Patent US5156710A successfully refreshed from Google Patents.
US5156710A
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US
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Method of laminating polyimide to thin sheet metal
Assignee: International Business Machines Corp
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Filing: 1991-05-06
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Granted: 1992-10-20
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Expires: 2011-05-06
Abstract
Abstract An improved method of laminating a metal foil or sheet to a polyimide material is provided. A solution of a precursor of an intractable (i.e. thermosetting) polyimide is applied to a substrate and the solvent is removed to form a dry tack-free film. Thereafter, a solution of a precursor of a thermoplastic polyimide is applied onto the first film of polyimide and the solvent is removed to form a dry tack-free second film. Both films are then cured concomitantly at a sufficiently rapid rate and low temperature to effect substantial imidization of the polyimide precursors of both films without substantial crosslinking or densification of the polyimides in either of the films. Thereafter, a metal sheet or foil is laminated onto the thermoplastic polyimide film according to the following process. The thermoplastic film is contacted with the sheet or foil of metal to be laminated thereto. A first pressure is applied to the metal sheet and the polyimide substrate composite, which pressure is sufficiently low to permit outgassing of any gases trapped or generated within the polyimides and the temperature is increased. The temperature is raised to a level to essentially complete imidization of the polyimides and also to expel any gases contained or generated by said polyimide films. Thereafter, the pressure is increased to a second level or value and the temperature is controlled to a value which temperature is above the T g of the thermoplastic film. This second pressure is sufficiently high to complete the lamination of the metal sheet or foil to the thermoplastic polyimide.
Inventors
- 👤 Pei C. Chen
- 👤 Thomas E. Kindl
- 👤 Paul G. Rickerl
- 👤 Mark J. Schadt
- 👤 John G. Stephanie
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 03:27
CPC Classifications
B; B32; B32B; B32B15/00; B32B15/04; B32B15/08; B32B27/00; B32B27/28; B32B27/281; C; C08; C08G; C08G73/00; C08G73/06; C08G73/10; C08G73/1039; C08G73/1057; C08G73/106; C08G73/1064; C08G73/1067; C08G73/1075; C08G73/1078; C08J; C08J5/00; C08J5/12; C08J5/124; C08J5/125; H; H05; H05K; H05K1/00; H05K1/02; H05K1/03; H05K1/0313; H05K1/032; H05K1/0346; H05K1/05; H05K1/056; B32B2250/00; B32B2250/04; B32B2309/00; B32B2309/02; B32B2309/022; B32B2311/00; B32B2379/00; B32B2379/08; C08J2379/00; C08J2379/02; H05K1/0353; H05K1/036; H05K2201/00; H05K2201/03; H05K2201/0332; H05K2201/0335; H05K2201/0355; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31536; Y10T428/31678; Y10T428/31681; Y10T428/31721
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
218 words
A method of laminating a metal sheet to a polyimide material comprising the steps of: applying a solution of a precursor of an intractable polyimide to a substrate, and removing the solvent to form a dry tack-free first film; applying a solution of a precursor of a thermoplastic polyimide material to said first film and removing the solvent to form a dry tack-free second film; curing both films sufficiently rapidly to effect substantial imidization of each film without substantial crosslinking or densification of either of the polyimide films internally; thereafter laminating a metal sheet onto said thermoplastic polyimide according to the following process: (a) contacting the imidized thermoplastic polyimide with a sheet of metal to be laminated thereto; (b) applying a first pressure to said sheet of metal and said polyimide substrate composite which is sufficiently low to permit outgassing of any gas trapped or generated within said polyimides; (c) increasing the temperature of the polyimides while maintaining said first pressure to thereby essentially completely imidize said polyimides and expel gases contained in said polyimides; (d) increasing the pressure to a second pressure value and heating to a temperature which is above the T g of said thermoplastic polyimide to complete lamination of the metal to the polyimide; and (e) thereafter cooling to ambient and removing the pressure.
