http://www.kinwong.

com

BOSCH CAF Failure Analysis

KINWONG(JIANGXI)
2019-09-20

1
 Analysis Procedure
http://www.kinwong.com

Yes SEM+EDX
Migration on
Surface
Microscope
(40X) No

HW-HW/HW-ILCAF Analysis

(Insulation
Low Resistance
Resistance
≤20MΩ-Failure Tester)

Horizontal
(Microscope)
Grinding CAF
Migration
Vertical Grinding

Side Grinding

Copper Particles
(SEM+EDX) 2
 Analysis Equipment
http://www.kinwong.com

KEYENCE VHX-5000 KEYENCE VK-X100

（ Japan ） （ Japan ）

HIOKI SM7110 JEOL JSM-IT300 + Oxford EDS 3

（ Japan ） （ Japan ）
 CAF Analysis Result-summary
http://www.kinwong.com

32 pcs in total, 25 of the 32 are found with failure points

Failures located
Analysis Party
Analysis Qty. H-IL H-H
MicroTek 3 2 1
SY 4 2 0
KWI 7 6 0
KWII 19 15 0
IN TOTAL 33 25 1
Failures(H-H) on Core 0
Failures(H-H) on PP L1-L2 1pcs
Failures(H-IL) on Core 0
L2-L1 4=2+2 pcs Failure closed to L2
L3-L4 7=6+1 pcs Failure closed to L3
Failures(H-IL) on PP
L4-L3 10=1+9 pcs Failure closed to L4
L5-L6 4=1+3 pcs Failure closed to L5
All failures are on PP and happen at the interface between glass
Conclusion
fiber and resin; No hollow fiber;
4
 CAF Analysis Result-summary
http://www.kinwong.com

5
 CAF Analysis Result-root cause finding
http://www.kinwong.com

1. — No evident difference among the 3 batches. All the

failure locations were at the interface between glass fiber
and resin.

6
 CAF Analysis Result-root cause finding
http://www.kinwong.com

2.— Why CAF failure occurred in glass fiber bundle– Ishikawa

Man Machine Measurement
PP resin dip
machine abnormal
Thin dielectric
Pre-layup operation thickness and thin
PP cutting machine
not good caused PP butter coat after hot
abnormal and caused
damaged press
to be pulled

Press machine
abnormal caused
poor curing of resin
Why CAF
occurred in
Insufficient RC of PP Butter coat not be
Condensed water glass fiber
appear on the surface
PP have hollow fiber issue
considered in the stack
design
layer of PP roll when bundle?
PP is transported from
Glass fiber cloth abnormal frozen warehouse to
Hot press parameters
PP cutting room
are not suitable
Resin abnormal caused
Improper drilling parameters
poor combination of glass
resulted large HW roughness,
fiber and resin
fiber crazing,
fiber whitening Foreign material from
Un-splitting fiber cloth Foreign Excessive lamination process
caused poor CAF ability material in PP desmear

Material Method Environment

7
 CAF Analysis Result-root cause finding
http://www.kinwong.com

3 .— Ishikawa Analysis Verification

Relevancy for
consideration
Ishikawa
Ishikawa (relevant for futher root
No. Cause Item Description Reason for excluding Evidence
Category cause analysis,
(Possible Cause)
or to be excluded from
analysis)

Operator follow SOP and do visual check to

Pre-layup operation not good caused the PP , core and inner layers after brown
1 Man Excluded Cause No
PP damaged oxide. Take the PP with both hands to finish
the pre-lay up.

SY internally checked that the resin dip

2 Machine Excluded Cause PP resin dip machine abnormal No machine no abnormal in the test board
material production period.

The PP cutting machine checklist showed

PP cutting machine abnormal and
3 Machine Excluded Cause No that there weren’t any abnormal in the
caused to be pulled
production day.

Press machine abnormal caused The profile and production record are
4 Machine Excluded Cause No
poor curing of resin normal, no any special remark.

Process cross-section picture showed that

Measure- Thin dielectric thickness and thin dielectric thickness and butter coat all be
5 Excluded Cause No
ment butter coat after hot press checked and can meet requirement. Butter
coat thickness all more than zero.

