60/193, 356, filed March 29,2000.

Field of the Invention This invention relates to thermally reworkable epoxy resin compositions, and more particularly to thermally reworkable carbamate or carbonate epoxide resin compositions which degrade at temperatures significantly lower than traditional cycloaliphatic epoxy resins.

BACKGROUND OF THE INVENTION In the field of electronic packaging and, in particular, the field of integrated circuit (IC) chip interconnection, the desirability of incorporating high input/output (I/O) capability and short IC interconnects, among others, typically has led to the adoption of the flip-chip technique of IC chip interconnection. Generally, the flip-chip technique involves electrically interconnecting an IC chip and a substrate with the use of solder joints which are disposed between the IC chip and the substrate.

As initially practiced, the flip-chip technique oftentimes utilized relatively high cost materials, such as high lead solder and ceramic substrate. However, the desire to reduce costs has prompted the use of less expensive materials, such as flip-chip on board (FCOB), which typically utilizes eutectic solder and organic printed wiring board (PWB). While reducing material costs, the use of FCOB packaged systems has accentuated the problem of coefficient of thermal expansion (CTE) mismatch between the IC chip and the organic substrate of the FCOB, particularly when large IC chips and fine pitch, low profile solder joints are utilized.

Due to the CTE mismatch between silicon IC chips (2.5 ppm/°C) and organic substrates, i. e., FR-4 PWB (18-24 ppm/°C), temperature cycle excursions experienced by the FCOB generate tremendous thermo-mechanical stress at the solder joints and, subsequently, can result in performance degradation of the packaged system.

It is also known in the prior art to fill the spaces or gaps remaining between an IC chip and substrate which are not occupied by solder with an underfill composition. The

undefill is an adhesive, such as a resin, that serves to reinforce the physical and mechanical properties of the solder joints between the IC chip and the substrate. The underfill typically not only provides fatigue life enhancement of a packaged system, but also provides corrosion protection to the IC chip by sealing the electrical interconnections of the IC chip from moisture, oftentimes resulting in an improvement in fatigue life of ten to over one hundred fold, as compared to an un-encapsulated packaged system.

Heretofore, cycloaliphatic epoxies, typically combined with organic acid anhydrides as a hardener, have been used in flip-chip packaged systems as an underfill. This is primarily due to the low viscosity of cycloaliphatic epoxies prior to curing, as well as their acceptable adhesion properties after curing. Other epoxies such as bisphenol A or F type or naphthalene type can also be used in the underfill formulations. Additionally, silica has been utilized as a filler in these underfill formulations, i. e., up to 70% (by weight), in order to lower the CTE of the epoxy resin. By way of example, the material properties represented in Table 1 typically are exhibited by typical prior art epoxy underfill compositions.

Table 1 Typical Underfill Properties SolidsContent 100% Form Single component, pre-mixed Coefficient of Thermal Expansion (ot,) 22-27 ppm/oC Tg > 125 °C CureTemperature < 165 oC Cure Time < 30 min. Working Life ((gi, l 25°C, visc. Double) > 16 hrs. Viscosity (@ 25°C) < 20 kcps FillerSize 95% < 15 um FillerContent < 70 wt % Alpha Particle Emission < 0.005 counts/cm2/hr. Hardness (Shore D) >85 Modulus 6-8 Gpa Fracture Toughness > 1.3 Moa mi4 Volume Resistivity (aì), 25°C) > 1013 ohm-cm Dielectric Constant (@ 25°C) <4. 0 Dissipation Factor (@ 250C, 1 kHz) < 0.005 Extractable Ions (e. g. Cl, Na, K, Fe, etc.) < 20 ppm total Moisture Absorption (8 hrs. boiling water) < 0. 25% Frequently, defects in a chip or circuit board are not discovered until after assembly of an electrical component using an underfill adhesive. Heretofore, it has generally been

commercially impractical to separate and clean the chip and/or board so that the non- defective components can be reused. This results in increased production costs due to the waste of otherwise usable components. An effective way to address this problem is to make the flip-chip devices reworkable under certain conditions.

