Photosensitive aqueous developable copper conductor composition

Abstract: A photosensitive aqueous developable photosensitive copper conductive composition is disclosed which is fireable in a nonoxidizing atmosphere is developable in an aqueous solution containing 0.8 percent by weight sodium carbonate.

Description: The present invention is directed to an improved photosensitive copper conductor composition with high resolving power and aqueous processability. Additionally, it functions as a precursor to a fired copper conductor pattern and has the ability to serve as a conductive material particularly useful in the formation of multilayer thick film circuits. BACKGROUND OF THE INVENTION Multilayer thick film circuits have been used for many years to increase circuit functionality per unit of area. Moreover, recent advances in circuit technology have placed new demands on copper materials for this use. Heretofore, most of the copper materials used in multiple circuits have been conventional thick film copper compositions. These are comprised of finely divided particles of copper solids and inorganic binders dispersed in an inert organic medium. Such thick film materials are usually applied by screen printing in the pattern desired for the conductor. Thick film materials of this type are very important and will continue to be so. However, when applying these thick film materials in patterns by screen printing, it is difficult to obtain fine line and space resolution. It is essential that all the screen printing variables such as screen quality, squeegee hardness, print speed, dispersion properties, etc., be most carefully controlled and constantly monitored to obtain good product yields. An alternative approach is (1) to apply a layer of the copper conductive material to a substrate by means of dispersion in a photosensitive medium, (2) to expose the layer imagewise to actinic radiation, (3) to solvent develop the pattern to remove unexposed portions of the layer, and (4) to fire the remaining exposed portions of the pattern to remove all remaining organic materials and to sinter the inorganic materials. Such an approach is found in Felton, USP 4,598,037 issued July 1, 1986. This patent discloses a coating composition which comprises an admixture of: (a) finely divided particles of copper having a size of 0.4-4 µm, (b) finely divided particles of a cadmium aluminosilicate inorganic binder dispersed in an organic medium comprising, (c) an organic polymeric binder selected from the group consisting of polyalkyl acrylates, polyalkyl methacrylates and mixtures thereof, (d) a photoinitiation system, (e) photohardenable monomer, and (f) volatile nonaqueous organic solvent. As set forth in this patent processing involves the coating composition being (1) screen printed onto a ceramic substrate, (2) exposed imagewise to actinic radiation to effect hardening of the exposed areas of the composition, (3) organic solvent developed to remove unexposed areas of the composition, and (4) fired in nitrogen to effect volatilization of the organic medium and sintering of the inorganic binder. A disadvantage of prior art photosensitive copper conductor compositions and particularly compositions disclosed in USP 4,598,037 is that an organic solvent is necessary to develop such material after imagewise exposure to actinic radiation, i.e., an organic solvent removes areas of the composition which have not been exposed to actinic radiation without removal of areas which have been exposed. Organic solvents often are undesirable as they may pose health and environmental hazards. There exists a need, therefore, for a photosensitive copper conductor composition which, after exposure to actinic radiation, is developable in aqueous solution. SUMMARY OF THE INVENTION In its primary aspect the present invention is directed to an aqueous developable photosensitive copper conductor composition which is fireable in a substantially nonoxidizing atmosphere comprising an admixture of: (a) finely divided particles of copper solids having a surface area-to-weight ratio of no greater than 20 m²/g and at least 80 wt. % of the particles having a size of 0.5-10 µm and (b) finely divided particles of an inorganic binder having a glass transition temperature in the range of from 550 to 825°C, a surface area-to-weight ratio of no greater than 10 m²/g and at least 90 percent by weight of the particles having a size of 1-10 µm, the weight ratio of (b) to (a) being in a range from 0.0001 to 0.25, dispersed in an organic vehicle comprising (c) an organic polymeric binder, (d) a photoinitiation system, (e) photohardenable monomer, and (f) an organic medium wherein the improvement comprises the organic polymeric binder is a copolymer or interpolymer of (1) a nonacidic comonomer comprising a C₁-C₁₀ alkyl acrylate or C₁-C₁₀ alkyl methacrylate, styrene, substituted styrene or combinations thereof and (2) an acidic comonomer comprising an ethylenically unsaturated carboxylic acid with the proviso that acidic comonomers comprise at least 15 weight percent of the polymer, wherein the organic polymeric binder has a molecular weight no greater than 50,000 and wherein the composition upon imagewise exposure to actinic radiation is developable in an aqueous solution containing 