Photosensitive polyimide resin composition and method of manufacturing cover film using the same

Abstract

A photosensitive polyimide resin composition is provided. The resin composition comprises an infrared absorber, an epoxy, a photosensitive polyimide and a photo initiator. The infrared absorber includes pigment and has an amount of weight accounting for 5-40% of total solid weight of the photosensitive polyimide resin composition. The epoxy has an amount of weight accounting for 5-40% of total solid weight of the photosensitive polyimide resin composition. The photosensitive polyimide has the structure of formula (1): ##STR00001## wherein m, n are independently 1 to 600; X is a tetravalent organic group, and the main chain of X includes alicyclic structure; Y is a divalent organic group, and the main chain of Y includes siloxane structure; Z is a divalent organic group, and the side chain of Z includes phenolic hydroxyl group or carboxyl group. The photosensitive polyimide has an amount of weight accounting for 30-90% of total solid weight of the photosensitive polyimide resin composition. The photo initiator has an amount of weight accounting for 0.1-15% of total solid weight of the transparent photosensitive resin.

Claims

1. A method for manufacturing a cover film comprising coating a photosensitive polyimide resin composition on a substrate and drying the photosensitive polyimide resin to obtain the cover film, wherein the photosensitive polyimide resin composition comprises: (a) a dye or a pigment serving as an infrared absorber, accounting for 5-40% of the solid weight of the photosensitive polyimide resin composition; (b) an epoxy compound accounting for 5-40% of the solid weight of the photosensitive polyimide resin composition; (c) a photosensitive polyimide having a structure of formula (1): ##STR00012## wherein m and n are independently 1 to 600; X is a tetravalent organic group, a main chain of which contains an alicyclic group; Y is a divalent organic group, a main chain of which contains a siloxane group; Z is a divalent organic group, a side chain of which at least contains a phenolic group or a carboxyl group; and the photosensitive polyimide accounts for 30-90% of the solid weight of the photosensitive polyimide resin composition; and (d) a photo initiator accounting for 0.1-15% of the solid weight of the photosensitive polyimide resin composition, wherein the epoxy compound is neopentyl glycol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,2-cyclohexanedicarboxylic acid diglycidyl ester, bisphenol A diglycidyl ether, 1,2-propanediol diglycidyl ether, trimethylolpropane triglycidyl ether, glycerol tripropoxy triglycidyl ether, m-benzenediol diglycidyl ether, or a combination thereof.

2. The method of claim 1, wherein the drying is carried out by irradiating the photosensitive polyimide resin composition with infrared rays having a wavelength of 500-4000 nm.

3. The method of claim 2, wherein the temperature for irradiating is between 180 to 200 C., and the time for irradiating is between 10 to 30 minutes.

4. The method of claim 2, wherein the source of infrared rays includes an infrared halogen lamp, an infrared quartz tube, and an infrared blackbody tube.

5. The method of claim 1, wherein the dye is a metal complex dye or a condensed polycyclic dye.

6. The method of claim 1, wherein the pigment is an organic pigment or an inorganic pigment.

7. The method of claim 1, wherein X of formula (1) does not contain a benzene ring.

8. The method of claim 7, wherein X of formula (1) is ##STR00013##

9. The method of claim 1, wherein Y of formula (1) is ##STR00014## wherein p=0-20.

10. The method of claim 1, wherein the phenolic group or the carboxyl group of Z in formula (1) accounts for 5-30% of the total number of moles of the photosensitive polyimide.

11. The method of claim 10, wherein Z of formula (1) is ##STR00015##

12. The method of claim 1, wherein the photo initiator is bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide, 2-phenylmethyl-2-dimethylamino-1-1-(4-morpholinophenyl)-butanone, (2,4,6-trimethylbenzyl)diphenylphosphine oxide, bis(2,6-difluoro-3-(1-hydropyrro-1-yl)-phenyl) titanocene, 4,4-bis(dimethylamino)diphenyl ketone, 4,4-bis(diethylamino) diphenyl ketone, or N-phenyl diethanolamine.

