Heat-Treated Polymer Particles for Electronic Component Adhesion
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Solution Overview
Problem
Conductive polymer particles used in electronics applications face issues with mechanical properties, thermal expansion, and surface adhesion, leading to reliability problems in components like ball grid arrays due to fatigue stresses and delamination.
Innovation Solution
Heat-treated and coated polymer particles are developed by swelling addition polymer core particles with a blend of aromatic alcohols or amines with aldehydes, followed by heat treatment and metal coating, which enhances mechanical properties and surface adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polymer particles are used without heat treatment, then the manufacturing process is simpler, but the mechanical properties (elastic modulus, thermal expansion coefficient, deformation resistance) are insufficient
Solution Approach 1:
Heat treatment is performed in advance before the particles are used in electronic components, pre-establishing the required mechanical properties and dimensional stability. This preliminary action ensures the particles can withstand subsequent assembly and operational stresses without failing.
Solution Approach 2:
The heat treatment process changes the physical and chemical parameters of the polymer particles, including increasing elastic modulus, reducing thermal expansion coefficient, and improving deformation resistance. These parameter changes transform the particles from a soft, easily deformed state to a rigid, stable state suitable for electronic applications.
2Reliability
If polymer particles are coated with conductive material without surface treatment, then the coating process is simpler, but the coating adhesion is poor leading to delamination
Solution Approach 1:
Surface treatment with aromatic compounds is performed before coating to prepare the particle surface in advance. This creates a chemically active surface that will strongly bond with the conductive coating material, preventing delamination during subsequent handling and operation.
Solution Approach 2:
Aromatic compounds serve as an intermediary layer between the polymer particle surface and the conductive coating. This intermediary layer chemically bonds to both the polymer matrix and the coating material, creating a strong adhesive interface that prevents delamination.
3Reliability
If polymer particles are not swollen with aromatic compounds, then the particle structure is simpler, but the surface adhesion for coating is insufficient
Solution Approach 1:
The polymer particle is transformed into a composite structure by incorporating aromatic compounds (such as resorcinol, phenol, or aniline) within the particle matrix. This composite structure provides both mechanical integrity and chemical reactivity for coating adhesion, combining the benefits of polymer flexibility with aromatic compound surface properties.
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 process results in polymer particles with improved elastic modulus, reduced thermal expansion, and better coating adhesion, addressing mechanical and thermal challenges in electronic components.
Implementation Method 1
a blend of an aromatic alcohol with an aldehyde or a blend of an aromatic amine or urea with an aldehyde has been subsequently heat treated
Implementation Method 2
which has been subsequently heat treated, e.g. to a temperature of at least 150° C.
Implementation Method 3
The invention further provides a polymer particle comprising an addition polymer core particle which has had swollen and polymerised therein a blend of an aromatic alcohol and an aldehyde or a blend of an aromatic amine or urea with an aldehyde and which has been subsequently coated, preferably heat-treated and coated, with at least one layer comprising a metal.
Data Source
AI summary
A heat-treated polymer particle comprising an addition polymer core particle which has had swollen and polymerized therein a blend of an aromatic alcohol with an aldehyde or a blend of an aromatic amine or urea with an aldehyde and which has been subsequently heat treated, e.g. to a temperature of at least 150° C.