One method which has been developed in an attempt create a reworkable flip-chip device has been to incorporate a non-stick release coating on the boundary surface between a chip and a substrate. For example, U. S. Patent No. 5,371,328 discloses a reworkable flip- chip type of circuit module using a non-stick release coating on all surfaces intermediate of the chip and the substrate. While this non-stick release coating may be suitable in some applications, it is likely that the use of such a release coating may reduce the adhesion of all the interfaces including those of the underfill to chip and underfill to substrate. These adhesions are important to the reliability of the flip-chip interconnections. Accordingly, this approach is not ideal for use in flip-chip applications.

Another approach to providing a reworkable flip-chip interconnection is to use a reworkable underfill. Presently, the materials that are undergoing development for reworkable underfills can be classified into two categories: chemically reworkable underfills and thermally reworkable underfills.

Chemically reworkable underfills generally require the use of harsh acids and/or bases. For example, U. S. Patent No. 5,560,934, issued to Afzali-Ardakani et al., discloses epoxy compositions that are soluble in an organic acid after curing. Utilizing relatively strong chemicals such as acids (or bases) during reworking, however, oftentimes leads to a messy, time-consuming rework process. Additionally, it has been found that the use of chemicals during the rework process typically makes localized repair of a packaged system difficult and, sometimes, impossible. Therefore, it is believed that use of a thermal rework process would avoid these problems and offer the possibility of a quick, clean, and localized rework process.

U. S. Patent No. 5,659,203, issued to Call et al., discloses a reworkable flip-chip module utilizing a specially defined thermoplastic resin as an encapsulant. The thermoplastic resin, such as polysulfone, polyetherimide, etc., possesses a high glass transition temperature (Tg), e. g., 120°C< Tg < 220°C, and must be either dissolved in a solvent or heated above its melting point during the encapsulation process. Therefore, use of these thermoplastic resins as encapsulants for FCOB applications may be undesirable, since such applications typically require an underfill which is free of solvent and in liquid form during the encapsulation

process, and typically require keeping the packaged system at lower temperatures in order to maintain the integrity of the eutectic solder which is utilized with the organic PWB.

U. S. Patents No. 6,197,122 and 5,948,922, issued to Ober et al., disclose thermally reworkable underfill formulations based on thermally decomposable epoxies containing secondard or tertiary oxycarbonyl (ester) moiety. However, secondard or tertiary oxycarbonyl moiety typically can easily be cleaved by weak acid or base, and is sensitive to moisture.

Also the epoxies containing the secondard or tertiary oxycarbonyl typically have higher moisture uptake than a standard epoxy. All these facts indicate that epoxies containing secondard or tertiary oxycarbonyl moiety might not be suitable for underfill application where high reliability is required.

Thus, it can be seen that none of the prior art methods are ideally suited for use as an underfill to bond chip and substrate to allow fast and efficient rework of FCOB devices without sacrificing the reliability of the devices. Therefore, it is desirable to provide an underfill composition that will not negatively affect the overall performance of the assembly, while still allowing cost effective and efficient rework.

SUMMARY OF THE INVENTION Accordingly, it is an object of this invention to provide a polymeric composition that has properties suited to use as an underfill while also offering thermal reworkability. The present invention is focused on epoxy base materials because epoxy base materials have desirable properties for use as an underfill and are the only materials that have been proven to provide flip-chip devices with acceptable reliability.

Most epoxy materials are thermosetting compositions and are difficult or impossible to remove after curing. The present invention overcomes this limitation by developing new diepoxides that contain thermally degradable groups within their structures and using these new diepoxides in the epoxy formulations to make the thermoset network degradable at a desired temperature. This makes the new epoxy formulations reworkable. Moreover, these thermally degradable groups have good properties such as high moisture resistance, high chemical resistance and low moisture uptake so that they are suitable for underfill application. This improvement is advantageous in flip-chip application of epoxy compositions where epoxy materials are used as the underfill to reinforce the solder joints.

Removal of the epoxy allows replacement of defective devices, saving the cost of discarding other valuable components in a microelectronic assembly.

