April 12, 1960 v. F. DAHLGREYN METHOD OF PREPARATION OF THERMO 'RESI N comm PRINTED CIRC 2,932,599 STIC Filed May 9, 1955 II ALKALINE BATH COPPER I 2 BLACK CUPRIC OXIDE I 0 RINSE + 3\HCI +' FeCI3 I RINSE I, THERMOSETTING Fig. 2 4\‘NoCN PHENOLIC RESIN I RINSE i 5\OXIDIZ|NG * AGENT I RINSE s\ N6 7 N \ CURED TH OSETT PHENO LA _, RE ATE II 8\ PRESS RE NOLIC BLACK OXID CuO RIC -| COPPER ‘II I COOL 9\ JIV-IING _T?. REMOVE |o FLUORO CHLOR ETHYL - THER ET PHENOLIC RE COPPER TRI- FLUORO L0 TRI-FLUORO - YL 8w PRESS | COOL I Fig | CURED THERMOSETTING PHENOLIC RESIN Victor F. Du INVEN III/Kama Attorney en I United States Patent 0 ICC 1 2,932,599 Patented Apr. 12, 1960 2 greater tendency to flow at a temperature substantially less than the given temperature is placed in contact with the 2,932,599 imprinted surface. The plastic resins are pressed together METHOD OF PREPARATION OF THERMOPLASTIC at a temperature substantially less than the given tem perature to force the second plastic resin into the follicles to provide a bond therebetween. In accordance with the invention there is further pro vided a method of bonding a thermoplastic resin to a RESIN COATED PRINTED CIRCUIT Victor F. Dahlgren, West Windham, N.H., assignor, by mesne assignments, to Sanders Associates, Incorpo rated, Nashua, N.H., a corporation of Delaware thermosetting resin. The method comprises oxidizing 10 the surfaces of a thin sheet of copper to provide the Application May 9, 1955, Serial No. 507,032 surfaces with a homogeneous coating of black cupric 10 Claims. (Cl. 154-129) oxide. The cupric oxide coated copper sheet is placed The present invention relates to printed circuits. More 15 particularly, the invention relates to printed circuits covered with insulating material. In the prior art, printed circuits are typically formed by a?ixing thin copper, sheets with a suitable adhesive to an insulator base formed from a thermosetting resin such 20 as XXXP-Phenolic (a paper base, phenolic resin lami— in contact with an uncured sheet of thermosetting resin. A sufficient degree of heat and pressure is applied to cure the thermosetting resin and press the copper and the thermosetting resin sheets together, forming thereby an imprint of the cupric oxide in the thermosetting resin. The cupric oxide coated copper clad resin sheet is then cooled. Cupric oxide coated copper is removed from the resin sheet to expose the plurality of randomly dis posed follicles in the resin provided by the imprint. The nate). The copper is then etched away, leaving a con thermoplastic resin is placed in contact with the imprinted ductive pattern in the con?guration of the desired circuit. surface. A su?lcient degree of heat and pressure is ap Thermosetting resins are characteristically excessively hy plied to the thermoplastic and thermosetting resins to force groscopic. Under high humidity conditions, insulation re 25 the thermoplastic resin into the follicles. The thermo< sistance between conductors is substantially reduced. A plastic and thermosetting resins are then cooled to pro relatively new material, tri~?uoro-chloro-ethylene, termed vide the bond therebetween. herein “KeL-Ff’. as trade marked and manufactured by In another embodiment of the invention there is pro the M. W. Kellogg Company, is substantially superior to such thermosetting resin material in that it has a very 80 vided a method of insulating a printed circuit with tri ?uoro-chloro-ethylene. The method comprises immers low permeability to humidity as well as enhanced in ing a thin sheet of clean copper in an oxidizing bath sulation resistance. It has been a great problem to ?nd comprising a hot aqueous solution consisting essentially a suitable means for causing Kel—F to adhere to other of an alkali selected from the group consisting of sodium systems. hydroxide and potassium hydroxide and a chlorite selected In my copending application ?led October 1, 1954, 35 from the group consisting of sodium chlorite and potas Serial No. 459,841, a method is disclosed for causing sium chlorite to provide the copper with a homogeneous copper to adhere to Kel-F. In US. Patent No. 2,551,591 coating of black cupric oxide. The oxidized copper sheet issued to S. G. Foord, May 8, 1951, a method is dis is placed in contact with an uncured sheet of phenolic closed for bonding polyethylene to copper vby means of resin laminate. A predetermined degree of heat and a layer of cuprous oxide. Foord expressly omits the pressure is applied to the sheets to cure the resin and press use of cupric oxide which is essential to the present in— the copper and resin sheets together, forming thereby vention. an imprint of the cupric oxide in the resin. The cupric It is an object of the present invention to provide an oxide coated copper clad phenolic laminate is then cooled. improved method of bonding thermosetting resins to Cupric oxide coated copper is removed from the sheet thermoplastic resins. 