Method of producing a laminated structure

专利摘要:
The present invention provides a method of laminating a structure comprising a photopolymerizable adhesive composition 16 between two or more layers 12, 14 and opaque, colored, or reflective layers 12, 14 . One or both of the layers 12, 14 are transmissive to actinic radiation in the wavelength range of 400 nm to 1200 nm. The photopolymerizable adhesive composition 26 absorbs radiation in the identified spectral region of the radiation-permeable layer. Cure 28 is performed by irradiating radiation in the identified spectral region through the radiation-transmissive layer into the photopolymerizable composition to create a laminate structure. The underfilled flip chip assembly 10 on an integrated circuit substrate can be manufactured by the method described above. The photopolymerizable adhesive composition 26 may be applied directly to one or both surfaces of the aligned chip 12 and the circuit board 14 or the chip 12 aligned on the integrated circuit board substrate 14, Can be underfilled with capillary action by the photopolymerizable adhesive composition 26 which is finally cured (28). A data storage disk can also be manufactured by the method of the present invention.
公开号:KR20020034172A
申请号:KR1020027001322
申请日:1999-11-30
公开日:2002-05-08
发明作者:옥스먼조엘디；크로프마이클에이；호거톤피터비
申请人:캐롤린 에이. 베이츠；쓰리엠 이노베이티브 프로퍼티즈 캄파니；
IPC主号:

专利说明:

