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

Patent metadata

Field	Value
Publication number	US-2016157362-A1
Application number	US-201514871991-A
Country	US
Kind code	A1
Filing date	Sep 30, 2015
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

What is claimed is:

1 . A method for producing an enhanced substrate for a printed circuit board (PCB) comprising:
providing a substrate, wherein the substrate comprises glass fiber impregnated with a base polymer; laminating a carbene-coated metal foil 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.

2 . The method as recited in claim 1 , wherein laminating a carbene-coated metal foil to a substrate includes laminating the carbene-coated metal foil to a prepreg comprising a sheet of woven glass fiber impregnated with the base polymer.

3 . The method as recited in claim 1 , wherein the carbene-coated metal foil comprises an electrodeposited copper foil having a copper surface treated with the NHC compound.

4 . The method as recited in claim 3 , wherein the copper surface of the electrodeposited copper foil is smooth and non-oxidized.

5 . The method as recited in claim 1 , wherein the NHC compound is represented by the following formula:

6 . The method as recited in claim 1 , wherein the NHC compound is represented by the following formula:

7 . The method as recited in claim 1 , wherein the NHC compound is represented by the following formula:

8 . The method as recited in claim 1 , 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.

9 . The method as recited in claim 1 , 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.

10 . A method for producing a carbene-coated metal foil comprising:
providing a metal foil having a surface; applying an N-heterocyclic carbene (NHC) compound to the surface of the metal foil to form a carbene-coated metal foil, wherein the NHC compound comprises 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; drying the carbine-coated metal foil.

11 . The method as recited in claim 10 , wherein applying an N-heterocyclic carbene (NHC) compound to the surface of the metal foil to form a carbene-coated metal foil includes feeding an electrodeposited (ED) copper foil into a bath containing the NHC compound dissolved in a solvent.

12 . The method as recited in claim 11 , wherein the ED copper foil includes a conductive surface that is smooth and non-oxidized.

13 . The method as recited in claim 12 , wherein the NHC compound forms a monolayer on the smooth and non-oxidized conductive surface of the ED copper foil.

14 . The method as recited in claim 10 , wherein the NHC compound is represented by the following formula:

15 . The method as recited in claim 10 , wherein the NHC compound is represented by the following formula:

16 . The method as recited in claim 10 , wherein the NHC compound is represented by the following formula:

17 . A carbene-coated metal foil produced according to claim 10 .

Assignees

• IBM

Inventors

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

Classifications

• C08L1/00

  Compositions of cellulose, modified cellulose or cellulose derivatives · CPC title

• B32B2260/046

  Synthetic resin · CPC title

• B32B2260/021

  Fibrous or filamentary layer · CPC title

• B01J31/2278

  Complexes comprising two carbene ligands differing from each other, e.g. Grubbs second generation catalysts · CPC title

• H05K2203/122

  Organic non-polymeric compounds, e.g. oil, wax or thiol · CPC title