IP Library Granted Patent US 12,262,468
Granted Patent B2
US 12,262,468 · App. 17/443,386 · Granted Mar 25, 2025

Copper-clad laminate and method of forming the same

Inventors: Jennifer Adamchuk (Marlborough, MA); Gerard T. Buss (Bedford, NH); Theresa M. Besozzi (Milford, MA)
Assignee: VERSIV COMPOSITES LIMITED
H05K1/056C09D5/24C09D127/12H05K3/44C08K3/34C08K3/36C08K2201/005C08K2201/006H05K2201/0355H05K2201/0358
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Quick Facts
Patent No.
US 12,262,468
App. No.
17/443,386
Granted
Mar 25, 2025
Kind
B2
Abstract

The present disclosure relates to a copper-clad laminate that may include a copper foil layer and a dielectric coating overlying the copper foil layer. The dielectric coating may include a resin matrix component, and a ceramic filler component. The ceramic filler component may include a first filler material. The dielectric coating may have an average thickness of not greater than about 20 microns.

Claims (43)

1. A copper-clad laminate comprising:

a copper foil layer, and a dielectric coating overlying the copper foil layer, wherein the dielectric coating comprises:

a resin matrix component; and

a ceramic filler component,

wherein the ceramic filler component comprises a first filler material wherein the content of the ceramic filler component is at least 30 vol. % for a total volume of the dielectric coating,

wherein the dielectric coating has an average thickness of not greater than about 20 microns, and

wherein the first filler material comprises silica and has a D 50 particle size distribution of at least about 0.5 microns and not greater than about 2.7 microns, and

wherein the dielectric coating has a porosity of not greater than about 8 vol. %.

2. The copper-clad laminate of claim 1 , wherein the first filler material further comprises a mean particle size of at not greater than about 10 microns.

3. The copper-clad laminate of claim 1 , wherein the first filler material comprises a particle size distribution span (PSDS) of not greater than about 5, where PSDS is equal to (D 90 -D 10 )/D 50 , where D 90 is equal to a D 90 particle size distribution measurement of the first filler material, D 10 is equal to a D 10 particle size distribution measurement of the first filler material, and D 50 is equal to a D 50 particle size distribution measurement of the first filler material.

4. The copper-clad laminate of claim 1 , wherein the first filler material

further comprises an average surface area of not greater than about 10 m 2 /g.

5. The copper-clad laminate of claim 1 , wherein the first filler material comprises a silica based compound.

6. The copper-clad laminate of claim 1 , wherein the resin matrix comprises a perfluoropolymer.

7. The copper-clad laminate of claim 6 , wherein the perfluoropolymer

comprises a copolymer of tetrafluoroethylene (TFE); a copolymer of hexafluoropropylene (HFP); a terpolymer of tetrafluoroethylene (TFE); polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer resin (PFA), fluorinated ethylene propylene (FEP), or any combination thereof.

8. The copper-clad laminate of claim 1 , wherein the content of the resin matrix component is at least about 50 vol. % and not greater than about 63 vol. % for a total volume of the dielectric coating.

9. The copper-clad laminate of claim 1 , wherein the content of the ceramic filler component is not greater than about 57 vol. % for a total volume of the dielectric coating.

10. The copper-clad laminate of claim 1 , wherein the content of the first filler material is at least about 80 vol. % and not greater than about 100 vol. % for a total volume of the ceramic filler component.

11. The copper-clad laminate of claim 1 , wherein the dielectric coating comprises a dissipation factor (5 GHz, 20% RH) of not greater than about 0.005.

12. The copper-clad laminate of claim 1 , wherein the dielectric coating

comprises a coefficient of thermal expansion (all axes) of not greater than about 80 ppm/° C.

13. The copper-clad laminate of claim 1 , wherein the copper-clad laminate comprises a peel strength between the copper foil layer and the dielectric coating of at least about 6 lb/in.

14. A printed circuit board comprising a copper-clad laminate, wherein the copper-clad laminate comprises:

a copper foil layer, and a dielectric coating overlying the copper foil layer, wherein the dielectric coating comprises:

a resin matrix component; and

a ceramic filler component,

wherein the ceramic filler component comprises a first filler material wherein the content of the ceramic filler component is at least 30 vol. % for a total volume of the dielectric coating, and

wherein the dielectric coating has an average thickness of not greater than 20 microns, and

wherein the first filler material comprises silica and has a D 50 particle size distribution of

at least about 0.5 microns and not greater than about 2.7 microns, and

wherein the dielectric coating has a porosity of not greater than about 8 vol. %.

15. The printed circuit board of claim 14 , wherein the first filler material further comprises a mean particle size of at not greater than about 10 microns.

16. The printed circuit board of claim 14 , wherein the first filler material comprises a particle size distribution span (PSDS) of not greater than about 5, where PSDS is equal to (D 90 -D 10 )/D 50 , where D 90 is equal to a D 90 particle size distribution measurement of the first filler material, D 10 is equal to a D 10 particle size distribution measurement of the first filler material, and D 50 is equal to a D 50 particle size distribution measurement of the first filler material.

17. The printed circuit board of claim 14 , wherein the first filler material further comprises an average surface area of not greater than about 10 m 2 /g.

18. The printed circuit board of claim 14 , wherein the first filler material comprises a silica based compound.

19. A method of forming a copper-clad laminate, wherein the method comprises:

providing a copper foil layer,

combining a resin matrix precursor component and a ceramic filler precursor component to form a forming mixture,

forming the forming mixture into a dielectric coating overlying the copper foil, wherein the dielectric coating has an average thickness of not greater than about 20 microns

wherein the ceramic filler precursor component comprises a first filler material wherein the content of the ceramic filler component is at least 30 vol. % for a total volume of the dielectric coating,

wherein the first filler material comprises silica and has a D 50 particle size distribution of at least about 0.5 microns and not greater than about 2.7 microns, and

wherein the dielectric coating has a porosity of not greater than about 8 vol. %.

Assignments (3)
CHANGE OF NAME Recorded Apr 12, 2024
From: SAINT-GOBAIN PERFORMANCE PLASTICS IRELAND LIMITED
To: VERSIV COMPOSITES LIMITED
Reel/Frame 067095/0019 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 12, 2024
From: SAINT-GOBAIN PERFORMANCE PLASTICS CORPORATION
To: SAINT-GOBAIN PERFORMANCE PLASTICS IRELAND LIMITED
Reel/Frame 067096/0147 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 24, 2021
From: ADAMCHUK, JENNIFER; BUSS, GERARD T.; BESOZZI, THERESA M.
To: SAINT-GOBAIN PERFORMANCE PLASTICS CORPORATION
Reel/Frame 057273/0056 →
Continuity (2)
Provisional Application 63057667 · Jul 28, 2020
Related Publication 20220039256A1 · Feb 3, 2022
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