[0001] METHOD OF PRODUCING A LAMINATED STRUCTURE [0002]
[2] Photopolymerization of monomers using UV light to make adhesive compositions is an established part of polymer chemistry. Compositions comprising a plurality of photopolymerizable compositions, such as ethylenically unsaturated monomers and at least one photoinitiator, are photopolymerized using UV radiation. The requisite for such photopolymerization is that the photopolymerizable composition must be exposed directly to UV radiation so that the photoinitiating component can form the free radicals necessary to initiate the photopolymerization process. Many industrial processes are based on selective UV photopolymerization, and in these processes, a mask is used to block UV irradiation to a specific portion of the surface or substrate so that photopolymerization occurs only in the exposed portion.
[3] In the electronics industry, a number of methods have been used to couple electronic components together for the purpose of forming multilayer components or simply attaching components onto a substrate. Methods involving photopolymerization are generally limited to situations where one or more substrates or parts are substantially transparent to UV radiation. However, it is rarely possible to use such a method when connecting components to a printed circuit board (PCB). Because PCBs are often made of opaque, colored materials, usually at least partly covered by metal circuit traces. In addition, the electronic component itself, e.g., a chip, is typically completely impermeable to electromagnetic radiation. Generally, in the electronics industry, thermally polymerizable adhesives are used when strengthening of solder bonding is required. This is entirely unsatisfactory because of the long heat curing cycle required. In addition, some electronic components can be sensitive to heat, and free radical thermal polymerization is generally not useful for patterned activation or selective activation.
[4] Light curing is used to combine electronic components. For example, the surfaces to be bonded may be coated with a photopolymerizable adhesive, followed by irradiation of the adhesive, then the two parts are placed together and the irradiated adhesive is fully cured. Alternatively, irradiating the peripheral edges of the parts to be joined may form a bond of sufficient strength to temporarily secure the part in place. For complete curing, it is often necessary to heat the bonded parts.
[5] A method of curing a photopolymerizable adhesive by UV irradiation through a substrate is known. For example, DE 3939628 discloses a method of bonding electronic components to an aluminum oxide ceramic substrate or an aluminum nitride ceramic substrate having a thickness of 1500 mu m or less by UV irradiation with a power density of at least 50 mW / cm. It has been reported that the transmittance of UU rays through an aluminum oxide ceramic substrate having a thickness of 1016 占 퐉 is about 0.6%.
[6] U.S. Patent No. 4,656,314 discloses a method of curing a conductive metal coated UV curable ink on a translucent PCB by UV irradiation from both the top and bottom of the PCB, wherein at least a portion of the UV light is directed from the back side To help complete curing of the ink. The substrate is characterized in that it is a sheet of polyester or polycarbonate which is at least partially translucent and preferably at least 50% translucent to UV light. Conventional printed MYLAR (DuPont) is said to be an effective commercially available substrate.
[7] U.S. Patent No. 5,065,505 discloses a method of connecting circuit boards, wherein the photo-curable adhesive is coated over a light-transmissive circuit board having electrodes formed thereon. The light beam is irradiated from the opposite side of the coated side through the circuit board to cure the adhesive in the portions not blocked by the electrode. The illustrated photoinitiator has an absorption peak wavelength in the range of 240 nm to 365 nm. No photoinitiators useful in the visible range are described. Suitable substrates for the circuit board include polyimide resin, polyester resin and the like.
[8] Japanese Patent Application Laid-Open No. 7-106723 discloses a method of curing an adhesive through a flexible circuit board having a transmittance of 5% or more with respect to an UV ray having a wavelength of 350 nm to 400 nm. Examples of the base film on which UV curing is performed include poly (etherimide), poly (ether sulfone), polyethylene naphthalate, polyether ether ketone, polycarbonate, and polyethylene terephthalate.
[9] Japanese Patent Application Publication No. 7-81114 discloses a method of curing a photo-curing adhesive in the presence of a diketone photo-initiator and a dialkylaminobenzophenone photoinitiator by irradiation through a translucent substrate using an irradiation wavelength of 436 nm or less have.
[10] U.S. Patent No. 5,607,985 discloses a photopolymerization initiator for visible light polymerization of an adhesive comprising a photopolymerization initiator, an aliphatic tertiary amine, and a radical polymerizable monomer. A sandwich-like structure comprising two opaque glass parts having a 10% light transmittance at 510 nm and 0% transmittance at 490 nm to 200 nm, respectively, when exposed to a metal halide lamp for 2 minutes have.
[11] U.S. Patent No. 5,798,015 discloses a method of generating a reactive species (adhesive) by providing a wavelength-specific photosensitizer in combination with a reactive species-generating photoinitiator and irradiating the wavelength-specific photosensitizer. The method is used to laminate two or more layers by coating the adhesive between the layers and causing the polymerization of the adhesive to take place so that at least one of the layers is a cellulosic or polyolefinic nonwoven web or film , The photosensitizer is one of a series of specific acryloalkenoic sites.
[12] Often, optical recording discs, such as compact discs and CD-ROMs, comprise two or more polymeric base substrate layers each comprising a recording layer, wherein the layers are bonded together by adhesive with both recording layers facing each other have. Typically, the recording layers comprise an opaque metal foil. It is difficult to uniformly cure the adhesive between the foils. U.S. Patent No. 5,360,652 discloses such an optical recording disc wherein the adhesive is a photocurable adhesive. In order to attach the two discs together, the recording medium is arranged so as not to extend to the periphery of the disc so that the adhesive around the edge of the disc is hardened rapidly by UV irradiation so that the masked adhesive under the recording medium It is only cured by contact with the initiator present.
[13] U.S. Patent No. 5,785,793 discloses a method of irradiating an optical recording disk having one or two back-to-back storage medium layers on one or both sides. In either case, since the curable adhesive is used on the surface facing the recording medium, the UV irradiation must pass at least through the recording medium in order to cure the adhesive. Thermal management is an issue in the manufacture of optical recording disks. Because the disc is easily twisted, and the recording medium is typically a low melting point metal, such as aluminum. A xenon flash lamp is preferred for irradiating the curable adhesive to bond the disks together.
[14] Methods of combining DVD (Digital Versatile Disks) substrates are described in [D. UV radiation of 320 to 390 nm wavelength is referred to as " UV light irradiation "," UV Curing Through Semi-transparent Materials "," The Challenge of the DVD Bonding Process ", RadCure Letter, April, 1998, p. It is proposed to pass a 40 nm thick aluminum coating on a carbonate substrate at 91% transmittance. A method of curing the adhesive under such conditions is not disclosed.
[1] The present invention relates to a method for depositing layers or articles comprising curing a photopolymerizable composition through a substrate that is colored, opaque, or reflective. The articles may be, for example, electronic components, printed circuit boards, and the layers may be two opposing sides of a compact disk.
[73] Figure 1A shows an unfilled flip chip assembly.
[74] 1B shows a flip chip assembly partially underfilled with a photopolymerizable adhesive.
[75] Figure 1C shows a flip chip assembly in which all of it is underfilled with a photopolymerizable adhesive.
[76] Figure 1D illustrates a fully underfilled flip chip assembly exposed to visible light to achieve a curing process of a photopolymerizable adhesive.
[77] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[78] The present invention provides means for quickly and easily combining many different articles on various substrates using actinic radiation in the visible or near infrared range. In some situations, it may be desirable, but not required, that the substrate be transparent to both visible and near-infrared radiation.
[79] In a preferred embodiment, the present invention provides a method of arranging an underfilled photopolymerizable adhesive resin with self-fluxing properties applied to a wafer, which can be maintained substantially uncured throughout, during the entire solder reflow process, and Assembly. After any subsequent evaluation of reflow and electrical function, heating in conjunction with the wavelength of the appropriate visible light applied through the backside of the printed circuit board provides a very fast cure if necessary. This can provide an adhesive resin that acts as a " clean " flux, that is, no cleaning or cleaning process of the PCB is required after the flux has been achieved. In a single set of process steps, precisely several hundred chips, As shown in FIG.
[80] The purpose of the flux is to remove the metal oxide from the surface of the solder and traces on the circuit board to completely wet the solder to the trace during reflow. This flux action may occur just prior to melting the solder. In a typical conveyor-supported solder material flow oven, the overall soldering operation usually takes 3 to 6 minutes. The actual reflow of the solder generally takes place during the last minute (in the case of euteric Sn / Pb solder) at which the temperature of the parts can reach 220 ° C. However, during most of the time in the oven, the temperature of the components is maintained at about 140-160 DEG C, which is the time at which the fluxing action occurs.
[81] Ideal scenarios may include: Underfill photocurable adhesive resin with fluxing activity is pre-applied to the chip at the wafer level. The chips are aligned on a circuit board assembly and adhesively bonded in a face-down manner, and the circuit board is placed in a re-flow oven supported in a Kenda bear. While in the oven, the circuit board assembly may be heated to a temperature of about 160 캜 for a period of time during which the adhesive is melted. The circuit board assembly can then be heated to about 160 DEG C for 3 minutes during the time that the adhesive acts as a flux and removes the metal oxide from the solder and circuit trace surface. At this point, the adhesive remains completely uncured and has a low viscosity. The circuit board assembly is then heated to a temperature of 220 DEG C for less than one minute during which time the solder melts and is wetted on the cleaned surface of the circuit trace. At this point, when the thermosetting adhesive is present, the thermosetting adhesive initiates the polymerization. However, it is desirable to keep the viscosity of the adhesive low, at least until the solder wetting is completed. In practice, it is substantially desirable to keep the adhesive resin in a migrated state after the reflow process. Using the photopolymerizable adhesive resin of the present invention, these objects are achieved. In this way, soldered assemblies can evaluate electrical properties, and if they are found to have no functionality, they can be easily disassembled, reprocessed, and recombined. The demand for reprocessability is very important for many flip chip assemblies because circuit board assemblies are often complex and expensive.
[82] Most fluxes in the art are known to be acidic. For example, most resin fluxes have a pH of 3-5. In particular, in most commercial fluxes the active ingredients contain carboxylic acid functionality. This poses a potential problem because the underfill adhesive material is almost always epoxy-based. This means that it is difficult to maintain a low viscosity until the solder is reflowed because the acidic material having the fluxing activity added to the underfill adhesive composition tends to act as a curing agent for the thermosetting adhesive resin.
[83] However, in the present invention, an underfill adhesive resin having a self-flux property to be applied to a photopolymerizable wafer can be partially or wholly uncured during the whole solder flow process described above.
[84] A detailed description of methods and materials for achieving flip chip assemblies can be found in U.S.S.N. 08/986661 (filed December 8, 1997). A typical assembly process for a flip chip assembly involves the following steps: (1) Apply the flux paste to the substrate bonding pad. (2) arranging and arranging the IC on the substrate, and at the same time fixing the chip to the spot by the stickiness in the flux. (3) passing the assembly through a reflow oven, melting the solder and metallurgically bonding it to the substrate pad. (4) The sample is passed through the flux cleaning operation.
[85] Thus, the final formed flip chip assembly must maintain electrical continuity throughout the life of the device, as measured by accelerated tests such as thermal cycling tests and thermal shock tests. Improper pairing of both the thermal expansion coefficient (CTE) and elastic modulus (E) between the silicon IC and the PCB substrate causes high stresses in the contact joints when the circuit passes thermal excursions. This stress can induce fatigue fracture of the solder joint after repeating the temperature cycle. This mechanism has limitations in the choice of substrate material for primarily ceramic hybrid substrates, such as Al ₂ O _3, and therefore has silicon-like properties, high modulus and low CTE. Even when a ceramic substrate is used, the flip chip assembly has a limitation in application using a small die.
[86] Over the last 10 to 15 years, there has been an increasing interest in learning how to attach such flip chip assemblies to larger size dies or to a wider range of printed circuit boards. In particular, increased wiring density available today as organic substrates has resulted in a low cost alternative suitable for ceramic substrates. However, the relatively high CTE of organic materials slows down the provision of flip chip assemblies on organic substrates due to the fatigue failure mechanism described above. Significant progress has been made by the development of underfill processes. The underfill process uses a high modulus hardenable adhesive to fill an empty space between the solder balls under the chip so that the stress at the joint is shaped by the adhesive and is even distributed over the entire interface opposite to that concentrated at the surrounding balls More uniformly distributed. The use of underfill adhesives, as described above, allows flip chip technology to be applied to a wider range of assemblies.
[87] The present invention provides advancement in the art in that the underfill adhesive resin is photopolymerizable and may allow reprocessability of the assembly after evaluation of the electrical function following solder reflow and prior to adhesive curing.
[88] 1A, 1B, 1C, and 1D illustrate a flip chip assembly 10 of the present invention having an integrated chip (IC) 12 and a printed circuit board (PCB) 14, (14) is bonded to the pad (18) in alignment with the solder bumps (16). In Fig. 1A, the IC 12 and the PCB 14 are fixed in an aligned state by a flux paste not shown. 1B, the flip chip assembly 10 includes a photopolymerizable adhesive 24 applied in the form of a wick in place using an applicator 22 at the interface between the IC 12 and the PCB 14 There is some underfill. 1C, the flip chip assembly 10 is completely underfilled with a photopolymerizable adhesive 24 at the interface between the IC 12 and the PCB 14. The photopolymerizable adhesive 24 is applied to one or both of the opposing surfaces of the IC 12 and the PCB 14 prior to aligning the IC 12 and the PCB 14. In other embodiments, The bonding pads 18 and the tips of the solder bumps 16 are free of adhesives when aligning the IC 12 and PCB 14 and curing the photopolymerizable adhesive 24. The adhesive may be removed from the bond pad by, for example, ablating, abrading, eroding or dissolving. 1D, the flip chip assembly 10 is irradiated by visible or near-infrared rays 28 passing through the PCB 14 to produce a photopolymerized adhesive 26. [
[89] Alternatively, a photopolymerizable adhesive, such as a photopolymerizable epoxy resin composition, may be introduced into the flip chip assembly pre-soldered by any useful method, e. G. By filling in a wick configuration or capillary action, Can be photopolymerized in place by the method.
[90] Other layers and articles that may be laminated using the method of the present invention include electronic components or substrates such as printed circuit boards or flexible printed circuit boards. It is also possible to use a combination of plate-to-plate lamination, lamination of metal circuits or traces, assembly of a connector such as a fiber optic connector, or a metalized substrate such as a compact disk, a RAM (Random Access Memory) disk, a CD- Such as an assembly of articles made of a data storage disk, including the < / RTI > In addition to being used directly in electronic components, the method of the present invention may also be used to laminate other substrates with wavelengths of 400 nm or less, or other substrates that may be opaque to certain areas of visible and near-infrared. Such substrates include those useful for multilayer tamper-evidence recording bodies such as passports, credit cards, smart cards, and the like. In addition, the substrate may be a multilayer film or a metallized reflective film, such as those useful in an optical system. The methods of the present invention can also be used to laminate or cure structural materials such as glass fiber reinforced polymers that may be useful in the manufacture of sporting goods such as boats, planes or other vehicles. The method of the present invention can be used, for example, to attach an automotive rearview mirror assembly to a UV absorbing windshield by irradiation with radiation through a windshield.