0.8 percent by weight sodium carbonate. In a secondary aspect, the invention is directed to a method of making the above-described photosensitive copper conductor composition wherein component (b) is freeze dried prior to mixing with the other components. DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to an improved photosensitive copper conductor composition. Since components found in Felton USP 4,598,037 can be employed in the present invention as modified herein, this patent is incorporated by reference with portions directly reproduced herein. Also the same processing steps can be employed with compositions of the present invention as in USP 4,598,037 with the exception that a different developer must be employed to remove areas of the composition which have not been exposed to radiation. A. Copper Solids Virtually any shape copper powder, including spherical particles and flake (rods, cones, plates) may be used in practicing the invention. It is preferred that the particles be spherical. It has been found that the dispersion of the invention must contain no significant amount of solids having a particle size of less than 0.2 µm. When particles of this small size are present it is difficult to adequately obtain complete burnout of the organic medium when the films or layers thereof are fired to remove the organic medium and to effect sintering of the inorganic binder and the copper solids. In addition, none of the copper solids should exceed 20 µm. When the dispersions are used to make thick film pastes, which are usually applied by screen printing, the maximum particle size must not exceed the thickness of the screen. When the dispersion is used to make dry photosensitive film the maximum particle size must not exceed the thickness of the film. It is preferred that at least 80 percent by weight of the copper solids fall within the 0.5-10 µm range. In addition, it is preferred that the surface area/weight ratio of the copper particles not exceed 20 m²/g. When copper particles having a surface area/weight ratio greater than 20 m²/g are used, the sintering characteristics of the accompanying inorganic binder are adversely affected. It is difficult to obtain adequate burnout and blisters may appear. B. Inorganic Binder The glass frit used in the present invention aids in sintering the copper particles and may be of any well known composition which has a melting temperature below that of the copper. Nevertheless, in order to get adequate conductivity of the devices, it is preferred that the glass transition temperature (T g ) of the inorganic binder be 550-825°C and still more preferably 575-750°C. If the melting takes place below 550°C, organic material will likely be encapsulated and blisters will tend to form in the composition as the organics decompose. On the other hand, a glass transition temperature above 825°C will tend to produce a composition with poor adhesion when sintering temperatures below 900°C are used. The glass frits most preferably used are the borosilicate frits, such as lead borosilicate frit, bismuth, cadmium, barium, calcium or other alkaline earth borosilicate frits. The preparation of such glass frits is well known and consists, for example, in melting together the constituents of the glass in the form of the oxides of the constituents and pouring such molten composition into water to form the frit. The batch ingredients may, of course, be any compound that will yield the desired oxides under the usual conditions of frit production. For example, boric oxide will be obtained from boric acid, silicon dioxide will be produced from flint, barium oxide will be produced form barium carbonate, etc. The glass is preferably milled in a vibratory (Sweco Co.) mill with water to reduce the particle size of the frit and to obtain a frit of substantially uniform size. The frit is passed through a fine mesh screen to remove large particles since the solid composition should be agglomerate free. The inorganic binder should have a surface to weight ratio of no more than 10 m²/g. Preferably at least 90 percent by weight of the particles have a particle size of 0.5-10 µm. The inorganic binder is preferably 0.01 to 25 percent by weight of the weight of the copper. At higher levels of inorganic binder, the bondability to the substrate is reduced. C. Organic Polymeric Binder The binder polymer is critical to the compositions of the invention. It must allow for aqueous processability and at the same time afford high resolution. It has been found that these requirements are met by selecting a binder which is a copolymer or interpolymer comprising (1) a nonacidic comonomer comprising a C₁-C₁₀ alkyl acrylate, C₁-C₁₀ alkyl methacrylate, styrene, substituted styrene, or combinations thereof and (2) an acid comonomer comprising an ethylenically unsaturated carboxylic acid containing moiety which is at least 15% by weight of the total polymer weight. The presence of the acidic comonomer component of the composition is critical to this technology. The acid functionality yields developability in aqueous base, such as a 0.8% solution of sodium carbonate. When the acid comonomer is present in concentrations of acid below 15%, the compositions do not wash out in aqueous base. When the acid comonomer is present in concentration above 30%, the compositions generally are unstable under humid conditions and also partially develop in the imaged areas. Suitable acidic comonomers include ethylenically unsaturated monocarboxylic acids such as acrylic, methacrylic and crotonic acids and ethylenically unsaturated dicarboxylic acids such as fumaric, itaconic, citraconic, vinyl succinic and maleic acids as well as their half esters and, where appropriate, their anhydrides and mixtures thereof. Because they are cleaner burning in low-oxygen atmospheres, methacrylic polymers are preferred over acrylic polymers. When the nonacidic comonomers is an alkyl acrylate or alkyl methacrylate, it is preferred that this comonomer constitute at least 50 and preferably 70-75 wt.