8
 CAF Analysis Result-root cause finding
http://www.kinwong.com

Relevancy for consideration

Ishikawa
Ishikawa (relevant for futher root cause
No. Cause Item Description Reason for excluding Evidence
Category analysis, or to be excluded from
(Possible Cause)
analysis)

PP RC tolerance spec is +/-2%, all PP

6 Material Excluded Cause Insufficient RC of PP No incoming inspection record showed that all
PP RC in spec, as attachment.
Refer
From all failed channels cross-section analysis
PP have hollow fiber
7 Material Excluded Cause No analysis results, not any one failure caused results in
issue
by hollow fiber. previous
page
For test board used with Asahi glass cloth,
SY checked the glass cloth incoming check
report, all check items result are good. The
Glass fiber cloth
8 Material Excluded Cause No glass cloth in shelf life, not expired. And SY
abnormal
explained, core board used the same 7628
PP lot, no one CAF failure occurred in core
layer
SY checked the resin incoming check
record, each item meet spec requirement.
Resin abnormal caused
SY also explained that they used the same
9 Material Excluded Cause poor combination of glass No
lot resin for PP7628 RC47%, RC50% and
fiber and resin
RC52% and for core layer, no CAF failure in
core layer, record as attachment.

Un-splitting fiber cloth Based on SY’s check result, the air

10 Material Excluded Cause No
caused poor CAF ability transmittance meet requirement.

Refer
analysis
From all cross-section pictures, not any
11 Material Excluded Cause Foreign material in PP No results in
picture showed there were foreign material
previous9
page
 CAF Analysis Result-root cause finding
http://www.kinwong.com

Relevancy for consideration

Ishikawa
(relevant for futher root
Ishikawa Cause Item
No. Description cause analysis, Reason for excluding Evidence
Category (Possible
or to be excluded from
Cause)
analysis)
In the design stage, KW design the
structure based on customer requirement
Excluded Butter coat not be considered
12 Method No and board thickness requirement, also
Cause in the stack design
considered the butter coat issue, selected
mid RC or high RC PP.
Based on KW and SY study, low heating
rate will cause poor resin fluidity, and low
hot press pressure, the resin cannot be
squeezed into glass fiber space very good.
Possible Hot press parameters are not
13 Method Yes The resin and glass fiber combination not
Cause suitable
good. These factor will raise CAF failure
probability.
The original program which SY provided as
attachment.
From the plating process cross-section
Improper drilling parameters
picture, the hole wall roughness and
Excluded resulted high value of HW
14 Method No wicking value are very small. From the
Cause roughness, wicking, fiber
CAF analysis data, the roughness and
crazing
wicking also in spec.
Excluded KW checked the record, desmear rate and
15 Method Excessive desmear No
cause chemistry concentration all in spec.
Condensed water beads on
KW checked the PP transportation process
the surface layer of PP roll
Excluded and each step are normal. The final check
16 Environment for PP transportation from No
Cause of the PP roll protection mylar surface
frozen warehouse to PP
found no condensed water.
cutting room
Refer analysis
Excluded Foreign material from No foreign material be found in all failed
17 Environment No results in
Cause lamination process coupon cross-section analysis.
previous page
10
 CAF Analysis Result-root cause finding
http://www.kinwong.com

4 .— 5Why for root cause

The problem
with which the Root Causes
1st Why? 2nd Why? 3rd Why? 4th Why? 5th Why? Measures (R, D)
5Why question (TRC, MRC)
chain is started
Why CAF Q: Why CAF occurred Q:Why have Q: Why have Q: Why designed Q: Why SY confirmed
occurred in glass in glass fiber bundle? combination of glass heating rate and the program as program have CAF
fiber bundle? A: Because the hot fiber and resin after the the maximum this: heating rate test failure?
press parameter not press step? pressure in the 1.27℃/min, and A: CAF test is long
suitable, caused poor A: According to the hot press programhigh pressure term reliability test, the
combination of glass investigation, both the are low issue? 320psi program trial run test
fiber and resin heating rate and the A:Hot press A:The hot press only checked simply
maximum pressure in equipment was program be defined reliability items, not
the hot press program normal, the by SY engineer included long term TRC Owner:
are low original program after the hot press item(like CAF). SY For this internal CAF Test board:
designed heating trial run with report showed that test failure, KW plan to Zhengkun Wang
rate 1.27℃/min, Autolad 1 in heating rate, pressure adjust the hot press
and high pressure KW(JX) plant, SY not change, only program to make Chamber test:
320psi provided the test adjusted press start sample board and test. Xianquan Huang
report and listed time and high temp Program adjustment:
the hot press curing time. raise heating rate to Prepare the test
program. 1.7℃/min, 2.0℃/min, board, and then
Q:Why the program Q:Why the parameter in Q: Q: Q: 2.5℃/min, and perform CAF test,
designed as heating SY Autlad1 operation A: A: A: increase hot press high the test focus on H-
rate 1.27℃/min, and guide file definition, still pressure from 320psi to IL0.26 coupon
high pressure 320psi have CAF failure? 360psi. which the most
can be use for the CAF A: SY explained that Use the verification test failures in last
test board production? the heating rate and sample to perform internal CAF test.
A: The program BS001 high pressure value chamber test and verify Check and
be provided by SY after both near the low limit, the adjusted parameter summary the CAF
their trial run hot press caused poor resin validity. test result at 600H.
test in KW(JX) plant. fluidity, and low
And, Autolad 1 pressure, the resin
operation guide defined cannot be squeezed
heating into glass fiber space
rate1.0-2.5℃/min, very good. The resin
pressure 300-420psi, and glass fiber
the program definition combination not good.
in this range.
11
 CAF Analysis Result-root cause finding
http://www.kinwong.com