45 of phenolic laminate to expose the plurality of follicles ‘ It is a further object of the present invent-ion to pro in the resin provided by the imprint. A sheet of tri vide a method of bonding Kel-F to a phenolic resin ?uoro-chloro-ethylene is placed in contact with the im laminate. printed surface of the phenolic laminate. A sufficient A still further object of the invention is to provide an of heat and pressure is applied to the tri-?uoro improved method for insulating a printed circuit with 50 degree chloro-ethylene and phenolic laminate to force the tri Kel-F. . a It is a further vobject of the invention to provide an im~ proved printed circuit insulated with Kel-F. ' Other and further objects of the invention will be ap ?uoro-chloro-ethylene into the follicles. The tri-?uoro chloro~ethylene and phenolic laminate are then cooled to provide the bond therebetween. . parent from. the following description of preferred methods 55 Further, in accordance with the invention there is pro vided, as an article of manufacture, an insulated printed and embodiments thereof, taken in connection with the circuit. The circuit comprises a sheet of phenolic resin accompanying drawing. lnaccordance with the invention there is presented a paper laminate to the surface of which are af?xed thin cupric oxide coated copper conductors. An insulating method of bonding plastic resin having substantially different flow characteristics relative to temperature. In 60 cover sheet of tri-?uoro-chloro-ethylene is bonded to the laminate and the copper conductors with the conductors accordance with the method a surface of a body of cop held in insulated spaced relation between the sheets. pet is oxidized to provide a coating of primarily black In the accompanying drawing: . cupric oxide. The oxide coated copper surface is placed Fig. 1 is a ?ow chart illustrating the preferred method in contact with a surface of first plastic resin having a ?ow characteristic at a given temperature. The plastic 65 of the invention; Fig. 2 is a sectional view of cupric oxide coated cop ‘and cooper are laminated together by means of‘a suf?cient per clad phenolic resin; degree of heat and pressure to form thereby an. imprint of Fig. 3 is a plan View of a Kel-F-coated printed circuit; the cupric oxide in the plastic. The laminated copper Fig. 4 is a sectional view of the printed circuit taken plastic is then cooled. The cupric oxide coated cooper is along the lines ‘IV-IV in Fig. 3; and removed from the plastic to expose the plurality of 70 Fig. 5 is a sectional view of a sheet of Kel-F bonded randomly disposed follicles-in said plastic provided by. the "imprint," A surface‘ of, a second plastic resin having a to a thermosetting resin. . Referring now to the drawing and with particular refer 2,932,599 , r . 3 ‘ XXXP from blistering, for example 5 pounds per square ence to Fig. 1, the thin sheets of copper 1 are ?rst pre inch pressure with the press 8; (20) Baking at a temperature in excess of 215° C. for 40 seconds to force the Kel-F into the exposed fol licles in the resin provided by the imprint of the removed pared in the following manner: (1) Immersing the sheets of copper 1 in a mild alkaline bath 2 such as Dy-Clene EW Metal Cleaner, as manufac tured by MacDermid, Inc., Waterbury, Connecticut for five seconds; cupric oxide coated copper; . , . (21) Water cooling the printed circuit in the press; ' (2) Rinsing in cold, running water for ?ve seconds; " (3) Dipping for 15 seconds in a 10 percent solution and > (22) Removing the Kel~F insulated printed circuit 3 of hydrochloric acid (HCl) which has dissolved in it from the press. ' 10 8 ounces per gallon of ferric chloride (FeOl3); in Fig. 3 