GRAPHENE COATED SILVER ALLOY WIRE AND METHODS FOR MANUFACTURING THE SAME

Abstract

A graphene coated silver alloy wire is provided. The composite wire includes a core wire and one to three layers of graphene covering surfaces of the core wire. The core wire is made of a silver-based alloy including 2 to 6 weight percent of palladium. The core wire may be optionally added with 0.01 to 10 weight percent of gold. The invention also includes a manufacturing method immersing the core wire into a solution including graphene oxide and applying bias to the core wire for manufacturing the graphene coated silver alloy wire.

Claims

1. A graphene coated silver alloy wire, comprising: a core wire made of a silver-based alloy including 2 to 6 weight percent of palladium; and at least one layer of graphene covering surfaces of the core wire.

2. The alloy wire as claimed in claim 1, wherein the at least one layer of graphene includes one to three layers of graphene.

3. The alloy wire as claimed in claim 1, wherein the core wire is made of a silver-palladium alloy including 2 to 6 weight percent of palladium and a balance of silver.

4. The alloy wire as claimed in claim 1, wherein the silver-based alloy further includes 0.01 to 10 weight percent of gold.

5. The alloy wire as claimed in claim 3, wherein the silver-palladium alloy further includes 0.01 to 10 weight percent of gold and the balance of silver.

6. The alloy wire as claimed in claim 1, wherein a diameter of the core wire is between 10 m and 300 m.

7. A manufacturing method of a graphene coated silver alloy wire, comprising: providing a thick wire made of a silver-based alloy including 2 to 6 weight percent of palladium; step-by-step decreasing a wire diameter of the thick wire to form a fine wire with a wire diameter less than that of the thick wire as a core wire of the graphene coated silver alloy wire utilizing alternative performance of a plurality of cold work shaping steps and a plurality of annealing steps; immersing the core wire into a solution including graphene oxide; and attaching the graphene oxide to the core wire and simultaneously reducing the attached graphene oxide into at least one layer of graphene covering surfaces of the core wire utilizing applying bias to the core wire.

8. The method as claimed in claim 7, wherein the cold work shaping steps are wire drawing steps, extrusion steps or a combination thereof.

9. The method as claimed in claim 7, wherein the annealing steps are performed under a passivation atmosphere.

10. The method as claimed in claim 7, wherein the provision of the thick wire comprises the following steps: melting raw materials of the material of the thick wire, followed by casting to form an ingot; and performing cold work on the ingot to complete the thick wire.

11. The method as claimed in claim 7, wherein the provision of the thick wire comprises steps of melting raw materials of the material of the thick wire, followed by a process of continuous casting to form the thick wire.

12. The method as claimed in claim 7, wherein the step of the annealing steps after the completion of the diameter of the fine wire is performed at an annealing temperature between 500 C. and 600 C. during an annealing period between 3 seconds and 60 seconds.

13. The method as claimed in claim 7, wherein the bios is between 0.5 and 2 volts.

14. The method as claimed in claim 7, wherein a wire diameter of the thick wire is between 5 mm and 10 mm, and a wire diameter of the fine wire is between 10 m and 300 m.

15. The method as claimed in claim 7, wherein the at least one layer of graphene includes one to three layers of graphene.

16. The method as claimed in claim 7, wherein the thick wire is made of a silver-palladium alloy including 2 to 6 weight percent of palladium and a balance of silver.

17. The method as claimed in claim 7, wherein the silver-based alloy further includes 0.01 to 10 weight percent of gold.

18. The method as claimed in claim 17, wherein the silver-palladium alloy further includes 0.01 to 10 weight percent of gold and the balance of silver.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present disclosure can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:

[0031] FIG. 1A schematically illustrates a wire segment of a graphene coated silver alloy wire of an embodiment of the present disclosure;

[0032] FIG. 1B is a lengthwise cross-section of the graphene coated silver alloy wire shown in FIG. 1A along a direction parallel to the longitudinal direction of the graphene coated silver alloy wire shown in FIG. 1A;

[0033] FIG. 2 is a flow chart showing an example of a manufacturing method of the graphene coated silver alloy wire of the an embodiment of the present disclosure;

[0034] FIG. 3 is a flow chart showing an example of provision of the thick wire in the flowing charts shown in FIG. 2;

[0035] FIG. 4 schematically shows another example of provision of the thick wire in the flowing charts shown in FIG. 2; and

[0036] FIG. 5 schematically illustrates steps relate to the performance about covering the surfaces of the core wire with graphene layer or layers.