5.—Corrective Actions
Estimated
No. Corrective Action effectiveness Owner Measures (R, D)
[%]
Prepare the test
board, and then
For this internal CAF test failure, KW plan to adjust the
Test board: perform CAF test, the
hot press program to make sample board and test.
Zhengkun Wang test focus on H-IL0.26
Program adjustment: raise heating rate to 1.7 ℃/min,
coupon which is the
1 2.0℃/min, 2.5℃/min, and increase hot press high 100%
CAF test: most failures in last
pressure from 320psi to 360psi.
Shengxian internal CAF test.
Use the verification test sample to perform chamber test
Huang Check and summary
and verify the adjusted parameter validity.
the CAF test result at
600H.

12
 CAF Analysis Result-root cause validation
http://www.kinwong.com

Validation Plan
1 、 Based on the root cause analysis, KW plan to perform validation test to
verify the action’s validity.
2 、 The material information from SYL showed that PP and core process and
quality check not any abnormal. Pls do note KW do not have ability to prove
that resin and glass cloth have issue.
3 、 KW plan to test TW glass cloth PP and CCL with Asahi glass cloth
material at the same time.
Plan No. Glass cloth Heating rate Pressure Samples (Produce PNL)
1 TW Glass 1.7℃/min 360PSI 24
2 TW Glass 2.0℃/min 360PSI 24
3 TW Glass 2.5℃/min 360PSI 24
4 Asahi 2.0℃/min 360PSI 24
5 Asahi 2.0℃/min 380PSI 24

Process Collect data Sample Number Method

Pressing heating rate 2 thermocouple
Pressing board thickness 24 thickness measure machine
Pressing buttercoat 3 cross section
DVCP wicking 3 cross section
DVCP roughness 3 cross section
DVCP H-H distances 3 cross section
DVCP H-IL distances 3 cross section 13
 CAF Analysis Result-optimize schedule
http://www.kinwong.com

14
 Why H-IL have many more CAF failure than H-IL?
http://www.kinwong.com

Kinwong set 30 channels for each test coupon and the failure time as
the table below shows. H-IL has higher failure than H-H. Per the box
plot, there is no abnormal data except H-IL 0.26mm of which the failure
time is around 500Hrs and only one 827Hrs. The 30 channels for H-IL
0.26mm all failed.

15
 Why H-IL have many more CAF failure than H-IL?
http://www.kinwong.com

After KW’s internal discussion again, conclusion is as the following:

1. Inner layer copper image design brings about this difference. In the inner
layers, the H-H 0.50mm area is with large copper free area, while the H-IL
0.26mm area is with 0.82mm dots and with large copper around(as the
below shows), which makes the resin flow and pressure different.H-IL area
with dots cause loss of pressure. What’s worse, the low heating rate low
pressure result in bad combination of resin and glass fiber.
2. The distance of different net was the other point to affect CAF performance.
From previous analysis, our other process control of brown oxide, ML
cleanliness, drilling and desmear are good. In this condition, IL pattern
difference, design distance gap combined with poor glass fiber and resin
combination caused H-H CAF results better than H-IL.
H-H0.50 IL pattern H-IL0.26 IL pattern

16
http://www.kinwong.com

THE END
17