[91] Substrates useful in the present invention include various transparent, translucent, or opaque materials such as plastics, ceramics, glass, films, and paper. Reflective substrates useful in the present invention include metal treated films, opaque multilayer films such as those disclosed in U.S. Patent Nos. 5,759,467, 5,822,774, 5,540,878, 5,448,404, 5,380,479, 5,234,729, 5,217,794 5,202,074 and 5,122,905, and retroreflective films such as those described in U.S. Patent No. 4,025,159. Printed circuit boards such as FR4, FR0406 and BT epoxies can be used, including colored or opaque substrates, including alumina, polyimide, colored solder masks or colored coatings, Must be sufficiently light-transmissive to permit initiation of the described photopolymerization reaction. UV or light absorbing or reflective substrates that are transmissive to actinic radiation having a wavelength between 400 nm and 1200 nm inclusive make it possible to produce substrates useful in the present invention. The substrate useful in the present invention is not particularly limited in thickness, as long as sufficient visible light and near-IR light can penetrate through and perform the polymerization reaction described herein.
[92] The present invention can provide curing on a variety of substrates conventionally impossible by conventional UV curing using visible and near-IR light curable adhesive systems. Such systems include, but are not limited to, systems for attaching reflective films to colored plastic substrates, systems for attaching metal sputtered films to epoxy substrates, systems for attaching articles to temperature sensitive substrates, and generally semitransparent, opaque or reflective Systems in which substrates are attached to each other by any combination of these. In addition, as described herein, the irradiation may be across one or both sides of the substrates. Also, as described herein, the radiation can be directed directly, or reflected from a mirror-reflected surface.
[93] The photocurable compositions of the present invention may be liquid, gel or film. The photopolymerizable composition useful in the present invention may comprise a free radically polymerizable moiety, a cationic polymerizable moiety or a hydrosilation polymerizable moiety. Such compositions include photopolymerizable sites and visible and / or near-infrared photoinitiators for the sites.
[94] In one preferred embodiment, the present invention provides a polymerizable composition comprising at least one cationically polymerizable material and a photoinitiator system active in the spectral range from greater than 400 nm to less than 1200 nm. Examples of suitable organic materials that can be polymerized by cationic polymerization and are suitable for the curable compositions according to the present invention are the following types, which can be used alone or as a mixture of two or more:
[95] A. Ethylenically unsaturated compounds polymerizable by a cationic mechanism.
[96] These compounds include
[97] 1. Monoolefins and diolefins such as isobutylene, butadiene, isoprene, styrene, alpha-methylstyrene, divinylbenzene, N-vinylpyrrolididone, N-vinylcarbazole and acrolein,
[98] 2. Vinyl ethers such as methyl vinyl ether, isobutyl vinyl ether, trimethyl octane trivinyl ether and ethylene glycol divinyl ether; Cyclic vinyl ethers such as 3,4-dihydro-2-formyl-2H-pyran (acrolein dimer) and 3,4-dihydro- Dihydro-2H-pyran-2-carboxylic acid esters, vinyl esters such as vinyl acetate and vinyl stearate.
[99] B. A heterocyclic compound polymerizable by cationic polymerization. Such compounds include, for example, ethylene oxide, propylene oxide, epichlorohydrin, glycidyl ethers of monohydric alcohols or phenols, such as n-butyl glycidyl ether, n-octyl glycidyl ether, Phenyl glycidyl ether and cresyl glycidyl ether; Glycidyl acrylate, glycidyl methacrylate, styrene oxide and cyclohexene oxide; Oxetanes such as 3,3-dimethyloxetane and 3,3-di (chloromethyl) oxetane; Tetrahydrofuran; Dioxolane, trioxane and 1,3,6-trioxycyclooctane; Spiroorthocarbonate; Lactones such as -Propiolactone, -Valerolactone and -Caprolactone; Thioxiranes such as ethylene sulfide and propylene sulfide; Azetidine, such as N-acylazetidine, such as N-benzoyl azetidine, as well as adducts of azetidine with diisocyanates such as toluene-2,4-diisocyanate, toluene-2,6-diisocyanate and 4 , 4'-diaminodiphenylmethane diisocyanate; Epoxy resin; And straight chain and branched chain polymers having glycidyl groups in the side chain, such as homopolymers and copolymers of polyacrylates and polymethacrylate glycidyl esters.
[100] Particularly important among these above-mentioned polymerizable compounds are epoxy resins, in particular epoxy resin prepolymers of the type used to make diepoxide and polyepoxide, and crosslinked epoxy resins.
[101] Epoxy compounds that can be cured or polymerized by the process of the present invention are those known to perform cationic polymerization, such as 1,2-cyclic ethers, 1,3-cyclic ethers and 1,4- Cyclic ethers (or 1,2-epoxide, 1,3-epoxide and 1,4-epoxide). Encyclopedia of Polymer Science and Technology, 6 (1986), p. 322 provides a description of suitable epoxy resins. In particular, useful cyclic ethers include cyclic aliphatic epoxides such as cyclohexene oxide and resins of the ERL series type (Union Carbide products, Cambridge, New York, USA), such as vinylcyclohexene oxide, vinylcyclohexene dioxide (ERL ^占 -4206), 3,4-epoxy-6-methylcyclohexylmethyl-3,4-epoxy-6-methylcyclohexenecarboxylate (ERL ^占 -4201), bis (2,3-epoxycyclopentyl) ether (ERL ^TM -0400), 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexane carboxylate (ERL ^TM -4221), bis- (3,4-epoxycyclohexyl) adipate (ERL ^TM -4289), aliphatic epoxies (ERL ^TM -4050 and ERL ^TM -4052), dipentene dioxide (ERL ^TM -4269), and 2- (3,4-epoxycyclohexyl- spiro-3,4-epoxy) cyclohexene-meta-dioxane may be mentioned (ERL -4234 ^TM), also in a glycidyl ether type When a resin, such as propylene oxide, epichlorohydrin, styrene oxide, glycidol, bisphenol A diglycidyl ether, and epoxy resins EPON ^TM series types, including chain extended variants of these substances (US Houston, Texas Such as EPON 828 ^TM , EPON 1001 ^TM , EPON 1004 ^TM , EPON 1009 ^TM and EPON 2002 ^TM or their equivalents commercially available from other manufacturers; Dicyclopentadiene dioxide; Epoxidized vegetable oils such as VIKOLOX ^TM resin and epoxidized linseed oil available as VIKOFLEX ^TM resin (Elf Atochem North America, Inc., Philadelphia, Pa.): Lineseed oil) And soybean oil; Epoxidized KRATON ^TM LIQUID polymers such as L-207 (Shell Chemical Company, Houston, Tex.); Epoxylated polybutadienes such as POLY BD ^TM resin (Elf Atochem, Philadelphia, Pennsylvania); 1,4-butanediol diglycidyl ether, polyglycidyl ether of phenol formaldehyde; Epoxylated phenolic novolak resins such as DEN 431 ^TM and DEN 438 ^TM (Dow Chemical Company, Midland, Mich.); Epoxidized cresol novolac resins such as ARALDITE ( ^TM) ECN 1299 (Shiba, Horn, NY); Resorcinol diglycidyl ether; Epoxylated polystyrene / polybutadiene mixtures such as EPOFRIEND ^TM resins, such as EPOFRIEND A1010 ^TM (Daicel USA Inc., Fort Lee, NJ); (C ₈ -C ₁₀ ) glycidyl ether (HELOXY Modifier 7 ^TM ), alkyl (C ₁₂ -C ₈ ) alkyl glycidyl ether of the HELOXY ^TM series (Shell Chemicals Company, Houston, Tex. ₁₄ ) HELOXY Modifier 8 ^TM , butyl glycidyl ether (HELOXY Modifier 61 ^TM ), cresyl glycidyl ether (HELOXY Modifier 62 ^TM ), pt-butylphenyl glycidyl ether (HELOXY Modifier 65 ^TM ) ^TM ), polyfunctional glycidyl ethers such as diglycidyl ether of 1,4-butanediol (HELOXY Modifier 67 ^TM ), diglycidyl ether of neopentyl glycol (HELOXY Modifier 68 ^TM ), cyclohexanedimethanol (HELOXY Modifier 107 ^TM ), trimethylol ethane triglycidyl ether (HELOXY Modifier 44 ^TM ), trimethylol propane triglycidyl ether (HELOXY Modifier 48 ^TM ), polyglycidyl ether of an aliphatic polyol (EHLOXY Modifier 84 ^TM ), polyglycol diepoxide (H ELOXY Modifier 32 ^TM ); And bisphenol F epoxide.
[102] Preferred epoxy resins include ERL type resins, especially 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, bis (3,4-epoxycyclohexyl) adipate and 2- (Epoxycyclohexyl-5,5-spiro-3,4-epoxy) cyclohexene-meta-dioxane and 2,2-bis- (p- (2,3-epoxypropoxy) phenylpropane) And bisphenol A EPON type resins, including chain extended versions thereof. It is also within the scope of the present invention to use mixtures of one or more epoxy resins.
[103] It is also within the scope of the present invention to use one or more epoxy resins mixed together. Different types of resins may be present in any proportion.
[104] Optionally, monohydroxy alcohols and polyhydroxy alcohols may be added to the curable compositions of the present invention as chain extenders of epoxy resins. The hydroxyl-containing material used in the present invention may be any organic material having at least one, preferably at least two, hydroxyl functionalities.
[105] The hydroxyl-containing material preferably contains two or more secondary or tertiary aliphatic hydroxyl groups (i. E., A hydroxyl group directly bonded to a non-aromatic carbon atom). The hydroxyl group may be located at the end, or may be located in the side chain of the polymer or copolymer. The molecular weight of the hydroxyl containing organic material can range from very low molecular weight (e.g., 32) to high molecular weight (above 10,000,000). Suitable hydroxyl containing materials may have low molecular weight, i.e., from about 32 to about 200, medium molecular weight, i.e., from about 200 to 10,000, or high molecular weight, i.e., about 10,000 or more. As used herein, all molecular weights are weight average molecular weights.
[106] The hydroxyl-containing material may optionally contain other functional groups that do not substantially interfere with cationic curing at room temperature. Thus, the hydroxyl-containing material may be non-aromatic in nature or may contain an aromatic functional group. The hydroxyl-containing material may optionally contain heteroatoms such as nitrogen, oxygen, sulfur, etc. in the backbone of the molecule, but the final hydroxyl-containing material does not substantially interfere with cationic cure at room temperature. The hydroxyl-containing material can be selected from, for example, natural cellulosic materials or cellulose-based materials synthesized. Of course, the hydroxyl-containing material is also substantially free of groups that may be thermally or photodegradably unstable. That is, the material does not decompose or release volatile components in the presence of actinic radiation, which may be encountered at temperatures below about 100 ° C or during certain curing conditions for the photopolymerizable composition.
[107] Useful hydroxyl-containing materials are described, for example, in U.S. Patent No. 5,856,373.
[108] The amount of the hydroxyl-containing organic material used in the composition of the present invention depends on the compatibility of the hydroxyl-containing material with the epoxide, the equivalence and functionality of the hydroxyl-containing material, the physical properties required for the final cured composition, It can vary over a wide range depending on the same factors.
[109] Mixtures of various hydroxyl-containing materials may be useful in the adhesives of the present invention. Examples of such mixtures may include two or more molecular weight distributions of the hydroxyl containing material, such as low molecular weight (less than 200), medium molecular weight (about 200 to 10,000), and high molecular weight (about 10,000 or more). Alternatively or additionally, the hydroxyl-containing material may contain a mixture of hydroxyl-containing materials having different chemical properties, such as aliphatic and aromatic or functional groups such as polar and nonpolar. As a further example, a mixture of two or more polyfunctional hydroxy materials or a mixture of one or more monofunctional hydroxy materials with a polyfunctional hydroxy material may be used.
[110] Any cationically reactive vinyl ether can be used in the polymerizable composition of the present invention. Examples of vinyl ethers that can be used include tri (ethylene glycol) divinyl ether (RAPI-CURE ^TM DVE-3, International Specialty Products, Wayne, NJ), di (ethylene glycol) divinyl ether, di Ethylene glycol monovinyl ether, triethylene glycol methyl vinyl ether, tetraethylene glycol divinyl ether, glycidyl vinyl ether, butanediol vinyl ether, 1,4-cyclohexanedimethanol divinyl ether (RAPI- CURE CHVE, International Specialty Products), 1,4-cyclohexanedimethanol monovinyl ether, 4- (1-propenyloxymethyl) -1,3-dioxolan- Methyl vinyl ether, ethyl vinyl ether, n-propyl vinyl ether, isopropyl vinyl ether, n-butyl vinyl ether, i-butyl vinyl ether, t-butyl vinyl ether Octyl vinyl ether, cyclohexyl vinyl ether, 4-hydroxybutyl vinyl ether, t-amyl vinyl ether, dodecyl vinyl ether, hexanediol divinyl ether, hexanediol monovinyl ether, trimethylolpropane trivinyl ether ( TMPTVE, a product of BASF Corporation of Mount Olive, New Jersey), aminopropyl vinyl ether, poly (tetrahydrofuran) divinyl ether, PLURIOL ^TM E200 divinyl ether, ethylene glycol butyl vinyl ether, 2-diethylaminoethyl vinyl Ether, dipropylene glycol divinyl ether, and VECTOMER ^TM divinyl ether resin (Allied Signal Inc., Morristown, NJ), such as vinyl ether-terminated aromatic urethane oligomers (VECTOMER ^TM 2010 and VECTOMER ^TM 2015), a vinyl ether end of the shoe aliphatic urethane oligomer (VECTOMER ^TM 2020), Hi Hydroxybutyl vinyl ether may be mentioned isophthalate (VECTPMER ^TM 4010) and cyclohexane dimethanol monovinyl ether glutarate (VECTOMER ^TM 4020), or their equivalents (products of other manufacturing bright). It is within the scope of the present invention to use mixtures of one or more vinyl ether resins.
[111] It is also within the scope of the present invention to use one or more epoxy resins mixed with one or more vinyl ether resins. Different types of resins may be present in any proportion.
[112] Bifunctional monomers may also be used, and examples useful in the present invention have functional groups capable of allowing functionalization with one or more cationic polymerizable functional groups or cationic polymerizable monomers, such as epoxy-alcohol copolymerization.
[113] When two or more polymerizable compositions are present, these compositions may be present in any ratio.
[114] A broad class of cationic photoactive groups recognized in the catalyst and photoinitiator industries can be used in the practice of the present invention. Photoactive cationic nuclei, photoactive cationic sites and photoactive cationic organic compounds are disclosed in U.S. Patent Nos. 4,250,311, 3,708,296, 4,069,055, 4,216,288, 5,084,586, 5,124,417, 4,985,340, 5,089,536 and 5,856,373 A class of materials such as those exemplified by the present application is recognized in the art.
[115] The cationically curable material may be combined with a three-component or three-component photoinitiator system. The three component initiator system is described in U.S. Patent No. 5,545,676, U.S. Patent Application No. 08 / 838,835, and U.S. Patent Application No. 08 / 840,093, both of which are now patents. In the photoinitiator system, the first component may be an iodonium salt, i. E. A diaryl iodonium salt. This iodonium salt is preferably soluble in the monomer, preferably in a storage stable state, and the storage stability means that the iodonium salt does not spontaneously promote polymerization when dissolved in the monomer in the presence of the photosensitizer and the donor. Thus, the choice of a particular iodonium salt may depend somewhat on the particular monomer, sensitizer and donor selected. Suitable iodonium salts are described in U.S. Patent Nos. 3,729,313, 3,741,769, 3,808,006, 4,250,053 and 4,394,403, the disclosures of which are incorporated herein by reference. The iodonium salt may be a single salt containing an anion such as Cl ^- , Br ^- , I ^- or C ₄ H ₈ SO ₃ ^- ; Or a metal complex salt containing an antimonate, an acenate, a phosphate or a borate such as SbF ₅ OH ^- or AsF ₆ ^- . If desired, mixtures of iodonium salts may also be used.
[116] Examples of useful aromatic iodonium complex photoinitiators include diphenyl iodonium tetrafluoroborate; Di (4-methylphenyl) iodonium tetrafluoroborate; Phenyl-4-methylphenyl iodonium tetrafluoroborate; Di (4-heptylphenyl) iodonium tetrafluoroborate; Di (3-nitrophenyl) iodonium hexafluorophosphate; Di (4-chlorophenyl) iodonium hexafluorophosphate; Di (naphthyl) iodonium tetrafluoroborate; Di (4-trifluoromethylphenyl) iodonium tetrafluoroborate; Diphenyl iodonium hexafluorophosphate; Di (4-methylphenyl) iodonium hexafluorophosphate; Diphenyl iodonium hexafluoroacetate; Di (4-phenoxyphenyl) iodonium tetrafluoroborate; Phenyl-2-thienyl iodonium hexafluorophosphate; 3,5-dimethylpyrazolyl-4-phenyliodonium hexafluorophosphate; Diphenyl iodonium hexafluoroantimonate; 2,2'-diphenyl iodonium tetrafluoroborate; Di (2,4-dichlorophenyl) iodonium hexafluorophosphate; Di (4-bromophenyl) iodonium hexafluorophosphate; Di (4-methoxyphenyl) iodonium hexafluorophosphate; Di (3-carboxyphenyl) iodonium hexafluorophosphate; Di (3-methoxycarbonylphenyl) iodonium hexafluorophosphate; Di (3-methoxy-fonylphenyl) iodonium hexafluorophosphate; Di (4-acetamidophenyl) iodonium hexafluorophosphate; Di (2-benzothienyl) iodonium hexafluorophosphate; And diphenyl iodonium hexafluoroantimonate (DPISbF ₆ ).
[117] Diaryl iodonium hexafluorophosphate and diaryl iodonium hexafluoroantimonate among aromatic iodonium complex salts suitable for use in the composition of the present invention are particularly preferred salts. These salts are generally preferred because they promote the reaction faster than other aromatic iodonium salts of complex ions and are more soluble in inert organic solvents.
[118] The second component of the photoinitiator system is a photosensitizer. The photosensitizer is preferably soluble in the monomer and is capable of absorbing light to some extent within a wavelength range of 400 nm to 1200 nm and is selected so as not to interfere with the cationic curing process.
[119] Suitable photoresists include the following categories: ketones, coumarin dyes (e.g., ketocumarines), xanthene dyes, acridine dyes, thiazole dyes, thiazine dyes, oxazine dyes, azine dyes, Compounds belonging to porphyrins, aromatic polycyclic hydrocarbons, p-substituted aminostyryl ketone compounds, aminotriarylmethane, merocyanine, squarylium dyes and pyridinium dyes. Ketone (e.g., monoketone or alpha-diketone), ketocoumarin, aminoarylketone, and p-substituted aminostyryl ketone compounds are preferred photosensitizers. For applications requiring high photosensitivity It is preferable to use a photosensitizer containing a julolidinyl moiety. For applications requiring deep cure (e.g., curing of highly filled composites), it is desirable to use a photosensitizer with an extinction coefficient of preferably less than or equal to about 1000, more preferably less than or equal to about 100 at a predetermined irradiation wavelength for photopolymerization good. Alternatively, a dye may be used that exhibits a decrease in light absorption at the excitation wavelength upon irradiation.