DETAILED DESCRIPTION OF THE INVENTION

[0037] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.

[0038] Note that the concepts and specific practice modes of the invention is described in detail by the embodiments and the attached drawings. In the drawings or description, similar elements are indicated by similar reference numerals and/or letters. Furthermore, the element shape or thickness in the drawings can be expanded for simplification or convenience of indication. Moreover, elements which are not shown or described can be in every form known by those skilled in the art.

[0039] It should be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of the invention. Specific examples of components and arrangements are described below to simplify the present disclosure. These are merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples.

[0040] In the subsequent description, phrases such as substantially the same . . . etc. mean the compared elements, components, conditions, . . . etc. are expected to be the same in design, as in practice, it is difficult to be measured to be mathematically or theoretically the same due to limits and errors of the practical measurement. Additionally, when deviation is in an acceptable range of a corresponding standard or specification, it is also recognized to be the same. Those skilled in the art are expected to acknowledge, that different standards or specifications, depend upon various properties and conditions, and thus, cannot be specifically listed.

[0041] Specific embodiments of the invention for graphene coated silver alloy wires and manufacturing methods thereof are described. It is noted that the concepts of the invention can be applied to any known or newly developed graphene coated silver alloy wires and manufacturing methods thereof.

[0042] Referring to FIGS. 1A and 1B showing a graphene coated silver alloy wire 20 of an embodiment of the present disclosure, FIG. 1A schematically illustrates a wire segment of the graphene coated silver alloy wire 20 of the embodiment of the present disclosure, and FIG. 1B is a lengthwise cross-section of the graphene coated silver alloy wire 20 shown in FIG. 1A along a direction parallel to the longitudinal direction of the graphene coated silver alloy wire 20 shown in FIG. 1A.

[0043] As shown in FIGS. 1A and 1B, the graphene coated silver alloy wire 20 of the embodiment of the present disclosure comprises a core wire 21 and at least one layer 25 of graphene. The at least one layer 25 of graphene covers surfaces of the core wire 21.

[0044] The core wire 21 is made of a silver-based alloy including 2 to 6 weight percent of palladium. In one embodiment, the core wire 21 is made of a silver-palladium alloy including 2 to 6 weight percent of palladium and a balance of silver. In an alternative embodiment, the core wire 21 is made of a silver-gold-palladium alloy including 2 to 6 weight percent of palladium, 0.01 to 10 weight percent of gold and a balance of silver. In an alternative embodiment, other element or elements can be optionally added to the silver-based alloy including 2 to 6 weight percent of palladium to a suitable concentration to form the core wire 21. For example, 0.01 to 10 weight percent of at least one of a group consisting of gold, copper and nickel can be optionally added to the silver-based alloy including 2 to 6 weight percent of palladium to form the core wire 21.

[0045] Furthermore, wire diameters of the core wire 21 can be properly selected according to the predetermined application, such as to medical probe cables, transmission lines for electronic signals of audios and videos, bonding wires for packages of electronic devices used in a high frequency field or other applications, of the graphene coated silver alloy wire 20 of the embodiment of the present disclosure. In one embodiment, the diameter of the core wire 21 is between 10 m and 300 m, which are suitable for wires utilized in wire bonding for packages of electronic devices. Note that a user can also apply the inventive alloy wires to other technical fields and purposes, such as enamelled wires, audio wires, signal or power transmission wires, voltage transformer wires . . . etc. as desired. The wire diameter of the core wire 21 may also be modified as desired, and is not limited in the described exemplary range.

[0046] In one embodiment, the reduced graphene layer 25 can be a single-layered structure if the reduced graphene layer 25 substantially completely covers the core wire 21. In an alternative embodiment, if there is defect in the single-layered structure, the reduced graphene layer 25 can be a two-layered or three-layered structure to substantially completely cover the core wire 21. Every layer of the two-layered or three-layered structure is a graphene structure based on the chemical structure of single-layered graphite. In a situation where the reduced graphene layer 25 can be a two-layered structure, a three-layered structure or a multi-layered structure having more than three layers, there is no chemical bond between any of the layers.