13. The method of claim 1, wherein the cover film is used as an insulating film.

Description

DETAILED DESCRIPTION OF THE EMBODIMENTS

(1) The present invention provides a photosensitive polyimide resin composition having a photosensitive polyimide of a particular molecular structure as the main component and solves the problems of high temperature and long baking during shaping by adding the infrared absorber.

(2) The photosensitive polyimide resin composition of the present invention may further be added the thermal crosslinking agent having a phenolic compound or an alkoxymethylamine resin in its structure so that the terminal group on the molecular chain of the polyimide forms a crosslinking structure with the thermal crosslinking agent in order to improve the chemical resistance and film-forming capability of the polyimide. The acrylic resin photocrosslinking agent may also be added to produce the acid upon exposure, thereby forming the acid-catalyzed crosslinking mechanism.

(3) The photosensitive polyimide resin composition of the present invention comprises (a) an infrared absorber, (b) an epoxy compound, (c) a photosensitive polyimide, and (d) a photo initiator.

(4) The infrared absorber of the component (a) comprises dyes and pigments, and the dyes having a maximum absorption wavelength of 500 to 1000 nm, preferably 700 to 1000 nm, and more preferably 800 to 1000 nm, may be used. The dye used may include the metal complex dyes or the condensed polycyclic dyes, such as the phthalocyanine dyes, the porphyrin dyes, the cyanine dyes, the Quaterrylene dyes, the squaraine dyes, the azo dyes, the ammonium dyes, the anthraquinone series, the diimine series, the naphthalocyanine dyes, the nickel complex dyes, the copper ion dyes, the dithiol metal complexes, the heterocyclic compounds, and the like, among which the heterocyclic compounds, the Quaterine dyes, the phthalocyanine dyes, and the naphthalocyanine dyes that also have absorption in the range of visible light are preferred. The actual products of dyes are, for example, SDO-C8, SDO-C33, Lumogen IR 765, Lumogen IR 788, and the like. Further, it is preferred that the dye has the maximum absorption in the above wavelength range, can efficiently absorb light, has a sensitizing effect, and contains the metal complex. One or more of the dyes described above may be used as the infrared absorber of the present invention.

(5) The pigment serving as the infrared absorber of the present invention comprises the organic pigment and the inorganic pigment. Among the organic pigments, the phthalocyanine series, dioxazine series, and perylene series are preferred due to their excellent photo-curing property, coloring property, and shading property in the range of visible light. Specific and preferred examples include Pigment Blue of the phthalocyanine series, Lumogen Black FK4280 and Lumogen Black FK4281 of the perylene series, and PigmentViolet 23 and 37 of the oxazine series. The pigments mentioned above may be used alone or in proper combination with two or more of others. The inorganic pigments comprise cobalt(II,III) oxide, titanium black, carbon black, etc., and may be used alone or in proper combination with two or more of others. In the photosensitive resin composition of the present invention, the content of the infrared absorber (a) accounts for 0.5 to 40% of the solid weight of the photosensitive polyimide resin composition.

(6) The main purpose of the addition of (b) epoxy compound is to make the epoxy compound crosslink with the OH group or COOH group on the main chain or the ortho position of the terminal OH group or COOH group of the photosensitive polyimide through acid catalysis or heat treatment during hard baking after the exposure. The content of the epoxy compound accounts for about 5 to 40% of the solid weight of the photosensitive polyimide resin composition. If it is less than 5%, then the hard-baked product will be insufficiently crosslinked and less resistant to chemical solvents; and if it exceeds 40%, then the developability is poor. The epoxy compound may be neopentyl glycol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,2-cyclohexanedicarboxylic acid diglycidyl ester, bisphenol A diglycidyl ether, 1,2-propanediol diglycidyl ether, trimethylolpropane triglycidyl ether, glycerol tripropoxy triglycidyl ether, m-benzenediol diglycidyl ether, or any combinations thereof.