[120] For example, a preferred class of ketone photosensitizers have the general formula ACO (X) _{b B.}
[121] Wherein X is CO or CR ⁵ R ⁶ wherein R ⁵ and R ⁶ can be the same or different and can be hydrogen, alkyl, alkylaryl or aralkyl, b is 0 or 1, A and B may be the same or different and may be substituted (having one or more non-aromatic substituents) or an unsubstituted aryl group, an alkyl group, an alkylaryl group or an aralkyl group, or alternatively A and B together may form a substituted or unsubstituted A cyclic aliphatic, an aromatic, a heteroaromatic ring, or a fused aromatic ring.
[122] Suitable ketones of the above formula include monoketones (b = 0) such as 2,2-dihydroxybenzophenone, 4,4-dihydroxybenzophenone, 2,4-dihydroxybenzophenone, di- Fluoro-9-fluorenone, 2-chlorothioquinone, di-2-thiophenyl ketone, benzoin, fluorenone, chalcone, Michler ketone, Acetylphenanthracene, 9-acetylphenanthracene, 4-acetylphenanthrene, 4-acetylphenanthrene, 4-acetylphenanthrene, Propylphenone, n-butyrophenone, valerophenone, 2-acetylpyridine, 3-acetylpyridine, 4-acetylpyridine, 3-acetylcoumarin and the like. Suitable diketones include aralkyldiketones such as anthraquinone, phenanthraquinone, o-diacetylbenzene, m-diacetylbenzene, p-diacetylbenzene, 1,3-diacetylnaphthalene, 1,4-diacetyl Naphthalene, 1,5-diacetylnaphthalene, 1,6-diacetylnaphthalene, 1,7-diacetylnaphthalene and 1,8-diacetylnaphthalene, 1,5-diacetylanthracene, 9,10-diacetylanthracene, and the like. Suitable alpha-diketones (b = 1 and X = CO) include 2,3-butanedione, 2,3-pentanedione, 2,3- hexanedione, 3,4- , 3,4-heptanedione, 2,3-octanedione, 4,5-octanedione, benzyl, 2,2'-dihydroxybenzyl, Benzyl, furyl, di-3,3'-indolylethanedione, 2,3-borandione (camphorquinone), baiacetyl, 1,2-cyclohexanedione, 1,2-naphthaquinone, .
[123] The third component of the initiator system is an electron donor. The electron donor compound (s) preferably meet the requirements set forth in U.S. Patent Application Serial Nos. 08 / 838,835 and 08 / 840,093, both of which are now patents, and must be soluble in the polymerizable composition do. In addition, the donor may be selected in consideration of other factors such as the storage stability and properties of the polymerizable material, the selected iodonium salt, and the photosensitizer. A class of donor compounds that may be useful in the initiator system of the present invention may be selected from a number of donors as described in U.S. Patent No. 5,545,676. Thus, possible donor compounds meeting the criteria set forth in the patent are tested using one or both of the methods described below to determine whether they are useful donors in the photopolymerizable compositions of the present invention Can,
[124] The donor is typically an alkylaromatic polyether compound or an N-alkylarylamino compound, wherein the allyl group is substituted by one or more electron withdrawing groups. Examples of suitable electron withdrawing groups include a carboxylic acid group, a carboxylic acid ester group, a ketone group, an aldehyde group, a sulfonic acid group, a sulfonate group and a nitrile group.
[125] A preferred group of N-alkylarylaminodoner compounds is represented by the formula:
[126]
[127] Wherein each R ¹ is independently H or (C ₁ -C ₁₈ ) alkyl optionally substituted by one or more halogens, -CN, -OH, -SH, (C ₁ -C ₈ ) alkoxy, (C ₁ -C ₈₎ alkylthio, (C ₃ -C ₈₎ cycloalkyl, _{aryl, COOH, COO (C 1 -C} 18) eolkil, [(C ₁ -C ₁₈₎ alkyl] _0-1 -CO- (C ₁ -C ₁₈ ) alkyl, SO ₃ R ² , CN, or (C ₁ -C ₁₈ ) alkyl optionally substituted by one or more electron withdrawing groups, or wherein the R ¹ groups are joined to form a ring, Lt; / RTI > substituted by an electron withdrawing group. Suitable electron withdrawing groups include -COOH, -COOR ² , -SO ₃ R ² , -CN, -CO- (C ₁ -C ₁₈ ) alkyl, and -C (O) ² may be a straight chain, branched chain or cyclic (C ₁ -C ₁₈ ) alkyl group.
[128] A preferred group of arylalkyl polyethers has the formula:
[129]
[130] And In the formula, n = 1~3, each R ³ can be independently H, or one or more halogen, -CN group, an -OH group, -SH group, (C ₁ -C ₁₈₎ alkoxy group, ( C ₁ -C ₁₈₎ alkylthio, (C ₃ -C ₁₈₎ cycloalkyl group, an aryl group, a substituted aryl group, a -COOH group, a -COO (C ₁ -C ₁₈₎ alkyl group, - [(C ₁ -C ₁₈₎ alkyl] _0-1 -COH _{group, - [(C 1 -C 18} ) _{alkyl] 0-1 -CO- (C 1 -C 18} ) alkyl, -CO- (C ₁ -C ₁₈₎ alkyl group, - (C ₁ -C ₁₈ ) alkyl optionally substituted by a C (O) H group or a - (C ₂ -C ₁₈ ) alkenyl group, each R ⁴ is independently selected from the group consisting of one or more halogen groups, -SH group, (C ₁ -C ₁₈₎ alkoxy, (C ₁ -C ₁₈₎ alkylthio, (C ₃ -C ₁₈₎ cycloalkyl group, an aryl group, a substituted aryl group, a -COOH group, a -COO ( C ₁ -C ₁₈₎ alkyl _{group, - [(C 1 -C 18} ) alkyl] _0-1 -COH _{group, - [(C 1 -C 18} ) _{alkyl] 0-1 -CO- (C 1 -C 18} ) It may be _{(C 2 -C 18) (C} 1 -C 18) which is optionally substituted by alkenyl, alkyl-alkyl, -CO- (C ₁ -C ₁₈₎ alkyl, -C (O) H group or.
[131] In each of the above formulas, the alkyl group may be linear or branched and the cycloalkyl group preferably has 3 to 6 carbon atoms, but may additionally have alkyl substitution up to a certain number of carbon atoms. The aryl group may be carbocyclic aryl or heterocyclic aryl, but a carbocyclic ring is preferred, and a phenyl ring is more preferred.
[132] Preferred donor compounds include 4-dimethylaminobenzoic acid, ethyl 4-dimethylaminobenzoate, 3-dimethylaminobenzoic acid, 4-dimethylaminobenzoin, 4-dimethylaminobenzaldehyde, 4-dimethylaminobenzonitrile and 1,2,4 -Trimethoxybenzene. ≪ / RTI >
[133] The photoinitiator compound is provided in an amount effective to initiate curing of the resin system or to improve its curing rate. The present inventors may be particularly important when the amount of donor used is an amine of the donor. Too much donor can hinder the curing properties. The photosensitizer is preferably present in an amount of about 0.05 to 5% by weight based on the resin compound of the total composition. Most preferably, the photosensitizer is present in an amount of 0.10 to 1.0% by weight. Similarly, the iodonium initiator is preferably present in an amount of 0.05 to 10.0 wt%, more preferably in an amount of 0.10 to 5.0 wt%, most preferably in an amount of 0.50 to 3.0 wt%. The donor is preferably present in an amount of 0.01 to 5.0% by weight, more preferably 0.05 to 1.0% by weight, most preferably 0.05 to 0.50% by weight.
[134] Photopolymerizable compositions useful in the present invention are prepared by simply mixing the ingredients as described above under " safe light " conditions. If necessary, suitable inert solvents may be used if it is necessary to perform such mixing. Any solvent that is not substantially reactive with the components of the composition of the present invention can be used. Examples of suitable solvents include acetone, dichloromethane and acetonitrile. The liquid material to be polymerized can be used as a solvent for another liquid substance or solid substance to be polymerized. Non-enamel compositions can be prepared by simply dissolving aromatic iodonium complexes and photosensitizers in an epoxy resin polyol mixture with or without light use to facilitate dissolution.
[135] Alternative photoinitiator systems for cationic polymerization include those using organometallic complex cations that are substantially free of metal hydride or metal alkyl functionality selected from those described in U.S. Patent No. 4,985,340, Is represented by the following formula (1).
[136] [(L ¹ ) (L ² ) M] ^{+ q}
[137] Wherein,
[138] M is at least one element selected from the group consisting of Cr, Mo, W, Mn, Re, Fe, Ru, Os, Co, Rh, Lr, Pd, Pt and Ni, preferably Cr, Mo, W, Mn, Fe, , Most preferably Mn and Fe,
[139] L ¹ is selected from substituted and unsubstituted cyclopentadienyl, cyclohexadienyl and cycloheptatrienyl, cycloheptatriene, cyclooctatetraene, substituted or unsubstituted arene compounds and 2 to 4 fused rings (Meth) acrylate), aromatic compounds, and polymeric units such as polystyrene, poly (styrene-butadiene), poly (styrene-methyl methacrylate) ; A cyclopentadiene group of poly (vinylcyclopenedadiene); And pyridine groups such as poly (vinylpyridine), each of which may be substituted with one or two cyclic polyunsaturated ligands which may be the same or different and each of which distributes three to eight electrons at the outermost valence of M You can,
[140] L ² is the same or different ligand selected from the group consisting of carbon monoxide, ketones, olefins, ethers, nitrosoniums, phosphines, phosphates and related derivatives of arsenic and antimony, organic nitriles, amines, alkynes, isonitriles, dinitrogen 0 or 1 to 3 nonionic ligands capable of distributing an even number of electrons where the total electron charge contributed to M must form a net residual positive charge q for the complex,
[141] q is an integer having a value of 1 or 2 and is the residual charge of the complex cation.
[142] Organometallic salts are well known in the art and may be prepared, for example, as described in EPO 094,914 and U.S. Pat. Nos. 5,089,536, 868,288 and 5,073,476.
[143] Examples of preferred cations include,
[144] Diphenyl iodonium, ditolyl iodonium, didodecylphenyl iodonium, (4-octyloxyphenyl) phenyliodonium and bis (methoxyphenyl) iodonium;
[145] Triphenylsulfonium, diphenyl-4-thiophenoxyphenylsulfonium and 1,4-phenylene-bis (diphenylsulfonium);
[146] (Η ⁵ -cyclopentadienyl) iron (1+), bis (η ⁵ -methylcyclopentadienyl) iron (1+), (η ⁵ -cyclopentadienyl) (η ⁵ -methylcyclopentadienyl Iron (1+) and bis ( ⁵ -trimethylsilylcyclopentadienyl) iron (1+);
[147] Bis (η ⁶ - xylene) iron (2+), bis (η ⁶ - mesitylene) iron (2+), bis (η ⁶ - duren) iron (2+), bis (η ⁶ - pentamethyl-benzene), iron (2+) and bis (eta ⁶ -dodecylbenzene) iron (2+);
[148] (Η ⁵ -cyclopentadienyl) (η ⁶ -xylene), commonly abbreviated as (CpFeXy) (1+)
[149] Iron (1+), (η ⁵ - cyclopentadienyl) ((η ⁶ - toluene) iron (1+), (η ⁵ - cyclopentadienyl) (η ⁶ - mesitylene) iron (1+), (η ⁵ -cyclopentadienyl) (η ⁶ -pyrene) iron (1+), (η ⁵ -cyclopentadiene
[150] Ene) (η ⁶ -naphthalene) iron (1+) and (η ⁵ -cyclopentadienyl) (η ⁶ -dodecylphenyl) iron (1+).
[151] In another embodiment, the present invention provides a photopolymerizable composition comprising at least one free radically polymerizable material and an optical initiation system exhibiting activity in the spectral range from 400 nm to 1200 nm.
[152] Suitable free radically polymerizable monomers may contain one or more ethylenically unsaturated double bonds, may be oligomers and polymers, and may undergo addition polymerization. Such monomers include mono-, di- or poly-acrylates and methacrylates such as methyl acrylate, methyl methacrylate, ethyl acrylate, isopropyl methacrylate, n-hexyl acrylate, stearyl acrylate, But are not limited to, allyl acrylate, glycerol diacrylate, glycerol triacrylate, ethylene glycol diacrylate, diethylene glycol diacrylate, triethylene glycol dimethacrylate, 1,3-propanediol diacrylate, Diol dimethacrylate, trimethylolpropane triacrylate, 1,2,4-butanetriol trimethacrylate, 1,4-cyclohexanediol diacrylate, pentaerythritol triacrylate, pentaerythritol tetraacryl Pentaerythritol tetramethacrylate, sorbitol hexaacrylate, bis [1- (2-acryloxy)] - p- Ethoxyphenyl dimethyl methane, bis [1- (3-acryloxy-2-hydroxy)] - p- propoxyphenyl dimethyl methane, tris (hydroxyethyl isocyanurate a) trimethacrylate; Bis-acrylates and bis-methacrylates of polyethylene glycols having a molecular weight of 200 to 500, copolymerized mixtures of acrylated monomers such as those described in U.S. Patent No. 4,652,274, and acrylated monomers such as those described in U.S. Patent No. 4,642,126 Oligomers, unsaturated amides such as methylene bis-acrylamide, methylene bis-methacrylamide, 1,6-hexamethylene bis-acrylamide, diethylenetriamine tris-acrylamide and beta-methacrylaminoethyl methacrylate; And vinyl compounds such as styrene, diaryl phthalate, divinyl succinate, divinyl adipate and divinyl phthalates. If necessary, a mixture of two or more monomers can be used.
[153] Visible or near-IR light photoinitiator systems can be used to photopolymerize free radically polymerizable materials useful in the present invention. For example, the monomers can be combined with a three-component or three-member photoinitiator system. The first component in the photoinitiator system is an iodonium salt, i.e., a diaryliodonium salt. This iodonium salt is preferably soluble in the monomer, and is preferably storage stable when dissolved in the monomer in the presence of the photosensitizer and the donor (i.e., does not spontaneously promote polymerization). Thus, the choice of a particular iodonium salt may depend to some extent on the particular monomer, polymer or oligomer, sensitizer and donor selected. Suitable iodonium salts are described in U.S. Patent Nos. 3,729,313, 741,769, 3,808,006, 4,250,053 and 4,394,403. The iodonium salt may be a simple salt (for example, a salt containing an anion such as Cl ^- , Br ^- , I ^- or C ₄ H ₅ SO ₃ ^- ) or a metal complex salt (for example, SbF ₅ OH ^- or AsF ₆ ^- ). ≪ / RTI > Mixtures of iodonium salts may also be used if desired.
[154] Preferred iodonium salts include diphenyl iodonium salts such as diphenyl iodonium chloride, diphenyl iodonium hexafluorophosphate or diphenyl iodonium tetrafluoroborate.
[155] The second component in the photoinitiator system is a photosensitizer. This compound has been disclosed above as a photosensitizer useful for cationically curable materials. The photosensitizer is preferably soluble in the monomer, preferably in a wavelength range of 400 nm or more and 1200 nm or less, more preferably 400 nm or more and 700 nm or less, most preferably 400 nm or more and 600 nm or less It is possible to absorb a certain amount of light in the wavelength range. The sensitizer may also be sensitized with 2-methyl-4,6-bis (trichloromethyl) -s-triazine using the test procedure described in U.S. Patent No. 3,729,313. In addition to passing this test, the photosensitizer may be selected based in part on storage stability considerations. Thus, the choice of a particular photosensitizer may depend somewhat on the particular monomer, oligomer or polymer, iodonium salt or donor selected.
[156] Preferred donors that are the third component of the photoinitiator system include amines (including aminoaldehydes and aminosilanes), amides (including phosphoamides), ethers (including thioethers), ureas (including thioureas), ferrocene, Salts of fumaric acid and its salts, salts of ferrocyanide, salts of ascorbic acid and its salts, salts of dithiocarbamic acid and its salts, salts of xanthates, salts of ethylenediaminetetraacetic acid and salts of tetraphenylboric acid. The donor may be unsubstituted or substituted by one or more non-aromatic substituents. Particularly preferred donors contain electron donor atoms such as nitrogen atoms, oxygen atoms, phosphorus atoms or sulfur atoms, and extractable hydrogen atoms bonded to alpha carbon atoms or silicon atoms for electron donor atoms. A variety of various donors are disclosed in U.S. Patent No. 5,545,676.
[157] Also, free radical initiators useful in the present invention, for example those that are photochemically active in the wavelength range from 400 nm to 1200 nm, include the class of acylphosphine oxides as described in European Patent Application 173567 . Such acylphosphine oxides have the formula _{^{(R 9) 2 -P (=}} O) -C (= O) -R 10. Wherein each R ⁹ can individually be a hydrocarbyl group such as alkyl, cycloalkyl, aryl and aralkyl, any of which may be substituted by a halo group, an alkyl group or an alkoxy group, or two R ⁹ may combine to form a ring along the phosphorus atom, R ¹⁰ is a hydrocarbyl group, S-, O- or N-containing 5 or 6 membered heterocyclic group, or -ZC (═O) -P (= O) - (R ⁹ ) ₂ group, wherein Z represents a divalent hydrocarbyl group such as alkylene or phenylene having 2 to 6 carbon atoms.
[158] Preferred acylphosphine oxides useful in the present invention are those wherein the R ⁹ group and the R ¹⁰ group are phenyl, lower alkyl substituted phenyl or lower alkoxy substituted phenyl. The terms " lower alkyl " and " lower alkoxy " mean such groups having one to four carbon atoms. The acylphosphine oxide is (2,4,6-trimethylbenzoyl) phenylphosphine oxide
[159] (IRGACURE ^TM 819, Ciba Specialty Chemicals, Tarrytown, NY).
[160] The tertiary amine reducing agent can be used in combination with acylphosphine oxide. Exemplary tertiary amines useful in the present invention include ethyl 4- (N, N-dimethylamino) benzoate and N, N-dimethylaminoethyl methacrylate. The initiator may be present in an amount effective for catalytic activity, for example, from about 0.1% to about 5% by weight acylphosphine oxide, based on the weight of the ethylenically unsaturated compound present, and from about 3% And about 0.1% to 5% by weight of a primary amine.
[161] Commercially available phosphine oxide photoinitiators that can perform free radical initiation when irradiated at wavelengths of 400 nm to 1200 nm include bis (2,6-dimethoxybenzoyl) -2,4,4-trimethylpentylphosphine oxide (IRGARCURE ^TM 1700, manufactured by Ciba Specialty Chemicals), 2-benzyl-2- (N, N-dimethylamino) -1- (2,6-difluoro-phenyl) -1-butanone (IRGACURE ^TM 369 from Ciba Specialty Chemicals) and bis (η ⁵ -2,4-cyclopentadien- A 25:75 mixture (by weight) of bis (2,4,6-trimethylbenzoyl) phenylphosphine (IRGACURE ^TM 784 DC, Ciba Specialty Chemicals) (DAROCURE ^TM 4265, available from Ciba Specialty Chemicals) and ethyl-2,4,6-trimethylbenzyl phenylphosphinate (LUCIRIN ^TM LR 8893X, available from Ciba Specialty Chemicals) and 2-hydroxy- , Charlotte, North Carolina, USA (Manufactured by BASF Corporation) in a weight ratio of 1: 1.
[162] Free radical initiators useful in the present invention, such as those that are photochemically active in the wavelength range of 400 nm to 1200 nm, include ionic dye-counter ion complex initiator classes including borate anions and complementary cation dyes . The borates useful in such initiators may generally have the formula R ¹ R ² R ³ R ⁴ B ^- . Wherein R ¹ , R ² , R ³ and R ⁴ are independently an alkyl group, an aryl group, an alkylaryl group, an allyl group, an aralkyl group, an alkenyl group, an alkynyl group, a cyclic aliphatic group and a saturated or unsaturated heterocyclic group . R ² , R ³ and R ⁴ are preferably an aryl group, more preferably a phenyl group, and R ¹ is preferably an alkyl group, more preferably a secondary alkyl group.
