Organic Insulating Body Particle Sizing for Metal Foil Adhesion
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Solution Overview
Problem
In the development of metal-clad laminates and wiring boards, reducing the surface roughness of the metal foil to enhance adhesion strength while maintaining flame retardance and electrical properties is a challenge, as excessive reduction in surface roughness can lead to poor adhesion and decreased flame retardance.
Innovation Solution
Incorporating a flame retardant with a particle size distribution where the maximum number frequency is within 1 μm or less in the organic insulating body, which includes finely divided structures that enhance adhesion by occupying smaller surface areas and improving flame retardance, and using inorganic particles with a similar distribution to further increase adhesion strength and reduce flame retardance variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the surface roughness of the metal foil is reduced to enhance adhesion strength, then the adhesion strength between the metal foil and the organic insulating body is improved, but the flame retardance is reduced
Solution Approach 1:
The patent changes the particle size parameter of the flame retardant to 1 μm or less, which fundamentally alters how the flame retardant interacts with the metal foil surface. This parameter change allows the flame retardant to occupy smaller surface areas, thereby maintaining adhesion strength while preserving flame retardance properties.
Solution Approach 2:
The patent creates a composite structure by combining the organic insulating body with fine particle flame retardants (1 μm or less). This composite material approach allows the flame retardant particles to be distributed throughout the insulating body, providing flame protection without compromising the adhesion between the metal foil and the insulating body.
2Strength
If the surface roughness of the metal foil is reduced to enhance adhesion strength, then the adhesion strength between the metal foil and the organic insulating body is improved, but the electrical properties are reduced
Solution Approach 1:
The patent applies parameter changes by reducing the flame retardant particle size to 1 μm or less, which modifies the surface characteristics of the organic insulating body. This parameter change enables better adhesion of the metal foil while maintaining the electrical properties of the insulating body, as the fine particles create a more uniform surface that does not interfere with electrical performance.
3Object-affected harmful factors
If flame retardants with larger particle sizes are used, then the flame retardance is enhanced, but the adhesion strength between the metal foil and the organic insulating body is reduced
Solution Approach 1:
The patent fundamentally changes the particle size parameter from conventional larger sizes to 1 μm or less. This parameter change resolves the contradiction by demonstrating that smaller particles provide both adequate flame retardance and superior adhesion strength, as they create a smoother surface that enhances metal foil bonding while maintaining flame protection capabilities.
Data Source
AI summary
A flame retardant is included in a resin phase, and the flame retardant has a maximum number frequency in a range of 1 μm or less when a particle size distribution is evaluated by dividing a particle size into 1 μm increments. The resin phase includes inorganic particles, and the inorganic particles have a maximum number frequency in a range of 0.5 μm or less when the particle size distribution is evaluated by dividing the particle size into 0.5 μm increments. The flame retardant has an average particle size larger than the average particle size of inorganic particles. The number frequency of the flame retardant and the inorganic particles, respectively, decreases with increasing the particle size.