There are two ways of developing reworkable epoxy base materials. One is to develop new epoxies that decompos at rework temperature. The other is to develop additives to add into the existing epoxy formulations that have previously been found suitable for use as underfill encapsulants. The present invention focuses on the first category and uses thermally degradable epoxies containing integral thermally cleavable groups that decompose at rework temperatures. The second category is the subject of U. S. Patent No. 6,172,141.

The thermally cleavable groups of the present invention have been selected to meet the following criteria: 1. The cleavable groups should be sufficiently stable to permit the epoxy network to perform its function in a specific application ; 2. The cleavable groups should be inert to the curing reaction of the epoxy network; 3. The cleavable groups should not adversely affect the overall properties of the epoxy network; 4. The cleavable groups should decompose quickly at elevated temperature so that they break down the structure of the epoxy network, leading to its easy rework.

5. The link should be stable in the environment to which the cured epoxy will be exposed.

6. The synthesis of the epoxides containing the cleavable link should be simple, with high yield, and cost effective.

The present invention discloses carbonate and carbamate epoxides which have been found to meet the above criteria. After introduction into the epoxy structure, the carbamate and carbonate groups do not significantly interfere with epoxy curing, nor do they adversely affect epoxy properties including Tg, modulus, CTE, adhesion. However, the existence of these groups inside the epoxy structure reduces the epoxy decomposition temperature from 350°C to as low as 200°C. Optimal rework temperatures for flip-chip devices are generally between 200 and 250°C because the eutectic solder reflow temperature is within this temperature region. Therefore, these two groups may be suitable for use in applications needing an epoxy which is reworkable around solder reflow temperature.

More particularly, the present invention is directed to a thermally reworkable epoxy composition for encapsulating and protecting an electronic device or assembly. The

thermally reworkable epoxy composition includes the cured reaction product of : a cycloaliphatic epoxide containing either a carbonate or a carbamate group; an organic hardener ; and a curing accelerator. The present invention is also direct to a method of protecting, encapsulating, reinforcing, assembling, or fabricating a device or a chemical product with a cured epoxy composition which is thermally reworkable, wherein the epoxy composition includes the reaction product of : a thermally degradable cycloaliphatic epoxide ; an organic hardener; and a curing accelerator.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a graph illustrating DCS scan data for EpoO and Epocarbl through Epocarb4.

FIG. 2 is a graph illustrating the normalized FT-IR absorbance of Epocarb2 from room temperature to 250°C at a heating rate of 10°C/min.

FIG. 3 is a graph illustrating the normalized FT-IR absorbance of Epocarb2 from 250°C to 350°C at a heating rate of 10°C/min.

FIG. 4 is a graph illustrating TGA curves for EpoO and Epocarbl through Epocarb4.

FIG. 5 is a graph illustrating a Tg-exposure temperature plot for Epocarbl and Epocarb2.

FIG. 6 is a graph illustrating the relative adhesion of EpoO and Epocarbl through Epocarb4.

FIG. 7 is a graph illustrating Moisture Uptake Data of EpoO, Epocarbl and Epocarb2.

FIG. 8 is a graph illustrating DSC cooling curves of EpoxyO and Epouretl through Epouret3.

FIG. 9 is a graph illustrating DSC cooling curves of Epouret4 through Epouret7.

FIG. 10 is a graph illustrating TGA curves of EpoxyO and Epouretl through Epouret3.

FIG. 11 is a graph illustrating TGA curves of Epouret4 through Epouret7.

FIG. 12 is a temperature profile of a thermocouple on the board during chip removal testing.

FIG. 13 is a schematic of an accessory designed for flip-chip rework.

FIG. 14 illustrates FT-IR spectra of a clean board and a board after cleaning

DETAILED DESCRIPTION The following illustrative embodiments describe the thermally degradable epoxy underfills of the invention and are provided for illustrative purposes and are not meant as limiting the invention.

