Aqueous processable, multilayer, photoimageable permanent coatings for printed circuits

• US 5,405,731 A
• Filed: 12/22/1992
• Issued: 04/11/1995
• Est. Priority Date: 12/22/1992
• Status: Expired due to Term

• Current Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: McKeever, Mark R., Chandrasekaran, Karuppiah, O'Neil, James W.
• Primary Examiner(s): Schilling, Richard L.
• Application Number:
  US07/993,477
• Time in Patent Office: 840 Days
• Field of Search: 430/258, 430/259, 430/260, 430/262, 430/263, 430/312, 430/288, 430/910
• US Class Current: 430/260
• CPC Class Codes: G03F 7/0955 one of the photosensitive systems comprising a non-macromolecular photopolymerisable compound having carbon-to-carbon double bonds, e.g. ethylenic compounds
• CPC Class Codes: H05K 3/287 Photosensitive compositions
• CPC Class Codes: Y10S 430/111 Polymer of unsaturated acid or ester

Abstract

The use of a two layer photoimageable, aqueous processable, resist with a hydrophic binder in the outermost layer provides a permanent coating highly resistant to printed circuit processing chemicals. This resistance results in levels of adsorbed or absorbed ionic contamination less than 14 micrograms per square inch.

Claims

1. An aqueous processable, storage stable, photoimageable permanent coating element capable of withstanding molten solder after cure, which comprises in order:

(a) a temporary support film;

(b) a first layer of a polymerizable permanent coating composition comprising;

(I) a hydrophobic binder consisting essentially of structural units A, structural units B or structural units A and B of the formula;

##STR4## in which;

R₁ is H or alkyl;

R₂ is phenyl, nitrile, hydroxyl or CO2R3;

R₃ is H or alkyl which is unsubstituted or substituted with one or more hydroxy groups, and

R₄, R₅, R₆ and R₇ are independently H or alkyl;

and

(II) a monomeric component containing at least two ethylenically unsaturated groups;

(c) a second layer of a photoimageable permanent coating composition comprising;

(I) a carboxyl containing copolymeric binder, wherein the level of carboxyl groups is determined for a given composition by optimizing the amount needed for good development in aqueous alkaline developer, having structural units of the formula;

##STR5## in which;

R₁ is H or alkyl;

R₂ is phenyl, CO₂ R₃ or macromer; and

R₃ is H or alkyl which is unsubstituted or substituted with one or more hydroxy groups,

(II) a monomeric component containing at least two ethylenically unsaturated groups,

(III) a photoinitiator or photoinitiator system, and

(IV) a thermal crosslinking agent,

(d) cover film,

wherein

the adhesion of said first layer (b) to said second layer (c) is greater than the adhesion between said first layer (b) and said support film (a) ;

the adhesion of said first layer (b) to said second layer (c) is greater than the adhesion between said second layer (c) and said cover film; and

the adhesion between said first layer (b) and said support film (a) is greater than the adhesion between said second layer (c) and said cover film.

2. The permanent coating element of claim 1 wherein said first layer (b) further comprises a carboxyl containing copolymer cobinder.

3. The permanent coating element of claim 2 wherein the copolymer cobinder consists essentially of a carboxyl containing copolymeric binder, wherein the level of carboxyl groups is determined for a given composition by optimizing the amount needed for good development in aqueous alkaline developer, having structural units:

##STR6## in which;

R₁ is H or alkyl;

R₂ is phenyl, CO₂ R₃ or macromer; and

R₃ is H or alkyl which is unsubstituted or substituted with one or more hydroxy groups.

4. The permanent coating element of claim 1 wherein the first layer further comprises a thermal crosslinking agent.

5. The permanent coating element of claim 1 wherein said thermal crosslinking agent is selected from the group consisting of an adduct of a polyisocyanate and an isocyanate-group blocking agent, a formaldehyde condensation product with melamine, and a formaldehyde condensation product with urea, the hydroxyl groups of the formaldehyde condensation product unsubstituted or having substitution with ether groups

6. The permanent coating element of claim 1 wherein said macromer component has a weight average molecular weight of about 5,000 or less and a polydispersity of about 3 or less.

7. The permanent coating element of claim 1 wherein the first or second layer further comprises an inorganic filler.

8. The permanent coating element of claim 7 wherein the inorganic filler is aminosilane treated talc.