Photosensitive and via-forming circuit board

Abstract

A photosensitive and via-forming circuit board comprising a laminate unit, a conductor unit, and a cover layer unit is provided. The laminate unit includes an insulating layer, a first conductive wiring layer and a second conductive wiring layer formed at two opposite sides of the insulating layer, respectively, and at least one through-hole surface defining a through hole extending from the upper surface of the first conductive wiring layer through the insulating layer to the lower surface of the second conductive wiring layer. The conductor unit is formed on the at least one through-hole surface. The cover layer unit is formed from a photosensitive composition comprising an epoxy group-containing compound and a photosensitive polyimide capable of reacting with the epoxy group of the epoxy group-containing compound, and includes a first cover layer formed on the first conductive wiring layer and extending into and filling the through hole.

Claims

1. A photosensitive and via-forming circuit board, comprising: a laminate unit including an insulating layer, a first conductive wiring layer and a second conductive wiring layer formed at two opposite sides of the insulating layer, respectively, and a through-hole surface defining a through hole extending from the upper surface of the first conductive wiring layer through the insulating layer to the lower surface of the second conductive wiring layer; a conductor unit formed on the through-hole surface and electrically connecting the first conductive wiring layer and the second conductive wiring layer; and a cover layer unit including a first cover layer and a second cover layer formed on the first conductive wiring layer and the second conductive wiring layer of the laminate unit, respectively, and extending into and together completely filling the through hole, wherein the cover layer unit is formed from a photosensitive composition, and the photosensitive composition comprises an epoxy group-containing compound and a photosensitive polyimide capable of reacting with the epoxy group of the epoxy group-containing compound, wherein the photosensitive polyimide is a photosensitive polyimide having the structure of formula (I); ##STR00009## R.sup.1, R.sup.2 and R.sup.3 are each a tetravalent group; X.sup.1 is a divalent group; X.sup.2 is a divalent group having a carboxylic acid group; X.sup.3 is a divalent group having (2-hydroxyl-3-acrylate)propyl group or a divalent group having (2-hydroxyl-3-methacrylate)propyl group; m is a positive integer from 30 to 70, n is a positive integer from 10 to 45, and o is a positive integer from 10 to 35, based on 100 of the sum of m+n+o; wherein the plural R.sup.1s are the same or different, the plural X.sup.1s are the same or different, the plural R.sup.2s are the same or different, the plural X.sup.2s are the same or different, the plural R.sup.3s are the same or different, and the plural X.sup.3s are the same or different.

2. The photosensitive and via-forming circuit board of claim 1, wherein the content of the epoxy group-containing compound ranges from 10 wt % to 70 wt %, based on 100 wt % of the photosensitive polyimide.

3. The photosensitive and via-forming circuit board of claim 1, wherein the divalent group having the carboxylic acid group is ##STR00010##

4. The photosensitive and via-forming circuit board of claim 1, wherein the divalent group is ##STR00011## wherein p is from 1 to 20, ##STR00012##

5. The photosensitive and via-forming circuit board of claim 1, wherein the epoxy group-containing compound is selected from neopentyl glycol diglycidyl ether, 1,4-butanediol diglycidyl ether, diglycidyl 1,2-cyclohexanedicarboxylate, bisphenol A diglycidyl ether, 1,2-propanediol diglycidyl ether, trimethylolpropane triglycidyl ether, glycerol propoxylate triglycidyl ether, resorcinol diglycidyl ether, dimer acid diglycidyl ester represented by formula (1), and a combination thereof ##STR00013##

6. The photosensitive and via-forming circuit board of claim 1, wherein the hole diameter of the through hole ranges from greater than 0 mm to 0.25 mm.

7. The photosensitive and via-forming circuit board of claim 1, wherein the insulating layer is a flexible insulating layer.