[163] The cation counter ion may be a cationic dye, a quaternary ammonium group, a transition metal coordination complex, or the like. Cationic dyes useful as counter ions may be cationic methine dyes, polymethine dyes, triarylmethine dyes, indoline dyes, thiazine dyes, xanthene dyes, oxazine dyes or acridine dyes. More specifically, the dye can be a cationic cyanine dye, a carbocyanine dye, a hemicyanine dye, a rhodamine dye, and an azomethine dye. Specific examples of useful cationic dyes include methylene blue, saprinin O, and malachite green. Quaternary ammonium groups useful as counter ions may be trimethylcetylammonium, cetylpyridinium and tetramethylammonium. Other organic affinity cations include pyridinium, phosphonium and sulfonium. Photosensitive transition metal coordination complexes that can be used include cobalt, ruthenium, osmium, zinc, iron and iridium and ridades such as pyridine, 2,2'-bipyridine, 4,4'-dimethyl-2,2'-bipyridine , 1,10-phenanthroline, 3,4,7,8-tetramethylphenanthroline, 2,4,6-tri (2-pyridyl-s-triazine) and related ligands have.
[164] Borate salt photoinitiators are described, for example, in U.S. Patent Nos. 4,772,530, 4,954,414, 4,874,450, 5,055,372, and 5,057,393.
[165] In another embodiment, a third type of photopolymerization reaction useful in the present invention includes visible light-activated addition reaction of a compound containing a silicon-bonded hydrogen with a compound containing an aliphatic unsaturation. This addition polymerization is typically referred to as a hydrosilation reaction. Silicon hydrosiliconation by visible light is described, for example, in U.S. Patent Nos. 4,916,169 and 5,145,886.
[166] Reactants useful for the radiation activated hydrosilation reaction include compounds containing aliphatic unsaturation or acetylenic unsaturation. Such compounds are well known in the art of silicon hydride addition and are disclosed in patents such as U.S. Pat. No. 3,159,662, U.S. Pat. No. 3,220,972 and U.S. Pat. No. 3,410,886. In the examples, when such an unsaturated compound contains other elements except carbon and hydrogen, it is preferable that these elements be oxygen, nitrogen, silicon, halogen, or a combination thereof. The aliphatically unsaturated compound may contain one or more carbon-carbon multiple bonds. Representative examples of aliphatically unsaturated hydrocarbons that can be used include monoolefins such as ethylene, propylene and 2-pentene, diolefins such as divinylbenzene, butadiene and 1,5-hexane diene, cycloolefins such as cyclo Hexene and cycloheptene, and monoalkyne such as acetylene, propyne and 1-butene-3-yne. The aliphatically unsaturated compound may have from 20 to 30 carbon atoms or less, or more carbon atoms.
[167] Particularly useful types of unsaturated compounds that can be used in the practice of the present invention are those containing silicon, such as compounds commonly referred to as organosilicon monomers or polymers. These unsaturated organosilicon compounds may have at least one aliphatically unsaturated organic group attached to silicon per molecule. Aliphatic unsaturated organosilicon compounds include monomeric or polymeric materials containing silicon atoms bonded together by a methylene or polymethylene group or by a phenylene group, as well as silanes, polysilanes, siloxanes, silazanes.
[168] The reactants containing silicon-hydrogen bonds may be polymeric compounds or compounds that are not polymers. These compounds are well known in the art and are disclosed in patents describing aliphatically unsaturated reactants as cited above. Reactants containing silicon-hydrogen bonds should contain at least one silicon-bonded hydrogen atom per molecule, with only one silicon atom bonded to only three hydrogen atoms.
[169] The hydrogenated silicon addition reaction composition useful in the synthesis of low molecular weight compounds by the process of the present invention is prepared by mixing about 0.1 to 10.0 equivalents of a compound having silicon-bonded hydrogen with 1 equivalent of a compound having aliphatic unsaturation, Can be prepared by adding an amount of platinum complex catalyst sufficient to catalyze. The amount of catalyst may range from about 5 parts by weight to about 5000 parts by weight, preferably from 25 parts by weight to 50 parts by weight, per 1,000,000 parts by weight of the total composition.
[170] The hydrogenation reaction can be carried out using known techniques. In carrying out the hydrosilylation reaction in the practice of the present invention, the reactants and catalyst can be introduced into a vessel equipped with a stirrer, the mixture stirred in the vessel, and exposed to actinic radiation until the reaction is complete. If the reactants are solid, or very viscous, solvents may be added into the vessel to facilitate uniform mixing of the reactants. Suitable solvents include aromatic hydrocarbons such as xylene and toluene, aliphatic hydrocarbons such as hexane and mineral alcohols, and halogenated hydrocarbons such as chlorobenzene and trichloroethane. The solvent is preferably permeable to actinic radiation. The solvent may be used in an amount of about 0.1 parts by weight to about 10.0 parts by weight based on the weight of the reactant compounded. The reaction product formed generally has purity sufficient for the desired use. However, if necessary, the solvent may be removed.
[171] The fully mixed composition may then be applied to the substrate by any suitable means, such as by spraying, dipping, knife coating, curtain coating, roll coating, etc., and the coating may be applied by conventional techniques for providing actinic radiation . The curing is preferably carried out by exposing the coated substrate to radiation having a wavelength of from 400 nm to 1200 nm. Depending on the strength of the particular silicone formulation, catalyst, and actinic radiation, curing may be carried out for less than 1 second to less than 2 minutes .
[172] Catalysts useful for the hydrosilylation reaction include, as disclosed in U.S. Patent No. 4,916,169, certain platinum complexes, such as one cyclopentadienyl group eta-bonded to a platinum atom, in combination with visible and near-IR radiation sensitizers A platinum complex catalyst having three aliphatic groups sigma-bonded to a platinum atom, and Pt (II) beta -diketonate as disclosed in U.S. Patent No. 5,145,886.
[173] Suitable useful in the practice of the present invention (η ⁵ - cyclopentadienyl) tree Representative examples of aliphatic platinum complexes are (Cp) a (η ⁵ - cyclopentadienyl) following things, which represents a, that is, (Cp) trimethyl (Cp) triethylpentyl platinum, (Cp) triethylpentyl platinum, (Cp) triethyl platinum, (Cp) triallyl platinum, ) Trimethylplatinum, (dimethylphenylsilyl-Cp) trimethylplatinum, and (Cp) acetyldimethylplatinum.
[174] Other suitable ( ⁵ -cyclopentadienyl) tri aliphatic platinum complexes suitable for the present invention are described in U.S. Patent No. 4,510,094.
[175] Photosensitive agents suitable for this embodiment of the present invention are compounds capable of absorbing actinic radiation in the visible light region of the electromagnetic spectrum, i. E., Between about 400 nm and about 800 nm, and are capable of transferring energy to a platinum complex. In general, these sensitizers should have a triple energy level of 31 Kcal / mole and should not inhibit the hydrosilation reaction. The photosensitizer is preferably selected from the following two classes of compounds: (1) a polycyclic aromatic compound and (2) an aromatic compound containing a ketone chromophore. The photosensitizer compound may be substituted by any substituent that does not interfere with the photosensitizer compound or the hydrosilation and energy transfer performance of the hydrosilation catalyst. Representative examples of the polycyclic aromatic photoresist suitable for the present invention include 9-vinyl anthracene, 9,10-dimethylanthracene, 9,10-dichloroanthracene, 9,10-dibromoanthracene, 9,10- Diethoxy anthracene, 2-ethyl-9,10-dimethyl anthracene, naphthacene, pentacene, benzanthracene, 7,12-dimethylbenzanthracene and azulene.
[176] Representative examples of suitable Pt (II) beta-diketonate complexes include Pt (II) bis (2,4-pentanedionate), Pt (II) bis (2,4- hexanedionate) (II) bis (3-heptanedionate), Pt (II) bis (3,5-heptanedionate) 1,3-diphenyl-1,3-propanedionate).
[177] Compositions useful in the present invention may contain a variety of various adjuvants depending on the desired end use. Suitable adjuvants include solvents, diluents, resins, binders, plasticizers, pigments, dyes, inorganic or organic reinforcing or expanding fillers (preferably from about 10% to about 90% by weight, based on the total weight of the composition) Thixotropic reagents, indicators, inhibitors, stabilizers, UV absorbers, and the like. The amount and type of such adjuvant and the manner of addition to the composition of the present invention are familiar to those skilled in the art.
[178] The actinic radiation useful in the present invention comprises wavelengths in the range of from greater than 400 nm to less than 1200 nm. Exemplary visible light sources include sun, laser, metal vapor (sodium and mercury) lamps, incandescent lamps, halogen lamps, mercury arc lamps, indoor fluorescent lamps, flash lamps, light emitting diodes, tungsten halogen lamps and xenon flash lamps , But is not limited thereto.
[179] The method of the present invention utilizes a photopolymerizable composition when necessary to indirectly bind the material through various substrates. The photocurable composition can be previously applied as a liquid or a gel. Alternatively, a thermally releasable adhesive that is permanently cured may be provided when the thermally-crosslinkable thermoplastic film is pre-applied to the substrate or article and then exposed to light through the substrate. Lt; RTI ID = 0.0 > and / or < / RTI > temperature sensitive substrates. The present invention also contemplates the use of photopolymerizable materials for photopolymerization through a substrate that absorbs UV light or visible light with a careful selection of an initiator system and light source to find correspondence with radiation source emissions having a photoinitiator absorption and a transmissive spectral region of the substrate Performance. .
[180] For example, an important key for successfully photo-curing a photopolymerizable composition through a circuit board, a recording disk, a multilayer reflective film, and a retroreflective film is as follows: (1) a light-transmitting spectral region associated with various substrates; (2) identifying a photoinitiator that absorbs light within the transmittance wavelength of the substrate, and (3) providing a light source that provides an actinic radiation that is easily transmitted through the substrate and easily absorbed by the photoinitiator It is to choose.
[181] Optical density and light transmittance
[182] Optical density relates to light absorption (Abs) characteristics and corresponding transmittance (T) characteristics associated with a particular material at a given thickness. This concept is typically described by the Beer's Law.
[183] Abs = ebc
[184] Wherein,
[185] e = molar absorption rate
[186] b = thickness or path length of the light absorbing material
[187] c = concentration of light absorbing species
[188] Or, Abs = -logT = Log1 / T
[189] Those skilled in the art can readily determine the light absorption (by using a UV / VIS spectrometer) or the transmittance (by using a spherical integration method), so that the absorption and absorption characteristics .
[190] For example,
[191] Absorption (Optical Density) T (%)
[192] 0.1 79.40
[193] 0.5 31.40
[194] 1.0 10.00
[195] 1.5 3.10
[196] 2.0 1.00
[197] 2.5 0.30
[198] 3.0 0.10
[199] 3.5 0.03
[200] 4.0 0.01
[201] 4.5 0.001
[202] As the optical density or absorption rate increases, the light transmittance decreases.
[203] For example, an industry standard known as DVD 10, in which two layers coated with a metal coating on both sides and sandwiched between the layers sandwiched between layers, is a laminated polycarbonate disc, (2) and (3) is the same as the light transmittance of 0.1% to 0.3% passing through one surface. Industrial standards known as DVD 5 are also stacked, but only one side is coated with a metallized film while the other side of the sandwich structure typically has a longer wavelength UV and visible light Transparent or transparent polycarbonate. A material having an optical density of 1.5 or more may be a material that is problematic for passing light and curing if there is no adequate understanding of the proper light source, initiator and desired substrate. Particularly, it is a reflective material having an optical density of 2 or more, such as the DVD 10. Characterization for the absorption or transmission of various substrates is essential for successful photocuring through the substrate.
[204] It has been recognized in the prior art that commonly used reflective materials are impermeable to radiation in the visible region. At present, only a perfect mirror recognizes that it reflects 100% of incident radiation. The present invention provides unique possibilities for photocuring through such a reflective substrate and is now recognized as being capable of transmitting light within specific wavelengths within the range of visible or near-IR radiation.
[205] Articles that can be bonded onto a substrate using the method of the present invention include, for example, electronic components to substrates such as printed circuit boards or flexible printed circuit boards. It will also be appreciated that the present invention may also be practiced with other types of computer-readable media, such as lamination of plate-to-plate, lamination of metal circuits or traces, assembly of connectors such as fiber optic connectors, or data storage discs, including compact discs, random access memory (RAM) Such as an assembly of an article made of a metal-treated substrate such as a metal substrate. In addition to its use in electronic components, the method of the present invention can be used to laminate light beams having wavelengths of 400 nm or less or other substrates that may be opaque to certain areas of visible and near-IR light. Such substrates include those useful for multilayer and tamper proof recording such as passports, credit cards, smart cards, and the like. In addition, the substrate may be a multilayer film or a metal-processed reflective film such as those useful in optical systems. The method of the present invention can also be used to laminate or cure structural materials such as fiber glass reinforced polymers that may be useful in the manufacture of sporting goods such as boats, aircraft or other transport media. The method of the present invention can be used, for example, to attach an automotive rearview mirror assembly to a UV absorbing windshield by irradiation through a windshield.
[206] The objects and advantages of the present invention are explained in more detail by the following examples. The specific materials of the invention and the amounts thereof as well as other conditions and details cited in the examples should not be used to inappropriately limit the invention.
[15] Summary of the Invention
[16] In summary,
[17] (a) providing a structure comprising at least two layers and a photopolymerizable adhesive composition therebetween,
[18] (1) at least one of the layers is opaque or colored and is transmissive to actinic radiation in the identified spectral region of at least one wavelength greater than or equal to 400 nm and less than or equal to 1200 nm, said layer comprising a cellulosic and olefinic Lt; RTI ID = 0.0 > a < / RTI &
[19] (2) the photopolymerizable composition comprises a photopolymerizable portion and a photoinitiator for the photopolymerizable portion that absorbs actinic radiation in the identified spectral region of the actinic radiation transparent layer, wherein the photopolymerizable portion is hydrosilation ) Polymerisation process, a cationic polymerization process or a free radical polymerization process, provided that said free radical polymerization process does not use a dialkylaminobenzophenone photoresist,
[20] (b) curing the photopolymerizable composition by irradiating actinic radiation in the identified spectral region for less than 2 minutes into the photopolymerizable composition via the radiation-permeable layer
[21] Lt; / RTI >
[22] The polymerized composition thus formed provides a laminate structure by adhering to the layers, thereby providing a method of laminating the structure.
[23] Optionally, the structure comprising the photopolymerized composition can be heated to complete polymerization of the photopolymerizable composition.
[24] Each layer of the present invention can be independently a coating, a film or a substrate, or it can be contained in an article. The article may be an electrical component, such as an integrated circuit chip (IC) or a printed circuit board (PCB).
[25] In another aspect, the present invention provides a method of identifying two layers of suitable materials, a photopolymerizable adhesive composition, and a source of radiation that can be used to produce a laminate structure,
[26] (a) identifying two layers, wherein at least one of the layers is colored, opaque, or reflective, and wherein at least one of the actinic radiation in the identified spectral region is greater than or equal to 400 nm and less than or equal to 1200 nm Wherein said layer is substantially free of cellulosic and olefinic functionalities when said radiation transparent layer is colored or opaque,
[27] (b) identifying a photopolymerizable composition disposed between the layers, said composition comprising a photopolymerizable site and a photoinitiator for said photopolymerizable site that absorbs radiation in the identified spectral region of the radiopaque layer In step,
[28] (c) identifying a source of radiation that provides actinic radiation within the identified spectral region of the radiopaque layer and the optical absorption wavelength of the photoinitiator
[29] Lt; / RTI >
[30] The actinic radiation is then irradiated, if necessary, for a time sufficient to polymerize the photopolymerizable composition through a colored, opaque, or reflective layer to produce a laminate structure.
[31] In another aspect, the invention provides a method for manufacturing a soldered and underfilled flip chip assembly on a circuit board, the method comprising:
[32] (a) providing an integrated circuit chip having a surface comprising (1) a reflowable solder bump with a contact tip, and (2) providing a printed circuit board having a bonding site, wherein at least one of the chip and the circuit board One having transparency to actinic radiation in the identified spectral region with a wavelength of greater than or equal to 400 nm and less than or equal to 1200 nm,
[33] (b) applying a photopolymerizable adhesive composition directly to either or both of the surface of the chip having the solder bumps and the bonding region of the printed circuit board to expose the contact tip of the solder bumps of the chip, Wherein the composition comprises a photopolymerizable moiety and a photoinitiator for the moiety, wherein the photopolymerizable composition is capable of absorbing radiation in the identified spectral region of the radiation transparent chip or circuit board,
[34] (c) aligning and pressing the exposed tip of the bump on the chip surface to the bonding site of the circuit board,
[35] (d) melting and reflowing the solder to establish electrical contact between the chip and the circuit board, wherein the photopolymerizable material remains substantially uncured; and
[36] (e) irradiating the radiation in the identified spectral region through the radiation transmissive chip or circuit board for a period of time sufficient to cure the photopolymerizable adhesive composition to form a brazed and underfilled flip chip assembly on the circuit substrate
[37] .
[38] Optionally, the functional evaluation of the soldered electrical contact may be performed prior to the irradiation as described in step (e). If the evaluation results in insufficient electrical contact between the chip and the substrate, the assembly can be reheated to easily remove chips from the substrate. The chip and the bonding area can then be cleaned, the soldering process can be repeated, and the functional evaluation can be repeated to insure sufficient electrical connection before irradiation.
[39] In another aspect,
[40] (a) providing a structure comprising at least two layers and a photopolymerizable adhesive composition therebetween,
[41] (1) at least one of the layers is one or both of a mixed layer and a reflective layer in an electronic component that is transmissive to actinic radiation in an identified spectral region of at least one wavelength greater than or equal to 400 nm and less than or equal to 1200 nm ,
[42] (2) the photopolymerizable composition comprises a photopolymerizable moiety and a photoinitiator for the photopolymerizable moiety that absorbs actinic radiation in the identified spectral region of the radiation-permeable layer, wherein the photopolymerizable moiety comprises a hydrosilation polymerization process, Which is polymerizable by a cationic polymerization process or a free radical polymerization process,
[43] (b) curing the photopolymerizable composition by irradiating actinic radiation in the identified spectral region for less than 2 minutes into the photopolymerizable composition via the radiation-permeable layer
[44] Lt; / RTI >
[45] The polymerized composition thus formed provides a laminate structure by adhering to the layers, thereby providing a method of laminating the structure. In a preferred embodiment, the method provides a data storage disk.
[46] In another preferred embodiment, the present invention provides a method for manufacturing a soldered and underfilled flip chip assembly on a circuit board,
[47] (a) underfilling a photopolymerizable adhesive composition comprising a photopolymerizable portion on a chip soldered on an integrated circuit substrate and a photoinitiator for the portion, in a capillary action mode,
[48] Wherein the circuit board is transmissive to actinic radiation in the identified spectral region where the wavelength is greater than or equal to 400 nm and less than or equal to 1200 nm,
[49] Wherein said photopolymerizable composition absorbs radiation in the identified spectral region of the radiation transmissive circuit board, and
[50] (b) irradiating the circuit board with actinic radiation in said identified spectral region from the opposite side of the side bearing the soldered chip,
[51] .
[52] In the present specification,
[53] The term " actinic radiation " includes, but is not limited to, photochemically active radiation comprising accelerating particles and particle beams, e. And electromagnetic radiation such as microwave, infrared, visible, ultraviolet, X-ray and gamma ray,
[54] The terms " cure " and " polymerization " are used interchangeably herein to denote chemical reactions in which relatively simple molecules combine to form macromolecules such as chains or reticulates,
[55] The term " colored " means a light having visually perceivable color in the naked eye or in the naked eye, or the eye wearing the eyeglasses, for example, a light ray visually recognized by the eye after irradiating the light beam on the substrate,
[56] The term " DVD " refers to a digital video disc and a digital versatile disc,
[57] The term " UV " or " ultraviolet " refers to actinic radiation having a spectral output from about 200 nm to about 400 nm,
[58] The term " visible light " refers to actinic radiation having a spectral output of greater than about 400 nm and less than about 700 nm,
[59] The term " near-IR " or " near-infrared radiation " means actinic radiation having a spectral output of about 700 nm to about 1200 nm,
[60] The term " transparent " means that when the material is viewed through an optical microscope (e.g., at 50X and under oblique incidence or under a stereoscopic microscope under transmitted light) Quot; means having a transmission characteristic with respect to a light ray,
[61] The term " translucent " means that the material has a property of transmitting a visible light to some extent, in whole or in part (when patterned), so as to have an unclear or blurred edge when viewed as described under an optical microscope In addition,
[62] The term " opaque " means that the material has the property of being impermeable to radiation of a given wavelength when observed under a microscope, and in a multi-layer material, one or more layers have a continuous or discontinuous opaque region And the cure occurs through the opaque region,
[63] The term " light transmissive " means that when irradiated with light having a wavelength of 400 nm or more and 1200 nm or less, the optical density is 4.0 or less, preferably the optical density is 4.0 to 2.0, and more preferably the optical density is 4.0 To 3.0, < / RTI >
[64] The term " reflective " means that incident light can warp, return, or reverse project at least 90% of its incident light from the irradiated surface,
[65] The term " group ", " compound " or " ligand " refers to a chemical species that may be substituted or that may be substituted by conventional substituents that do not interfere with the desired product, Alkyl, alkoxy, aryl, phenyl, halo (F, Cl, Br, I), cyano, nitro,
[66] The term " photopolymerizable moiety " means a photopolymerizable monomer, oligomer or polymer,
[67] The term " reflow " means melting of the solder.
[68] The present invention is advantageous in that it provides a unique method for layering layers or articles using photopolymerizable adhesive compositions. The adhesive may be cured indirectly through a variety of substrates that are colored, opaque, or reflective using actinic radiation in the range of 400 nm to 1200 nm, if desired. Curing can occur at high temperatures or at ambient temperatures (20-25 ° C), which can be beneficial for temperature sensitive substrates.
[69] Conventional methods of attaching a facedown integrated circuit (e.g., flip chip) or other article to a ceramic, polyimide or epoxy-filled printed circuit board (PCB) or other substrate use an epoxy adhesive that is thermally cured, After the solder connection is achieved in advance, if strengthening is required, it can be applied by capillary action. This becomes increasingly difficult, for example as the chip size increases and as the number of electrical connections per chip increases. Also, in the art, when curing of the adhesive is required, it is necessary to apply a low temperature, for example less than 50 캜, in advance and does not use a UV-activated system. UV activated systems may be impractical due to the ability to transmit UV light through or through the epoxy PCB or other substrate. Prior art UV methods typically require a colorless transparent substrate. The method of the present invention is advantageous in that a colored and opaque substrate can be used because it involves photo-curing using visible or near-infrared radiation. It is also advantageous that a UV absorbing or reflective substrate that is transmissive to actinic radiation within a given spectral range can be used in the method of the present invention. It is also desired to produce a wafer or circuit that has previously been applied and self-fluxing curable adhesive is applied to the back side of the chip or circuit (e.g., bumped side). In addition, rapid curing of the adhesive is also required to minimize the manufacturing time.
[70] The present invention relates to a radiation curable composition that can be applied directly to various PCB substrates or other substrates using visible light and / or near-infrared curing systems to provide various radiation curable compositions (such as thermoplastic films And a flowable resin), overcoming the deficiencies of conventional curing systems. Curing performance through the backside of the circuit board depends on a number of factors including line width and spacing, angle of illumination, substrate and circuit thickness, and the type of metal-processed tracing. The low temperature method of the present invention may be useful for temperature sensitive substrates. Any composition that can be polymerized or crosslinked through direct photodegradation or indirect photochemical generation of a thermal catalyst or initiator can be used in the approach of the present invention. The storage stable premixed composition can be cured using the process of the present invention if desired.
[71] The present invention is also advantageous in that it is possible to use a variety of conventional sources of light, such as halogen bulbs or other sources of visible and / or near-infrared, to initiate photopolymerization responses. Thus, the method of the present invention is inherently safer for humans than for example using ultraviolet light. This is because visible light and / or near-infrared light is less needed than ultraviolet light to produce the same amount of light density. Also, visible light and / or near-infrared light sources are advantageous over UV light sources because UV light has a known degradative effect on substrates such as polymers. Finally, the present invention can easily cure a photopolymerizable composition comprising useful UV absorbing additives, such as UV stabilizers and antioxidants, in a visible light.
[72] U.S.S.N. No. 08 / 986,661 filed on December 8, 1997, the disclosure of which is hereby incorporated by reference in its entirety, relates to a method and assembly for contacting an integrated circuit chip to a circuit board.
[207] Unless otherwise noted, all materials may be obtained either directly from the manufacturer, or from Aldrich Chemical Company, Milwaukee, Wisconsin, USA.
[208] Example 1
[209] Two visible light polymerizable compositions were prepared as shown in Table 1 below.
[210] Adhesive composition ingredient1A (parts by weight)1B (parts by weight) Bis (phenol A) diglycidyl dimethacrylate (Bis GMA)50.0050.00 Triethylene glycol dimethacrylate (TEGDMA)50.0050.00 Campoquinone (CPQ)00.1700.10 Ethyl p-dimethylaminobenzoate (EDMAB)01.0001.00 Diphenyl iodonium hexafluorophosphate (DPIPF ₆ )00.6000.60 Rose Bengal (RB)00.0000.10
[211] Composition 1A containing photosensitizer CPQ had a light absorption of 400 nm to 500 nm, while Composition IB containing both CPQ and RB had a light absorption of about 400 nm to 580 nm. One drop of Composition 1A was applied to the area of the FR4 Epoxy Printed Circuit Board (PCB) (TRC Circuits, Minneapolis, Minn.), Which had no conductive metal contacts on one side. The circuit board was about 1.5 nmm thick. The 3M XL 3000 dental curing lamp (3M, St. Paul, MN, USA, with a light output of 400-500 nm) is placed in direct contact with the adhesive side of the light guide and the PCB on the directly facing side Respectively. The light was activated for about 10 seconds and then the liquid was polymerized into a cured solid that adhered well to the PCB. Composition 1B was evaluated in a similar manner, and it was also found that the composition 1B quickly cured to a cured adhesive film. In addition, Composition 1B was initially colored red, which showed a visual change that was almost colorless upon exposure to light and curing.
[212] In the second test, compositions 1A and 1B were applied to two distinct areas of the PCB, which contained copper metal traces. One region has about 25 lines of traces spaced evenly spaced apart per cm and the other has about 1 mm of traces spaced about 1.5 mm wide. To apply both the metal treated surface and the untreated metal surface, the beads of the adhesive to be tested were applied to the entire trace. The various areas were irradiated from the opposite side of the PCB for about 20 seconds as described for the compositions 1A and 1B. Surprisingly, the liquid resin was polymerized over all parts of the PCB, including the metallized traces.
[213] The data show that the methacrylate functional composition was readily polymerized by visible light at 400 to 500 nm through the FR4 printed circuit board at room temperature.
[214] Example 2
[215] Various UV and visible light photopolymerizable compositions were prepared as illustrated below.
[216] Storage solution 1
[217] The storage solution (storage solution 1) was prepared by mixing 100 g each of Bis GMA and TEGDMA, followed by thorough mixing until homogeneous.
[218] Ten photopolymerizable compositions were prepared by mixing 10.0 parts by weight of the stock solution with the photoinitiator or photoinitiator system as shown in Table 2A below. Each composition contained different photoinitiators capable of initiating free radical polymerization at a particular range of wavelengths.
[219] Adhesive composition ExamplePhotoinitiatorVolume, weightwavelength 2A (comparative example)IRGACURE ^TM 184 ¹ 00.30(254 to 365 nm) 2B (comparative example)IRGACURE ^TM 500 ² 00.30(254 to 360 nm) 2C (comparative example)IRGACURE ^TM 651 ³ 00.30(254 to 380 nm) 2D (comparative example)IRGACURE ^TM 907 ⁴ 00.30(254 to 375 nm) 2EIRGACURE ^TM 369 ⁵ 00.30(254-425 nm) 2FIRGACURE ^TM 1700 ⁶ 00.30(254-425 nm) 2GCPQ00.05(400 to 500 nm)EDMAB00.07 DPIPF ₆ 00.062HRose Bengal00.015(450 to 580 nm)EDMAB00.07 DPIPF ₆ 00.602IToluidine blue O00.01(450 to 690 nm)EDMAB00.05 DPIPF ₆ 00.052JMethylene blue00.01(500 to 700 nm)EDMAB00.05 DPIPF ₆ 00.50
[220] ¹ IRGACURE ^TM 184: 1-hydroxycyclohexyl phenyl ketone (HCPK), Ciba Specialty Chemicals Inc., Tarrytown, New York.
[221] ² IRGACURE ^TM 500: a mixture of 1-hydroxycyclohexyl phenyl ketone and benzophenone, Ciba Specialty Chemicals Placement Products, Tarrytown, NY, USA.
[222] ³ IRGACURE ^TM 651: 2,2-dimethoxy-2-phenylacetophenone (BDK), Ciba Specialty Chemicals Sp.
[223] ⁴ IRGACURE ^TM 907: 2-methyl-1- (4-methylthio) phenyl) -2-morpholinopropane-1-one (MMMP), Ciba Specialty Chemicals Sp.
[224] ⁵ IRGACURE ^TM 369: 2-benzyl-2-N, N-dimethylamino-1- (4-morpholinophenyl) -1-butanone (DBMP), Ciba Specialty Chemicals SpA.
[225] ⁶ IRGACURE ^TM 1700: 25% of bis (2,6-dimethoxybenzoyl) -2,4,4-trimethylpentylphosphine oxide (DMBAPO) and 2-hydroxy- (HMPP) 75%, a product of Ciba Specialty Chemicals SpA.
[226] The photopolymerizable composition comprises three different light sources: (1) EFOS ^TM Ultra Cure 100 Medium Pressure Mercury Arc Lamp (254 nm, 313 nm, 365 nm, 405 nm, 430 nm, 530 nm, 545 nm, 575 nm, (EFOS Inc., Mississauga ON, Canada); (2) GE Light Engine ^TM (wide band visible light 380-700 nm; GE Company of Cleveland, Ohio, USA) GE Lighting Division) and (3) 3M XL 3000 dental curing lamps (400-500 nm).
[227] The resin was transferred to the sheet of polyester film one drop each, and irradiated from a distance of about 10 mm to a maximum of 60 seconds until a polymerized solid was obtained using each of the three light sources. The test results confirmed the performance or inability of each composition to be polymerized by each light source in the absence of various printed circuit board materials. The results can be found in Table 2C below. Careful selection of both the light source and the photoinitiator system was important for successful polymerization to occur.
[228] In addition, the composition may further comprise (1) alumina (white), (2) FR epoxy (yellow), (3) FR4 epoxy + green solder mask (green), (4) FR0406 epoxy (Brown) and (6) polyimide (brown). The PCB substrate 1 is available from MMC Americas, Inc., Rolling Meadows, Illinois, USA. PCV substrates 2, 3, 4, and 5 are available from TRC Circuits, Inc., Minneapolis, Minn. The PCB substrate 6 is available from 3M, St. Paul, Minnesota, USA. The PCBs ranged in thickness from about 1 mm to about 2 mm. Each photopolymerizable composition was evaluated for photocuring using each curing lamp and each PCB material according to the following procedure. One drop of the photopolymerizable composition was applied to a thin film of polyester placed directly on the PCB. The light guides of the respective light sources were arranged in direct contact with the PCB on the side opposite to the side where the adhesive was dropped. The lamp was activated for about 20 seconds. After exposure to light, the composition was inspected to determine the physical state as uncured (NC), slight gelation (some solid formed in the liquid), soft gelation (formed a soft solid), gelation (solid formed) Solid < / RTI > solid formed). The results are shown in Table 2C below.
[229] Overall light transmission spectrum of various printed circuit boards
[230] Each of the printed circuit board materials described above was evaluated for total light transmittance from 200 to 2500 nm according to the following procedure. All measurements were performed on a Perkin Elmer Lambda 19 spectrometer (Perkin Elmer Corporation, Norwalk, Conn., USA) with RSA-PE-19a spherical integral accessory. The spheres have a diameter of 150 mm (6 inches) and can be prepared according to the ASTM method, for example as disclosed in ASTM Standards on Color and Appearance Measurement, 3rd ed., ASTM, West Conshohocken, Pennsylvania, In accordance with D1003-97 and E308-96. The instrument had a white plate at the back sample position and was zero for air. A mask having a window of 0.32 cm x 1.6 cm was placed directly on the front of each circuit board sample. The settings described in Table 2B below describe the critical transmission wavelengths for each of the printed circuit board materials being evaluated.
