Crosslinked Fluoropolymer Layers for Low-Loss Telecom Patterning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Perfluoropolymers have not been widely used in electronic telecommunications due to the lack of materials that can be crosslinked by actinic radiation, particularly UV radiation, and they lack improved mechanical properties compared to uncrosslinked counterparts.
Innovation Solution
Development of crosslinked fluoropolymer compositions with at least 80% polymerized units of perfluorinated monomers and cure sites such as nitrile, iodine, or bromine, which can be crosslinked using heat or actinic radiation, applied as layers in electronic telecommunications articles like integrated circuits, antennas, and optical fiber cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If perfluoropolymer materials are used in electronic telecommunications, then low dielectric constant and loss properties are achieved, but mechanical properties remain insufficient due to lack of crosslinking
Solution Approach 1:
The patent applies parameter changes by introducing crosslinking chemistry to the perfluoropolymer material. Specifically, it incorporates vinyl ether groups that can undergo cationic crosslinking reactions, transforming the material from a thermoplastic state with insufficient mechanical properties to a crosslinked network structure with enhanced strength, adhesion, and thermal stability while preserving the low dielectric properties
Solution Approach 2:
The patent creates a composite material system combining perfluoropolymer chains with crosslinking agents. The crosslinked perfluoropolymer forms a network structure that integrates the beneficial low dielectric properties of fluorinated materials with the mechanical strength and dimensional stability of crosslinked networks, effectively merging two material property sets into one functional material
2Loss of energy
If perfluoropolymers are used as coatings or films, then low dielectric constant is achieved, but processing and patterning capability are limited without crosslinking
Solution Approach 1:
The patent applies preliminary action by incorporating latent crosslinking functionality into the perfluoropolymer material during synthesis. The vinyl ether groups are built into the polymer structure beforehand, allowing the material to be processed in a uncrosslinked state for easy coating and patterning, then crosslinked later through UV irradiation or thermal treatment to achieve final mechanical and adhesion properties
Solution Approach 2:
The patent introduces dynamic properties to the material system by enabling it to transition between uncrosslinked and crosslinked states. This allows the material to exhibit different properties at different stages of manufacturing: processable and soluble before crosslinking, and mechanically robust and insoluble after crosslinking, thereby facilitating multi-step fabrication processes
3Loss of energy
If conventional fluoropolymers are applied as layers, then low dielectric properties are obtained, but adhesion to substrates and other layers is insufficient
Solution Approach 1:
The patent applies parameter changes by modifying the surface energy and chemical reactivity parameters of the perfluoropolymer through crosslinking. The crosslinked network structure creates stronger interfacial bonding with substrates and adjacent layers, transforming the material from one with poor adhesion to one with enhanced adhesive strength while maintaining its low dielectric properties in the bulk
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The crosslinked fluoropolymer layers offer improved mechanical and dielectric properties, such as lower dielectric constants and losses, making them suitable replacements for polyimides in various electronic telecommunications components.
Implementation Method 1
crosslinking the fluoropolymer by exposure to heat, actinic radiation, or a combination thereof
Implementation Method 2
removing uncrosslinked portions of the fluoropolymer film
Data Source
AI summary
Electronic telecommunication articles are described comprising a crosslinked fluoropolymer layer. In typical embodiments, the crosslinked fluoropolymer layer is a substrate, patterned (e.g. photoresist) layer, insulating layer, passivation layer, cladding, protective layer, or a combination thereof. Also describes are methods of making an electronic telecommunications article and method of forming a patterned fluoropolymer layer. The fluoropolymer preferably comprises at least 80, 85, or 90% by weight of polymerized units of perfluorinated monomers and cure sites selected from nitrile, iodine, bromine, and chlorine. Illustrative electronic communication articles include integrated circuits, printed circuit boards, antennas, and optical fiber cables. Fluoropolymer compositions are also described.