a plan view of the insulated printed circuit (4) Rinsing in cold, running water ‘for ?ve seconds; is shown. The Kel-F ‘inside diameter is shown incom (5) Immersing in a 10 percent solution 4 of sodium plete to expose the copper 1 and cured thermosetting cyanide (NaCN) for 15 seconds; phenolic resin laminate 7. In the sectional'v'iew of Fig. ’ (6) Rinsing in cold, running water; ('7) Immersing in an oxidizing agent 5, such as a so 15 lution of 11/2 pounds per gallon of water of Ebonol “C” Special as manufactured by Enthone Company, New 4, the cupric oxide, CuO, coating 11 is shown greatly magni?ed. ' ' " It will be apparent that in place of the resin-impreg nated paper, an epoxy resin or silicone resin may just Haven, Connecticut, for 10 minutes at l90-205° F. to as well be used. In the place of the impregnated paper, provide a homogeneous coating of black cupric oxide impregnated glass cloth may be used to withstand higher 20 (CuO) on the copper surfaces. The Ebonol “C” Special temperature operation. ' ‘ ' i is substantially described in US. Patent #2,364,993 is It has been found that polytetrailuoroethylene, fa sued to ‘Walter R. Meyer; miliarly termed “Te?on” as trade marked and manu (8) Immersing in cold, running water; (9) Rinsing in hot, running water for 10 to 20 sec onds; , factured by E. I. du 'Pont de Nemours and Company, 25 may be utilized in place of the Kel~F at a press tem p (10) Baking in a preheated oven 6 above 212° F until all traces of moisture are removed. 7 The sheets of cupric oxide coated copper are bonded perature of approximately 625 ° F. ' , In Fig. 5 the cross-section of lamination of a thermo plastic resin and a thermosetting resin is shown. Cured or thermoset phenolic resin 7 is bonded to tri-?uoroe to a thermosetting resin, for example, a laminate of , _ ' paper impregnated with a phenolic resin such as XXXP 30 chloro-ethylene 10 as illustrated. The use of a thermoplastic overcoat vof the type de Phenolic, in the following manner: scribed to encapsulate printed circuits greatly decreases (11) Placing a sheet of metallic foil, such as alu ' the hygroscopic characteristics of commonly used ther minum, on the platen of a press 8, such as manufactured by Wabash Press Company, Wabash, Indiana. The mosetting plastic materials by'cutting down their ex XXXP-Phenolic and the platen; (12) Placing, for example, six stacked sheets of un cured XXXP-type phenolic resin impregnated paper, each, for example, 6 inches long, 2 inches wide and ings increase the resistivity between electrical conductors aluminum foil is. used to prevent adherences between the 35 posed surface areas. Te?on or Kel-F insulating coat on the surface of a printed circuit. The Te?on or Kel-F insulating coating may be utilized as a resist mask for plating,v and soldering purposes. Such coatings permit sealing joints as between a baseplate and a printed circuit .010 of an inch thick, on the aluminum foil to provide 40 cable, whereby soldering and sealing can be accomplished an uncured thermosetting laminate 7; simultaneously. The present» invention naturally lends (13) Placing the cupric oxide coated sheet of copper itself to ?ush mounting of printed circuits. While there has been hereinbefore describedwhat are 45 at present considered preferred embodiments of the in sure; vention, it will be apparent that many and various , (l4) Baking at 300-3500 F. under pressure for 20' changes and modi?cations may be made with respect minutes to cure the resin and provide the cup'ric oxide to the embodiments illustrated, without departing from imprint in the resin of the top sheet of the laminate; the spirit of the invention. It will be understood, ‘there (15) Water cooling the copper and resin laminate under maintained pressure in the press to prevent blister 60 fore, that all such changes andv modi?cations as fall fairly within the scope of the present invention, as de ing of the XXXP-resin; t?ned in the appended claims, are to be considered as a (l6) Removing the cupric oxide coated copper clad part of the present invention. resin laminate from the press 8 and the aluminum foil in contact with the sheets of resin impregnated paper and applying 300-1000 pounds per square inch of pres~ What is claimed is: ' from the laminate. , l. The method of bonding a thermoplastic resin to a I