Generally, the reworkable epoxy compositions of the present invention include: a cycloaliphatic epoxide containing either carbonate or carbamate group; an organic hardener; and a curing accelerator. The compositions of the present invention may also include : a silane coupling agent; a rubber toughening agent; and/or silica filler. In accordance with the exemplary embodiments of the present invention, the cycloaliphatic epoxide used may contain either a carbonate or a carbamate group. The structures of several thermally degradable epoxy resins containing a carbonate group, Carbl through Carb4, are shown below in accordance with the present invention. Among these epoxides, Carb3 is a monoepoxide while all others are diepoxides. 0 oy-o Carbl CRsSowRocco O Carbl 0 CH3 o@EXCh sOf 0 O Carb2 o CH3 c \y ' [r>o Carb3 Carb3 cars3 fl I \0^11 CHEZ Carb4

Likewise, the structures of several thermally degradable diepoxides containing a carbamate (urethane) group, Uretl through Uret7 are illustrated below in accordance with the present invention. TUT o<YfPo o Uret2 0 O aN\ CSjCBhIB-So,, . ,,. 0 0 Uret3 CH2M-, OCH : Co Uret3 CE, c cC4wC ßNH/\owC49 Uret5 coq ? o c"Cli o o cl C Uret6 o. J r c cij/CC4 Uret6 The properties of several of the compounds are set forth in more detail in the following sections.

EXAMPLE 1 This example discloses the synthesis of Carbl.

1) Synthesis of di-cyclohex-3-enylmethyl carbonate Triphosgene (4.40g) was dissolved in methylene chloride (80 ml), and added slowly to the methylene chloride solution (200 ml) of 3-cyclohexene-1-methanol (9.2 ml), and pyridine (16 ml). The addition was finished in 1 hr. Then the mixture was kept refluxing for 7

hrs, washed with 0.5 M HCl solution (100 ml), 5% sodium bisulfite (500 ml), 2.5% sodium bicarbonate (500 ml), dried with magnesium sulfate, filtered and evaporated to give a 76 % yield of liquid product identified by IR and NMR. IR (neat): 3024,2916,2839,1747,1402, 1259,962,751,656 cm~l. lH NMR (CDC13) : 8 5.6 (s, 4H, =CH), 4.0 (d, 4H, CH2O), 2.2-1.9 (complex m, 8H, CH2), 1. 8-1. 6 (complex m, 4H, CH2), 1.4-1.2 (complex m, 2H, CH) ppm.

2) Synthesis of di-3, 4-epoxycyclohexylmethyl carbonate (Carbl) Di-cyclohex-3-enyhnethyl carbonate (9.80 g) was dissolved in methylene chloride (75 ml) and acetone (75 ml) in a four-neck flask equipped with a mechanical stirrer, a pH meter and two adding funnels. A pH 7.5/0.1 M phosphate buffer (50 ml) and an 18-crown-6 crown ether (0.75 g) were then added into the mixture. The mixture was stirred in an ice bath to reduce its temperature to below 5°C before the start of the simultaneous addition of a 0.5 M KOH aqueous solution and a solution of OXONE (potassium peroxymonosulfate, 36.9 g in 200 ml water containing 0.05 g of ethylenediaminetetraacetic acid). Rapid stirring was continued throughout the addition, and the temperature was kept below 5°C all the time. The relative addition speed of the two solutions was adjusted to keep the pH of the reaction mixture in between 7 and 8. Addition of the OXONE solution was completed in 2 hrs, followed by additional 3.5 hrs of stirring, and the pH was maintained in the above range by a slow addition of 1.0 M KOH. Then the organic phase was isolated, dried with magnesium sulfate, filtered and evaporated to give a 90% yield of the liquid diepoxide identified by IR and NMR. IR (neat): 2930,1744,1403,1259,960,790 cm-'H NMR (CDC13, in ppm): S 4.0-3.8 (m, 4H, CH20), 3.1 (d, 4H, CH on epoxide ring), 2.1-0.9 (complex m, 14H, CH2+CH) ppm. The synthesis scheme for Carbl is diagrammed below: 0 O CH2.. 0. C.., O.,.-CH2 OZONEC13COCOCC1 I'r' o '", ,. a osorE CH2. -G,. p. CH

EXAMPLE2 This example discloses the synthesis of Carb2 1)Synthesis of di-1-(3-cyclohexenyl) ethyl carbonate The same procedure as of di-cyclohex-3-enylmethyl carbonate was followed except that the alcohol used is 1- (3-cyclohexenyl)- 1-ethanol instead of 3-cyclohexene-1-methanol.