Claim 2
Independent Claim
218 words
A method of laminating a metal sheet to a polyimide material comprising the steps of: applying a solution of a precursor of an intractable polyimide to a substrate, and removing the solvent to form a dry tack-free first film; applying a solution of a precursor of a thermoplastic polyimide material to said first film and removing the solvent to form a dry tack-free second film; curing both films sufficiently rapidly to effect substantial imidization of each film without substantial crosslinking or densification of either of the polyimide films internally; thereafter laminating a metal sheet onto said thermoplastic polyimide according to the following process: (a) contacting the imidized thermoplastic polyimide with a sheet of metal to be laminated thereto; (b) applying a first pressure to said sheet of metal and said polyimide substrate composite which is sufficiently low to permit outgassing of any gas trapped or generated within said polyimides; (c) increasing the temperature of the polyimides while maintaining said first pressure to thereby essentially completely imidize said polyimides and expel gases contained in said polyimides; (d) increasing the pressure to a second pressure value and heating to a temperature which is above the T g of said thermoplastic polyimide to complete lamination of the metal to the polyimide; and (e) thereafter cooling to ambient and removing the pressure.
Claim 3
Dependent Claim
23 words
The method as defined in claim 1 wherein the cure of the polyimide to effect substantial imidization includes the use of infrared energy.
Claim 4
Dependent Claim
15 words
The method as defined in claim 1 wherein said metal sheet is a copper alloy.
Claim 5
Dependent Claim
14 words
The method as defined in claim 3 wherein the copper alloy is beryllium copper.
Claim 6
Dependent Claim
25 words
The method as defined in claim 1 wherein said temperature is raised to a second value when said pressure is raised to said second value.
Claim 7
Dependent Claim
14 words
The method as defined in claim 1 wherein said substrate is a steel alloy.
Claim 8
Dependent Claim
47 words
The method as defined in claim 2 wherein said cure which includes infrared energy is performed at a temperature sufficiently low to prevent any substantial crosslinking or densification of the thermoplastic polyimide, with said infrared energy including radiation in the band width of 2.82 to 3.28 microns.
Claim 9
Dependent Claim
17 words
The method as defined in claim 7 wherein said cure temperature does not exceed about 250° C.
Claim 10
Dependent Claim
32 words
The method as defined in claim 2 wherein said first pressure is not greater than about 10 psi and the temperature is increased while at said first pressure to about 340° C.
Claim 11
Dependent Claim
16 words
The method as defined in claim 9 wherein the second pressure value is about 675 psi.
Claim 12
Dependent Claim
24 words
The method as defined in claim 10 wherein the temperature is raised to about 360° C. during the time the second pressure is applied.
Claim 13
Dependent Claim
57 words
The method as defined in claim 1 wherein the thermoplastic polyimide precursor has the structure: ##STR5## or --(i.e. a single bond); x is 1-10 R 3 =is a linear or branched alkyl group which is partially or completely halogenated or an aromatic or heteroaromatic group; R 2 =is a divalent aromatic group; Ar=is a trivalent aromatic group.
Claim 14
Dependent Claim
21 words
The method in claim 12 wherein: R 1 is: C 3 F 6 ; R 2 is; ##STR6## Ar is: ##STR7##
Claim 15
Dependent Claim
20 words
The method as defined in claim 1 wherein a vacuum is applied during at least a portion of step (c).
Claim 16
Independent Claim
189 words
A method of laminating a metal sheet to a polyimide material comprising the steps of: applying a solution of a precursor of a thermoplastic polyimide material to a substrate and removing the solvent to form a dry tack-free film; curing said film sufficiently rapidly to effect substantial imidization of said film without substantial crosslinking or densification of the film internally; thereafter laminating a metal sheet onto said thermoplastic polyimide film according to the following process: (a) contacting the imidized thermoplastic polyimide with a sheet of metal to be laminated thereto; (b) applying a first pressure to said sheet of metal and said polyimide substrate composite which is sufficiently low to permit outgassing of any gas trapped or generated within said polyimide; (c) increasing the temperature of the polyimide while maintaining said first pressure to thereby essentially completely imidize said polyimide and expel gases contained in said polyimide; (d) increasing the pressure to a second pressure value and heating to a temperature which is above the T g of said polyimide to complete lamination of the metal to the polyimide; and (e) thereafter cooling to ambient and removing the pressure.