% of the polymer. When the nonacidic comonomer is styrene or substituted styrene, it is preferred that this comonomer be present as 50% by weight of the polymers, where the other 50% is a half ester of an acid anhydride such as maleic anhydride. A preferred substituted styrene is α-methyl styrene. Although not preferred, the nonacidic portion of the polymer binder can contain up to about 50 wt.% of other nonacidic comonomers as a substitute for the alkyl acrylate, alkyl methacrylate, styrene or substituted styrene portion of the polymer. Examples include acrylonitrile, vinyl acetate, acrylamide, and the like so long as the previously discussed compositional criteria are met as well as the physical criteria mentioned below. However, it is preferred to use not more than about 25 wt.% of the total binder polymer of such monomers because they are more difficult to burn out cleanly. It will be recognized that a single copolymer or a combination of copolymers, each of which satisfies the above criteria, may be used as the binder. In addition to the above-described copolymers, it is possible to add small amounts of other polymeric binders. Examples of these include polyolefins such as polyethylene, polypropylene, polybutylene, polyisobutylene, and ethylene-propylene copolymers; and polyethers which are polymers of lower alkylene oxides, such as polyethylene oxide. Polymers can be made by those skilled in the art of acrylate polymerization by conventional solution polymerization techniques. Typically, such acidic acrylate polymers are prepared by combining an α or β-ethylenically unsaturated acid (acidic comonomer) with one or more copolymerizable vinyl monomers (nonacidic comonomer) in a relatively low boiling (75°-150°C) organic solvent to obtain a 10 to 60% solution of the monomer mixture, then subsequently causing the monomers to polymerize by the addition of a polymerization catalyst and heating the mixture at the reflux temperature of the solution at atmospheric pressure. After the polymerization reaction is essentially complete, the resulting acid polymer solution is cooled to room temperature and samples are removed to determine the viscosity, molecular weight, acid equivalent, etc. of the polymer. Additionally it is necessary to keep the molecular weight of the acid containing binder-polymer to a value no greater than 50,000, preferably not greater than 25,000, and more preferably no greater than 15,000. If the composition is to be applied by screen printing the T g of the binder polymer preferably is above 100°C. After being screen printed the paste is usually dried at temperatures up to 100°C and a T g below this value generally results in a very tacky composition. A lower T g value can be employed for a material applied by other than screen printing. The organic polymeric binder is generally present in an amount of 5-45 percent by weight based on the total weight of the dry photopolymerizable layer. D. Photoinitiation System Suitable photoinitiation systems are those which are thermally inactive but which generate free radicals upon exposure to actinic light at or below 185°C. These include the substituted or unsubstituted polynuclear quinones which are compounds having two intracyclic carbon atoms in a conjugated carbocyclic ring system, e g., 9,10-anthraquinone, 2-methylanthraquinone, 2-ethylanthraquinone, 2-tert-butylanthraquinone, octamethylanthraquinone, 1,4-naphthoquinone, 9,10-phenanthrenequinone, benz(a)anthracene-7,12-dione, 2,3-naphthacene-5,12-dione, 2-methyl-1,4-naphthoquinone, 1,4-dimethylanthraquinone, 2,3-dimethylanthraquinone, 2-phenylanthraquinone, 2,3-diphenylanthraquinone, retenequinone, 7,8,9,10-tetrahydronaphthacene-5,12-dione, and 1,2,3,4-tetrahydrobenz(a)anthracene-7,12-dione. Other photoinitiators which are also useful, even though some may be thermally active at temperatures as low as 85°C, are described in U.S. Patent 2,760,863 and include vicinal ketaldonyl alcohols such as benzoin, pivaloin, acyloin ethers, e.g., benzoin methyl and ethyl ethers; α-hydrocarbon-substituted aromatic acyloins, including α-methylbenzoin, α-allylbenzoin and α-phenylbenzoin. Photoreducible dyes and reducing agents disclosed in U.S. Patents 2,850,445, 2,875,047, 3,097,096, 3,074,974, 3,097,097 and 3,145,104, as well as dyes of the phenazine, oxazine, and quinone classes, Michler's ketone, benzophenone, 2,4,5-triphenylimidazolyl dimers with hydrogen donors including leuco dyes and mixtures thereof as described in U.S. Patents 3,427,161, 3,479,185, and 3,549,367 can be used