The yield was 80%. Its structure was identified by IR and NMR. IR (neat): 3024,2918,2839, 1739,1438,1378,1263,1141,1035,920,658 cm~l. IH NMR (CDC13) : 8 5.6 (s, 4H, =CH), 4.6 (m, 2H, CHO), 2.2-1.9 (complex m, 8H, CH2), 1.8-1.6 (complex m, 4H, CH2), 1.4-1.2 (complex, 8H, CH3+CH) ppm.

2) Synthesis of di-l- (3, 4-epoxycyclohexenyl) ethyl carbonate (Carb2) Following the same epoxidation procedure as for CARB1, a liquid with 89% yield was obtained which was identified by IR and NMR. IR (neat): 2984,2938,1736,1436, 1363,1268,1058,1030,927,794,736 cm~l. lH NMR (CDC13) : S 4.6 (m, 2H, CHO), 3.1 (d, 4H, CH on epoxide ring), 2.1-0.9 (complex m, 20H, CH3+CH2+CH) ppm.

EXAMPLE 3 This example discloses the synthesis of Carb3.

1) Synthesis of cyclohex-3-enylmethyl t-butyl carbonate Triphosgene (4.40g) was dissolved in the methylene chloride solution (50 ml) and cooled in an ice bath. To this solution a methylene chloride solution (50 ml) of 3- cyclohexene-1-methanol (4.6 ml) and pyridine (8 ml) was slowly added. The addition was finished in 1 hr. Then the mixture was kept stirring for 4 hours in the ice bath during which 3-cyclohexene-1-methyl chloroformate was formed.

To the above mixture a methylene chloride solution (50 ml) of 2-methyl-2-propanol (3.0 ml) and pyridine (8 ml) was then added in one protion. The mixture was then stirred at room temperature for overnight. It was washed with 0. 5 M HC1 solution (100 ml), 5% sodium bisulfite (500 ml), 2.5% sodium bicarbonate (500 ml), and dried with magnesium sulfate. The organic phase was then concentrated and purified with column chromatography on silica gel with methylene chloride to give a 47% yield of the product as a colorless liquid identified by IR and NMR. IR (neat): 3025,2918,2840,1743,1396,1259,1165,961,858, 739,656 cm~l. tH NMR (CDC13) : 8 5.6 (s, 2H, =CH), 4.0-3.8 (d, 2H, CH20), 2.2-1.2 (complex m, 7H, CH2+CH), 1.4 (s, 9H, CH3) ppm.

2) Synthesis of 3, 4-epoxycyclohexylmethyl t-butyl carbonate (Carb3) Following the same epoxidation procedure as for Carbl, a liquid with 89% yield was obtained which was identified by IR and NMR. IR (neat): 2982,2933,1743,1255,1163, 859,790 cm~l. lH NMR (CDC13) : 8 4.0-3.8 (m, 2H, CHO), 3.2 (d, 2H, CH on epoxide ring), 2.2-1.0 (complex m, 7H, CH2+CH), 1.4 (s, 9H, CH3) ppm. The synthesis scheme for Carb3 is diagrammed below: 0 CH20H triphosgene mCH2so, pyridine, ice bath t-butyl alcohol 0H3 CH-CH. XON O O I c3 oH3CH3 040/°'°'& 3 EXAMPLE4 This example discloses the synthesis of Carb4.

1) Synthesis of 4-vinylphenyl 2-(3-methyl-3-cyclohexenyl)-2-propyl carbonate In a 250 ml three-necked round-bottomed flask equipped with a dropping funnel, a nitrogen bubblier and a magnetic stirring bar, triphosgene (1.0 g) in methylene chloride solution (50 ml) was placed. The temperature was lowed to 0°C with ice bath. A methylene chloride solution (50 ml) of 4-vinyl phenol (1. 2 g) and pyridine (8 ml) was added dropwise over 30 min from the dropping funnel. The resulting mixture was stirred at 0-5°C for 8 hr and the reaction proceeding was monitored with TLC till all 4-vinyl phenol was converted to 4-vinylphenyl chloroformate.

