Dri-film

First planar integrated circuits fabricated r Electron beam lithography demonstrated Dry film laminate resist introduced... 

Dry-Film Resists Based on Radical Photopolymerization. Photoinitiated polymerization (PIP) is widely practiced ia bulk systems, but special measures must be taken to apply the chemistry ia Hthographic appHcations. The attractive aspect of PIP is that each initiator species produced by photolysis launches a cascade of chemical events, effectively forming multiple chemical bonds for each photon absorbed. The gain that results constitutes a form of "chemical amplification" analogous to that observed ia silver hahde photography, and illustrates a path for achieving very high photosensitivities. 

Fig. 8. Protection of a plated through-hole in a PWB during etching by using a tenting dry-film photoresist.

One potential approach extends the idea of chemical amplification introduced in our preceding description of dry-film resists. In 1982, Ito and co-workers (37,38) recognized that if a photosensitizer producing an acidic product is photolyzed in a polymer matrix containing acid-labile groups, the acid will serve as a spatially localized catalyst for the formation or cleavage of chemical bonds. 

Natural Gums. These were used in early styling products, formerly called wave sets. Natural gums generally make hazy solutions and the dried film tends to flake. For these reasons they are rarely used. Some of these gums, eg, tragacanth and alginates, can create humidity-resistant films and have limited use for specific product concepts. 

AppHcation of an adhesion-promoting paint before metal spraying improves the coating. Color-coded paints, which indicate compatibiHty with specific plastics, can be appHed at 20 times the rate of grit blasting, typically at 0.025-mm dry film thickness. The main test and control method is cross-hatch adhesion. Among the most common plastics coated with such paints are polycarbonate, poly(phenylene ether), polystyrene, ABS, poly(vinyl chloride), polyethylene, polyester, and polyetherimide. 

Drum Drying. The dmm or roHer dryers used for milk operate on the same principles as for other products. A thin layer or film of product is dried over an internally steam-heated dmm with steam pressures up to 620 kPa (90 psi) and 149°C. Approximately 1.2—1.3 kg of steam ate requited per kilogram of water evaporated. The dry film produced on the roHer is scraped from the surface, moved from the dryer by conveyor, and pulverized, sized, cooled, and put iato a container. 

Chemical modification of the wax can improve smear resistance (5). Sihcones, which do not harm furniture finishes (6), are incorporated as film-forming ingredients in furniture pohshes. The lubricant properties of sihcones improve ease of apphcation of the pohsh and removal of insoluble soil particles. In addition, sihcones make dry films easier to buff and more water-repeUent, and provide depth of gloss, ie, abihty to reflect a coherent image as a result of a high refractive index (7). Wax-free pohshes, which have sihcones as the only film former, can be formulated to dehver smear resistance (8). Another type of film former commonly used in oil-base furniture pohshes is a mineral or vegetable oil, eg, linseed oil. 

One-step clean-and-shine products have become popular in the household market. These products are appHed to the floor with a sponge mop and their detergent action removes and suspends soil, which coUects on the mop and is removed when the mop is rinsed with water. The formulation, which remains on the floor, dries to a poHsh film. An earlier product of this type was dispensed from an aerosol as a foam. Formulas as of this writing (ca 1995) are appHed as Hquids (29,30). In one product, the dried film obtained from the formulation is soluble in the formulation, which includes low molecular weight, high acid polymers and a fairly large amount of ammonia (31). Repeated use does not contribute to a buildup of poHsh. 

The characteristics of soluble sihcates relevant to various uses include the pH behavior of solutions, the rate of water loss from films, and dried film strength. The pH values of sihcate solutions are a function of composition and concentration. These solutions are alkaline, being composed of a salt of a strong base and a weak acid. The solutions exhibit up to twice the buffering action of other alkaline chemicals, eg, phosphate. An approximately linear empirical relationship exists between the modulus of sodium sihcate and the maximum solution pH for ratios of 2.0 to 4.0. 

Dried film (0.025 mm) oa paper cast from 10 wt % resia ia 60 40 tolueae ethanol heat sealer dwell time, 1.5 s at 0.4 MPa (60 psi). 

Graphite lubricants include the dry powder, admixtures with liquid lubricants or greases, volatile liquids compounded with film-forming substances to produce bonded dry films, synthetic resins and powder metal compositions containing graphite for bearings, and finely divided suspensions in liquids (colloidal graphite). 

A water-reducible coating or resin is one that is diluted with water before use. Water-reducible alkyds give comparable drying performance to solvent-bome alkyds. However, they are not widely used because film properties tend to be poorer than those of solvent-bome alkyds, especially in air-dry systems (26). This is pardy because of alcoholysis of the alkyd by primary alcohols such as 1-butanol [71-36-3] C H qO, a common solvent in water-reducible alkyds (27,28) secondary alcohols such as 2-butanol [78-92-2] C qH O, minimize this problem (27). In any case, the slow loss of amine or ammonia leads to short-term high sensitivity to water. Even in the fully dry films, the presence of unreacted carboxyHc acid groups leads to films having comparatively poor water resistance limiting their usehilness. 

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