as initiators. Also useful with photoinitiators and photoinhibitors are sensitizers disclosed in U.S. Patent 4,162,162. The photoinitiators or photoinitiator system is present in an amount of 0.05 to 10% by weight based on the total weight of the dry photopolymerizable layer. E. Photohardenable Monomer The photohardenable monomer component of the invention is comprised of at least one addition polymerizable ethylenically unsaturated compound having at least one polymerizable ethylenic group. Such compounds are capable of forming a high polymer by free radical initiated, chain propagating addition polymerization. The monomeric compounds are nongaseous, i.e., they have a normal boiling point above 100°C and a plasticizing action on the organic polymeric binder. Suitable monomers which can be used alone or in combination with other monomers include t-butyl acrylate and methacrylate, 1,5-pentanediol diacrylate and dimethacrylate, N,N-diethylaminoethyl acrylate and methacrylate, ethylene glycol diacrylate and dimethacrylate, 1,4-butanediol diacrylate and dimethacrylate, diethylene glycol diacrylate and dimethacrylate, hexamethylene glycol diacrylate and dimethacrylate, 1,3-propanediol diacrylate and dimethacrylate, decamethylene glycol diacrylate and dimethacrylate, 1,4-cyclohexanediol diacrylate and dimethacrylate, 2,2-dimethylolpropane diacrylate and dimethacrylate, glycerol diacrylate and dimethacrylate, tripropylene glycol diacrylate and dimethacrylate, glycerol triacrylate and trimethacrylate, trimethylolpropane triacrylate and trimethacrylate, pentaerythritol triacrylate and trimethacrylate, polyoxyethylated trimethylolpropane triacrylate and trimethacrylate and similar compounds as disclosed in U.S. Patent 3,380,831, 2,2-di(p-hydroxyphenyl)-propane diacrylate, pentaerythritol tetraacrylate and tetramethacrylate, 2,2-di-(p-hydroxyphenyl)-propane dimethacrylate, triethylene glycol diacrylate, polyoxyethyl-1,2-di-(p-hydroxyphenyl)propane dimethacrylate, di-(3-methacryloxy-2-hydroxypropyl) ether of bisphenol-A, di-(2-methacryloxyethyl)ether of bisphenol-A, di-(3-acryloxy-2-hydroxypropyl)ether of bisphenol-A, di-(2-acryloxyethyl) ether of bisphenol-A, di-(2-acryloxyethyl) ether of bisphenol-A, di-(3-methacryloxy-2-hydroxypropyl) ether of 1,4-butanediol, triethylene glycol dimethacrylate, polyoxypropyltrimethylol propane triacrylate, butylene glycol diacrylate and dimethacrylate, 1,2,4-butanetriol triacrylate and trimethacrylate, 2,2,4-trimethyl-1,3-pentanediol diacrylate and dimethacrylate, 1-phenyl ethylene-1,2-dimethacrylate, diallyl fumarate, styrene, 1,4-benzenediol dimethacrylate, 1,4-diisopropenyl benzene, and 1,3,5-triisopropenyl benzene. Also useful are ethylenically unsaturated compounds having a molecular weight of at least 300, e.g., alkylene or a polyalkylene glycol diacrylate prepared from an alkylene glycol of 2 to 15 carbons or a polyalkylene ether glycol of 1 to 10 ether linkages, and those disclosed in U.S. Patent 2,927,022, e.g., those having a plurality of addition polymerizable ethylenic linkages particularly when present as terminal linkages. Preferred monomers are polyoxyethylated trimethylolpropane triacrylate and methacrylate, ethylated pentaerythritol triacrylate, trimethylopropanetriacrylates and methacrylates, dipentaerythritol monohydroxypentaacrylate and 1, 10-decanediol dimethylacrylate. Other preferred monomers are monohydroxypolycaprolactone monoacrylate, polyethyleneglycol diacrylate (mol. wt. approximately 200), and polyethylene glycol 400 dimethacrylate (mol. wt. approximately 400). The unsaturated monomeric component is present in an amount of 2-20% by weight based on the total weight of the dry photopolymerizable layer. F. Dispersant It is preferred to add dispersant to insure the efficient wetting of the inorganic by the organic polymers and monomers. A thoroughly dispersed inorganic is desirable in the preparation of a photoactive paste with the needed characteristics of good screen printing and leveling and fire out characteristics. The dispersant acts to allow the polymeric binder to associate or wet the inorganic solids, giving an agglomerate free system. The dispersants of choice are the A-B dispersants generally described in "Use of A-B Block Polymers as Dispersants for Non-aqueous Coating Systems" by H. K. Jakubauskas, Journal of Coating Technology, Vol. 58; Number 736; Pages 71-82. Useful A-B dispersants are disclosed in U.S. Patents 3,684,771, 3,788,996, 4,070,388 and 4,032,698 and U.K. Patent 1,339,930 each of which is incorporated herein by reference. Preferred A-B dispersants are polymeric materials disclosed in U.S. Patent 4,032,698 supra represented by the structure where Q is a polymeric or copolymeric segment of a. an ester of acrylic acid or methacrylic acid with an alkanol or 1-18 carbon atoms; b. styrene or acrylonitrile; c. a vinyl ester whose ester moiety contains 2-18 carbon atoms; or d. a vinyl ether; X is the residue of a chain transfer agent; Y is the residue of a di-, tri, or tetraisocyanate radical after removal of isocyanate groups; A is the residue of a basic radical which, as an entity before reaction, has a pk a value of 5-14, or a salt thereof; and m and n are 1, 2 or 3, the total not exceeding 4, provided that when n is 2 or 3, only one of A need