Electronic device
An electronic device is provided. The device comprises a singulated carrier portion, a substrate molded onto the singulated carrier portion, and conductive traces disposed on the substrate. The substrate comprises a polymer composition that includes an aromatic polymer and an electrically conductive filler, wherein the polymer composition exhibits a surface resistivity of from about 1×10 12 ohms to about 1×10 18 ohms as determined in accordance with ASTM D257-14.
1. An electronic device comprising:
a singulated carrier portion;
a substrate molded onto the singulated carrier portion, wherein the substrate comprises a polymer composition that includes an aromatic polymer, an electrically conductive filler, and a mineral filler, wherein the mineral filler is present in the polymer composition in an amount of from about 10 to about 80 parts by weight per 100 parts by weight of the polymer matrix, wherein the polymer composition exhibits a surface resistivity of from about 1×10 12 ohms to about 1×10 18 ohms as determined in accordance with ASTM D257-14; and
conductive traces disposed on the substrate.
2. The electronic device of claim 1 , wherein the polymer composition exhibits a volume resistivity of 1×10 10 ohm-m to about 1×10 16 ohm-m as determined in accordance with ASTM D257-14.
3. The electronic device of claim 1 , wherein the polymer matrix constitutes from about 30 wt. % to about 80 wt. % of the polymer composition.
4. The electronic device of claim 1 , wherein the aromatic polymer has a melting temperature of about 200° C. or more.
5. The electronic device of claim 1 , wherein the aromatic polymer is a polyamide, polyester, polyarylene sulfide, polycarbonate, polyphenylene oxide, polyetherimide, liquid crystalline polymer, or a combination thereof.
6. The electronic device of claim 1 , wherein the aromatic polymer comprises a liquid crystalline polymer.
7. The electronic device of claim 6 , wherein the liquid crystalline polymer contains one or more repeating units derived from an aromatic hydroxycarboxylic acid, wherein the hydroxycarboxylic acid repeating units constitute about 40 mol. % or more of the polymer.
8. The electronic device of claim 7 , wherein the liquid crystalline polymer contains repeating units derived from 4-hydroxybenzoic acid, 6-hydroxy-2-naphthoic acid, or a combination thereof.
9. The electronic device of claim 7 , wherein the liquid crystalline polymer contains repeating units derived from 4-hydroxybenzoic acid in an amount of from about 30 mol. % to about 90 mol. % of the polymer and contains repeating units derived from 6-hydroxy-2-naphthoic acid in amount of from about 1 mol. % to about 30 mol. % of the polymer.
10. The electronic device of claim 7 , wherein the liquid crystalline polymer further contains repeating units derived from terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, hydroquinone, 4,4′-biphenol, acetaminophen, 4-aminophenol, or a combination thereof.
11. The electronic device of claim 1 , wherein the electrically conductive filler includes a carbon material.
12. The electronic device of claim 11 , wherein the carbon material has a volume resistivity of less than about 0.1 ohm-cm.
13. The electronic device of claim 11 , wherein the carbon material includes graphite, carbon black, carbon fibers, graphene, carbon nanotubes, or a combination thereof.
14. The electronic device of claim 1 , wherein the electrically conductive filler is present in the polymer composition in an amount of from about 0.5 to about 20 parts by weight per 100 parts by weight of the polymer matrix.
15. The electronic device of claim 1 , wherein the weight ratio of the mineral filler to the electrically conductive filler ranges from about 2 to about 500.
16. The electronic device of claim 1 , wherein the mineral particles include talc, mica, or a combination thereof.
17. The electronic device of claim 16 , wherein the mineral particles include talc, mica, or a combination thereof.
18. The electronic device of claim 16 , wherein the mineral fibers include wollastonite.
19. The electronic device of claim 16 , wherein the mineral fibers have a median diameter of from about 1 to about 35 micrometers.
20. The electronic device of claim 16 , wherein the mineral fibers have an aspect ratio of from about 1 to about 50.
21. The electronic device of claim 1 , wherein the polymer composition has a melt viscosity of from about 10 to about 250 Pa-s, as determined in accordance with ISO Test No. 11443:2014 at a shear rate of 1,000 s −1 and temperature that is 15° C. above the melting temperature of the composition.
22. The electronic device of claim 1 , wherein the singulated carrier portion comprises a metal.
23. The electronic device of claim 1 , wherein the substrate contains a channel within which a seed layer is disposed, and further wherein the circuit traces are disposed on the seed layer.
24. The electronic device of claim 23 , wherein the channel is formed by a laser.
25. The electronic device of claim 1 , wherein the polymer composition exhibits a dielectric constant of about 4 or more and a dissipation factor of about 0.3 or less, as determined at a frequency of 2 GHz.
26. The electronic device of claim 25 , wherein the composition exhibits a dielectric constant after being exposed to a temperature cycle of from about −30° C. to about 100° C., wherein the ratio of the dielectric constant after the temperature cycle to the dielectric constant prior to the heat cycle is about 0.8 or more.
27. The electronic device of claim 25 , wherein the composition exhibits a dissipation factor after being exposed to a temperature cycle of from about −30° C. to about 100° C., wherein the ratio of the dissipation factor after the temperature cycle to the dissipation factor prior to the heat cycle is about 1.3 or less.
28. The polymer composition of claim 1 , wherein the polymer composition is free of spinel crystals.