8. The photosensitive and via-forming circuit board of claim 1, wherein the material of the conductor unit is selected from a conductive metal, a conductive polymer, and a combination thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other features and effects of the present invention will be clearly presented in the detailed description with reference to the drawings, in which:

(2) FIG. 1 is a schematic cross-section view of a traditional printed circuit board;

(3) FIG. 2 is a schematic cross-section view of the first embodiment of the photosensitive and via-forming circuit board of the present invention;

(4) FIGS. 3-13 are infrared absorption spectra illustrating the positions of infrared absorption peaks of the cover layer units having the photosensitive openings in the circuit boards having the photosensitive openings from Application Examples 1 to 11, respectively;

(5) FIGS. 14-17 are infrared absorption spectra illustrating the positions of infrared absorption peaks of the cover layer units having the photosensitive openings in the circuit boards having the photosensitive openings from Comparative Application Examples 1 to 4, respectively; and

(6) FIGS. 18-20 are photographs illustrating the porosity of the cover layer units at the through-hole positions in the circuit boards having the photosensitive openings from Application Example 7, and Comparative Application Example 1 and Comparative Application Example 4, respectively.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(7) The present invention will be further clarified in terms of the following embodiments. It is to be understood, however, that those embodiments are merely illustrative and should not be construed as limitation to the practice of the present invention.

Synthesis Example 1

(8) 16.95 g (0.111 mol) of 3,5-diaminobenzoic acid, 13.07 g (0.032 mol) of 2,2-bis[4-(4-aminophenoxy)phenyl]propane, 75.60 g (0.080 mol) of bisaminopropyltetramethyldisiloxane, and 126.72 g of N-methyl-2-pyrrolidone were mixed to form a homogeneous mixture. 46.61 g (0.188 mol) of bicyclo[2,2,2]oct-7-ene-2,3,5,6-tetracarboxylic dianhydride was added to the homogeneous mixture, which was then mixed for 2 hours. Afterwards, 14.85 g (0.033 mol) of 4,4-(hexafluoroisopropylidene)diphthalic anhydride was added and mixed for 4 hours at room temperature. After that, 65 g of xylene was added and then heated to the temperature for the polymerization reaction and mixed for 3 to 6 hours. After the temperature was down to 80 C., 7.92 g (0.056 mol) of glycidyl (meth)acrylate was added and then mixed between 80 C. to 120 C. for 12 hours. Next, the temperature was down to 25 C. and 301.72 g of the constituent containing the photosensitive polyimide was obtained. The solid content of the constituent containing the photosensitive polyimide was 58 wt % [(16.95+13.07+75.60+46.61+14.85+7.92)100/(16.95+13.07+75.60+46.61+14.85+7.92+126.72)], and the content of the photosensitive polyimide was 58 wt % [(16.95+13.07+75.60+46.61+14.85+7.92)100/(16.95+13.07+75.60+46.61+14.85+7.92+126.72)], based on 100 wt % of the total amount of the constituent containing the photosensitive polyimide.

Synthesis Example 2

(9) 16.45 g (0.108 mol) of 3,5-diaminobenzoic acid, 6.77 g (0.032 mol) of 1,3-bis(4-aminophenoxy)benzene, 80.70 g (0.085 mol) of bisaminopropyltetramethyldisiloxane, and 168.14 g of N-methyl-2-pyrrolidone were mixed to form a homogeneous mixture. 46.93 g (0.178 mol) of 5-(2,5-dioxotetrahydro-3-furanyl)-3-methyl-3-cyclohexene-1,2-dicarboxylic anhydride was added to the homogeneous mixture, which was then mixed for 2 hours. Afterwards, 16.46 g (0.037 mol) of 4,4-(hexafluoroisopropylidene)diphthalic anhydride was added and mixed for 4 hours at room temperature. After that, 65 g of xylene was added and then heated to the temperature for the polymerization reaction and mixed for 3 to 6 hours. After the temperature was down to 80 C., 7.68 g (0.054 mol) of glycidyl (meth)acrylate was added and then mixed between 80 C. to 120 C. for 12 hours. Next, the temperature was down to 25 C. and 343.13 g of the constituent containing the photosensitive polyimide was obtained. The solid content of the constituent containing the photosensitive polyimide was 50.998 wt % [(16.45+6.77+80.70+46.93+16.46+7.68)100/(16.45+6.77+80.70+46.93+16.46+7.68+168.14)], and the content of the photosensitive polyimide was 50.998 wt % [(16.45+6.77+80.70+46.93+16.46+7.68)100/(16.45+6.77+80.70+46.93+16.46+7.68+168.14)], based on 100 wt % of the total amount of the constituent containing the photosensitive polyimide.