(7) The photosensitive polyimide of component (c) is the photosensitive polyimide having the structure of formula (1):

(8) ##STR00006##
in which m and n are independently 1 to 600. X is a tetravalent organic group, the main chain of which contains the alicyclic group, preferably the alicyclic group having no benzene ring, including (but not limited to)

(9) ##STR00007##

(10) Y is a divalent organic group, a main chain of which contains the siloxane group, such as:

(11) ##STR00008##
in which the chain length of Y is preferably short (p=0), and the longest chain length of Y may be p=20. If the chain length is too long, the properties of the polyimide will be deteriorated. Z is a divalent organic group, a side chain of which at least contains the phenolic group or carboxyl group. The phenolic group or the carboxyl group approximately accounts for 5 to 30% of the number of moles of the polyimide. The development time may be controlled by adjusting the molar ratio of the side chain cover group, and when the content of the branched phenol group or carboxyl group is high, the alkaline developer is preferred due to its better solubility and may improve the developability. Z may include, but not be limited to, the following groups:

(12) ##STR00009##

(13) The synthesis steps of the photosensitive polyimide of component (c) were carried out by dissolving appropriate amount of the diamine monomer and the dianhydride monomer in N-methylpyrrolidone (NMP), followed by addition of another diamine monomer containing the phenol or carboxyl group to react at 80 C. for 2 hours, followed by addition of xylene and heating to 180 C. for 4 hours to obtain the distillate, which was then cooled. The amount of the photosensitive polyimide accounts for 30-90% of the solid weight of the photosensitive polyimide resin composition.

(14) The amount of the photo initiator of component (d) accounts for 0.1-15% of the solid weight of the photosensitive polyimide resin composition. For example, the photo initiator may be selected from the following compounds: bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide, 2-phenylmethyl-2-dimethylamino-1-1-(4-morpholinophenyl)-butanone, (2,4,6-trimethylbenzyl)diphenylphosphine oxide, bis(2,6-difluoro-3-(1-hydropyrro-1-yl)-phenyl)titanocene, 4,4-bis(dimethylamino)diphenyl ketone, 4,4-bis(diethylamino) diphenyl ketone, or N-phenyl diethanolamine.

(15) The method for preparing the photosensitive polyimide resin composition of the present invention was carried out by adding the infrared absorber, the epoxy compound, and the photo initiator into the photosensitive polyimide colloid prepared above to obtain the photosensitive polyimide resin composition.

(16) The photosensitive polyimide resin composition of the present invention was coated on the substrate, and then dried and shaped to form the cover film. The method for shaping had two steps. After the resin composition was coated on the substrate, the soft baking (pre-baking) was carried out first at a temperature of about 100 C. for about 10 minutes to form a film, which was then exposed to, e.g., ultraviolet light and developed to leave the desired pattern. The composition was further subjected to hard baking and drying after development to allow the epoxy compound in the composition to be sufficiently crosslinked with other ingredients for avoiding peeling. The method of drying might be carried out, for example, by using the infrared lamp emitting infrared rays having a wavelength of 500-4000 nm at a temperature of 180 to 200 C. for an irradiation time of 10 to 30 minutes. The infrared lamp might be selected from the infrared halogen lamp, the infrared quartz tube, or the infrared blackbody tube.

Example 1

(17) 19.88 g (80 mmol) of 1,3-bis (3-aminopropyl)-1,1,3,3-tetramethyldisiloxane, 80.7 g of N-methylpyrrolidone (NMP), 39.68 g (160 mmol) of bicyclo[2,2,2]oct-7-ene-2,3,5,6-tetracarboxylic dianhydride, and 21.14 g (80 mmol) of 2-(2-Methacryloyloxy)ethyl 3,5-diamino benzoate were added into a 500 ml three-necked round bottom flask equipped with the mechanical stirrer and nitrogen inlet to form a solution. The solution was reacted at 50 to 80 C. for 2 hours. Afterwards, 45 g of xylene was added and the temperature was risen to 180 C. The mixture was kept stirring for 4 hours and then cooled to give a PIA-1 solution. 11.38 g of glycidyl methacrylate (GMA) was added into 50 g of the PIA-1 solution, which was then stirred at 70 to 100 C. for 24 hours to give the polyimide PSPI-1.