be as defined. A particularly preferred member of this class is a polymeric material, hereinafter identified as A-B Dispersant I, represented by the structure where Q is a methylmethacrylate polymeric segment having a weight average molecular weight between 6000 and 8000. Also particularly preferred is a member of a class of polymeric materials represented by the structure wherein Q is an alkyl methacrylate polymeric segment containing about 20 units of butyl methacrylate, n is 20, m is 8 to 12 and R is a chain terminator residue. This dispersant is hereinafter identified as A-B Dispersant II. The dispersant is generally present in an amount of 0.1-5.0 percent by weight based on the photosensitive conductor composition. G. Stabilizer In the copper conductor compositions, it is preferred to add a stabilizer. Without the stabilizer the copper reacts with the acid functionality in the polymeric binder resulting in the crosslinking of the formulation to an intractable hard mass. Any compound may be used which prevents such crosslinking without adversely affecting the other properties of the photosensitive conductor composition, either before or after firing. This may be accomplished by complexation with the copper, by salt formation with the acid functionality, or other reactions. Although the mechanism is not clearly understood, it has been found that triazole compounds function well as stabilizers in the compositions of the invention. Particularly preferred, is benzotriazole. H. Organic Medium The main purpose of the organic medium is to serve as a vehicle of the dispersion of the finely divided solids of the composition in such form that it can readily be applied to a ceramic or other substrate. Thus, the organic medium must first be one in which the solids are dispersible with an adequate degree of stability. Secondly, the rheological properties of the organic medium must be such that they lend good application properties to the dispersion. When the dispersion is to be made into a film, the organic medium in which the ceramic solids and inorganic binder are dispersed consists of the polymeric binder, monomer and initiator which are dissolved in a volatile organic solvent and, optionally, other dissolved materials such as plasticizers, release agents, dispersing agents, stripping agents, antifouling agents and wetting agents. The solvent component of the organic medium, which may be a mixture of solvents, is chosen so as to obtain complete solution therein of the polymer and other organic components and to be of sufficiently high volatility to enable the solvent to be evaporated from the dispersion by the application of relatively low levels of heat at atmospheric pressure. In addition, the solvent must boil well below the boiling point and decomposition temperature of any other additives contained in the organic medium. Thus, solvents having atmospheric boiling points below 150°C are used most frequently. Such solvents include benzene, acetone, xylene, methanol, ethanol, methylethyl ketone, 1,1,1-trichloroethane, tetrachloroethylene, amyl acetate, 2,2,4-triethyl pentanediol-1,3-mono-isobutyrate, toluene, methylene chloride, and ethylene glycol monoalkyl and dialkyl ethers such as ethylene glycol mono-n-propyl ether. For casting films, methylene chloride is particularly preferred because of its volatility. Frequently the organic medium may also contain one or more plasticizers which serve to lower the Tg of the binder polymer. Such plasticizers help to assure good lamination to ceramic substrates and enhance the developability of unexposed areas of the composition. However, the use of such materials should be minimized in order to reduce the amount of organic materials which must be removed when the films cast therefrom are fired. The choice of plasticizers is, of course, determined primarily by the polymer which must be modified. Among the plasticizers which have been used in various binder systems are diethyl phthalate, dibutyl phthalate, butyl benzyl phthalate, dibenzyl phthalate, alkyl phosphates, polyalkylene glycols, glycerol, poly(ethylene oxides), hydroxy ethylated alkyl phenol, tricresyl phosphate triethyleneglycol diacetate and polyester plasticizers. Dibutyl phthalate is frequently used in acrylic polymer systems because it can be used effectively in relatively small concentrations. The photopolymerizable composition is coated upon a support film at a dry coating thickness of about 0.0001 inch (0.00025 cm) to about 0.01 inch (0.025 cm) or more. A suitable strippable support which preferably has a high degree of dimensional stability to temperature changes may be chosen from a wide variety of films composed of high polymers, e.g., polyamides, polyolefins, polyesters, vinyl polymers, and cellulose esters and may have a thickness of from 0.0005 inch (0.0013 cm) to 0.008 inch (0.02 cm) or more. If exposure is to be made before removing the strippable support, it must, of course, transmit a substantial fraction of the actinic radiation incident upon it. If the strippable support is removed prior to exposure, no such restrictions apply. A particularly suitable support is transparent polyethylene terephthalate film having a thickness of about 0.0001 inch (0.00025 cm). When an element contains no removable, protective