Metal-clad laminate with segmented insulating layer
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Solution Overview
Problem
The existing metal-clad laminates struggle to lower the relative dielectric constant of the insulating layer without compromising the peel strength of the metal layer, as the use of fluororesin particles tends to decrease the peel strength.
Innovation Solution
A metal-clad laminate structure is developed with an insulating layer comprising a first layer containing composite particles with a fluororesin core and silicon oxide shell, and a second layer with either composite particles or no particles, where the ratio of composite particles in the second layer is lower than in the first layer, to maintain a high peel strength and low dielectric constant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If fluororesin particles are added to the insulating layer to lower the relative dielectric constant, then the dielectric constant decreases, but the peel strength of the metal layer with respect to the insulating layer decreases
Solution Approach 1:
The insulating layer is divided into a first layer (away from the metal layer) and a second layer (adjacent to the metal layer). The first layer contains composite particles with fluororesin cores to lower the dielectric constant, while the second layer has reduced or no composite particles to maintain peel strength. This spatial segmentation allows different regions to serve different functions.
Solution Approach 2:
Different regions of the insulating layer are given different compositions and properties. The first layer has high composite particle content for low dielectric constant, while the second layer has low or no composite particles for high peel strength. This local differentiation resolves the contradiction by allowing each region to optimize for its specific requirement.
2Quantity of substance
If composite particles with fluororesin cores are used to achieve low dielectric constant, then the dielectric constant is lowered, but the peel strength deteriorates
Solution Approach 1:
The insulating layer is segmented into two distinct layers with different composite particle concentrations. The first layer (远离金属层) contains composite particles to lower dielectric constant, while the second layer (相邻金属层) contains reduced or no composite particles to maintain reliable adhesion to the metal layer.
Solution Approach 2:
The patent applies local quality by giving different regions different compositions. The first layer has high composite particle content for dielectric performance, while the second layer has low or no composite particles for adhesion performance. This local differentiation ensures both low dielectric constant and high peel strength are achieved.
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
This configuration effectively reduces the chances of peel strength decrease while achieving a relative dielectric constant of 3.15 or less and a peel strength of 5 N/cm or higher, enhancing the dimensional stability and dielectric properties of the laminate.
Implementation Method 1
the relative dielectric constant of an insulating layer of a metal-clad laminate may be lowered by forming the insulating layer of a resin composition including a modified polyphenylene ether having, at one terminal, a substituent with a carbon-carbon double bond, a cross-linking agent with a carbon-carbon double bond, and particles containing a fluororesin
Implementation Method 2
the relative dielectric constant of the insulating layer certainly tended to be lowered by the particles containing the fluororesin
Data Source
AI summary
A metal-clad laminate includes: an insulating layer; and a metal layer stacked on the insulating layer. The insulating layer includes: a first layer; and a second layer interposed between the first layer and the metal layer. The first layer contains a cured product of a first resin composition containing composite particles. The second layer contains a cured product of a second resin composition. The first resin composition contains composite particles, each having a core containing a fluororesin and a shell containing a silicon oxide that coats the core at least partially. The second resin composition may or may not contain composite particles. When the second resin composition contains the composite particles, a ratio of the composite particles in the second resin composition to solid content of the second resin composition is lower than a ratio of the composite particles in the first resin composition to solid content of the first resin composition.