PBI-acrylate coatings for microelectronics thermal resistance
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Solution Overview
Problem
Current polymer coatings for microelectronics face challenges in achieving high thermal resistance, uniformity, and ease of rework, particularly in thinning and backside processing of substrates, where temperatures exceed 200°C and aggressive chemicals are used, limiting their applicability and durability.
Innovation Solution
Development of polybenzimidazole (PBI) compositions combined with acrylate monomers, which form thermally resistant, electrically insulating coatings that can be applied as solutions or coatings, offering high thermal resistance up to 300°C and facilitating smooth, thick film deposition with rapid curing and easy rework capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional polymer coatings are used for dielectric applications, then electrical insulation is provided, but thermal resistance is insufficient at temperatures exceeding 200°C
Solution Approach 1:
The patent combines polybenzimidazole (PBI) polymer with acrylate monomers to create a composite coating material. PBI provides high thermal resistance and stability at temperatures exceeding 200°C, while acrylate monomers enable smooth film formation and rapid curing. This composite approach allows the coating to withstand harsh thermal and chemical conditions while maintaining reliability and ease of rework.
2Length of stationary object
If thick dielectric coatings are deposited to meet minimum thickness requirements, then electrical isolation is improved, but coating uniformity and smoothness become difficult to achieve
Solution Approach 1:
The patent utilizes the viscosity-changing properties of acrylate monomers during the coating process. The monomers allow the coating composition to flow smoothly at application, then rapidly polymerize to lock in the uniform thickness. This parameter change from fluid to solid state enables achieving both thick coatings (greater than 5 μm) and high uniformity, as the rapid curing prevents defects while the initial fluid state ensures even distribution.
Solution Approach 2:
The acrylate monomers undergo rapid phase transition from liquid to solid through polymerization after coating application. This phase change occurs quickly upon exposure to initiators or UV light, allowing the coating to maintain its spread-out uniform configuration while achieving the desired thickness. The rapid transition prevents sagging or unevenness that would occur with slow-curing materials.
3Reliability
If high molecular weight polymers are used to provide insulative properties, then electrical isolation is improved, but ease of rework and processing becomes difficult
Solution Approach 1:
The patent creates a dynamic system where the coating can transition between different states. The acrylate-based coating remains processable and removable under controlled conditions (ease of rework), yet provides high insulative properties when cured (reliability). The coating can be removed by soaking in appropriate solvents or by mechanical means if rework is needed, while maintaining its insulating function during normal operation. This dynamic characteristic allows the material to serve multiple functions throughout the product lifecycle.
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 PBI-acrylate coatings provide superior thermal resistance, adhesion, and dielectric properties, enabling efficient substrate thinning and backside processing, withstanding high temperatures and chemical exposure, and allowing for simple rework and cleaning processes.
Implementation Method 1
The PBI compositions may be used as, among other things, solutions, or thermally resistant and electrically insulating (dielectric) coatings and adhesives
Implementation Method 2
thermally resistant and electrically insulating (dielectric) coatings and adhesives
Implementation Method 3
The PBI-acrylate coatings provide superior thermal resistance, adhesion, and dielectric properties
Data Source
AI summary
PBI compositions include solutions comprising PBI and acrylate monomer and coatings comprising PBI and polyacrylate. The solutions may also include polymerization initiator, solvent, co-polymers. The coatings are thermally resistant, electrically insulating (dielectric), and adhesive. The PBI compositions are used in the manufacture of microelectronics and related products. Methods for applying the PBI compositions are also discussed.