The XXXP-Phenolic may, of course, be copper clad 55 thermosetting resin comprising, oxidizing the surfaces on both sides merely by placing sheets of copper both of a thin sheet of copper .to provide said surfaces with above and below the sheets of impregnated paper. The cup'ric oxide coated copper clad phenolic sheet is shown ' in crosssection in Fig. 2. The cupric oxide shown is greatly‘ magni?ed to more clearly illustrate its imprint upon the phenolic resin. The cupric oxide coated cop per clad phenolic laminate is then prepared to provide‘ _ a‘ printed circuit in the desired con?guration and im a homogeneous coating of black cupric oxide; placing said cupric oxide coated copper sheet in contact with an uncured sheet of thermosetting resin; applying a suf ticient degree of heat and pressure to cure'said thermo setting resin and press said copper and said thermosetting resin sheets together, forming thereby an imprint. of said mersed, for'example, in an acid etching bath 9 in ac cupric oxide in said thermosetting resin; cooling said cupric oxide coated copper cladresin sheet; removing cordance with well-known, conventional photoetching 'cupric oxide coated copper from said resin .sheet to techniques.’ ’ . ~ ‘ Theprinted circuit thus prepared is covered with an insulating sheet 10 of Kel-F in the following manner: expose the plurality of randomly disposed follicles in said resin provided by said imprint; placing said thermo plastic resin in contact with said imprinted surface; and (17) Placing the printed circuit'on the platen of the 70 applying a sufficient degree of heat and pressure to said thermoplastic and thermosetting resins to 'force said ther moplastic resin into said follicles to provide said bond press 8.; _ (18) Placing a sheet of Kel-F, for example, 6, inches long, 2 inches Wide and .002 of an inch thick, over the therebetween. ' g . t 2. The method of bonding tri-?uoro-chloro-ethylene ‘ (19) Applying su?icient pressure to prevent the 75 to aphenolic-resinilaminate comprising, immersing athin printed circuit; 5 2,982,599 sheet of clean copper in an oxidizing bath to provide the copper with a homogeneous coating of black cupric oxide; placing said oxidized copper sheet in contact with an uncured sheet of phenolic resin laminate; applying a predetermined degree of heat and pressure to cure said phenolic resin and press said copper and phenolic laminate 6 nate; applying a predetermined degree of heat and pressure to cure said resin and press said copper and resin sheets together, forming thereby an imprint of said cupric oxide in said resin; cooling said cupric oxide coated copper clad phenolic laminate; removing selected areas of cupric oxide coated copper from said sheet of phenolic laminate to sheet together, forming thereby an imprint of said cupric oxide in said laminate; cooling said cupric oxide coated copper clad phenolic laminate; removing cupric oxide provide a predetermined conductive pattern and expose phenolic laminate to force said tri-?uoro-chloro-ethylene into said follicles; and cooling said t-ri-?uoro-ehloro ethylene and phenolic laminate to provide said bond chloro-ethylene and phenolic laminate to provide said bond therebetween. 6. The method of bonding plastic resins having sub~ stantially different flow characteristics relative to tempera the plurality of follicles in said phenolic laminate sheet coated copper from said sheet of phenolic laminate to 10 provided by the exposed areas of said imprint; placing tri ‘ uoro-chloro-ethylene in contact with said imprinted sur expose the plurality of follicles in said phenolic laminate face of said phenolic laminate; applying a su?icient degree sheet provided by said imprint; placing tri-?uoro-chloro of heat and pressure to said tri-?uoro~chloro-ethylene ethylene in contact with said imprinted surface of said and said phenolic laminate to force said tri-?uoro-chloro phenolic laminate; applying a su?icient degree of heat and pressure to said tri-?uoro-chloro-ethylene and said 16 ethylene into said follicles; and cooling said tri-?uoro therebetween. 