Multilayer Polyimide Film Thickness Control via Solvent Dilution
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Solution Overview
Problem
Current methods for manufacturing multilayer polyimide films struggle to achieve uniform thickness of each layer in the film-width direction, leading to non-uniform coefficients of linear expansion and dimensional changes when metal foils are laminated, particularly with existing extrusion casting methods which are complex and difficult to control.
Innovation Solution
The method involves using a multilayer coextrusion die where the concentration of polyimide resin solutions is adjusted by adding a solvent, allowing independent control of the solvent amount in each flow channel to achieve uniform thickness of each layer, and optionally incorporating a chemical dehydrating agent and imidization catalyst to enhance imidization reactions and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extrusion casting method is used to manufacture multilayer polyimide film, then productivity is improved, but manufacturing precision of thickness uniformity deteriorates
Solution Approach 1:
The patent divides the film formation process into multiple independent flow channels within the extrusion die, where each channel corresponds to a specific layer. This segmentation allows independent control of resin flow and thickness for each layer, resolving the contradiction between high productivity and thickness uniformity.
Solution Approach 2:
The patent applies local quality control by providing independent adjustment mechanisms for each flow channel, allowing different resin solutions to be precisely controlled in terms of flow rate and thickness. This enables each layer to achieve uniform thickness while maintaining overall high productivity.
2Ease of manufacture
If conventional extrusion die is used, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The patent designs a universal multilayer coextrusion die structure that can accommodate multiple flow channels and resin solutions through a standardized configuration. This multi-functional design simplifies manufacturing while managing device complexity through systematic organization of multiple functions within a single die structure.
3Manufacturing precision
If multilayer coextrusion die with independent flow channel control is used, then manufacturing precision of thickness uniformity is improved, but device complexity increases
Solution Approach 1:
The extrusion die is segmented into multiple independent flow channels, each with its own control mechanism for resin flow and thickness. This segmentation achieves precise thickness uniformity for each layer while the modular nature of the segmentation keeps the overall device complexity manageable through systematic design.
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 approach simplifies the manufacturing process, resulting in multilayer polyimide films with minimal fluctuations in properties, enabling high-accuracy lamination of semiconductor chips and other components with improved heat resistance and reliability.
Implementation Method 1
adding a solvent to the resin solutions to be fed into at least one of the flow channels; and adjusting, independently of amounts of the resin solutions to be fed, an amount of the solvent to be added
Implementation Method 2
incorporating a chemical dehydrating agent and imidization catalyst to enhance imidization reactions
Implementation Method 3
a self-supporting film is obtained by evaporating a solvent
Data Source
AI summary
It is an object of the present invention to provide a method for manufacturing a multilayer polyimide film, uniform in film thickness and rate of dimensional change in the width direction of the film, which has a thermoplastic polyimide layer or the like serving as an adhesive layer. The object is attained by a method for manufacturing a multilayer polyimide film by width-spreading and flow-casting at least two types of polyimide resin solutions or polyimide precursor resin solutions fed into a multilayer coextrusion die including a plurality of flow channels, the method being characterized in that the thickness of each layer of the multilayer film is controlled by adding a solvent to the resin solutions to be fed into at least one of the flow channels and by adjusting, independently of the amounts of the resin solutions to be fed, the amount of the solvent to be added.