The resulting mixture above was used directly without treatment and the same reaction system was used continuously. The dropping funnel on the flask was charged of a- terpineol (7.7 g) and quinoline (6.5 g). The formed solution was added dropwise to the reaction system at room temperature over vigorous stirring. The mixture was stirred over night and a white salt gradually precipitated. The salt was separated and the organic phase was washed with 2 N HC1 and water until all pyridine and quinoline were neutralized and

washed out. The organic phase was separated, washed with sodium bicarbonate and sodium bisulfite solution, and then dried over anhydrous magnesium sulfate. The column chromatography of the products on silica gel with 10: 1 hexane/ethyl acetate gave 32% yield of the product as a colorless viscous liquid. FT-IR (neat): 2925,1757,1508,1446,1376, 1264, 1214,1157,1123,1018,990,903,840,809 cm~l.'H NMR (CDC13) : 8 7.40 (d, 2H, aromatic), 7.12 (d, 2H, aromatic), 6.69 (dd, 1H, =CH, aromatic), 5.70 (dd, 1H, =CH2), 5.38 (m, 1H, =CH), 5.24 (dd, 1H, =CH2), 2.19-1. 83 (m, 6H, CH2), 1.66 (s, 3H, CH3) 1.54 (s, 3H, CH3), 1.51 (s, 3H, CH3), 1.44-1.25 (m, 1H, CH) ppm.

2) Synthesis of 4-epoxyethyllphenyl 2- (3-methyl-3, 4-epoxycyclohexyl)-2 propyl carbonate (Carb4) Following the same epoxidation procedure as for Carbl, a viscous colorless liquid with 89% yield was obtained. FT-IR (neat): 2925,1757,1508,1446,1376,1264,1214,1157, 1123,1018,990,903,840,809 cvn~l. lHNMR (CDC13) : 8 7.40 (d, 2H, aromatic), 7.11 (d, 2H, aromatic), 3.70 (dd, 1H, CO), 3.14 (t, 1H, CO), 2.89 (d, 1H, CHO), 2.81 (d, 1H, CHO), 2.12- 1.44 (m, 6H, CH2), 1.62 (s, 3H, 1CH3), 1.52 (s, 3H, 1CH3), 1.50 (s, 6H, 2CH3), 1.42-1.20 (m, 1H, CH) ppm. The synthesis scheme for Carb4 is diagrammed below: 0 OHquinoline, 250C \triphosgene p Cl a-terpineol 1- uc OXONE CH3 aCH3 0 /c\ CH-3 0-I P\O-1 0 ( C-o CH3 CH3 CH3 CH3 EXAMPLE5 This example discloses Epoxide Equivalent Weights (EEWs) of Carbl through

Carb4.

Their EEWs were measured according to ASTM titration procedure D1652-90. Table 1 shows their theoretical and measured EEW values. It can be seen that the measured values were generally in good agreement with the theoretical values.

Table 1 EEWs of Carb 1 through Carb4 Sample EEW (g/mol.) Theoretical Measured Carbl 141 157 Carb2 153 165 Carb3 228 235 Carb4 165. 5 207 EXAMPLE 6 This example discloses the synthesis of Uretl.

1) Synthesis of 3-cyclohexene-1-isocyanate Sodium azide (8. 00 g) was dissolved in water (20 ml) in a 250 ml 3-neck flask. The flask was put in an ice path to control the temperature around 0°C. While the aqueous solution was stirred, benzene solution (100 ml) of 3-cyclohexene-1-carbonyl chloride (8.70 g) was added in dropwise. The addition was completed in about 2 hrs. The mixture was stirred for another 4 hrs, with the temperature around 0°C. Then the aqueous phase was separated from the organic phase, extracted with benzene (50 ml). The two organic phases were combined and dried with magnesium sulfate for several hours. The dried benzene solution was then heated to 50°C in a 250 ml flask in a water bath for several hours until no gas was emitted. The obtained benzene solution of isocyanate was directly used for later synthesis.

