion/exchange reaction) is much less corrosive to the underlying metal surface. The electroless silver plated surface is additionally useful in applications such as LEDs where surface reflectivity is important.
Electroless silver plating is a well-known process. However, application of electroless silver plating in industries such as PCB, IC, and LED manufacturing is limited due to several fundamental issues of the process. Some of the issues are:
a) The plating baths tend to spontaneously decompose forming silver particles throughout the solution. This decomposition causes loosely adherent, very fine silver metal particles on the deposit and short bath life.
b) An immersion reaction occurs during plating due to the difference of reduction potential between Ag and the metal substrates, such as copper and nickel. This reaction causes severe metal substrate corrosion (see
c) Undesirable extraneous Ag plating is a widely experienced problem (See
Although electroless silver technology is well known, electroless silver plating has not become a widely used commercial technology due to issues mentioned above.
There have been attempts to cure the problem of extraneous plating while maintaining a stable silver plating bath as set out in U.S. Pat. No. 5,322,553, US Patent Application 2012/0061698 A1, and International Publication WO 2006/065221 A1. These patents are hereby incorporated by reference in their entirety.
In U.S. Pat. No. 5,322,553 the inventors found that a thiosulfate salt in combination with a sulfite salt in an electroless silver plating solution allowed for a uniform deposit. By using this redox system there is no need for any additional type of reducing agent and the bath does not contain ammonia or cyanide ions. While the inventors show that a reasonable silver deposit may be plated over nickel, the bath is said to be sensitive to silver concentration such that if the concentration is out of the desired range then the bath is difficult to control and uncontrolled plating may occur in the container holding the solution or on areas of the substrate where plating is not desired. This is likely due to use of sulfur stabilization which is difficult to control and makes the plating solution very sensitive and often times unstable.
In U.S. 2012/0061698 A1, the inventors have used an immersion silver plating bath over electroless nickel to increase solderability in electronics packaging applications. While the method is useful, the silver thickness is limited due to the immersion type reaction and corrosion of the nickel surface is still an issue if the article to be plated is left in the plating solution for extended time.
In International Publication WO 2006/065221 A1 describes an electroless silver plating bath which must operate with two phases present to deposit a uniform silver deposit. The bath is stabilized based on a multi-phase process using non-ionic surfactants where the bath is operated above the cloud point of the surfactants. While the process of this invention results in a desirable deposit, bath control is critical. The bath should be kept warm to prevent decomposition and unwanted deposition, which is not practical when considering commercially viable options.
In this invention, stabilizers that contain heavy metal ions were introduced into the electroless silver plating solution which surprisingly addresses the issues found within the prior art, therefore making it possible to move forward with a commercially available process.
Heavy metal based stabilizers allow for precise determination of their concentration within the plating solution, prevent extraneous plating, and reduce the amount of corrosion on the underlying metal surface.
It is therefore an object of the present invention to provide an improved method of plating electroless silver on an article with exposed copper or copper alloy that has been plated with a barrier metal layer prior to plating the article in electroless silver. The inventors have surprisingly discovered that by using a heavy metal based stabilizer, such as lead in an electroless silver plating bath, the underlying nickel layer is not corroded and extraneous plating is eliminated. This is a significant advance since extraneous plating can cause bridging and electrical shorts between finely spaced traces. The use of such metal based stabilizers in the electroless silver plating bath is believed to be responsible for the elimination of any extraneous plating as seen in
In addition to the clear advantages found by using a metal based stabilizer, there are additional benefits over the typical sulfur based stabilizers. The metal based stabilizers can be analyzed and measured in the solution, which is not typically possible when using sulfur based stabilizers due to the low concentration of bath stabilizers along with other interfering organic components. Therefore, the use of heavy metal based stabilizers allows for tighter process control and better bath stability.
It is another object of the present invention to provide an electroless silver plating bath for use over an electroless nickel deposit, in which the nickel corrosion is minimized or eliminated.
It is another object of the present invention to provide control over the stabilizer concentration in the electroless silver plating bath.
It is still another object of the present invention to provide a method of using heavy metal based stabilizers in an electroless silver bath to prevent extraneous plating on areas where plating is not desired.
It is still another object of the present invention to provide an electroless silver plating bath which is stable and not prone to plating out on the vessel in which plating takes place.
To that end, in one embodiment, the present invention relates generally to an electroless silver plating bath and method or using such bath for producing an article that has previously been plated with electroless nickel or electroless cobalt, in which extraneous plating is prevented and the plating bath remains stable, the method comprising, in order, the steps:
The inventors of the present invention have found that the use of heavy metal based stabilizers in an electroless silver plating composition can be used to prevent extraneous, control plating rate, and reduce corrosion of the underlying metal surface. Thus, the electroless silver composition described herein allow for controlled electroless plating on metal surfaces exposed on an article without plating on other areas of the article surface, while maintaining a stable bath and not plating out on the vessel walls where the bath is held. In addition, the method described herein can be used to plate in various applications across multiple industries.
To that end, in one embodiment the present invention relates generally to an electroless silver bath which can be used over an electroless metal surface that has previously been plated with a barrier metal such as nickel or cobalt, which prevents extraneous plating while maintaining a stable plating bath. The method of the current invention includes the steps of:
The inventors of the present invention have found that the inclusion of a heavy metal stabilizers in an electroless silver plating, following the plating of an electroless metal barrier layer and an optional immersion silver strike layer, allows for elimination of extraneous and provide bath stability. While not wishing to be bound by theory, the inventors believe that this is likely due to use of heavy metal based stabilizers which prevents extraneous plating. The ability of the heavy metal ion to aid in bath stability and prevent extraneous plating is both surprising and unexpected.
