Flexible metal-clad laminates and preparation of the same

• US 6,340,518 B1
• Filed: 03/16/1999
• Issued: 01/22/2002
• Est. Priority Date: 09/02/1996
• Status: Expired due to Term

• Current Assignee: Mitsui Chemicals Incorporated (Mitsui Chemicals)
• Original Assignee: Mitsui Chemicals Incorporated (Mitsui Chemicals)
• Inventors: Kitahara, Mikio, Mori, Minehiro, Kayama, Takashi, Mineta, Naoshi
• Primary Examiner(s): Nakarani, D. S.
• Application Number:
  US09/268,684
• Time in Patent Office: 1,043 Days
• Field of Search: 156/330.9, 156/331.5, 156/308.2, 156/309.6, 156/153, 428/332, 428/337, 428/458, 428/214, 428/215, 428/473.5
• US Class Current: 428/215
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: H05K 1/0346 containing N
• CPC Class Codes: Y10T 428/24959 of adhesive layers
• CPC Class Codes: Y10T 428/24967 Absolute thicknesses specified
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/266 of base or substrate
• CPC Class Codes: Y10T 428/31681 Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31721 Of polyimide

Abstract

A flexible metal foil laminate sheet wherein a polyimide layer comprises a polyimide laminate having a three-layer structure in which thermoplastic polyimide layers are formed on both the surfaces of a polyimide film; metal foil layers are heated and pressed against both the sides of the polyimide laminate; and the thickness of the thermoplastic polyimide layer is 100% or more of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer; and a method for manufacturing the flexible metal foil laminate sheet. According to the present invention, there can be manufactured the flexible metal foil laminate sheet in which a necessary and sufficient adhesive force is present in an interface between a metal foil and an insulating layer and which is excellent in heat resistance, chemical resistance, electrical properties and the like.

Claims

1. A metal foil laminate wherein a polyimide layer (A) comprises a polyimide laminate having a three-layer structure in which thermoplastic polyimide layers are formed on both the surfaces of a polyimide film;

metal foil layers are heated and pressed against both the sides of the polyimide laminate; and

the thickness of the thermoplastic polyimide layer is 100% or more and less than 300% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer, wherein said average roughness of said metal foil is 0.47 to 1.85 μ

m.

2. The metal foil laminate according to claim 1 wherein the thickness of the metal foil is in the range of 5 to 175 μ

m.

3. The metal foil laminate according to claim 1 wherein the glass transition temperature of the thermoplastic polyimide is in the range of 150 to 350°

C.

4. The metal foil laminate according to claim 1 wherein the thickness of the polyimide layer (A) is in the range of 5 to 150 μ

m.

5. The metal foil laminate according to claim 1 wherein heating and pressing conditions are the glass transition temperature or more of the thermoplastic polyimide and in the range of 20 to 150 kg/cm².

6. The metal foil laminate according to claim 1 wherein the metal foil is selected from copper, iron, nickel, chromium, molybdenum, aluminum, or alloys mainly including these metals.

7. The metal foil laminate according to claim 6 wherein the metal foil is copper.

8. The metal foil laminate according to claim 1 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 200% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

9. The metal foil laminate according to claim 1 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 150% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

10. The metal foil laminate according to claim 1 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 120% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

11. A method for manufacturing a metal foil laminate wherein a polyimide layer (A) comprises a polyimide laminate having a three-layer structure in which thermoplastic polyimide layers are formed on both the surfaces of a polyimide film;

said method comprising the steps of placing the metal foil layers on both the sides of the polyimide laminate, respectively, and then by heating and pressing them, the thickness of the thermoplastic polyimide layer being 100% or more and less than 300% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer, wherein said average roughness of said metal foil is 0.47 to 1.85 μ

m.

12. The method for manufacturing the metal foil laminate according to claim 11 wherein the thickness of the metal foil is in the range of 5 to 175 μ

m.

13. The method for manufacturing the metal foil laminate according to claim 11 wherein the glass transition temperature of the thermoplastic polyimide is in the range of 150 to 350°

C.

14. The method for manufacturing the metal foil laminate according to claim 11 wherein the thickness of the polyimide layer (A) is in the range of 5 to 150 μ

m.

15. The method for manufacturing the metal foil laminate according to claim 11 wherein heating and pressing conditions are the glass transition temperature or more of the thermoplastic polyimide and in the range of 20 to 150 kg/cm².

16. The method for manufacturing the metal foil laminate according to claim 11 wherein the metal foil is selected from copper, iron, nickel, chromium, molybdenum, aluminum, or alloys mainly including these metals.

17. The method for manufacturing the metal foil laminate according to claim 16 wherein the metal foil is copper.

18. The method for manufacturing the metal foil laminate according to claim 11 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 200% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

19. The method for manufacturing the metal foil laminate according to claim 11 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 150% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

20. The method for manufacturing the metal foil laminate according to claim 11 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 120% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

21. A method for manufacturing a metal foil laminate having a polyimide layer between two metal foil layers;

said method comprising the steps of heating and pressing one metal foil and a polyimide/metal foil laminate including the other metal foil and a polyimide layer comprising a thermoplastic polyimide layer outermost to the other metal foil so that the thermoplastic polyimide layer is put on the former metal foil, the thickness of the thermoplastic polyimide layer being 100% or more and less than 300% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer, wherein said average roughness of said metal foil is 0.47 to 1.85 μ

m.

22. The method for manufacturing the metal foil laminate according to claim 21 wherein the thickness of the metal foil is in the range of 5 to 175 μ

m.

23. The method for manufacturing the metal foil laminate according to claim 21 wherein the glass transition temperature of the thermoplastic polyimide is in the range of 150 to 350°

C.

24. The method for manufacturing the metal foil laminate according to claim 21 wherein the thickness of the polyimide layer between the two metal foil layers is in the range of 5 to 150 μ

m.

25. The method for manufacturing the metal foil laminate according to claim 21 wherein heating and pressing conditions are the glass transition temperature or more of the thermoplastic polyimide and in the range of 20 to 150 kg/cm².

26. The method for manufacturing the metal foil laminate according to claim 21 wherein the metal foil is selected from copper, iron, nickel, chromium, molybdenum, aluminum, or alloys mainly including these metals.

27. The method for manufacturing the metal foil laminate according to claim 26 wherein the metal foil is copper.

28. The method for manufacturing the metal foil laminate according to claim 21 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 200% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

29. The method for manufacturing the metal foil laminate according to claim 21 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 150% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.

30. The method for manufacturing the metal foil laminate according to claim 21 wherein the thickness of the thermoplastic polyimide layer is 100% or more and less than 120% of an average roughness at 10 points on the surface of the metal foil which contacts the thermoplastic polyimide layer.