[0047] Although the conventional silver-gold-palladium alloy wires provide improvements in wire strength, anti-corrosion properties against humidity, and ionic migration, it is difficult to solve the problems of corrosion, low reliability, and damage to chips that occurs when employing technologies that utilize copper wires. This may also overcome the drawbacks of high prices, and cracks forming at the joint interface due to fast growth of intermetallic compounds. These can occur when employing technologies that utilize gold wires. The electrical resistivity of the silver alloy wires may apparently increase if somewhat elemental gold and/or palladium are added to the silver alloy wire. The silver alloy wires with gold and/or palladium may be slightly eroded or oxidized during exposure to an environment with high humidity or sulfur for a long period. In order to enhance the performance of the silver alloy wires even further, an embodiment of the present disclosure provides a silver-based alloy wire (e.g. a silver-palladium alloy wire or a silver-gold-palladium alloy wire) acting as a core wire with one to three layers of graphene coated on the surfaces thereof.

[0048] The graphene has a thermal conductivity greater than 4,000 Wm.sup.1K.sup.1, an electron transmission rate greater than 10.sup.6 cm.sup.2V.sup.1S.sup.1, an electrical resistivity as low as 10.sup.6 .Math.cm, a tensile strength as high as 125 GPa or higher, a density as high as 2.2 g/cm.sup.3 or higher. When covering the surfaces of the silver-based alloy wire with graphene, the structure of graphene can block oxygen and sulfur, and therefore, the core wire of silver-based alloy can be protect from corrosion and oxidization, or at least the corrosion rate and oxidization rate of the core wire of silver-based alloy can be decreased. However, it is necessary for the graphene layer covering the surfaces of the core wire to have at least complete single layer, which is the threshold for protecting the core wire of silver-based alloy. On the other hand, if too many layers of graphene are formed, the three-dimensional graphite structure will be formed, and the properties of graphene will disappear. Therefore, one of the preferred structures is the one to three layers of graphene covering the core wire of silver-based alloy. It is preferred that the core wire of silver-based alloy comprises 2 to 6 weight percent of palladium with or without 0.01 to 10 weight percent of gold with correspondence to the structure of graphene covering the core wire of silver-based alloy, resulting in the complete silver alloy composite wire having not only high resistance to oxidation, but also excellent strength, excellent ductility and excellent reliability.

[0049] Conventionally, graphene is grown on a surface of a material mainly by a chemical vapor deposition. Specifically, CH.sub.4 or C.sub.2H.sub.2 gas is induced at a high temperature between 700 C. and 1000 C., resulting in depositing carbon atoms on surfaces of a metal substrate to form graphene. However, only copper or nickel can be utilized as the metal substrate in the process, and the grains of the copper or nickel substrate may become extremely great due to the extremely high temperature. If the substrate is a copper or nickel wire, the copper or nickel wire will deform to have a bamboo-like profile due to grain growth under the extremely high temperatures, resulting in an abrupt decrease in strength and elongation. In the present disclosure, the metal wire is immersed into a solution comprising graphene oxide, followed by applying bias to the metal wire utilizing the electrochemical mechanism to attach graphene oxide to the surfaces of the metal wire and simultaneously provide electrons to reduce graphene oxide into a graphene film covering the surfaces of the metal wire. The process temperature is between room temperature and 100 C., and therefore the grains of the metal wire are not coarsened, and the strength and ductility thereof can be kept. More advantageously, the metal wire is not limited to copper or nickel used in the conventional chemical vapor deposition. According to the example 1 listed below, the fact one to three layers graphene can be successfully grown on surfaces of a silver alloy wire is verified. The corrosion potential performance of the resulting wire is better than that of the original wire, and the electrical resistivity of the resulting wire is lower than that of the original wire.

[0050] The present disclosure provides a manufacturing method of a graphene coated silver alloy wire different from the conventional technology. In the method, a core wire is immersed into a solution comprising graphene oxide, followed by applying bias to reduce the graphene oxide into a graphene film covering the surfaces of the alloy wire. This is how the graphene coated silver alloy wire is manufactured.

