Dielectric composition

Claim 2

A castable dielectric composition comprising a dispersion of finely divided solids comprising: (a) 50-75% wt. noncrystallizable glass of which the deformation temperature (T d ) is 580°-625° C. and the softening point (T s ) is 630°-700° C. and (T s -T d ) is 50°-75° C. (b) 50-25% wt. refractory which is substantially insoluble in the glass at temperatures of 825°-900° C., the refractory and glass solids being selected from the group consisting of Al 2 O 3 , mullite, cordierite, SiO 2 , CaZrO 3 , forsterite, ZrO 2 and mixtures thereof both dispersed in a solution of (c) an organic polymeric binder in (d) volatile nonaqueous organic solvent.

Claim 3

A method of forming a green tape by casting a thin layer of the dispersion of claim 1 onto a flexible substrate and heating the cast layer to remove the volatile organic solvent therefrom.

Claim 4

A method for forming a multilayer interconnection comprising the steps of: (a) forming a patterned array of vias in a plurality of layers of green tape made by the process of claim 2; (b) filling the vias in the green tape layer(s) of step (a) with thick film conductor composition; (c) printing at least one patterned thick film functional layer over a surface of each of the via-filled green tape layers of step (b); (d) laminating the printed green tape layers of step (c) to form an assemblage comprising a plurality of interconnected functional layers separated by unfired green tape; and (e) cofiring the assemblage of step (d).

Claim 5

The composition of claim 1 in which the polymeric binder is a mixture of compatible polymers of 0-100% wt. C 1-8 alkyl methacrylate, 100-0% wt. C 1-8 alkyl acrylate and 0-5% ethylenically unsaturated carboxylic acid or amine, the multipolymer being further characterized as having a number average molecular weight (M n ) of 50,000-100,000, a weight average molecular weight (M w ) of 150,000-350,000, the ratio of M w to M n being no greater than 5.5, the total amount of unsaturated carboxylic acid or amine in the multipolymer mixture is 0.2-2.0% wt. and the glass transition temperature of the polymer and plasticizer therein if any is -30° to +45° C.

Claim 6

The composition of claim 4 in which the alkyl methacrylate is ethyl methacrylate and the alkyl acrylate is methyl acrylate.

Claim 7

The composition of claim 4 in which the ethylenically unsaturated carboxylic acid is a monocarboxylic acid selected from the group consisting of acrylic acid, methacrylic acid and mixtures thereof.

Claim 8

The composition of claim 1 in which the solvent is comprised on a weight basis of 70-83.5% by wt. 1,1,1-trichloroethane, 7-3% methylene chloride, 9-4% methyl ethyl ketone, 6-3% isopropanol and 9.3-6.5% fluorocarbons.

Claim 9

A method of forming a green tape by casting a thin layer of the dispersion of claim 1 onto a flexible substate, heating the cast layer to remove the volatile organic solvent therefrom and separating the solvent-free layer from the substrate.