2) Synthesis of 3-cyclohexen-1-isocyanate cyclohex-3-enylmethyl carbamate A Benzene solution of isocyanate (65 ml), 3-cyclohexene-1-methanol (3.50 ml), and pyridine (3.00 ml) were mixed in a 250 ml 3-neck flask, refluxing for 6 hrs. Then water (100 ml) was added in. The mixture was refluxed for another 1 hr. The mixture was then washed with 0.05 M HC1 three times, followed by water three times. The organic phase was then separated from the water phase and dried with magnesium sulfate for several hours before benzene was removed by rotary evaporation to give a liquid. It was purified by column

chromatography with 60% yield. This liquid material was identified by its spectra. IR (neat, in cri ') : 3340,3025,2915,2845,2255,1700,1525,1440,1305,1270,1235,1140, 1050, 975,925,875,780,750,720,655.'HNMR (CDC13, in ppm): 8 7.1 (d, m, 1H), 5.7-5.5 (d, s, 4H), 3.8 (d, s, 2H), 3.5 (s, m, 1H), 3.3 (d, s, 2H), 2.2-1.6 (complex, s, 9H), 1.5-1.1 (complex, m, 2H). Its purity was verified by TLC.

3) Synthesis of 3, 4-epoxycyclohexyl-1-isocyanate 3,4-epoxycyclohexylmethyl carbamate (Uretl) 3-cyclohexen-l-isocyanate cyclohex-3-enylmethyl carbamate (9.80 g) was dissolved in methylene chloride (75 ml) and acetone (75 ml) in a four-neck flask equipped with a mechanical stirrer, a pH meter and two adding funnels. A pH 7.5/0.1 M phosphate buffer (50 ml) and an 18-crown-6 crown ether (0.75 g) were then added into the mixture. The mixture was stirred in an ice bath to reduce its temperature to below 5°C before the start of the simultaneous addition of a 0.5 M KOH aqueous solution and a solution of OXONE (potassium peroxymonosulfate, 36.9 g in 200 ml water containing 0.05 g of ethylenediaminetetraacetic acid). Rapid stirring was continued throughout the addition, and the temperature was kept below 5°C all the time. The relative addition speed of the two solutions was adjusted to keep the pH of the reaction mixture in between 7 and 8. Addition of the OXONE solution was completed in 2 hrs, followed by additional 3.5 hrs of stirring, and the pH was maintained in the above range by a slow addition of 1.0 M KOH. Then the organic phase was isolated, dried with magnesium sulfate, filtered and evaporated to give a 92% yield of the liquid diepoxide identified by IR and NMR. IR (neat, in cri') : 3340,2940, 1700,1530,1435,1310,1255,1225,1045,800.'H NMR (CDC13, in ppm): 8 5.0 (d, m, 1H), 4.6 (s, m, 1H), 3.8 (m, m, 2H), 3.6 (s, m, 1H), 3.2-3.0 (m, s, 4H), 2.4-0.9 (complex, 12H).

The synthesis scheme for Uretl is diagrammed below: 0I-CHOH (1. NCO (2). heat'' pyridine H /C ? CH2, r'^., O- /0, acetone H 01_j \C/\CH2/ (> o EXAMPLE 7 This example discloses the synthesis of Uret2.

1)Synthesis of 3-cyclohexen-1-isocyanate 2- (3-cyclohexenyl)-2-propyl carbamate 3-cyclohexen-l-isocyanate 2- (3-cyclohexenyl)-2-propyl carbamate was obtained by following the same procedure as for 3-cyclohexen-l-isocyanate cyclohex-3-enylmethyl carbamate except 2- (3-cyclohexenyl)-2-propanol was used to replace 3-cyclohexen-1- methanol. It was purified by column chromatography with 44% yield. Spectra confirmed the structure. IR (neat, in cm") : 3333,3025,2928,2825,1620,1531,1438,650.'H NMR (CDCl3, in ppm) : 8 5.7-5.5 (d, s, 4H), 3.7 (s, m, 1H), 2.4-1.3 (complex, 14H), 1.2 (m, s, 6H).

