Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/18—Fireproof paints including high temperature resistant paints
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/49—Phosphorus-containing compounds
  • C08K5/51—Phosphorus bound to oxygen
  • C08K5/53—Phosphorus bound to oxygen bound to oxygen and to carbon only
  • C08K5/5313—Phosphinic compounds, e.g. R2=P(:O)OR'
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
  • C09D175/04—Polyurethanes
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K21/00—Fireproofing materials
  • C09K21/14—Macromolecular materials
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
  • H05K3/00—Apparatus or processes for manufacturing printed circuits
  • H05K3/22—Secondary treatment of printed circuits
  • H05K3/28—Applying non-metallic protective coatings
  • H05K3/285—Permanent coating compositions
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
  • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
  • H05K2201/01—Dielectrics
  • H05K2201/0104—Properties and characteristics in general
  • H05K2201/012—Flame-retardant; Preventing of inflammation
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Definitions

• the present disclosure generally relates to the field of flame-resistant covercoats.
• the disclosure relates to flame-resistant covercoats for flexible circuits.
• Flexible circuits are widely used in the area of consumer electronics due to the substantial reduction in the thickness and size of the resulting product.
• flexible circuits are currently being used in the construction of disc drives and flat panel displays for consumer products such as television monitors, computer monitors, and mobile telephone monitors.
• consumer products such as television monitors, computer monitors, and mobile telephone monitors.
• the use of flexible circuits in the construction of television, computer, and phone monitors allows the thickness and weight of the panels to be substantially reduced, providing a more compact product.
• care must be taken to prevent the product from igniting or shorting.
• the electrical components of all consumer electronics must pass Underwriters Laboratories (IJL) registration, which provides fire protection testing and approval procedures.
• IJL Underwriters Laboratories
• flexible circuits are typically covered with a protective covercoat to protect the flexible circuit from the external elements of the environment.
• the covercoat on the flexible circuit is desirably flame-resistant and moisture impervious, providing protection to the flexible circuit when exposed to a high humidity or high temperature environment.
• While some existing current covercoat compositions are capable of passing flame- resistance tests, most are not capable of passing electrical bias tests at high humidity and high temperatures. This is due to the fact that the covercoats tend to absorb moisture from the environment, causing the electrical resistance to break down over time.
• An example of a current covercoat composition being used is an epoxy-based covercoat.
• Epoxy-based covercoats are typically not capable of passing flame-resistance tests without the use of a halogen, such as a brominated flame retardant, and are typically not capable of passing electrical resistance tests at all, and therefore cannot be used to protect flexible circuits in. consumer electronics. Additionally, current covercoat compositions typically include at least one chemical halogen, which can be environmentally unfriendly.
• One embodiment of the present invention is a composition for a flame-resistant electrical circuit covercoat including a phosphinate and a urethane solder mask.
• a flexible circuit in another embodiment, includes a substrate and a flame-resistant covercoat comprising a mixture of a urethane and a phosphinate.
• a method of forming a flexible circuit with a flame-resistant covercoat includes (1) mixing a phosphinate and a urethane solder mask to form a composition for the covercoat, (2) coating the composition on the flexible circuit, and (3) curing the coated flexible circuit.
• Covercoat 10 comprises a single or multi-layer phosphinate composition that is flame-resistant and maintains electrical bias in harsh environments for an extended period of time.
• the high flame and electrical resistance properties of covercoat 10 make covercoat 10 and flexible circuit 12 durable and capable of withstanding high humidity and high temperatures.
• Another advantage of covercoat 10 is that the thickness of the coating on flexible circuit 12 is decreased. Additionally, the composition can also be easily applied to flexible circuit 12 by conventional coating methods. The resulting flexible circuit 12 thus maintains electrical -resistance and flame- resistance needed in the construction of consumer electronics, improving the durability of flexible circuit 12 that covercoat 10 is protecting.
• covercoat 10 is particularly desirable for protecting flexible circuits when constructing electrical components of consumer electronics. While covercoat 10 is discussed in reference to coating a flexible circuit, covercoat 10 can coat any electrical component in which flame-resistance and electrical-resistance in high temperature and high humidity environments are desired characteristics.
• composition of covercoat 10 includes a phosphinate and a urethane solder mask. All concentrations herein are expressed in weight percent, unless otherwise stated.
• Suitable component concentrations are in the composition range from about 10% to abouf 30% phosphinate and about 70% to about 90% urethane solder mask, based on the total compositional weight of the composition. Particularly suitable component concentrations are in the composition range from about 15% to about 25% phosphinate and 75% to about 85% urethane solder mask, based on the total compositional weight of the composition.
• the phosphinate is represented by:
• R 1 and R 2 are the same or different and are each Ci-C ⁇ alkyl, linear or branched, and/or aryl groups;
• M is Mg, Ca, Al, Sb, Sn, Ge, Ti, Zn, Fe, Zr 5 Ce, Bi, Sr, Mn, Li, Na, and/or K; and n is from 1 to 4.
• Suitable phosphinates include halogen-free organic phosphinates.