The problem of extraneous plating and bath plate out, both commonly seen when sulfur stabilizers are used in electroless silver plating baths, is effectively eliminated by using a heavy metal based stabilizer or combinations thereof. The current invention provides an electroless silver bath plating formulation that is useful for plating over an electroless metal barrier layer and an optional immersion silver strike layer. The electroless silver deposit provides desired characteristics such that good wirebonding, good solderability, and high reflectance can all be achieved, all with very little or no corrosion of the underlying electroless metal barrier layer as seen in
Table 1 presents a rate curve produced by the inventors in which a ceramic LED coupon with exposed copper areas was processed through an electroless nickel bath, followed by an immersion silver strike, and then plated in an electroless silver plating composition of the current invention. As the plating time increased in the electroless silver plating solution, the thickness continued to increase linearly. This indicates that the bath is plating by an electroless mechanism. The thickness continues to increase as plating time increases using the current invention, while if the bath was plating by an immersion reaction the thickness would not continue to grow linearly. An immersion reaction would show a plateau when graphed over time.
A typical process cycle for preparing an article with exposed copper or copper alloy for electroless plating consists of optionally cleaning and/or micro etching the exposed copper or copper alloy, activating using a precious metal catalyst, immersing the article in an acid based solution after activation and then electrolessly plating the areas of exposed copper or copper alloy. A metal barrier layer is created using a first electroless plating bath and then a subsequent electroless silver bath is used to give the final deposit the desired properties.
The metal barrier layer can be either nickel or cobalt which is electrolessly plated over a copper or copper alloy that has been prepared as described above. Any typical electroless nickel or cobalt plating solutions are suitable for use in the current invention. The metal barrier layer may be anywhere from 10-400 microinches thick.
After the electroless metal barrier layer is plated, an immersion silver strike layer may be plated over the barrier layer. This will ensure that any gaps or pores that may be present in the barrier layer will be capped with silver prior to electroless silver plating. The silver strike layer will deposit less than 10 microinches of silver, if used, on top of the metal barrier layer.
The inventors have found that heavy metal based stabilizers or combinations of such compounds, including compounds with metal ions from Group IIIA, Group IVA, Group VA, Group VIA, and the lanthanide series are useful in an electroless silver plating composition.
Examples of these heavy metal based stabilizers that may be used alone or in combination in the current invention are as follows: lead chloride, lead acetate, lead lactate, lead citrate, bismuth citrate, tin sulfate, thallium nitrate, telluric acid, antimony chloride, potassium antimony (III) tartarate, lanthanum (III) nitrate, europium (III) nitrate, indium (III) nitrate, seleneous acid, and sodium selenite.
The heavy metal based stabilizer or combination of such compounds is present in the electroless silver plating composition of the current invention, such that the metal ion is present at a concentration of at least 0.1 mg/L. The metal ion of the heavy metal based stabilizer compound or combination of compounds may be present in total anywhere from 0.1 mg/L-1,000 mg/L. The metal ion of the heavy metal based stabilizer compound or combination of compounds is preferably present anywhere from 0.5 mg/L-100 mg/L, and most preferably from 1 mg/L-10 mg/L.
In addition to the stabilizer compounds as described above, the electroless silver bath comprises at least one source of silver ions, a buffer, a surfactant, a reducing agent, and a complexing agent. Other ingredients may be incorporated as necessary that would be familiar to a skilled artisan. The silver ions are present in the electroless silver composition from 0.1-10 g/L, the buffer is present between 0.1-5 g/L, a surfactant is present between 0.1-5 g/L, the reducing agent is present between 0.1-5 g/L, and the complexing agent(s) is present between 0.1-5 g/L.
The electroless silver bath can be operated at a temperature between 30° C. and 80° C. The bath is more preferably run at an operating temperature between 40° C. and 70° C., and most preferably between 50° C. and 60° C. Plating times are dependent on the desired thickness. The thickness of the silver deposit will increase linearly with the immersion time in the plating composition. A typical deposit may range anywhere from 5-50 microinches, wherein good solderability, good wirebonding and high reflectivity can all be achieved.
The pH of the electroless silver bath should be maintained between 9 and 11, and more preferably between 9.5 and 10.5. The pH is most preferably maintained between 10.1 and 10.4.
The electroless silver bath composition may be utilized with or without a source of air bubbling through the solution.
The amount of stabilizer in solution can easily be analyzed by simple analytical techniques such as titration, using a polaragraph, or by atomic absorption spectroscopy. This is a significant advantage over electroless silver baths that contain sulfur based stabilizers. Sulfur based stabilizers are often difficult to analyze and control once they are in solution due to their low concentration and interference with other organic compounds. In turn, solutions that contain sulfur based stabilizers frequently become either too stable to plate or unstable such that plating rate cannot be controlled, and decomposition of the plating solution occurs. By using a heavy metal based stabilizer, the bath is extremely stable and the plating rate becomes reliably controllable.
The invention as described herein is a novel electroless silver plating composition and method for using the composition. The invention described herein is thought to be useful for a wide variety of applications wherein a final layer of silver can be deposited to provide excellent wirebonding, solderability, and reflectivity. Electroless silver may now be considered useful in commercial applications since the current invention has overcome the long enduring issues of bath stability and extraneous plating (see
