Morphology-controlled synthesis of polymethylsilsesquioxane (PMSQ) microsphere and its applications in enhancing the thermal properties and flow improving ability of ethylene-vinyl acetate copolymer

Preparation and Characterization of Narrow Size Distribution PMSQ Microspheres for High-Frequency Electronic Packaging

Polymethylsilsesquioxane (PMSQ) has become a kind of widely studied filler used in the electronic circuit board substrates due to its organic-inorganic hybrid structure, low dielectric constant, and good thermal stability, among other factors. Herein, the PMSQ microspheres were prepared by a two-step acid-base-catalyzed sol-gel method; the influences of reaction conditions including the ratio of water/methyltrimethoxysilane (MTMS), reaction temperature, concentration of the catalyst, and stirring time were systematically investigated; and the optimized reaction condition was then obtained towards a narrow particle size distribution and good sphericity. The microstructure of PMSQ microspheres was analyzed by the infrared spectrum and X-ray diffraction (XRD), which indicated that the as-prepared PMSQ had a ladder-dominant structure. The thermogravimetric analysis (TGA) demonstrated an excellent thermal stability of as-prepared PMSQ microspheres. More specifically, the dielectric constants at high frequency (1~20 GHz) of as-prepared PMSQ microspheres were measured to be about 3.7, which turned out a lower dielectric constant compared to SiO₂ powder (≈4.0). This study paves the way to further improve the performance of the electronic circuit board substrates for the application of high-frequency electronic packaging.

Formation Mechanism of Monodispersed Polysilsesquioxane Spheres in One-Step Sol-Gel Method

Monodispersed polysilsesquioxane (PSQ) spheres with diameters from hundreds of nanometers to several microns have been successfully synthesized; however, the knowledge of their formation mechanism still lags behind. Herein, with methyltrimethoxysilane and 3-mercaptopropyl trimethoxysilane as model silicon sources, the formation process of PSQ spheres in the one-step sol-gel method was revealed for the first time by monitoring the time evolution of particle morphology, size, and size distribution via transmission electron microscopy and dynamic light scattering. A four-stage formation mechanism was proposed: rapid hydrolysis of organic silicon source and subsequent oligomer micelle nucleation, fast growing of nuclei particles and formation of their aggregates, followed by a further relatively fast growth of dispersed particles, and finally a slow growth to form monodispersed PSQ spheres. Due to the reversibility of hydrolysis and condensation reactions, thermodynamically unstable particles gradually transformed to hydrolytic monomers/oligomers and then regrew on the thermodynamically stable particles until the concentration of hydrolytic oligomers reached the dissolution equilibrium in the alkaline reaction solution. The variation of growth rate during the formation process and the effects of NH₄OH concentration on the yield and particle size were investigated to facilitate analyses and understanding of the formation mechanism.