cover sheet and is to be stored in roll form, the reverse side of the strippable support preferable has applied thereto a thin release layer of a material such as wax or silicone to prevent it from sticking to the photopolymerizable material. Alternatively, adhesion to the coated photopolymerizable layer may be preferentially increased by flame treating or electrical discharge treating the support surface to be coated. Suitable removable, protective cover sheets when used may be chosen from the same group of high polymer films described above and may have the same wide range of thicknesses. A cover sheet of 0.0001 inch (0.00025 cm) thick polyethylene is especially suitable. Supports and cover sheets as described above provide good protection to the photopolymerizable layer during storage prior to use. On the other hand, when the dispersion is to be applied as a thick film paste, conventional thick film organic media can be used with appropriate rheological adjustments and the use of lower volatility solvents. When the compositions of the invention are formulated as thick film compositions, they will usually be applied to a substrate by means of screen printing. In this case, the composition is applied as a smooth continuous layer rather than in a pattern. Therefore, the compositions must have appropriate viscosity so that they can be passed through the screen readily. While the rheological properties are of primary importance, the organic medium is preferably formulated also to give appropriate wettability of the solid and the substrate, good drying rate, dried film strength sufficient to withstand rough handling and good firing properties. Satisfactory appearance of the fired composition is also important. In view of all these criteria, a wide variety of inert liquids can be used as organic media. The organic medium for most thick film compositions is typically a solution of organic constituents (binder, monomer, photoinitiator, etc.) in a solvent. The solvent usually boils within the range of 130-350°C. The most widely used solvents for thick film applications are terpenes such as α-or β-terpineol, kerosene, dibutylphthalate, carbitol acetate, butyl carbitol acetate, hexamethylene glycol and high boiling alcohols and alcohol esters or mixtures thereof. Various combinations of these and other solvents are formulated to obtain the desired viscosity and volatility requirements for each application. In accordance with conventional techniques, the final composition may be thioxotropic or possess Newtonian characteristics dependant on the additives introduced into the composition. It is preferred that the composition be Newtonian. The ratio of organic medium to inorganic solids in the dispersions can vary considerably and depends upon the manner in which the dispersion is to be applied and the kind of organic medium used. Normally, to achieve good coverage, the dispersion will contain complementally by weight 50-90% solids and 50-10% organic medium. Such dispersions are usually of semifluid consistency and are referred to commonly as "pastes". The pastes are conveniently prepared on a three-roll mill. The viscosity of the pastes is typically within the range of 25-200 p.s. The amount and type of organic medium utilized is determined mainly by the final desired formulation viscosity and print thickness. The organic medium may include small amounts of other components, e.g., pigments, dyes, thermal polymerization inhibitors, adhesion promoters, such as organosilane coupling agents, plasticizers, coating aids such as polyethylene oxides, etc. so long as the photopolymerizable compositions retain their essential properties. Organosilanes are particularly useful in quantities of 3.0 wt. % or less based on the weight of the inorganic particles. Treated particles have a lower demand for organics. Thus, the level of organics in the coating can be reduced, which results in easier burnout upon firing. Processing The photosensitive copper conductor compositions are conventionally applied to a substrate in the form of a film applied to the substrate or in the form of a paste applied such as by screen printing. Thereafter the copper conductor composition is imagewise exposed to actinic radiation to define areas which have been exposed. Development is achieved by removal of the unexposed areas of the layer. For aqueous development the composition will be removed in portions which are not exposed to radiation but exposed portions will be substantially unaffected by using a liquid such as wholly aqueous solutions containing 0.8% sodium carbonate by weight. In the present disclosure, it is understood that in actual use, development need not be with 0.8% by weight sodium carbonate solutions, e.g., aqueous solutions of other alkalies may be employed. However, the compositions of the present invention have the capability of development in such carbonate solutions. Generally development takes place within 0.25 to 2 minutes. Other processing steps which may be conventional can take place before a firing operation takes place. Firing is done to volatilize organic components and to sinter the inorganic binder and gold solids. Firing of the photosensitive copper conductor compositions can take place in a substantially nonoxidizing