(18) ##STR00010##
The structure of PSPI-1 was represented by formula (1) above, wherein X is

(19) ##STR00011##

(20) 0.30 g of the infrared absorber (SDO-C33), 3.00 g of bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide, and 7.50 g of 1,4-butanediol diglycidyl ether were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR1. PSPI-IR1 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out at a wavelength of 500 nm to 4000 nm for 10 to 30 minutes to obtain a developed pattern with heat resistance.

Example 2

(21) 3.00 g of the infrared absorber (SDO-C33), 3.00 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, and 7.50 g of 1,4-butanediol diglycidyl ether were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR2. PSPI-IR2 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out at a wavelength of 500 nm to 4000 nm for 10 to 30 minutes to obtain a developed pattern with heat resistance.

Example 3

(22) 3.00 g of the infrared absorber (carbon black), 3.00 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, and 7.50 g of 1,4-butanediol diglycidyl ether were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR3. PSPI-IR3 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out at a wavelength of 500 nm to 4000 nm for 10 to 30 minutes to obtain a developed pattern with heat resistance.

Example 4

(23) 3.00 g of the infrared absorber (SDO-C33), 3.00 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, and 24.00 g of 1,4-butanediol diglycidyl ether were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR4. PSPI-IR4 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out at a wavelength of 500 nm to 4000 nm for 10 to 30 minutes to obtain a developed pattern with heat resistance.

Example 5

(24) 3.00 g of the infrared absorber (SDO-C33), 0.30 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, and 7.50 g of 1,4-butanediol diglycidyl ether were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR5. PSPI-IR5 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out at a wavelength of 500 nm to 4000 nm for 10 to 30 minutes to obtain a developed pattern with heat resistance.

Comparative Example 1

(25) 3.00 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide and 24 g of 1,4-butanediol diglycidyl ether were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR6. PSPI-IR6 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out at a wavelength of 500 nm to 4000 nm for 10 to 30 minutes to obtain a developed pattern with heat resistance.

Comparative Example 2

(26) 3.00 g of the infrared absorber (SDO-C33) and 3.00 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR7. PSPI-IR7 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out at a wavelength of 500 nm to 4000 nm for 10 to 30 minutes to obtain a developed pattern with heat resistance.

Comparative Example 3

(27) 3.00 g of the infrared absorber (SDO-C33), 3.00 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, and 7.50 g of 1,4-butanediol diglycidyl ether were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR2. PSPI-IR2 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out in nitrogen atmosphere at 200 C. in the hot air oven for 120 minutes to obtain a developed pattern with heat resistance.

Comparative Example 4

(28) 3.00 g of the infrared absorber (SDO-C33) and 3.00 g of bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide were added into 60.00 g of PSPI-1 and mixed uniformly to obtain the photosensitive polyimide resin composition PSPI-IR7. PSPI-IR7 was coated on the substrate by using a wire bar. After the pre-baking procedure at 90 C. in the oven for 8 minutes, a film having a film thickness of about 15 m was obtained. The film was then exposed to energy of about 400 mJ/cm.sup.2 from the exposure machine (with a power of 7 kW) and then developed with 1 wt % (by weight) of sodium carbonate developer for 1 minute. After that, the hard baking procedure was carried out in nitrogen atmosphere at 200 C. in the hot air oven for 120 minutes to obtain a developed pattern with heat resistance.

(29) The photosensitive polyimide resin compositions of the Examples of the present invention and the Comparative Examples were soaked in the solvent, such as 10% HCl, 10% H.sub.2SO.sub.4, and 10% NaOH for 30 minutes, respectively, and then tested for the solvent resistance. The results are shown in Table 1 below:

