Porous Liquid Crystal Polymer Sheets for Metal Bonding and Via Holes
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Solution Overview
Problem
Porous liquid crystal polymer sheets with low compressive strength, such as those described in Patent Document 1, face difficulties in processing, particularly in pressure bonding metal layers and forming via holes, which are essential for producing electronic circuit boards.
Innovation Solution
A porous liquid crystal polymer sheet is designed with a specific composition where a second component, having a higher weight percentage and smaller average particle size than the pores, enhances compressive strength by ensuring it does not contact the pores' interior, thereby improving processability and mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If polytetrafluoroethylene is used as a component in the porous liquid crystal polymer sheet, then the sheet can be formed with continuous porous matrix, but the compressive strength becomes low
Solution Approach 1:
The invention changes the compositional parameters by replacing polytetrafluoroethylene with liquid crystal polymer as the matrix material, and by controlling the particle size of the second component to be smaller than the average pore size. This parameter change transforms the material from having low compressive strength to high compressive strength while maintaining the continuous porous matrix structure.
Solution Approach 2:
The invention creates a composite material system consisting of liquid crystal polymer as the matrix and a second component (with specific particle size characteristics) as the filler. This composite structure achieves both high compressive strength and continuous porous matrix, resolving the contradiction between structural stability and strength.
2Quantity of substance
If porous liquid crystal polymer sheet with low compressive strength is used, then the sheet can be produced with certain material properties, but processing difficulties occur in pressure bonding metal layers and forming via holes
Solution Approach 1:
The invention changes the mechanical parameters of the material by optimizing the composition and particle size distribution, thereby improving compressive strength from low to high levels. This parameter change directly resolves the processing difficulties in pressure bonding and via hole formation while maintaining the desired material composition.
3Ease of manufacture
If the second component has large particle size, then the manufacturing process is simpler, but the compressive strength is reduced
Solution Approach 1:
The invention optimizes the particle size parameter of the second component to be smaller than the average pore size. This parameter optimization enhances compressive strength by improving the reinforcement effect within the porous structure, while the manufacturing process remains feasible with appropriate control of particle size distribution.
Data Source
AI summary
A porous liquid crystal polymer sheet that includes: a resin sheet having pores and containing a first component composed of a liquid crystal polymer and a second component accounting for a highest weight percentage of the resin sheet except for the first component, wherein, when a region containing the second component is defined as a first region, and a region having a smaller content of the second component than the first region is defined as a second region in the porous liquid crystal polymer sheet, the first region has higher compressive strength than the second region, the second component has an average particle size smaller than an average pore size of the pores, and the second component is not in contact with an inside of the pores.