atmosphere. By the term "substantially nonoxidizing atmosphere" is meant an atmosphere which contains insufficient oxidant to effect any significant oxidation of copper metal, but which nevertheless contains sufficient oxidant to effect oxidation of the organic materials. In practice, it has been found that a nitrogen atmosphere of 10-200 ppm O₂ can be used for firing the conductor compositions of the invention. In addition, an atmosphere of CO and CO₂ may be used as described in U.S. patent application Ser. No. 235273, filed August 23, 1988. EXAMPLES In the following examples all concentrations are in parts by weight and degrees are in centigrade unless otherwise indicated. Component Materials A. Inorganics Glass Frit: (component mole %) bismuth oxide (82.0) lead oxide (11.0), boron oxide (3.5), silicon dioxide (3.5) Copper: Spherical copper, particle size 1.5-7.5 µm. B. Polymeric Binder Binder: Copolymer of 75% methylmethacrylate, and 25% methacrylic acid, Mw=7000, Tg=120°C, acid No. 164. C. Monomers Monomer I: TEOTA 1000 - Polyoxyethylated trimethylolpropane triacrylate, MW 1162. Monomer II: TMPTA - Trimethylolpropane triacrylate, D. Solvents Butyl carbitol acetate E. Initiators BP: Benzophenone MK: Michler's ketone F. Stabilizers Ionol: 2,6-di-tert-butyl-4-methylphenol Benzotriazole G. Dispersant A-B Dispersant I - see description above A-B Dispersant II - see description above. PREPARATION OF PHOTOACTIVE AQUEOUS PROCESSABLE PASTE A. Preparation of Organic Vehicle Organic components, solvent and binder polymer were mixed and heated with stirring to 120°C and heating and stirring continued until all the binder polymer had dissolved. The solution was then cooled to 90°C and the initiator and stabilizer added. This mixture was then stirred at 90°C until the solids had dissolved, after which the solution was passed through a 400 mesh filter and allowed to cool. The vehicle used had the following composition with concentration in parts: B. Preparation of Glass Frit The glass frit, 8 kg, was milled in 8 liters of water in a Sweco Mill using 0.5 in (1,27 cm) diameter by 0.5 in (1,27 cm) long alumina cylinders for approximately 16 hours to achieve a D50 particle size distribution of 2.3-2.7 microns. The frit water mixture was then passed through an S. G. Franz Model 241F2 Magnetic Separator at a DC setting of 11.5v and 30 amps. The glass frit mixture was then freeze dried using a Virtis Consol 12 Freeze Drier. This procedure usually required three days to remove all the water. C. Paste Formulation The copper paste was prepared under yellow light by mixing the organic vehicle, monomer or monomers, and dispersant into a mixing vessel. The glass frit and copper powder were then added. The composition was then mixed for 30 minutes. The mixture was aged for approximately 12 hours and then roll milled using a three roll mill, at a roll pressure of 150 psi (1034 kPa). Usually five passes through the mill were sufficient to thoroughly mix the composition. The paste was then screened through a 400 mesh screen. The paste viscosity at this point could be adjusted with carbitol acetate solvent to achieve a viscosity optimum for screen printing. D. Process Conditions Care was taken to avoid dirt contamination in the process of preparing coating compositions and in preparing parts since such contamination can lead to defects. The process work was done in a class-100 clean room. The paste was applied to ceramic parts by screen printing using 325-400 mesh screen. The parts were dried at between 75 and 100°C in a nitrogen atmosphere oven. The dried coating had a thickness of 16-20 microns. The parts were exposed through a phototarget with either a Berkey-Askor vacuum printer or a collimated HTG UV exposure source, using a 15 second nitrogen purge and a 15 second drawdown in the vacuum printer. The optimum exposure time was determined from an exposure series that yielded information on the best exposure to yield the correct size lines after development. The exposed parts were developed using a Du Pont ADS-24 Processor containing 0.8% by weight sodium carbonate as the developer. The temperature was maintained at 20-45°C. The sodium carbonate developer solution was sprayed at 30 psi (206,8 kPa) for a development rate of 3.4-15 ft/minute (1,04-4,57 m/min) through a 4 ft (1,22 m) chamber. The developed parts were dried in a forced draft oven at 75°C for 15 minutes. The dried parts were fired in a nitrogen atmosphere containing 10-50 ppm oxygen at 900°C for 2 and 1/2 hours. The resolution was determined from parts exposed through the test target as the finest line spacing for which the lines were straight and non-overlapping and which could be achieved reproducibly. The photospeed was determined by measuring the light intensity at the surface of the dried photosensitive conductor composition with a light meter and multiplying by the time required for optimum exposure. Examples 1-5 Parts were made as described above using the compositions given below. In all cases it was possible to achieve 1 mil (0,25 µm) line resolution and the photospeed was 750-1500 mj/square cm. Example 6 Parts were made as described above using the composition of Example 6. The resistance was determined using a Fluke® Multimeter and was found to be 4.0 milliohms per square.