3. The method of insulating a printed circuit with tri 20 ture, comprising: oxidizing a surface of a body of copper to provide a coating of primarily black cupric oxide; placing said cupric-oxide-coated-copper surface in contact of clean copper in an oxidizing bath to provide the copper ?uoro-chloro-ethylene comprising, immersing a thin sheet with a surface of a ?rst plastic resin having a ?ow charac teristic at a given temperature; applying a su?icient sheet of phenolic resin laminate; applying a predeter 25 degree of heat and pressure to laminate said plastic and copper together, forming thereby an imprint of said cupric mined degree of heat and pressure to cure said resin oxide in said plastic; cooling said laminated copper plastic; and press said copper and resin sheets together, forming removing said cupric-oxide-coated-copper from said plas thereby an imprint of said cupric oxide in said resin; tic to expose the plurality of randomly disposed follicles cooling said cupric oxide coated copper clad phenolic with a homogeneous coating of black cupric oxide; placing said oxidized copper sheet in contact with an uncured laminate; removing selected areas of cupric oxide coated 30 in said plastic provided by said imprint; placing a surface of a second plastic resin having a greater tendency to copper from said sheet of phenolic laminate to provide ?ow at a temperature substantially less than said given a predetermined conductive pattern and expose the temperature in contact with said imprinted surface; and plurality of follicles in said phenolic laminate sheet pressing said plastic resins together at a temperature formed by the exposed areas of said imprint; placing tri-?uoro-chloro-ethylene in contact with said, imprinted 35 substantially less than said ?rst given temperature to force said second plastic resin into said follicles to provide surface of said phenolic laminate; applying a sufficient said bond therebetween. ‘ degree of heat and pressure to said tri-?uoro-chloro 7. The method of bonding tri-?uoro-chloro-ethylene ethylene and said phenolic laminate to force said tri to a thermosetting resin laminate comprising, immersing ?uoro-chloro-ethylene into said follicles; and cooling said tri-?uoro-chloro-ethylene and phenolic laminate to provide 40- a thin sheet of clean copper in an oxidizing bath to thermosetting resin comprising, immersing a thin sheet provide the copper with a homogeneous coating of black cupric oxide; placing said oxidized copper sheet in contact with an uncured sheet of thermosetting resin laminate; of clean copper in an oxidizing bath comprising a hot aqueous solution consisting essentially of an alkali selected of heat and pressure to cure said resin and press said said bond therebetween. 4. The method of bonding a thermoplastic resin to a from the group consisting of sodium hydroxide and potassium hydroxide and a chlorite selected from the group consisting of sodium chlorite and potassium chlorite to provide said surfaces with a homogeneous coating of applying resin laminate; applying a predetermined degree copper and laminate sheets together, forming thereby an imprint of said cupric oxide in said laminate; cooling said cupric oxide coated copper clad laminate; removing cupric oxide coated copper from said sheet of laminate to expose the plurality of follicles in said laminate sheet black cupric oxide; placing said cupric oxide coated 50 provided by said imprint; placing tri-?uoro-chloro-ethylene copper sheet in contact with an uncured sheet of thermo in contact with said imprinted surface of said laminate; setting resin; applying a su?icient degree of heat and pressure to said thermosetting resin and press said copper applying a sufficient degree of heat and pressure to said and thermosetting resin sheets together, forming thereby tri-?uoro-chloro-ethylene and said laminate to force said said thermoplastic and thermosetting resins to provide mined degree of heat and pressure to cure said phenolic tri-?uoro-chloro-ethylene into said follicles; and cooling an imprint of said cupric oxide in said thermosetting said tri-?uoro-chloro-ethylene and laminate to provide resin; cooling said cupric oxide coated copper clad resin said bond therebetween. sheet; removing cupric oxide coated copper from said 8. The method of bonding a thermoplastic resin to a resin sheet to expose the plurality of randomly disposed phenolic resin laminate comprising, immersing a thin sheet follicles in said resin provided by said imprint; placing said thermoplastic resin in contact with said imprinted iii) of clean copper in an oxidizing bath to provide the copper with a homogeneous coating of black cupric oxide; placing surface; applying a su?