• Commercially available examples of suitable phosphinates include, but are not limited to those available under the trade designations EXOLIT OP 930, EXOLIT 935, and EXOLIT OP 1230, from Clariant Corporation, Charlotte, NC.
• An example composition of a suitable phosphinate includes a polyol mixture, polypropylene glycol, polyisocyanate, and phosphinate.
• Suitable commercially available urethane solder masks include, but are not limited to those available under the trade designation AR7100 Solder Mask, from Ajinomoto Fine Technology Company, Incorporated, Kawasaki-Shi, Japan and Thermal Curable Solder Mask TF-200 TR6368/MK-20S, from Taiyo Ink Manufacturing Company, Limited, Tokyo, Japan.
• the composition of covercoat 10 may also include additional materials in varying concentrations as individual needs may require.
• the composition may further include pigments, hardeners, flow-promoting agents, viscosity modifiers, and combinations thereof.
• the composition of covercoat 10 is flame-resistant while also maintaining electrical resistance.
• the flame-resistance of the composition is measured pursuant to a flammability test provided below in the Examples section of the specification.
• An example of the flame-resistance of a sample coated with the composition of the present invention is that the sample did not continue to burn for a significant amount of time after the sample was exposed to a flame for ten seconds. The sample was later exposed to the flame again for another ten seconds, and also did not continue to burn for a significant amount of time. Additionally, the sample did not burn to a clamp holding the sample, or ignite cotton positioned beneath the sample. Because covercoat 10 is flame-resistant, flexible circuit 12 coated with the composition resists ignition and burning. Flexible circuit 12 coated with the composition is thus capable of withstanding high temperatures.
• the composition of covercoat 10 also maintains electrical resistance in harsh environments for an extended period of time. This is accomplished by using phosphinate in the composition of covercoat 10.
• the phosphinate maintains the electrical resistance of covercoat 10 in harsh environments when compared to currently used covercoats.
• the electrical resistance of the composition allows a flexible circuit coated with the composition to be exposed to high temperatures and high humidity without damaging the flexible circuit.
• the electrical resistance of the composition' of covercoat 10 is measured pursuant to an electrical bias test provided below in the Examples section of the specification. A resistance equal to or higher than approximately 1E+9 ohms is an example of good electrical resistance of the composition.
• the electrical resistance of covercoat 10 increases the durability of flexible circuit 12 coated with covercoat 10. Because the composition maintains electrical resistance when exposed to high humidity and high temperatures, flexible circuit 12 protected by covercoat 10 can withstand harsh environments for an extended period of time.
• Covercoat 10 may be made using a mixing and coating process.
• a sample of covercoat 10 is prepared by adding phosphinate into a urethane solder mask at a ratio of between approximately 10% to approximately 20% by solid weight of the solder mask. The mixture is well mixed. After mixing, the composition is applied to flexible circuit 12 to obtain a final film thickness of between approximately 20 microns and approximately 40 microns when dry. The final film thickness is preferably between approximately 25 microns and approximately 35 microns when dry.
• the coated material is then cured in an oven at between approximately 100 0 C and approximately 200 0 C for about one hour. The coated material is preferably cured at approximately 150 0 C.
• At least one embodiment of the present invention provides the composition of a covercoat that can be used on the surface of any article where flame-resistance and electrical bias are desired.
• a covercoat that can be used on the surface of any article where flame-resistance and electrical bias are desired.
• the covercoat is described with reference to flexible circuits for use in consumer electronics, it is understood that the covercoat may be adapted for use with materials or substances of any type.
• EXOLIT 930 a halogen-free organic phosphinate, available from Clariant
• EXOLIT 1230 a halogen-free organic phosphinate, available from Clariant Corporation.
• AR7100 Solder Mask a urethane solder mask, available from Ajinomoto Fine Technology Company, Incorporated, Kawasaki-Shi, Japan.
• This test is a measurement of the tendency of an article to either extinguish or to spread a flame once the article has been ignited.
• the articles are first coated with the covercoat and cut into one-half inch by five inch pieces.
• the articles are preconditioned at 50% humidity and 23°C for at least 48 hours.
• a gas burner and flame are set up pursuant to American Standard Test Methods (ASTM) D5207-97.
• the articles are oriented and clamped in a vertical position and subjected to the flame for ten seconds.
• the flame is then withdrawn and the first burn time is recorded. After the burning ceases, the flame is applied for an additional ten seconds.
• the flame is again withdrawn and the second burn time is recorded. Additional data recorded include: the afterglow after the second application, whether the article burns to the clamp, and whether the articles drop flaming particles that ignite cotton positioned underneath the article.
• This test is a measurement of the electrical resistance of articles coated with the composition of the present invention.
• the samples Prior to applying the covercoat, the samples are cleaned in an ultrasonic cleaner for 30 seconds.
• the articles are then placed on lint-free tissue paper and dried with filtered, compressed air. After cleaning, the articles are coated with the composition of the covercoat to a film thickness of approximately 50 microns.