[0051] Specifically, referring to the flow chart shown in FIG. 2, an exemplary embodiment of the manufacturing method of the graphene coated silver alloy wire may comprise the subsequent steps 202, 204, 206 and 208.

[0052] In step 202, a thick wire made of a silver-based alloy including 2 to 6 weight percent of palladium is provided.

[0053] In step 204, a wire diameter of the thick wire is step-by-step decreased to form a fine wire with a wire diameter less than that of the thick wire utilizing alternative performance of a plurality of cold work shaping steps and a plurality of annealing steps. The fine wire is acted as a core wire of the graphene coated silver alloy wire.

[0054] In step 206, the core wire is immersed into a solution including graphene oxide.

[0055] In step 208, the graphene oxide is attached to the core wire and simultaneously the attached graphene oxide is reduced into at least one layer of graphene covering surfaces of the core wire utilizing applying bias to the core wire.

[0056] In the steps that have been described, the diameter of the thick wire may be between 5 mm and 10 mm. After steps 202 and 204, the diameter of the resulting fine wire is between 10 m and 50 m in one embodiment, and between 10 m and 300 m in an alternative embodiment. As described above, the fine wire can be utilized as the core wire 21 as shown in FIGS. 1A and 1B, and the graphene coated silver alloy wire 20 of the embodiment of the present disclosure can be used as a bonding wire in wire-bonding technology.

[0057] In the steps that have been described, the thick wire may be made of a silver-palladium alloy including 2 to 6 weight percent of palladium and a balance of silver.

[0058] In the steps that have been described, the thick wire may further includes 0.01 to 10 weight percent of gold.

[0059] In the steps that have been described, the silver-palladium alloy further includes 0.01 to 10 weight percent of gold and the balance of silver.

[0060] In step 204, the cold work shaping steps may be wire drawing steps, extrusion steps or a combination thereof.

[0061] In step 204, the annealing steps may be performed under a passivation atmosphere. The passivation atmosphere can be nitrogen atmosphere, an atmosphere of inert gas or a combination thereof.

[0062] In step 204, the step of the annealing steps after the completion of the diameter of the fine wire may be performed at an annealing temperature between 500 C. and 600 C. during an annealing period between 3 seconds and 60 seconds. As a result, the grain growth in the resulting fine wire can be suppressed, the mechanical properties of the fine wire can be enhanced, and the reliability performance, especially the reliability performance after wire-bonding of the graphene coated silver alloy wire 20 of the embodiment of the present disclosure may be improved.

[0063] In the described method, an example of a method of provision of the thick wire may comprise the subsequent cast step 302 and cold work step 304.

[0064] In the cast step 302, raw materials of the material of the thick wire are heated and melted, followed by casting to form an ingot.

[0065] In the cold work step 304, the step performs cold work on the ingot to complete the thick wire. Similarly, the cold work step 304 can also be a wire drawing step, an extrusion step or a combination thereof.

[0066] In the described method, another example of a method of provision of the thick wire preferable comprises the subsequent continuous casting step 402 with reference to the schematic drawing shown in FIG. 3.

[0067] In the continuous casting step 402, raw materials of the material of the thick wire are heated and melted, followed by a process of continuous casting to form the thick wire.

[0068] Next, details of the described steps 206 and 208 are further discussed.

[0069] Referring to FIG. 5 that schematically illustrates steps (the described steps 206 and 208) relate to the performance about covering the surfaces of the core wire with graphene layer or layers.

[0070] In step 206, the fine wire completed by step 204 is utilized as the core wire 21 and is coiled on a line shaft 501. Then, the core wire 21 is uncoiled and pulled out from the line shaft 501, followed by immersing the core wire 21 into an electrolytic tank 500 comprising a solution 510 including graphene oxide to attach graphene oxide to the surfaces of the core wire 21 and simultaneously reduce the attached graphene oxide into graphene layer or layers covering the surfaces of the core wire 21. The resulting graphene coated silver alloy wire 20 of the embodiment of the present disclosure is then coiled on the line shaft 502. The immersing depth of the core wire 21 in the solution 510 can be properly adjusted as required. In one embodiment, the solution 510 is received in the electrolytic tank 500, and the solution 510 is the solution where graphene oxide is dispersed in water with a concentration between 0.01 g/l and 1 g/l, for example. In an alternative embodiment, water acted as a dispersion medium can be replaced by a polar solvent which does not chemically react with the core wire 21. The concentration of graphene oxide can be properly adjusted as required, and is not limited to the described range.