‘icient degree of heat and pressure said oxidized copper sheet in contact with an uncured to said thermoplastic and thermosetting resins to force sheet of phenolic resin laminate; applying a predeter said thermoplastic resin into said follicles; and cooling said bond therebetween. 65 resin and press said copper and phenolic laminate sheets together, forming thereby an imprint of said cupric oxide 5. The method of insulating a printed circuit with tri-?uoro~chloro-ethylene comprising, immersing a thin in said laminate; cooling said cupric oxide coated copper sheet of clean copper in an oxidizing bath comprising a hot aqueous solution consisting essentially of an alkali clad phenolic laminate; removing cupric oxide coated copper from said sheet of phenolic laminate to expose selected from the group consisting of sodium hydroxide 70 the plurality of follicles in said phenolic laminate sheet and potassium hydroxide and a chlorite selected from provided by said imprint; placing a thermoplastic resin the group consisting of sodium chlorite and potassium in contact with said imprinted surface of said phenolic chlorite to provide the copper with a homogeneous coating laminate; applying a sufficient degree of heat and pressure of black cupric oxide; placing said oxidized copper sheet to said thermoplastic resin and said phenolic laminate to in contact with an uncured sheet of phenolic resin lami TI force said thermoplastic resin into said follicles; and 2,982,599 circling said. thermoplastic resin and phenolic laminate tolprovide said bond therebetween. , 9. The method of bonding poly-tetra-?uoro-ethylene to a phenolic resin laminate comprising, immersing a thin sheet of clean copper in an oxidizing bath to provide the copper with a homogeneous coating of black cupric' 8 copper with‘ a ‘homogeneous coating of black cnpri‘c oxide; placing said: oxidized copper sheet in contact with an uncured sheet'of epoxy resin laminate; applying a predetermined degree of heat and pressure to cure said epoxy resin and press‘ said copper and epoxy laminate sheets together, forming thereby an imprint of said cupr-ic oxide in said‘ laminate; cooling said cupric oxide coated oxide; placing said- oxidized copper sheet'in contact with; copper‘ clad epoxy laminate; removing cupricjoxide an uncured sheet of phenolic resin laminate; applying a coated copper from said sheet of epoxy laminate to ex predetermined degree of‘heat and pressure to cure said pose the plurality of follicles in said epoxy laminate sheet 10 phenolic resin and press said copper and‘ phenolic lami provided by said imprint; placing tri-flnoro-chloro~ethyl nate sheets together, forming thereby an imprint ‘of said ene in contactwith said imprinted surface of said epoxy cupric oxide in said laminate; cooling said: cupric oxide laminate; applying a su?icient degree of heat and pres coated copper clad phenolic laminate; removing cnpric sure to said tri-?noro-ohloro-ethylene and said epoxy oxide coated copper from said sheet of phenolic laminate laminate to force said tri’?uoro-chloro-ethylene into said to expose the plurality of follicles in said phenolic lami 15 follicles; and cooling, said tri—?uoro-ehloro-ethylene and nate sheet provided by said imprint; placing poly'tetra-v epoxy laminatepto provide said bond therebetween._ ?uoro-ethylene in contact with said imprinted surface of said phenolic laminate; applying a su?icient degree of ReferencesCited in the ?le of this patent heat and pressure to said poly-tetra-?uoro-ethylene ‘and 20 _ UNITED, STATES PATENTS said phenolic laminate to force said poly-tetra-?uoro~ ethylene into said follicles; and cooling said poly-tetra 'Daly __U_____-_ ________ __ Apr. 10, 1934 fluoro-ethylene and phenolic laminate to provide said bond therebetween. 10. The method of bonding tri-v?uoro-chloroethylene to an epoxy resin laminate comprising, immersing a thin 25 sheet of clean copper in an oxidizing bath to provide the 1,954,403 ' ’ ‘ 2,551,591 .FOOl'd __‘___________ __'__ May 8, 1951 2,728,698 Rudner _____________ _._ Dec. 27, 1955 2,745,898 Hplllfd ______________ __'. May 15, 1956 2,768,923 Kepple et al. _' _________ __ Oct. 30, 1956