• the articles are then placed in an 85% humidity and 85 0 C temperature environment. At this environment, a continuous 90 volts is applied to the articles and the current between the positive and negative biased regions of the articles are measured. Low electrical currents indicate high resistance values. Articles having resistance values around 1E+9 are considered to have very good resistance. If the current exceeds 0.01 milliamps, the voltage to that article is shut off and the article is considered to have failed the test.
• Examples 1, 3, 5, and 7 are compositions of the present invention, with component concentrations (in weight percent) of EXOLIT 930 and AR7100 Solder Mask applied onto a polymide film, as provided in Table 1.
• Examples 2, 4, 6, and 8 are also compositions of the present invention, with component concentrations (in weight percent) of EXOLIT 1230 and AR7100 Solder Mask applied onto a polymide film, also provided in Table 1.
• Example 1 was made using a mixing and coating process.
• a sample of the covercoat was prepared by adding the phosphinate into a urethane solder mask at a ratio of approximately 15% by solid weight of the solder mask. The mixture was subsequently well mixed. After mixing, the composition was applied to a polymide film to obtain a final film thickness of between approximately 20 microns and approximately 40 microns when dry. The coated material was then cured in an oven at approximately 150 0 C for about one hour.
• Examples 2-8 were made using the same process as discussed for
• Example 1 except that the concentrations of EXOLIT 930 and EXOLIT 1230 were varied. The thickness of the polymide film as well as the final film thickness was also varied.
• Table 1 provides the composition concentrations, bum times, afterglow time, whether the article burned to a clamp, and whether the article ignited cotton, as analyzed pursuant to the methods discussed above, of Example 1-8.
• Table 1 illustrates the flame-resistance exhibited by the addition of a phosphinate, such as EXOLIT 903 or EXOLIT 1230, to the coating composition of an article, as depicted by Examples 1-8.
• a phosphinate such as EXOLIT 903 or EXOLIT 1230
• the articles of Examples 1-6 exhibited minimal to no burn time after being subjected to a flame for 10 seconds, as well as no afterglow. Additionally, the articles of Examples 1-6 did not bum to the clamp maintaining them in position during the flammability test, and did not drip flaming particles that ignited cotton placed under the articles.
• the compositions of Examples 7 and 8 were coated onto a polymide film having a thickness of 2 millimeters. In contrast, the compositions of Examples 1 and 2 were coated onto a polymide film having a thickness of 4 millimeters. While the articles of Examples 1 and 2 both passed the VO Flammability Test, the articles of Examples 7 and 8 were consumed after being subjected to a flame for 10 seconds. The Example 7 and 8 articles also burned to the clamp holding the articles. In contrast, the articles of Examples 1 and 2 "did not burn after being exposed to a flame, exhibited no afterglow, did not burn to the clamp, and did not ignite cotton. The fact that the articles of Examples 7 and 8 burned after being exposed to a flame for 10 seconds can be attributed to the fact that thinner articles tend to burn more easily than thicker articles. The only difference between the articles of Examples 7 and 8, and the articles of
• Examples 3 and 4 were the weight percent of phosphinate in the coating compositions.
• the articles of Examples 7 and' 8 were coated with compositions that comprised 15% by weight phosphinate.
• the articles of Examples 3 and 4 were coated with compositions that comprised 20% by weight phosphinate.
• Table 1 While the compositions of Examples 3 and 4 both passed the VO Flammability
• the articles of Examples 5 and 6 differed from the articles of Examples 7 and 8 in two respects. First, the compositions of Examples 5 and 6 were coated on thicker polymide films and second, the compositions of Examples 5 and 6 also comprised a greater amount of phosphinate. As with the articles of Examples 1, 2, 3, and 4, the articles of Examples 5 and 6 also did not burn after being exposed to a flame for 10 seconds. The articles of Examples 5 and 6 also did not exhibit an afterglow, burn to the clamp, or ignite cotton positioned beneath the examples.
• Examples 9 and 10 are compositions of the present invention, with component concentrations (in weight percent) of EXOLIT 930 and AR7100 Solder Mask applied onto a polymide film, as provided in Table 2.
• Examples 11 and 12 are also compositions of the present invention, with component concentrations (in weight percent) of EXOLIT 1230 and AR7100 Solder Mask applied onto a polymide film, also provided in Table 2.
• Table 2 provides the composition concentrations and resistance, as analyzed pursuant to the methods discussed above, of Example 9-12.
• Example 9 had a resistance of 9.51E+9 ohms
• Example 10 had aresistance of 4.04E+10 ohms
• Example 11 had a resistance of 2.28E+10 ohms
• Example 12 had a resistance of 3.8E+9 ohms.
• the covercoat composition of the present invention is flame-resistant and exhibits high electrical resistivity at high temperatures and high humidity without using any chemical halogens.
• the covercoat also may have a reduced thickness and is easily applied by conventional coating methods, making its application desirable in the field of consumer electronics, particularly for use with flexible circuits.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Medicinal Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Health & Medical Sciences (AREA)
• Polymers & Plastics (AREA)
• Manufacturing & Machinery (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Non-Metallic Protective Coatings For Printed Circuits (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Fireproofing Substances (AREA)
• Paints Or Removers (AREA)

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• 2006
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