[0071] A platinum electrode (not shown), for example, acted as an anode, and the core wire 21, acted as a cathode, are respectively electrically connected to the same power source (not shown). The anode and the cathode (core wire 21) are also immersed together into the solution 510 and are separated from each other with a predetermined distance in the solution 510. The predetermined distance may be properly adjusted as required. Furthermore, a reference electrode (not shown) may further be disposed between the anode and the core wire 21 acted as the cathode. The reference electrode is also electrically connected to the power source and immersed in the solution 510. The immersion depth of the reference electrode in the solution 510 can also be properly adjusted as required. In FIG. 5, the anode, the power source and the reference electrode are not shown.

[0072] The reference electrode can be a hydrogen electrode, a silver/silver chloride electrode or a calomel electrode. In step 208, the bios applying to the anode and the cathode (core wire 21) is adjusted relatively according to the type of the selected reference electrode. In this embodiment, the hydrogen electrode is utilized as the reference electrode, while the bios applying to the core wire 21 is preferably between 0.5 to 2 volts, and a current region is preferably between 5 mA and +5 mA.

[0073] In step 208, an immersing period of the core wire 21 in the solution 510 (reaction period) is controlled to be between 5 seconds and 60 seconds, for example, due to the properly controlled speed of the core wire 21 from the line shaft 501 through the solution 510 in the electrolytic tank 500 to the line shaft 502 to continuously pass the core wire 21 through the solution 510. Under the bios and the condition of the current region, the graphene oxide is attached to the core wire 21 from the solution 510, and the attached graphene oxide is simultaneously reduced into the graphene layer or layers 25 covering the core wire 21 as shown in FIGS. 1A and 1B. At this time, the graphene layer or layers attached to the core wire 21 can be as thick as a range between 10 nanometers and 1 micrometer.

[0074] As described, the graphene layer or layers 25 covering the surfaces of the silver alloy wire can be a single-layered structure, a two-layered structure, a three-layered structure or even a multi-layered structure more than three layers, which can be controlled by the control of parameters such as the concentration of graphene oxide in the solution 510, the bios and the current region applying to the core wire 21, moving speed of the core wire 21 (the immersing period in the solution 510).

[0075] An example is described. However, the present disclosure is not limited to the example given.

Example 1

[0076] A silver-4 wt % palladium alloy was smelted by high-frequency electric smelting, followed by continuous casting to form a thick wire with a wire diameter of 6 mm. The thick wire became an initial wire with a wire diameter of 1 mm after an initial drawing step, and then it became a fine wire with a wire diameter of 17.6 m after alternative performance of a plurality of steps including wire drawing elongation steps and annealing treatment steps, followed by the performance of the last step of the annealing treatment at an annealing temperature of 570 C for 4.8 seconds. Every step of the annealing treatment was performed at a nitrogen passive atmosphere. Completing the last step of the annealing treatment, the fine wire acted as a core wire was sent to be immersed into and passed a solution including graphene oxide with 1V bias applied, such that graphene oxide was attached to the fine wire and the attached graphene oxide was simultaneously reduced into graphene layer or layers covering the surfaces of the Ag-4Pd core wire. The graphene coated silver alloy wire was then coiled to complete the product of a silver alloy composite wire.

[0077] In order to verify the formation or growth of graphene, the completed graphene coated silver alloy wire was inspected by a raman spectrometer, and the result showed one layer of graphene was grown at the surfaces of the graphene coated silver alloy wire. The results from other inspections showed the graphene coated silver alloy wire has an electrical resistivity of 2.96 .Math.cm, lower than that (3.54 .Math.cm) of the original Ag-4Pd alloy, and a corrosion potential of 72 mV in a bath of an aqueous solution of 3% NaCl, much lower than that (149 mV) of the original Ag-4Pd alloy. That means the graphene coated Ag-4Pd alloy wire has lower corrosion tendency.

[0078] While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the Art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.