Synthesis Example 3

(10) 18.62 g (0.122 mol) of 3,5-diaminobenzoic acid, 17.94 g (0.044 mol) of 2,2-bis[4-(4-aminophenoxy)phenyl]propane, 74.73 g (0.079 mol) of bisaminopropyltetramethyldisiloxane, and 231.98 g of N-methyl-2-pyrrolidone were mixed to form a homogeneous mixture. 41.82 g (0.213 mol) of cyclobutane-1,2,3,4-tetracarboxylic dianhydride was added to the homogeneous mixture, which was then mixed for 2 hours. Afterwards, 13.20 g (0.030 mol) of 4,4-(hexafluoroisopropylidene)diphthalic anhydride was added and mixed for 4 hours at room temperature. After that, 65 g of xylene was added and then heated to the temperature for the polymerization reaction and mixed for 3 to 6 hours. After the temperature was down to 80 C., 8.70 g (0.061 mol) of glycidyl (meth)acrylate was added and then mixed between 80 C. to 120 C. for 12 hours. Next, the temperature was down to 25 C. and 406.99 g of the constituent containing the photosensitive polyimide was obtained. The solid content of the constituent containing the photosensitive polyimide was 43.00 wt % [(18.62+17.94+74.73+41.82+13.20+8.70)100/(18.62+17.94+74.73+41.82+13.20+8.70+231.98)], and the content of the photosensitive polyimide was 43.00 wt % [(18.62+17.94+74.73+41.82+13.20+8.70)100/(18.62+17.94+74.73+41.82+13.20+8.70+231.98)], based on 100 wt % of the total amount of the constituent containing the photosensitive polyimide.

Preparation Example 1: Photosensitive Composition

(11) 41.48 g of bisphenol A diglycidyl ether, 3.37 g of phenyl bis(2,4,6-trimethylbenzoyl)-phosphine oxide (Manufacturer: BASF; brand name: Irgacure 819), and 301.72 g of the constituent containing the photosensitive polyimide from the Synthesis Example 1 were mixed. The solid content of the photosensitive composition was 63.44 wt % [(41.48+3.37+175)100/(41.48+3.37+301.72)], and the content of the photosensitive polyimide was 50.49 wt % [175100/(41.48+3.37+301.72)], based on 100 wt % of the total amount of the photosensitive composition.

Preparation Examples 2 to 6

(12) The steps for preparing the photosensitive compositions of Preparation Examples 2 to 6 were the same as those for Preparation Example 1, except that the kind and amount of the epoxy resin were varied as shown in Table 1.

Preparation Example 7: Photosensitive Composition

(13) 52.15 g of bisphenol A diglycidyl ether, 3.37 g of phenyl bis(2,4,6-trimethylbenzoyl)-phosphine oxide, and 343.13 g of the constituent containing the photosensitive polyimide from Synthesis Example 2 were mixed. The solid content of the photosensitive composition was 57.82 wt % [(52.15+3.37+174.99)100/(52.15+3.37+343.13)], and the content of the photosensitive polyimide was 43.90 wt % [174.99100/(52.15+3.37+343.13)], based on 100 wt % of the total amount of the photosensitive composition.

Preparation Examples 8 to 9

(14) The steps for preparing the photosensitive compositions of Preparation Examples 8 to 9 were the same as those for Preparation Example 7, except that the kind and amount of the epoxy resin were varied as shown in Table 1.

Preparation Example 10: Photosensitive Composition

(15) 67.90 g of dimer acid diglycidyl ester represented by formula (1) above, 3.37 g of phenyl bis(2,4,6-trimethylbenzoyl)-phosphine oxide, and 406.99 g of the constituent containing the photosensitive polyimide from Synthesis Example 3 were mixed. The solid content of the photosensitive composition was 51.50 wt % [(67.90+3.37+175.01)100/(67.90+3.37+406.99)], and the content of the photosensitive polyimide was 36.59 wt % [175.01100/(67.90+3.37+406.99)], based on 100 wt % of the total amount of the photosensitive composition.