[231] Substrate materialObserved colorUseful visible light transmission wavelength (nm) (1) alumina(White)> 400 nm (2) FR4 epoxy(yellow)> 400 nm (3) F4 epoxy + green solder mask(green)475 to 575, > 650 nm (4) FR 0406 Epoxy(yellow)> 475 nm (5) BT-Epoxy(Brown)> 525 nm (6) Polyimide(Brown)> 525 nm
[232] Investigation of photopolymerizable composition through various printed circuit board materials using three light sources Initiator systemLight source compoundAbsorption wavelengthPrinted circuit board materialEFOS ^TM UV / VIS Medium Pressure Hg Arc 254, 313, 365, 405, 430, 530, 545,GE Light Engine ^TM Visible light 380 - 700 nm3M Dental Light Tungsten Halogen 400-500 nm Light curing (20 seconds or less exposure) IRACURE ^TM 184 (3%) (comparative example)254 to 365 nmradish<2 secondsNC ^(e) NC AluminaCuring ^(a) NCNC FR4 Epoxy (without mask)NCNCNC FR4 Epoxy (green mask)NCNCNC FR0406 EpoxyNCNCNC BT-EpoxyNCNCNC PolyimideNCNCNCIGACURE ^TM 500 (3%) (comparative example)254 to 360 nmradish<2 seconds5 Premature Gel ^(c) NC AluminaSoft gelationSlight gelation ^(d) NC FR4 Epoxy (without mask)NCNCNC FR4 Epoxy (green mask)NCNCNC FR0406 EpoxyNCNCNC BT-EpoxyNCNCNC PolyimideNCNCNCIRGACURE ^TM 651 (3%) (comparative example)254-280 nmradish<2 seconds& Lt ^; 5 seconds gelation ^(b) NC AluminaHardeningNCNC FR4 Epoxy (no mask)NCNCNC FR4 Epoxy (green mask)NCNCNC FR0406 EpoxyNCNCNC BT-EpoxyNCNCNC PolyimideNCNCNC
[233] IRACURE ^TM 907 (3%) (comparative example)254 to 375 nmradish<2 secondsNC ^(e) 20 Superelastic Gelation AluminaHardeningSoft gelationNC FR4 Epoxy (without mask)NCNCNC FR4 Epoxy (green mask)NCNCNC FR0406 EpoxyNCNCNC BT-EpoxyNCNCNC PolyimideNCNCNCIGACURE ^TM 369 (3%)254-425 nmradish<2 seconds<2 seconds<2 seconds AluminaHardeningHardeningHardening FR4 Epoxy (without mask)HardeningHardeningHardening FR4 Epoxy (green mask)NCSoft gelationHardening FR0406 EpoxyNCNCNC BT-EpoxyNCNCNC PolyimideNCNCNCIGACURE ^TM 1700 (3%)254-425 nmradish<2 seconds<2 seconds<2 seconds AluminaHardeningHardeningHardening FR4 Epoxy (without mask)HardeningHardeningHardening FR4 Epoxy (green)NCSoft gelationHardening FR0406 EpoxyNCNCNC BT-EpoxyNCNCNC PolyimideNCNCNCCampoquinone (0.50%)400 to 500 nmradish<2 seconds<2 seconds<2 seconds Ethyldimethylaminobenzoate (0.70%) AluminaHardeningHardeningHardening Diphenyl iodonium PF ₆ (0.60%) FR4 Epoxy (without mask)HardeningHardeningHardening FR4 Epoxy (green mask)HardeningHardeningHardening FR0406 EpoxySoft gelationHardeningHardening BT-EpoxyNCNCSoft gelation PolyimideNCNCNC
[234] Rose Bengal (0.15%)450 to 580 nmradish<2 seconds<2 seconds<2 seconds Ethyldimethylaminobenzoate (0.70%) AluminaHardeningHardeningHardening Diphenyl iodonium PF ₆ (0.60%) FR4 Epoxy (without mask)HardeningHardeningHardening FR4 Epoxy (green mask)HardeningHardeningHardening FR0406 EpoxyHardeningHardeningHardening BT-EpoxySoft gelationHardeningCuring (bottom only) PolyimideSoft gelationHardeningNCToluidine Blue O (0.10%)450 to 690 nmradishHardeningHardeningGelling Ethyldimethylaminobenzoate (0.50%) AluminaGellingHardeningNC Diphenyl iodonium PF ₆ (0.50%) FR4 Epoxy (without mask)GellingHardeningNC FR4 Epoxy (green)GellingHardeningNC FR0406 EpoxyGellingHardeningNC BT-EpoxyGellingHardeningNC PolyimideGellingHardeningNCMatallen Blue (0.10%)500 to 700 nmradishHardeningHardeningNC Ethyldimethylaminobenzoate (0.50%) AluminaGellingGellingNC Diphenyl iodonium PF ₆ (0.50%) FR4 Epoxy (without mask)NCGellingNC FR4 Epoxy (green mask)GellingHardeningNC BT-EpoxyNCGellingNC PolyimideGellingHardeningNC
[235] ^(a) Curing = Hard solid formed
[236] ^(b) Gelation = solid formed
[237] ^(c) Soft gelation = Soft solid formed
[238] ^(d) slight gelation = solid formed in some liquid
[239] ^(e) NC = not cured
[240] The data in Table 2C can be used to identify (1) a light-transmitting spectral region associated with a variety of substrates, (2) identify a photoinitiator that absorbs light within the transmission wavelength of the substrate, and (3) Illustrate the successful curing of the composition through a printed circuit board which requires three important factors, including the selection of a light source that provides actinic radiation within the wavelength to be absorbed. Successful photopolymerisation through most PCSs required wavelengths of light exceeding the UV portion of the electromagnetic spectrum, i.e., wavelengths of 400 nm or more.
[241] Example 3
[242] Several adhesive liquids and films were prepared as follows.
[243] Adhesive film:
[244] Sample 3-A
[245] 7 g of a sample of acrylated epoxy CN 104 (available from Sartomer Company, Inc. of Exton, Pa.) Was mixed with the powdered phenoxy resin PKHP (phenoxy resin available from Rock Hill, (28.6% w / w in tetrahydrofuran (THF)). A clear solution was obtained. To this solution, camphorquinone (0.05 g), Ph ₂ ISbF ₆ (0.05 g) and EDMAB (0.05 g) were added. The solution was coated to a thickness of 0.15 mm (6 mil) on a siliconized poly (ethylene terephthalate) (PET) release liner (Kotalz Erospace Inc., Glendale, CA) Lt; / RTI &gt; All coating and drying processes were carried out under a yellow light.
[246] Sample 3-B
[247] 7 g of a sample of tris (hydroxyethyl) isocyanurate triacrylate (SR 368 ^TM , available from Satomar Company) was dissolved in a mixture of bisphenol Z type polycarbonate (TS2020 ^RM , Tei (Gene Chemicals Limited) solution (30% w / w in THF). Bisphenol Z is 1,1-bis (4-hydroxyphenyl) cyclohexane. A clear solution was obtained. The same catalyst and amount was added as described in Sample 3-A above. The coating was carried out as described above.
[248] Liquid adhesive:
[249] Sample 3-C
[250] Epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate (ERL) was added to 1.25 g of a solution of a polyetherimide oligomer (ULTEM ^TM , GE Plastic Division, GE Company, Pittsfield, ^TM 4221, Union Carbide Corporation, Danbury, Conn.) Were added. The sample was shaken until homogeneous. To the resulting solution was added 0.10 g of an organometallic photoinitiator (antimony pentafluoride salt of cyclopentadienyl iron xylene, CpFeXySbF ₆ , 3M). The solution was poured into a small aluminum pan to evaporate the solvent. A clear liquid was obtained and protected from light.
[251] Additional liquid adhesives 3-D and 3-E having the formulations shown in Table 3A below were prepared by mixing the ingredients as indicated.
[252] Adhesive composition ingredient3-D (parts by weight)3-E (parts by weight) Bis (glycidyl methacrylate) (Bis GMA)22.5012.50 Triethylene glycol dimethacrylate (TEGDMA)02.1212.50 Campoquinone (CPQ)00.1200.17 Ethyl p-dimethylaminobenzoate (EDMAB)00.1201.00 Diphenyl iodonium hexafluorophosphate00.1201.60 Rose Bengal (RB)00.01200.10 R976 fumed silica00.0003.50
[253] Curing of adhesive:
[254] Procedure 1
[255] Silica chips were mounted on alumina and FR4 circuit boards with solder mask using adhesives 3-A, 3-B and 3-C. In the case of a film adhesive, the adhesive was laminated on a chip or a circuit board. In the case of a liquid adhesive, a small droplet was placed on the circuit board to fix the chip in place. To cure the adhesive, all samples were placed in direct contact with the hot plate on a hot plate at a temperature of 180 占 폚. An additional chip was used as a spacer on the perimeter of the circuit board. The adhesive was irradiated through the circuit board for 20 seconds using a 3M XL 3000 dental curing lamp having a light output of 400 nm to 500 nm. All adhesives were hardened with a hard material and the chip could not be removed even when picked up by a tweezer.
[256] Procedure 2
[257] Compositions 3-A, 3-D, and 3-E were evaluated for possible adhesives for loading silica chips into FR4 circuit boards according to the following procedure. The silica chip was placed in contact with a metal plate heated to 180 DEG C for about 30 seconds. The FR4 PCB was fixed to a transparent quartz plate in a vacuum. The liquid resin or thermoplastic film was applied to the PCB and the PCV and chips were attached together for about 10 seconds under a pressure of 30 psi at 207 KPa and then immersed in a quartz plate for 20 seconds to 30 seconds using a 3M XL3000 dental curing lamp Respectively. The vacuum was removed and the PCB and silica chip were stripped. As a comparative example, the above test was repeated without exposure to light. All samples were evaluated with a tweezer and measured as well (" good adhesion ") or easily removed (" poor adhesion "). The results are shown in Table 3B.
[258] SampleRay exposureRay unexposed 3AWell cured / Good adhesionUncured / poor adhesion 3DWell cured / Good adhesionUncured / poor adhesion 3EWell cured / Good adhesionUncured / poor adhesion
[259] The data clearly show that the chip can be effectively coupled to the printed circuit board by light exposure through the circuit board surface opposite the chip / PCB interface. In the absence of light exposure, the adhesive composition remains uncured, thus providing the possibility of solder free of mature polymerization. Both the film and liquid compositions (cationically curable system and / or free radical curable system) were effective.
[260] Example 4
[261] Optical stratification of a compact disk
[262] Two metal-treated polycarbonate halves of a compact disc (CD), each having an optical density of about 2.5, were photocompatible with each other according to the following method.
[263] A thin film of the adhesive according to the formulation shown in Table 4 below was applied on the metal side of one disk and then the metal side of the second disk was placed in contact with the coated adhesive. A slight pressure was applied to the sandwich structure to provide a thin and relatively uniform adhesive layer. The sample was then exposed to a Fusion Q bulb (Fusion UV Systems, Inc., Gettysburg, Maryland, USA), which provides an output of about 2.6 watts / cm ² (400 nm to 500 nm) at a line speed of about 2.4 m / ) Was placed in a standard radiation processing line at a distance slightly exceeding the manufacturer recommended exposure distance. This provided a residence time of light for about 0.6 seconds and a dose of 2.6 J / cm &lt; ² &gt;. The formed samples were adhered well and they were separated to delaminate the metal coating from the polycarbonate disk. Thus, using this approach, we confirmed the ability to quickly photolitically layer through the reflective substrate. For the DVD application, two adhesive formulations were evaluated as follows. This material absorbed visible light of 400 to 500 nm and was well adhered by a Fusion Q bulb. This method provided a fast and simple process for depositing a variety of reflective substrates, including DVD-RAM, DVD, CD, and the like.
[264] Adhesive 1 ingredientWeight portion UV-6100B / HPA DVD Adhesive50.00 Camphorquinone0.50 Ethyl p-dimethylaminobenzoate0.35 Adhesive 2 ingredientWeight portion UV-6100B / HPA DVD Adhesive50.00 Camphorquinone0.50 Ethyl p-dimethylaminobenzoate0.25 Diphenyl iodonium hexafluorophosphate0.50
[265] UV 6100B is a urethane diacrylate monomer available from Nippon Kosei Kagaku (Nippon Synthetic Chemical Industry Inc., Osaka, Japan).
[266] HPA is a hydroxypropyl acrylate monomer available from Rohmtech, Inc., Maldon, Mass., USA.
[267] Example 5
[268] Lamination of reflective film using cationic curable epoxy composition
[269] Two highly reflective metallized sputtered aluminum PET films, each having an optical density of about 2.5, were layered photocrosslinked to one another with a photocurable epoxy composition according to the following procedure.
[270] A thin film of liquid epoxy adhesive (formulation shown in Table 5 below) was applied to a metal surface of a 2.5 cm x 2.5 cm sample of a sputtered aluminum coated PET film followed by an aluminum-treated PET film to contact the coated adhesive A similar 2.5 cm x 2.5 cm metal layer was placed. The sandwich structure was subjected to slight pressure to provide a thin, relatively flat adhesive layer. The samples were contacted directly with a light guide (12 mm diameter) of a 3M XL-3000 dental curing lamp providing about 500 mw / cm ² of blue light with a wavelength between 400 nm and 500 nm and irradiated for 60 seconds. This sample was inspected after 30 minutes and it was observed whether it adhered well only to the area immediately below the lamp. The remainder of the epoxy composition was uncured. This example confirms that the reflective substrate has been rapidly photocatalysted with the photocurable epoxy by light exposure through the highly reflective aluminum-treated PET film.
[271] Adhesive composition ingredientWeight portion ERL 4221E Epoxy9.50 p-THF 250 diol0.50 Camphorquinone0.10 Ethyl p-dimethylaminobenzoate0.01 Dodecyldiaryl iodonium methine0.15
[272] ERL 4221E is a cyclic aliphatic diepoxide available from Union Carbide.
[273] Dodecyldiaryl iodonium methide is bis (dodecylphenyl) iodonium tris (trifluoromethylsulfonyl) methide prepared as described in Example 2 of U.S. Patent No. 5,554,664.
[274] Example 6
[275] Lamination of reflective film and colored multilayer film
[276] Two highly reflective (metal untreated) multilayer films, each having an optical density of about 2.5, were layered photolithographically with a visible light photocurable methacrylate composition in the following manner.
[277] A thin film of a methacrylate adhesive (formulation below) was applied to one side of a 5 cm x 5 cm multilayer reflective film as described in U.S. Patent Application No. 09 / 126,917, followed by a 5 cm x 5 cm A multilayer reflective film having a surface area of 5 cm was disposed. This sandwich structure was subjected to slight pressure to provide a thin, relatively flat adhesive layer. The sample was applied to a 3M XL-3000 dental curing lamp providing a blue light of about 500 mw / cm &lt; ² &gt; Was directly contacted with a light guide (12 mm diameter) and irradiated for 10 seconds. This sample was inspected immediately and observed whether it was well cured and adhered to the area just below the lamp. Most residual methacrylates were uncured. This confirms that the reflective multilayer film was rapidly photolabile with the photo-curing composition by light exposure through a highly reflective multilayer film. This approach provides a fast and simple process for depositing a variety of reflective films and colored multilayer films.
[278] Adhesive agent ingredientWeight portion Bis GMA5.00 TEGDMA5.00 Camphorquinone0.02 Ethyl p-dimethylaminobenzoate0.10 Diphenyl iodonium hexafluorophosphate0.06
[279] Example 7
[280] Underfilled electronic devices (acrylate adhesives)
[281] Black opaque electronic chips were brazed in place on a 1.5 mm thick FR4 printed circuit board with metal contacts on top and both sides were coated with a solder mask. A space of about 0.10 mm was maintained between the top of the PCB mask and the soldered chip. This assembly was placed on a hot plate at 100 DEG C for about 1 minute and then the droplets of the red colored acrylate adhesive formulation described above as Example 1B in Table 1 were applied on one side of the soldered chip on the gap between the circuit board and the chip . The adhesive formulation was applied in a wick form below the chip within about 5 seconds. The assembly was removed from the hot plate and irradiated with XL-3000 dental blue light (3M) through FR4 circuit board from the side opposite to the directly soldered chip. The adhesive was observed to see if it solidified rapidly in less than 20 seconds and changed from red to colorless.
[282] Example 8
[283] Underfilled electronic devices (acrylate adhesives)
[284] The procedure of Example 7 was repeated except that the circuit board with soldered chips was not heated prior to application of the adhesive. This adhesive formulation needed to be applied in a wick form under the chip for about 2 minutes at 23 占 폚. When the adhesive was applied in a wick form below the chip, the assembly was heated on a hot plate of 100 캜 for 20 seconds, and then the adhesive was formed in the shape of a bead around all sides of the chip. The assembly was removed from the hot plate and exposed to light for 20 seconds as described in Example 7, with the adhesive cured.
[285] Example 9
[286] Underfilled electronics (epoxy adhesive)
[287] The procedure of Example 7 was repeated except that the epoxy adhesive formulation shown in Table 5 was used instead of the acrylate adhesive. An epoxy adhesive was formed under the chip in a wick configuration for about 5 seconds. This assembly was removed from the soleplate and irradiated with XL-3000 blue dental light (3M) through the FR4 circuit board from the side opposite the directly soldered chip. The adhesive was observed to see if it solidified rapidly in less than 20 seconds and changed from red to colorless.
[288] Example 10
[289] Underfilled electronics (filled acrylate adhesive)
[290] The procedure of Example 7 was repeated except that the acrylate adhesive was modified by the addition of filler before the adhesive was applied to the chip-circuit board interface. An amorphous spherical silica powder having an average particle diameter of about 5 microns (SILSTAR ^TM LE-05, Nippon Shintech Industries Co., Ltd., Tokyo, Japan) was added in an amount of 1.44 g per g acrylate adhesive, Lt; / RTI &gt; The filled adhesive was dispensed along one side of the heated chip assembly. After 2 minutes on the hot plate, there was no evidence that any fillet was formed on the opposite side from where the adhesive was dispensed. The adhesive was cured using a XL-3000 blue dental light, and then the chip was disassociated from the circuit board for inspection purposes. Approximately 90% of the area under the chip was encapsulated and the adhesive appeared to be fully cured.
[291] Example 11
[292] Underfilled electronics (filled epoxy adhesive)
[293] The procedure of Example 10 was repeated except that the acrylate adhesive was replaced with an epoxy adhesive as described in Example 9. [ The amorphous silica filler was used as a 65 wt% load. After 2 minutes on the hot plate, there was no adhesive formation on the opposite surface from where the adhesive was dispensed. Finally, the dispensed adhesive was cured in the same manner as described in Example 7, and the chip was then unbonded from the circuit board for inspection purposes. Approximately 90% of the area under the chip was encapsulated and the adhesive appeared to be fully cured.
[294] Those skilled in the art will appreciate that various modifications and changes may be made without departing from the spirit and scope of the invention. The present invention should not be unduly limited by the exemplary embodiments described herein.