Claim 17
Independent Claim
189 words
A method of laminating a metal sheet to a polyimide material comprising the steps of: applying a solution of a precursor of a thermoplastic polyimide material to a substrate and removing the solvent to form a dry tack-free film; curing said film sufficiently rapidly to effect substantial imidization of said film without substantial crosslinking or densification of the film internally; thereafter laminating a metal sheet onto said thermoplastic polyimide film according to the following process: (a) contacting the imidized thermoplastic polyimide with a sheet of metal to be laminated thereto; (b) applying a first pressure to said sheet of metal and said polyimide substrate composite which is sufficiently low to permit outgassing of any gas trapped or generated within said polyimide; (c) increasing the temperature of the polyimide while maintaining said first pressure to thereby essentially completely imidize said polyimide and expel gases contained in said polyimide; (d) increasing the pressure to a second pressure value and heating to a temperature which is above the T g of said polyimide to complete lamination of the metal to the polyimide; and (e) thereafter cooling to ambient and removing the pressure.
Claim 18
Dependent Claim
23 words
The method as defined in claim 15 wherein the cure of the polyimide to effect substantial imidization includes the use of infrared energy.
Claim 19
Dependent Claim
15 words
The method as defined in claim 15 wherein said metal sheet is a copper alloy.
Claim 20
Dependent Claim
14 words
The method as defined in claim 17 wherein the copper alloy is beryllium copper.
Claim 21
Dependent Claim
25 words
The method as defined in claim 15 wherein said temperature is raised to a second value when said pressure is raised to said second value.
Claim 22
Dependent Claim
14 words
The method as defined in claim 15 wherein said substrate is a steel alloy.
Claim 23
Dependent Claim
46 words
The method as defined in claim 16 wherein said cure which includes infrared energy is performed at a temperature sufficiently low to prevent any substantial crosslinking or densification of the polyimide, with said infrared energy including radiation in the band width of 2.82 to 3.28 microns.
Claim 24
Dependent Claim
17 words
The method as defined in claim 21 wherein said cure temperature does not exceed about 250° C.
Claim 25
Dependent Claim
32 words
The method as defined in claim 22 wherein said first pressure is not greater than about 10 psi and the temperature is increased while at said first pressure to about 340° C.
Claim 26
Dependent Claim
16 words
The method as defined in claim 23 wherein the second pressure value is about 675 psi.
Claim 27
Dependent Claim
24 words
The method as defined in claim 24 wherein the temperature is raised to about 360° C. during the time the second pressure is applied.
Claim 28
Dependent Claim
56 words
The method as defined in claim 15 wherein the polyimide has the structure: ##STR8## or --(i.e. a single bond); x is 1-10 R 3 is a linear or branched alkyl group which is partially or completely halogenated or an aromatic or heteroamatic group; R 2 is a divalent aromatic group; Ar is a trivalent aromatic group.
Claim 29
Dependent Claim
21 words
The method in claim 26 wherein: R 1 is: C 3 F 6 ; R 2 is: ##STR9## Ar is: ##STR10##
Claim 30
Dependent Claim
20 words
The method as defined in claim 15 wherein a vacuum is applied during at least a portion of step (c).
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-10-20 | 1996-04-20 | 1996-10-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-10-20 | 2000-04-20 | 2000-10-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-10-20 | 2004-04-20 | 2004-10-20 | $7700.00 | Window Closed / Lapsed |