Claims: An aqueous developable photosensitive copper conductor composition which is fireable in a substantially nonoxidizing atmosphere comprising an admixture of: (a) finely divided particles of copper solids having a surface area-to-weight ratio of no greater than 20 m²/g and at least 80 percent by weight of the particles having a size of 0.5-10 µm and (b) finely divided particles of an inorganic binder having a glass transition temperature in the range of from 550 to 825°C, a surface area-to-weight ratio of no greater than 10 m²/g and at least 90 wt. % of the particles having a size of 1-10 µm, the weight ratio of (b) to (a) being in a range from 0.0001 to 0.25, dispersed in an organic vehicle comprising (c) an organic polymeric binder, (d) a photoinitiation system, (e) photohardenable monomer, (f) an organic medium wherein the improvement comprises the organic polymeric binder is a copolymer or interpolymer comprising (1) a nonacidic comonomer comprising a C₁-C₁₀ alkyl acrylate or C₁-C₁₀ alkyl methacrylate, styrene, substituted styrene or combinations thereof and (2) an acidic comonomer comprising an ethylenically unsaturated carboxylic acid, wherein the acidic comonomer comprises at least 15 weight percent of the polymer with the proviso that the acidic comonomers comprise at least 15 weight percent of the polymer wherein the organic polymeric binder has a molecular weight no greater than 50,000 and wherein the composition upon imagewise exposure to actinic radiation is developable in an aqueous solution containing 0.8 percent by weight sodium carbonate. The composition of claim 1 wherein the organic polymeric binder is a copolymer of methylmethacrylate. The composition of claim 1 wherein the acidic comonomer comprises less than 30 percent by weight of the binder. The composition of claim 3 wherein the molecular weight of the organic polymeric binder is no greater than 25,000. The composition of claim 4 wherein said molecular weight is no greater than 15,000. The composition of claim 1 wherein the organic medium is carbitol acetate. The composition of claim 1 wherein the organic medium contains a dispersant. A method of making an aqueous developable photosensitive copper conductor composition which is fireable in a substantially nonoxidizing atmosphere comprising an admixture of: (a) finely divided particles of copper solids having a surface area-to-weight ratio of no greater than 20 m²/g and at least 80 wt. % of the particles having a size of 0.5-10 µm and (b) finely divided particles of an inorganic binder having a glass transition temperature in the range of from 550 to 825°C, a surface area-to-weight ratio of no greater than 10 m²/g and at least 90 wt. % of the particles having a size of 1-10 µm, the weight ratio of (b) to (a) being in a range from 0.0001 to 0.25, dispersed in an organic vehicle comprising (c) an organic polymeric binder, and (d) a photoinitiation system, dissolved in (e) photohardenable monomer, and (f) an organic medium the improvement comprising the organic polymeric binder is a copolymer or interpolymer comprising (1) a nonacidic comonomer comprising a C₁-C₁₀ alkyl acrylate or C₁-C₁₀ alkyl methacrylate, styrene, substituted styrene or combinations thereof and (2) an acidic comonomer comprising an ethylenically unsaturated carboxylic acid, wherein the acidic comonomer comprises at least 15 weight percent of the polymer with the proviso that the acidic comonomers comprise at least 15 weight percent of the polymer wherein wherein the organic polymeric binder has a molecular weight no greater than 50,000 wherein the composition upon imagewise exposure to actinic radiation is developable in an aqueous solution containing 0.8 percent by weight sodium carbonate, and further wherein prior to mixing of the components, component (b) of finely divided particles of an inorganic binder is freeze dried. The method of claim 8 wherein the organic medium contains a dispersant.

Inventors: NEBE WILLIAM JOHN, OSBORNE JAMES JERRY, NEBE, WILLIAM JOHN, OSBORNE, JAMES JERRY
Applicants: DU PONT, E.I. DU PONT DE NEMOURS AND COMPANY
Application year: 1990
Main classification: G03F7
IPC codes: H05K3, H01B1, C08K3, G03F7, H05K1, C08L101