权利要求:
Claims (10)
[1" claim-type="Currently amended] (a) providing a structure comprising at least two layers and a photopolymerizable adhesive composition between the layers,
(1) at least one of the layers is opaque or colored and is transmissive to actinic radiation in the identified spectral region of at least one wavelength greater than or equal to 400 nm and less than or equal to 1200 nm, said layer comprising a cellulose- Substantially free of olefinic functional groups,
(2) the photopolymerizable composition comprises a photopolymerizable portion and a photoinitiator for the photopolymerizable portion that absorbs actinic radiation in the identified spectral region of the radiopaque layer, wherein the photopolymerizable portion is selected from the group consisting of silicon hydride hydrosilation polymerization process, a cationic polymerization process, or a free radical polymerization process, with the proviso that said free radical polymerization process does not use a dialkylaminobenzophenone sensitizer,
(b) curing the photopolymerizable composition by irradiating actinic radiation in the identified spectral region for less than 2 minutes into the photopolymerizable composition via the radiation-transparent layer
Wherein the formed polymerized composition is adhered to the layers to provide a laminate structure.
[2" claim-type="Currently amended] (a) identifying two layers, wherein at least one of the layers is colored, opaque, or reflective, and wherein at least one of the actinic radiation in the identified spectral region is greater than or equal to 400 nm and less than or equal to 1200 nm Wherein said layer is substantially free of cellulosic and olefinic functionalities when said radiation-permeable layer is colored or opaque,
(b) identifying a photopolymerizable composition to be disposed between the layers, the composition comprising a photopolymerizable portion and a photoinitiator for the photopolymerizable portion that absorbs radiation in the identified spectral region of the radiopaque layer ; And
(c) identifying a source of radiation which provides the identified spectral region of the radiation-permeable layer and the actinic radiation within the radiation absorption wavelength of the photoinitiator
And then irradiating the actinic radiation, if necessary, through the radiation-permeable layer for less than 2 minutes to polymerize the photopolymerizable composition to provide a laminate structure, two layers for producing a laminate structure, A method of identifying an adhesive composition and a radiation source.
[3" claim-type="Currently amended] (a) providing a structure comprising at least two layers and a photopolymerizable adhesive composition between the layers,
(1) at least one of the layers is either (a) a reflective layer and (b) a layer incorporated into an electronic component, or both, and wherein the layer is a layer having at least one wavelength greater than or equal to 400 mm and less than or equal to 1200 nm Lt; RTI ID = 0.0 &gt; radiation, &lt; / RTI &gt;
(2) the photopolymerizable composition comprises a photopolymerizable site and a photoinitiator for the photopolymerizable site that absorbs actinic radiation in the identified spectral region of the radiopaque layer, wherein the photopolymerizable site is a hydrogenated silicon polymerization Which is polymerizable by a process, a cationic polymerization process or a free radical polymerization process,
(b) curing the photopolymerizable composition by irradiating actinic radiation within the identified spectral region for less than 2 minutes into the photopolymerizable composition via the radiation-transparent layer
Wherein the formed polymerized composition is bonded to the layer to provide a laminate structure.
[4" claim-type="Currently amended] 4. The method of claim 3, wherein the layer further comprises at least one layer of a colored solder mask or colored coating.
[5" claim-type="Currently amended] 4. The method of claim 3, wherein the transmissive layer further comprises a metallized region.
[6" claim-type="Currently amended] The method of claim 3, wherein the transmissive reflective layer is selected from the group consisting of a metal-treated film, a multilayer optical film, and a retroreflective film.
[7" claim-type="Currently amended] (a) (1) an integrated circuit chip having a surface including a reflow solder bump with a contact tip,
(2) providing a printed circuit board having a bonding site,
Wherein at least one of the chip and the circuit board is transmissive to actinic radiation in the identified spectral region with a wavelength of greater than or equal to 400 nm and less than or equal to 1200 nm,
(b) directly applying a photopolymerizable adhesive composition to one or both of a surface of a chip having a solder bump and a bonding region of a printed circuit board, and exposing the contact tip of the solder bump of the chip, Wherein the adhesive composition comprises a photopolymerizable portion and a photoinitiator for the portion, wherein the photopolymerizable composition absorbs radiation in the identified spectral region of the radiopaque chip or circuit board,
(c) aligning and pressing the exposed tip of the bump on the surface of the chip to the bonding site of the circuit board,
(d) melting and reflowing the solder to establish electrical contact between the chip and the circuit board, wherein the photopolymerizable material remains substantially uncured; and
(e) irradiating the radiation in said identified spectral region through said radiation transmissive chip or circuit board for a time sufficient to cure said photopolymerizable adhesive composition to form said brazed and underfilled flip chip assembly on said circuit board; Step
&Lt; / RTI &gt; wherein the flip chip assembly is brazed and underfilled on a circuit board.
[8" claim-type="Currently amended] 8. The method of claim 7, further comprising performing a functional evaluation of the soldered electrical contact prior to performing the irradiating step (e).
[9" claim-type="Currently amended] 9. The method of claim 8,
(i) removing chips from the circuit board if the functional evaluation results in insufficient electrical contact between the chip and the circuit board, and
(ii) cleaning the bonding sites of the chip and the circuit board and repeating steps (a) to (e)
&Lt; / RTI &gt;
[10" claim-type="Currently amended] (a) capillary capping a photopolymerizable adhesive composition comprising a photopolymerizable region on a chip soldered on an integrated circuit substrate and a photoinitiator for the region,
Wherein the circuit board is transmissive to actinic radiation in the identified spectral region having a wavelength of from 400 nm to 1200 nm,
Wherein said photopolymerizable composition absorbs radiation in said identified spectral region of said radiopaque circuit board, and
(b) irradiating the circuit substrate from the opposite side of the side bearing the soldered chip for a time sufficient to cure the photopolymerizable composition with actinic radiation in the identified spectral region, thereby forming the soldered and underfilled flip chip assembly Steps to Offer
&Lt; / RTI &gt; wherein the flip chip assembly is brazed and underfilled on a circuit board.

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同族专利:

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公开号 | 公开日

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EP1200533B1|2007-04-11|

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US20020062919A1|2002-05-30|

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EP1200533A1|2002-05-02|

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AU1835300A|2001-02-19|

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KR100672791B1|2007-01-23|

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US6692611B2|2004-02-17|

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WO2001009262A1|2001-02-08|

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US6395124B1|2002-05-28|

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JP2003506860A|2003-02-18|

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DE69935810T2|2007-12-27|

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DE69935810D1|2007-05-24|

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US20020066528A1|2002-06-06|

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US20040134604A1|2004-07-15|

引用文献:

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公开号 | 申请日 | 公开日 | 申请人 | 专利标题

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法律状态:
1999-07-30|Priority to US09/365289

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1999-07-30|Priority to US09/365,289

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1999-11-30|Application filed by 캐롤린 에이. 베이츠, 쓰리엠 이노베이티브 프로퍼티즈 캄파니

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2002-05-08|Publication of KR20020034172A

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2007-01-23|Application granted

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2007-01-23|Publication of KR100672791B1

优先权:

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申请号 | 申请日 | 专利标题

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US09/365289|1999-07-30|

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US09/365,289|US6395124B1|1999-07-30|1999-07-30|Method of producing a laminated structure|