Preparation Example 11

(16) The steps for preparing the photosensitive compositions of Preparation Example 11 were the same as those for Preparation Example 10, except that the kind and amount of the epoxy resin were varied as shown in Table 1.

Preparation Example 12: Photosensitive Composition

(17) 3.37 g of phenyl bis(2,4,6-trimethylbenzoyl)-phosphine oxide, and 301.72 g of the constituent containing the photosensitive polyimide from Synthesis Example 1 were mixed. The solid content of the photosensitive composition was 58.46 wt % [(3.37+175)100/(3.37+301.72)], and the content of the photosensitive polyimide was 57.36 wt % [175100/(3.37+301.72)], based on 100 wt % of the total amount of the photosensitive composition.

Preparation Examples 13 to 14

(18) The steps for preparing the photosensitive compositions of Preparation Examples 13 to 14 were the same as those for Preparation Example 12, except that the kind and amount of the constituent containing the photosensitive polyimide were varied as shown in Table 1.

Embodiment 1: Photosensitive and Via-Forming Circuit Board

(19) Referring to FIG. 2, the first embodiment of the photosensitive and via-forming circuit board of the present invention includes a laminate unit 4, a copper conductor unit 5, and a cover layer unit 6. The laminate unit 4 includes a polyimide insulating layer 41, a first circuitized copper conductive layer 42 and a second circuitized copper conductive layer 43 formed at two opposite sides of the polyimide insulating layer 41, respectively, and a through-hole surface 44. The through-hole surface 44 defines a through hole 441 extending from the upper surface of the first circuitized copper conductive layer 42 to the lower surface of the second circuitized copper conductive layer 43. The cover layer unit 6 includes a first cover layer 61 and a second cover layer 62 formed on the first circuitized copper conductive layer 42 and the second circuitized copper conductive layer 43, respectively, and extending into and filling the through hole.

(20) The method of preparing the first embodiment comprised the step of providing a laminate including a laminate unit 4 and a copper conductor unit 5. The laminate unit 4 included a polyimide insulating layer 41 having a thickness of 12 m, a first circuitized copper conductive layer 42 having a thickness of 12 m and a second circuitized copper conductive layer 43 having a thickness of 12 m formed at two opposite sides of the polyimide insulating layer 41, respectively, and a through-hole surface 44. The through-hole surface 44 defined a through hole 441 extending from the upper surface of the first circuitized copper conductive layer 42 to the lower surface of the second circuitized copper conductive layer 43 and having a hole diameter of 0.1 mm. The copper conductor unit 5 was formed on the through-hole surface by chemical plating for electrically connecting the first circuitized copper conductive layer 42 and the second circuitized copper conductive layer 43. The photosensitive composition from Preparation Example 1 was coated on the first circuitized copper conductive layer 42 and the second circuitized copper conductive layer 43, filling the through hole 441, and baked in an oven with hot air at 80 C. for 10 minutes to obtain a first cover layer 61 having a thickness of 20 m and a second cover layer 62 having a thickness of 20 m. The first cover layer 61 and the second cover layer 62 formed the cover layer unit 6.

Embodiments 2 to 11 and Comparative Embodiments 1 to 3

(21) The steps for preparing the photosensitive and via-forming circuit boards of Embodiments 2 to 11 and Comparative Embodiments 1 to 3 were the same as those for Embodiment 1, except that the kind of the photosensitive composition was varied, as shown in Table 1.

Comparative Embodiment 4

(22) The steps for preparing the photosensitive and via-forming circuit board of Comparative Embodiment 4 were the same as those for the Embodiment 1, except that the photosensitive composition was photosensitive epoxy resin (Manufacturer: TAYIO INK; model number: PSR-4000 EG23; solid content: 79 wt %).

