Coating metal foil with n-heterocyclic carbene compounds containing organic functionalities for improving metal-to-resin adhesion

Patent metadata

Field	Value
Publication number	US-2016157361-A1
Application number	US-201414557818-A
Country	US
Kind code	A1
Filing date	Dec 2, 2014
Priority date	Dec 2, 2014
Publication date	Jun 2, 2016
Grant date	—

Abstract

A carbene-coated metal foil is produced by applying an N-heterocyclic carbene (NHC) compound to one or more surfaces of a metal foil (e.g., an electrodeposited copper foil having a surface that is smooth and non-oxidized). The NHC compound contains a matrix-reactive pendant group that includes at least one of a vinyl-, allyl-, acrylic-, methacrylic-, styrenic-, amine-, amide- and epoxy-containing moiety capable of reacting with a base polymer (e.g., a vinyl-containing resin such as a polyphenylene oxide/triallyl-isocyanurate (PPO/TAIC) composition). The NHC compound may be synthesized by, for example, reacting a halogenated imidazolium salt (e.g., 1,3-bis(4-bromo-2,6-dimethylphenyl)-4,5-dihydro-1H-imidazol-3-ium chloride) and an organostannane having a vinyl-containing moiety (e.g., tributyl(vinyl)stannane) in the presence of a palladium catalyst. In some embodiments, an enhanced substrate for a printed circuit board (PCB) is produced by laminating the carbene-coated metal foil to a substrate that includes glass fiber impregnated with the base polymer.

First claim

1 - 9 . (canceled)

10 . An enhanced substrate comprising:
a substrate, wherein the substrate comprises glass fiber impregnated with a base polymer; a carbene-coated metal foil laminated to the substrate, wherein the carbene-coated metal foil comprises a conductive surface treated with an N-heterocyclic carbene (NHC) compound comprising a matrix-reactive pendant group that includes at least one of a vinyl-, allyl-, acrylic-, methacrylic-, styrenic-, amine-, amide- and epoxy-containing moiety capable of reacting with the base polymer.

11 . The enhanced substrate as recited in claim 10 , wherein the carbene-coated metal foil comprises an electrodeposited copper foil having a copper surface treated with the NHC compound.

12 . The enhanced substrate as recited in claim 11 , wherein the copper surface of the electrodeposited copper foil is smooth and non-oxidized.

13 - 20 . (canceled)

21 . The enhanced substrate as recited in claim 11 , wherein the substrate is a prepreg comprising a sheet of woven glass fiber impregnated with the base polymer.

22 . The enhanced substrate as recited in claim 11 , wherein the NHC compound is represented by the following formula:

23 . The enhanced substrate as recited in claim 11 , wherein the NHC compound is represented by the following formula:

24 . The enhanced substrate as recited in claim 11 , wherein the NHC compound is represented by the following formula:

25 . The enhanced substrate as recited in claim 11 , wherein the base polymer comprises a vinyl-containing resin, and wherein the matrix-reactive pendant group includes at least one of a vinyl-, allyl-, acrylic-, methacrylic-, and styrenic-containing moiety.

26 . The enhanced substrate as recited in claim 11 , wherein the base polymer comprises epoxy resin, and wherein the matrix-reactive pendant group includes at least one of an amine-, amide- and epoxy-containing moiety.

27 . An enhanced substrate comprising:
a substrate, wherein the substrate comprises is a prepreg comprising a sheet of woven glass fiber impregnated with a base polymer; a carbene-coated metal foil laminated to the substrate, wherein the carbene-coated metal foil comprises an electrodeposited copper foil having a smooth and non-oxidized copper surface treated with an N-heterocyclic carbene (NHC) compound comprising a matrix-reactive pendant group that includes at least one of a vinyl-, allyl-, acrylic-, methacrylic-, styrenic-, amine-, amide- and epoxy-containing moiety capable of reacting with the base polymer.

28 . The enhanced substrate as recited in claim 27 , wherein the NHC compound is represented by the following formula:

29 . The enhanced substrate as recited in claim 27 , wherein the NHC compound is represented by the following formula:

30 . The enhanced substrate as recited in claim 27 , wherein the NHC compound is represented by the following formula:

31 . The enhanced substrate as recited in claim 27 , wherein the base polymer comprises a vinyl-containing resin, and wherein the matrix-reactive pendant group includes at least one of a vinyl-, allyl-, acrylic-, methacrylic-, and styrenic-containing moiety.

32 . The enhanced substrate as recited in claim 27 , wherein the base polymer comprises epoxy resin, and wherein the matrix-reactive pendant group includes at least one of an amine-, amide- and epoxy-containing moiety.

Assignees

• IBM

Inventors

• Boday Dylan J
• Kuczynski Joseph
• Wertz Jason T
• Zhang Jing

Classifications

• B32B2262/101

  Glass fibres · CPC title

• B32B2260/021

  Fibrous or filamentary layer · CPC title

• H05K1/0366

  reinforced, e.g. by fibres, fabrics (H05K1/036 takes precedence) · CPC title

• B32B2255/26

  Polymeric coating · CPC title

• B32B2457/08

  PCBs, i.e. printed circuit boards · CPC title