Process for preparing a nonconductive substrate for electroplating

Abstract

Described herein is an improved process for electroplating a conductive metal layer to the surface of a nonconductive material comprising pretreating the material with a carbon black dispersion followed by a graphite dispersion before the electroplating step.

What is claimed is:  
     
       1. A process for electroplating a conductive metal layer to the surface of a nonconductive material, comprising the following steps: 
       (a) contacting said nonconductive surface with a liquid carbon black dispersion comprising:  
       (1) carbon black particles having an average particle diameter of less than about 3.0 microns in said dispersion;  
       (2) an effective dispersing amount of a surfactant which is compatible with said carbon black; and  
       (3) a first liquid dispersing medium, wherein the amount of carbon black is sufficient to coat substantially all of said nonconducting surfaces and is less than about 4% by weight of said liquid carbon black dispersion;  
       (b) separating substantially all of said first liquid dispersing medium from said carbon black particles, whereby said particles are deposited on said nonconductive surface in a substantially continuous layer; and  
       (c) contacting said carbon black-coated nonconductive surface with a liquid conductive graphite dispersion comprising:  
       (1) conductive graphite particles having an average particle diameter of less than about 1.5 microns in said dispersion;  
       (2) an effective dispersing amount of a surfactant which is compatible with said conductive graphite; and  
       (3) a second liquid dispersing medium, wherein the amount of conductive graphite is less than about 4% by weight of said liquid conductive graphite dispersion;  
       (d) separating substantially all of said second liquid dispersing medium from said conductive graphite particles, whereby said particles are deposited on said carbon black-coated nonconductive surface; and  
       (e) electroplating a substantially continuous conductive metal layer over the deposited carbon black layer and the deposited conductive graphite layer and said nonconductive surface.  
     
     
       2. The process of  claim 1  wherein said carbon black particles have an average diameter of from about 0.05 to about 3.0 microns. 
     
     
       3. The process of  claim 2  wherein said carbon black particles have an average diameter of from about 0.08 to about 2.0 microns. 
     
     
       4. The process of  claim 1  wherein said graphite particles have an average particle diameter of from about 0.05 to about 0.8 microns. 
     
     
       5. The process of  claim 1  wherein both said first and second liquid dispersing medium are water. 
     
     
       6. The process of  claim 1  wherein said liquid carbon black dispersion contains less than about 10% by weight solids constituents. 
     
     
       7. The process of  claim 1  wherein said liquid graphite dispersion contains less than about 10% by weight solids constituents. 
     
     
       8. The process of  claim 1 , wherein said contacting steps (a) and (c) are carried out by immersing the non-conductive material into said liquid carbon black dispersion and liquid conductive graphite dispersion, respectively. 
     
     
       9. The process of  claim 1  wherein said separating steps (b) and (d) are carried out by heating the deposited dispersions. 
     
     
       10. The process for electroplating the walls of through holes in a laminated printed wiring board comprised of at least one nonconducting layer laminated to at least two separate conductive metal layers, said process comprising the steps: 
       (a) contacting said printed wiring board having said through holes in a bath of a liquid carbon black dispersion comprised of:  
       (1) carbon black particles having an average particle diameter of less than about 3.0 microns in said dispersion;  
       (2) an effective dispersing amount of a surfactant which is compatible with said carbon black; and  
       (3) a first liquid dispersing medium wherein the amount of carbon black is sufficient to coat substantially all of said nonconducting surfaces and is less than about 4% by weight of said liquid carbon black dispersion;  
       (b) separating substantially all of the liquid dispersing medium from said dispersion, thereby depositing said carbon black particles is substantially continuous layer on said nonconducting portions of said hole walls; and  
       (c) contacting said carbon black-coated printed wiring board with a liquid conductive graphite dispersion comprising:  
       (1) conductive graphite particles having an average particle diameter of less than about 1.5 microns in said dispersion;  
       (2) an effective dispersing amount of a surfactant which is compatible with said conductive graphite; and  
       (3) a second liquid dispersing medium, wherein the amount of conductive graphite is less than about 4% by weight of said liquid conductive graphite dispersion;  
       (d) separating substantially all of said second liquid dispersing medium from said conductive graphite particles, whereby said particles are deposited on said printed wiring board;  
       (e) microetching said metal layers of said printed wiring board to remove any deposited carbon black and graphite therefrom; and  
       (f) electroplating a substantially continuous conductive metal layer over the deposited carbon black layer and the deposited conductive graphite layer on said nonconductive portions of said hole walls, thereby electrically connecting said metal layers of said printed wiring board.  
     
