Polymeric Resin Copolymerization for Low Dielectric Loss

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Solution Overview

Problem

There is a need for polymeric resin compositions with improved mechanical, adhesive, and dielectric properties, specifically high tensile strength, tensile elongation, good adhesion to copper, and low relative permittivity and loss tangent at high frequencies, while also requiring lower temperature curing without excessive cure times.

Innovation Solution

A polymer is developed through copolymerization of a mixture comprising 10-50 mol % arylcyclobutene, 15-50 mol % diene, and 15-60 mol % aromatic vinyl monomers, with specific monomers and a radical initiator in a polar solvent, allowing for the formation of a dielectric film with enhanced properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional polymeric resins are used to achieve good mechanical properties and adhesion, then tensile strength and adhesion are improved, but dielectric properties (relative permittivity and loss tangent) worsen at high frequencies

Engineering Contradiction:
Improvetensile strengthVSAvoiddielectric properties
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent employs a composite material system consisting of polymeric resin combined with specific inorganic fillers (such as silica, alumina, or boron nitride) to achieve both good mechanical properties and excellent dielectric properties. The resin matrix provides structural integrity and adhesion, while the inorganic filler particles contribute to low relative permittivity and low loss tangent at high frequencies, resolving the contradiction between mechanical strength and dielectric performance.

Inventive Principle:
Principle #40Composite materials

2Strength

If conventional polymeric resins are used to achieve good adhesion to copper, then adhesive properties are improved, but dielectric properties (loss tangent) worsen at high frequencies

Engineering Contradiction:
Improveadhesion to copperVSAvoidloss tangent
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent uses a composite formulation where the polymeric resin provides adhesion to copper substrates through functional groups in its structure, while inorganic fillers with inherent low dielectric loss characteristics (such as boron nitride or silica) are incorporated to maintain low loss tangent at high frequencies. This composite approach allows simultaneous achievement of good adhesion and excellent high-frequency dielectric performance.

Inventive Principle:
Principle #40Composite materials

3Reliability

If conventional polymeric resins are used to achieve low relative permittivity, then dielectric properties are improved, but mechanical properties (tensile elongation) worsen

Engineering Contradiction:
Improverelative permittivityVSAvoidtensile elongation
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent formulates a composite material where inorganic fillers with low dielectric constants (such as silica or alumina) are dispersed in a polymeric resin matrix that provides good mechanical properties including tensile elongation. The resin matrix acts as a binding phase that maintains the structural flexibility and ductility, while the inorganic filler particles contribute to low relative permittivity, thus resolving the contradiction between dielectric performance and mechanical elongation.

Inventive Principle:
Principle #40Composite materials

4Reliability

If conventional polymeric resins are used to achieve low loss tangent at high frequencies, then dielectric properties are improved, but adhesion to copper worsens

Engineering Contradiction:
Improveloss tangentVSAvoidadhesion to copper
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent employs a composite system where inorganic fillers with inherently low dielectric loss (such as boron nitride or silica) are combined with a polymeric resin that contains adhesion-promoting functional groups. The resin phase ensures good bonding to copper substrates through chemical or physical adhesion mechanisms, while the inorganic filler phase maintains low loss tangent at high frequencies, thereby resolving the contradiction between adhesion and dielectric loss.

Inventive Principle:
Principle #40Composite materials

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 resulting polymer achieves good tensile strength, tensile elongation, adhesion to copper, and low dielectric loss at high frequencies, with Dk values less than 3.0 and Df values less than 0.004 at high frequencies, without the need for inorganic fillers.

Implementation Method 1

A polymer is developed through copolymerization of a mixture comprising 10-50 mol % arylcyclobutene, 15-50 mol % diene, and 15-60 mol % aromatic vinyl monomers, with specific monomers and a radical initiator

Methodology Applied
Scientific EffectCopolymerization: Chemical Bonding

Implementation Method 2

copolymerization of a mixture comprising 10-50 mol % arylcyclobutene, 15-50 mol % diene, and 15-60 mol % aromatic vinyl monomers, with specific monomers and a radical initiator

Methodology Applied
Scientific EffectRadical polymerization: Chemical Bonding

Data Source

PatentUS11603422B2Polymeric resin for dielectric applications
Publication Date: 2023.03.14 DUPONT ELECTRONIC MATERIALS INT LLC
  • US11603422B2 patent drawing
  • US11603422B2 patent drawing
  • US11603422B2 patent drawing

AI summary

There is provided a polymer which is the copolymerization product from a mixture including: (a) 10-50 mol % of at least one addition polymerizable arylcyclobutene monomer; (b) 15-50 mol % of at least one addition polymerizable diene monomer; and (c) 15-60 mol % of at least one addition polymerizable aromatic vinyl monomer. The polymer can be used in electronic applications.