Application Example 1

(23) The photosensitive and via-forming circuit board of Embodiment 1 was irradiated with the mercury arc lamp having a wavelength between 250 nm and 400 nm to perform the exposure treatment. The exposure energy of the exposure treatment was 800 mJ, and the exposure duration was 18 seconds. Then, development was carried out at 30 C. for 60 seconds by using a 1.5 wt % aqueous solution of sodium carbonate as the developer. Next, the circuit board was washed with deionized water for 30 seconds and dried with the air gun. Finally, the circuit board was baked in the oven with hot air circulation at 200 C. for 60 minutes to obtain the circuit board having the photosensitive opening, wherein the cover layer unit was formed into the cover layer unit having the photosensitive opening of 20 m. The positions of the infrared absorption peaks of the cover layer unit having the photosensitive opening in the circuit board having the photosensitive opening from Application Example 1 could be referred to FIG. 3.

Application Examples 2 to 11 and Comparative Application Examples 1 to 4

(24) The steps for preparing the circuit boards having the photosensitive openings from Application Examples 2 to 11 and Comparative Application Examples 1 to 4 were the same as those for Application Example 1, except that the kind of the photosensitive and via-forming circuit board was varied as shown in Table 1. The positions of the infrared absorption peaks of the cover layer units having the photosensitive openings in the circuit boards having the photosensitive openings from Application Examples 2 to 11 and Comparative Application Examples 1 to 4 could be referred to FIGS. 4 to 17, respectively.

(25) <<Evaluation Items>>

(26) Flexibility test: The circuit boards having the photosensitive openings of Application Examples 1 to 11 and Comparative Application Examples 1 to 4 were bent and pressed with a weight of 500 g for 60 seconds, and then, the weight was removed to allow the circuit boards to recover themselves for observing whether the cover layer units having the photosensitive openings cracked or peeled. If not, the circuit board was bent and pressed by the weight for 60 seconds, and then, the weight was removed to allow the circuit board to recover itself for observing again, until the cracking or peeling of the cover layer unit was observed. The number of bending was recorded.

(27) Acid resistance test: The circuit boards having the photosensitive openings of Application Examples 1 to 11 and Comparative Application Examples 1 to 4 were immersed in a 10 wt % hydrochloric acid solution at 25 C. for 30 minutes, respectively, and then rinsed with water and wiped to dry for forming 15 samples to be tested, which were then subjected to the adhesion test according to the standard method of IPC-TM-650 2.4.28.1. The adhesion test was performed by scoring a test area on the surface of the sample using a cutting blade. The test area had 1010 (100) grids, each had a size of 1 mm1 mm. Each score line was as deep as the bottom layer of the cover layer unit having the photosensitive opening. The test area was brushed to clean the debris. The grids in the test area were stuck with a 3M 600 tape and applied a pressure of 2 kg to firmly adhere the tape to the test area. Then, the tape was quickly torn off in the vertical direction (90). The evaluation criteria were as follows:

(28) ISO class 0: The edges of the cuts were completely smooth, and no peeling was observed in the test area.

(29) ISO class 1: Small flakes peeled off the intersections of the cuts, and the percentage of the broken area in the rest area was less than 5%.

(30) ISO class 2: Peeling was observed along the edges or at the intersections of the curs, and the percentage of the broken area in the test area was greater than 5% and less than 15%.

(31) ISO class 3: A portion of peeling was observed along the edges or at the intersections of the cuts or a portion of the grids flaked wholly. The percentage of the broken area in the test area was greater than 15% and less than 35%.

(32) ISO class 4: A large piece peeled along the edges of the cuts or some of the grids flaked partly or wholly, and the percentage of the broken area in the test area was greater than 35% and less than 65%.

(33) ISO class 5: A piece flaked along the edges and at the intersections of the cuts, and the percentage of the broken area in the test area was greater than 65%.

(34) Heat resistance test: The circuit boards having the photosensitive openings from Application Examples 1 to 11 and Comparative Application Examples 1 to 4 were placed in a furnace containing tin at 300 C. and immersed for 10 seconds. After being removed from the furnace, the appearance of the circuit board was observed with a 20 magnification microscope to determine whether the board burst or not. If not, the immersion and observation was performed again until the appearance of the board burst. The number of immersion was recorded.

(35) Measurement of porosity: The circuit boards having the photosensitive openings from Application Example 7, Comparative Application Example 1, and Comparative Application Example 4 were fixed between two acrylic plates, and then ground to the center of through hole by utilizing the cutting force of the sandpaper. The porosity of the cover layer unit at the through-hole position was observed by using a polarizing microscope (Manufacturer: OLYMPUS; Model: BX51). The porosities of the cover layer units of the circuit boards having the photosensitive openings from Application Example 7, Comparative Application Example 1, and Comparative Application Example 4 at the through-hole position were shown in FIGS. 18-20, respectively.