     
       11. The process of  claim 10  wherein said first and second liquid dispersions further comprise a sufficient amount of at least one alkaline hydroxide to raise the pH of said liquid dispersion in the range from about 10 to 14. 
     
     
       12. The process of  claim 11  wherein said alkaline hydroxide is selected from the group consisting of potassium hydroxide, sodium hydroxide, and ammonium hydroxide. 
     
     
       13. The process of  claim 10  wherein said first and second liquid dispersion contain less than about 10% by weight solids constituents. 
     
     
       14. The process of  claim 10  wherein said carbon black particles have an initial pH from about 2 to about 4. 
     
     
       15. The process of  claim 10  wherein said surfactant is a phosphate ester anionic surfactant. 
     
     
       16. The process of  claim 10  wherein said conductive metal is copper. 
     
     
       17. The process of  claim 10  wherein said first and second liquid dispersing medium is water. 
     
     
       18. The process of  claim 10  wherein said process further comprises, before step (a), contacting said printed wiring board with a cleaning solution and a conditioner solution. 
     
     
       19. The process of  claim 18  wherein said process further comprises a water rinse after said microetching step (e). 
     
     
       20. A nonconductive surface covered with a deposit of a substantially continuous layer of carbon black having an average particle diameter of less than about 3.0 microns thereon and a layer of conductive graphite having an average particle diameter of less than about 1.5 microns deposited over said carbon black deposit. 
     
     
       21. The  A nonconductive surface of  claim 20 covered with a deposit of a substantially continuous layer of carbon black having an average particle diameter of less than about  3 . 0  microns thereon and a layer of conductive graphite having an average particle diameter of less than about  1 . 5  microns deposited over said carbon black deposit, wherein said nonconductive surface comprises at least one through hole of a printed wiring board. 
     
     
       22. A metal-plated nonconductive surface covered with a deposit of a substantially continuous layer of carbon black having an average particle diameter of less than about 3.0 microns thereon and a layer of conductive graphite having an average particle diameter of less than about 1.5 microns deposited over said carbon black deposit and underlying the plated on metal. 
     
     
       23. The metal-plated nonconductive surface of  claim 22  wherein said nonconductive surface comprises at least one through hole of a printed wiring board. 
     
     
       24. The metal-plated nonconductive surface of  claim 22  wherein said metal is copper. 
     
     
       25. A liquid disperson suitable for use in enhancing the electroplating of a nonconducting surface comprised of: 
       (a) conductive graphite particles having an average particle diameter of less than about 1.5 microns in said dispersion;  
       (b) an effective dispersing amount of a surfactant which is compatible with said conductive graphite;  
       (c) optionally, a sufficient amount of at least one alkaline hydroxide to raise the pH of said liquid dispersion in the range from about 9 to 14; and  
       (d) liquid dispersing medium, wherein the amount of conductive graphite is sufficient to coat substantially all of said nonconducting surface and is less than about 4% by weight of said liquid dispersion and wherein said liquid dispersion contains less than about 10% by weight solids constituents.  
     
     
       26. The dispersion of  claim 25  wherein said alkaline hydroxide is selected from the group consisting of potassium hydroxide, sodium hydroxide, and ammonium hydroxide. 
     
     
       27. The dispersion of  claim 25  wherein said surfactant is a phosphate ester anionic surfactant. 
     
     
       28. The dispersion of  claim 25  wherein said liquid dispersion medium is water. 
     
     
       29. The dispersion of  claim 25  wherein said dispersion further comprises an alkaline hydroxide and said liquid dispersing medium is water, wherein the percentages of each component of said dispersion is as follows: 
       conductive graphite having an average particle diameter about 0.05-0.8 microns: 0.1-4% by weight  
       surfactant: 0.01-4% by weight  
       alkaline hydroxide: 0-1% by weight  
       water: Balance.  
     
     
       30. The dispersion of  claim 29  wherein said dispersion consists essentially of: 
       conductive graphite having an average particle diameter of about 0.01-0.4 microns: 0.2-2% by weight  
       phosphate ester anionic surfactant: 0.05-2% by weight  
       potassium hydroxide: 0.4-0.8% by weight  
       water: Balance.