Method of glass fabric production including resin adhesion for printed circuit board formation

• US 9,827,590 B2
• Filed: 08/12/2015
• Issued: 11/28/2017
• Est. Priority Date: 06/17/2015
• Status: Expired due to Fees

• Current Assignee: International Business Machines Corporation
• Original Assignee: International Business Machines Corporation
• Inventors: Czaplewski, Sarah K., Kuczynski, Joseph, Wertz, Jason, Zhang, Jing
• Primary Examiner(s): Lazorcik, Jason L
• Application Number:
  US14/824,839
• Publication Number:
  US 20160368820A1
• Time in Patent Office: 839 Days
• CPC Class Codes: B05D 2203/35 Glass
• CPC Class Codes: B05D 3/002 Pretreatement
• CPC Class Codes: C01P 2004/61 Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C03B 19/1065 by liquid phase reactions, e.g. by means of a gel phase
• CPC Class Codes: C03C 25/1095 to obtain coated fabrics
• CPC Class Codes: C03C 25/255 Oils, waxes, fats or derivatives thereof
• CPC Class Codes: C03C 25/28 obtained by reactions involving only carbon-to-carbon unsaturated bonds
• CPC Class Codes: C03C 25/40 Organo-silicon compounds
• CPC Class Codes: C09C 1/3072 Treatment with macro-molecular organic compounds
• CPC Class Codes: C09C 1/3081 Treatment with organo-silicon compounds
• CPC Class Codes: C09C 1/309 Combinations of treatments provided for in groups C09C1/3009 - C09C1/3081
• CPC Class Codes: D03D 1/0082 Fabrics for printed circuit boards
• CPC Class Codes: D03D 15/267 Glass
• CPC Class Codes: H05K 1/0306 Inorganic insulating substrates, e.g. ceramic, glass
• CPC Class Codes: H05K 1/0366 reinforced, e.g. by fibres, fabrics H05K1/036 takes precedence
• CPC Class Codes: H05K 1/038 Textiles used as reinforcing materials for organic insulating substrates H05K1/0366
• CPC Class Codes: H05K 2201/0251 Non-conductive microfibers
• CPC Class Codes: H05K 2201/029 Woven fibrous reinforcement or textile

Abstract

Embodiments generally relate to devices and methods for production of fibers and threads for use in electronic device manufacturing. Described here, fibers can be produced and manipulated using a dual-surfaced sizing material. The dual-surfaced sizing material has a surface which binds a fiber and a surface which binds a resin. Thus, the dual-surfaced sizing material can be left attached to the fibers without adversely affecting the resin binding in later production steps.

Claims

1. A method of producing a sizing material, sequentially comprising:

forming a silicon-containing core;

exposing the silicon-containing core to a surfactant;

embedding the silicon-containing core in a lipophilic component of an emulsion, the silicon-containing core having a first surface and a second surface, the silicon-containing core being embedded such that the first surface is exposed and the second surface is obstructed by the lipophilic component;

washing the first surface to create a clean first surface;

exposing the clean first surface to a vinyl chloride resin-binding functionalizing material;

removing the lipophilic component to expose the second surface; and

exposing the second surface to chlorotriethoxysilane.

2. The method of claim 1, wherein the silicon-containing core is exposed to the surfactant at a ratio of surfactant to silicon-containing of from about 5×

10<sup>−

6</sup> to about 2.5×

10<sup>−

6</sup> mol L<sup>−

1</sup>m<sup>−

2</sup>.

3. A method of producing a material, comprising:

producing a sizing material by a process comprising;

forming a silicon-containing core having a first surface and a second surface;

exposing the first surface to a resin-binding functionalizing material selected from the group consisting of vinyls, amines, epoxies, allyls, and acrylates;

exposing the second surface to a silanizing agent to form a sizing material having an anisotropic surface chemistry between a first region of the sizing material and a second region of the sizing material;

extruding a plurality of fibers, the fibers comprising glass; and

coating at least a portion of a surface of at least one of said fibers with the sizing material, wherein the first region interacts with the portion of the surface of the at least one of said fibers; and

forming the plurality of fibers into a plurality of strands.

4. The method of claim 3, further comprising:

spooling the plurality of strands; and

weaving a cloth from the plurality of strands.

5. The method of claim 4, further comprising impregnating the cloth with a resin.

6. The method of claim 5, wherein the second region interacts with the resin.

7. A method of producing a sizing material, sequentially comprising:

forming a silicon-containing core;

exposing the silicon-containing core to a surfactant;

embedding the silicon-containing core in a lipophilic component of an emulsion, the silicon-containing core having a first surface and a second surface, the silicon-containing core being embedded such that the first surface is exposed and the second surface is obstructed by the lipophilic component;

washing the first surface to create a clean first surface;

exposing the clean first surface to a vinyl chloride resin-binding functionalizing material;

removing the lipophilic component using a hydrocarbon solvent to expose the second surface; and

exposing the second surface to chlorotriethoxysilane.