(36) TABLE-US-00001 TABLE 1 The circuit board having the photosensitive Application Example opening 1 2 3 4 5 6 7 8 The photosensitive and Embodiment 1 2 3 4 5 6 7 8 via-forming circuit board Comparative Embodiment The Preparation Example 1 2 3 4 5 6 7 8 photosensitive Solid content (wt %) composition 63.43 67.77 67.05 65.13 71.12 59.37 57.82 63.34 The Synthesis 301.72 301.72 301.72 301.72 301.72 301.72 constituent Example 1 containing Synthesis 343.13 343.13 the Example 2 photosensitive Synthesis polyimide Example 3 (g) Epoxy resin E-1 41.48 88.03 133.70 6.83 52.15 (g) E-2 79.45 112.18 E-3 58.28 Photo initiator P-1 3.37 3.37 3.37 3.37 3.37 3.37 3.37 3.37 (g) Epoxy resin/ 0.237 0.503 0.454 0.333 0.764 0.039 0.298 0.641 photosensitive polyimide Evaluation Items Number of bending 25 25 30 25 15 20 25 30 Acid resistance 1 1 1 0 2 2 0 0 Number of 7 8 8 8 4 4 7 7 immersion Porosity No No No No No No No No porosity porosity porosity porosity porosity porosity porosity porosity Comparative The circuit board having the photosensitive Application Example Application Example opening 9 10 11 1 2 3 4 The photosensitive and Embodiment 9 10 11 via-forming circuit board Comparative 1 2 3 4 Embodiment The Preparation Example 9 10 11 12 13 14 photosensitive Solid content (wt %) composition 64.65 51.50 51.67 58.46 51.47 43.47 The Synthesis 301.72 constituent Example 1 containing Synthesis 343.13 343.13 the Example 2 photosensitive Synthesis 406.99 406.99 406.99 polyimide Example 3 (g) Epoxy resin E-1 (g) E-2 67.90 E-3 129.15 69.65 Photo initiator P-1 3.37 3.37 3.37 3.37 3.37 3.37 (g) Epoxy resin/ 0.738 0.388 0.398 photosensitive polyimide Evaluation Items Number of bending 20 30 25 20 20 20 5 Acid resistance 1 1 1 3 3 3 1 Number of 7 8 8 5 5 5 3 immersion Porosity No No No With With With With porosity porosity porosity porosity porosity porosity porosity E-1: bisphenol A diglycidyl ether; E-2: dimer acid diglycidyl ester represented by formula (1); E-3: resorcinol diglycidyl ether; P-1: phenyl bis(2,4,6-trimethylbenzoyl)-phosphine oxide.

(37) Referring to FIGS. 18 to 20, it could be seen that the cover layer units of the circuit boards having the photosensitive openings from Comparative Application Examples 1 and 4 had porosity at the through-hole positions, as shown in the circle, such that the circuit boards having the photosensitive openings might have the problem of burst during the heat resistance test. Nevertheless, the cover layer unit of the circuit board having the photosensitive openings and formed from the photosensitive and via-forming circuit board of the present invention didn't have porosity at the through-hole position, so no burst problem would occur.

(38) In view of the above, in addition to the function of protecting the first conductive wiring layer and the second conductive wiring layer, the cover layer unit of the photosensitive and via-forming circuit board of the present invention can also serve as the plug piece for the through hole of the laminate unit. After being subjected to the lithography process, the photosensitive and via-forming circuit board of the present invention can be formed with the cover layer unit having the photosensitive opening filled with the photosensitive composition, due to which the circuit board having the photosensitive opening can have heat resistance and flexibility, resulting in the achievement of the objects of the present invention.

(39) Those described above are merely embodiments of the present invention, and cannot be used to limit the scope of the implementation of the present invention. Any simple equivalent variations and modifications made in accordance with the contents of the claims and the specification of the present invention are still within the scope of the present invention.