(30) TABLE-US-00001 TABLE 1 Formulations of photosensitive polyimide resin compositions and test results of solvent resistance thereof Infrared absorber Epoxy Photosensitive Photo initiator [component (a)] compound polyimide [component percentage.sup.1 (wt%) [component (b)] [component (c)] (d)] Photosensitive $\frac{W_{\left(a\right)}}{W_{\mathrm{total}}0.5}100\%$ percentage percentage percentage Solvent polyimide resin SDO-C Carbon Hard baking conditions resist- composition 33 black $\frac{W_{\left(b\right)}}{W_{\mathrm{total}}0.5}100\%$ $\frac{W_{\left(c\right)}}{W_{\mathrm{total}}0.5}100\%$ $\frac{W_{\left(d\right)}}{W_{\mathrm{total}}0.5}100\%$ means Temp. time ance.sup.2 Example 1 0.74 18.38 73.53 7.35 Infrared 180 10 min rays C. Example 2 6.90 17.23 68.97 6.90 Infrared 180 10 min rays C. Example 3 6.90 17.23 68.97 6.90 Infrared 180 10 min rays C. Example 4 5.00 40.00 50.00 5.00 Infrared 180 10 min rays C. Example 5 7.35 18.38 73.53 0.74 Infrared 180 10 min rays C. Comparative 18.52 74.07 7.41 Infrared 180 10 min X Example 1 rays C. Comparative 8.33 83.34 8.33 Infrared 180 10 min X Example 2 rays C. Comparative 6.90 17.23 68.97 6.90 Hot air 200 120 X Example 3 oven C. min Comparative 8.33 83.34 8.33 Hot air 180 120 X Example 4 oven C. min .sup.1Percentage represents the weight percentage (Wt %) of the solid weight of the photosensitive polyimide resin composition that the component accounts for. The solid percentage will vary depending on the formulation. The solid in the Examples of the present invention or the Comparative Examples accounts for 50% of the total weight of the composition colloid, and therefore the denominator was multiplied by 0.5 in the calculation. .sup.2The solvent resistance test was carried out by soaking the finished products in 10% HCl, 10% H.sub.2SO.sub.4, and 10% NaOH, respectively, for 30 minutes and performing the cross-cut (100/100) test to confirm whether or not the film of the photosensitive polyimide resin composition had peeled off. In the case of peeling, it meant that the composition was insufficiently crosslinked and recorded as X.

(31) The photosensitive polyimide resin compositions of Examples 1-2 of the present invention used the same photo initiator and epoxy compound, but added different weight percentages (wt %) of dyes as the infrared absorber. Example 3 chose the pigment as the infrared absorber. Examples 4-5 used the same infrared absorber (dyes) and photo initiator, but added different weight percentages (wt %) of epoxy compound. After hard baking by infrared rays, all the photosensitive polyimide resin compositions of the Examples described above had excellent solvent resistance.

(32) In contrast, the photosensitive polyimide resin composition of Comparative Example 1 was not added with the infrared absorber, and after the hard baking procedure with infrared rays having a wavelength of 500 nm to 4000 nm for 10 to 30 minutes, crosslinking was not achieved, resulting in poor solvent resistance. Though the photosensitive polyimide resin composition of Comparative Example 2 had infrared absorber, it didn't contain the epoxy compound. After the hard baking procedure with the same infrared rays, the solvent resistance was found to be equally poor. The formulation of the photosensitive polyimide resin composition of Comparative Example 3 was the same as that of Example 2 except that the hot baking was carried out by hot air drying for a longer period of time (120 minutes). However, the solvent resistance of the film was poorer. The photosensitive polyimide resin composition of Comparative Example 4 was the same as that of Comparative Example 2. Both comprised the infrared absorber but didn't contain the epoxy compound. Though the hard baking was carried out in the hot air oven for a longer period of time (120 minutes), the chemical resistance was still poor.

(33) The traditional polyimide or photosensitive polyimide needs to be heated at a high temperature of about 350 C. for up to 2 hours for curing and being applicable in electronic components. The photosensitive polyimide resin composition of the present invention can achieve sufficient cross-linking and shaping inside the photosensitive polyimide resin composition using a lower temperature and a shorter heating time by adding the infrared absorber and the epoxy compound in cooperation of the infrared irradiation. Therefore, not only is the yield improved (without high temperature damage to the electronic components), but the process time is significantly saved.

(34) While the present invention has been illustrated above by the Examples, these Examples are not intended to limit the invention. Equivalent implementations or alterations may be made to these Examples by those skilled in the art without departing from the scope of the spirit of the art of the invention. Therefore, the protection scope of the present invention should be determined by the appended claims.