Its purity was verified by TLC.

2) Synthesis of 3, 4-epoxycyclohexyl-1-isocyanate 2- (3, 4-epoxyeyclohexyl)-2- propyl carbamate (TJret2) Following the same procedure as for Uretl, a 95% yield of Uret2 was obtained and identified by IR and NMR. IR (neat, in cri') : 3345,2974,2925,1700,1525,1358,802.'H NMR (CDC13, in ppm) : 8 3.6 (s, m, 1H), 3.3-3.0 (d, s, 4H), 2.4-1.3 (complex, 14H), 1.2 (m, s, 6H). EXAMPLE 8 This example discloses the synthesis of Uret3.

24. 1) Synthesis of cyclohex-3-enylmethyl chloroformate 2-(1-cyclohexenyl) ethyl

carbamate To the methylene chloride solution (40 ml) of triphosgene (2.20 g), a methylene chloride solution (60 ml) of 3-cyclohexen-1-methanol (2.40 ml) and pyridine (3.50 ml) was slowly added. The addition was completed in 1 hr. The mixture was then refluxed for 1 hour, cooled down to room temperature, and stirred for another 2 hrs. A yellowish green solution was obtained.

Methylene chloride solution (50 ml) of 2- (1-cyclohexenyl) ethylamine (2.70 ml) and pyridine (3.50 ml) was added into the above mentioned yellowish green solution in one portion. Instantly, the color of the mixture changed from yellowish green to pink. The mixture was refluxed for 2 hrs. Then it was washed with O. 5M HCI, water, 5% sodium bisulfite solution, 2.5% sodium bicarbonate solution, and saturated sodium chloride solution before it was dried with magnesium sulfate, filtered, and evaporated to give a 80% yield of liquid. Its structure was confirmed by the IR and NMR spectra. IR (neat, in cm'') : 3403, 3341,3019,3017,2845,1718,1515,1439,1254,742,653.'H NMR (CDC13, in ppm): 5 5.6 (t, s, 2H), 5. 5-5.3 (m, m, 1H), 4.0 (m, m, 2H), 3.5 (d, s, 2H), 3.3 (d, m, 1H), 2.2-1.2 (complex, 17H). Its purity was verified by TLC.

25. 1) Synthesis of 3, 4-epoxycyclohexylmethyl 2- (1, 2-epoxycyclohexyl) ethyl carbamate (Uret3) Following the same procedure as for Uretl, an 89% yield of Uret3 in the form of a liquid was obtained and identified by IR and NMR. IR (neat, in cm'') : 3345,2932,1708, 1520,1436,1252,735.'H NMR (CDC13, in ppm): 8 5.1 (s, w, 1H), 3.9-3.7 (m, m, 2H), 3.4- 2.9 (complex, 6H), 2.2-0.9 (complex, 16H). The synthesis scheme for Uret3 is diagrammed below: O SCH2CX2NH2 hosgene ii a jr-)-CH20H tr'p b. CH20CCI lb zu CH2/O\C/NH-CH2-CH2OXONE, a Opyridine oCCH2wz \C/NHzH2CHæ O

EXAMPLE 9 This example discloses the synthesis of Uret4.

1) Synthesis of Phenylene-1, 4-diisocyanate Bis- (cyclohex-3-enylmethyl) dicarbamate To a pyridine solution (40 ml) of 3-cyclohexene-1-methanol (12.00 ml) in the 500 ml 3-neck flask equipped with a temperature controller, a condenser, and an adding funnel, an acetone solution (150 ml) of phenylene-1, 4-diisocyanate (12.00 g) was slowly added in, while the mixture was kept stirring. The addition was completed in 1 hr, followed by refluxing for 6 hrs. Then acetone and pyridine were evaporated out to give a raw solid product with 79% yield. The raw solid was washed with 0.5 M HC1 and water several times, before it was dried in vacuum. Spectra confirmed the structure. IR (KBr pellet, in en') : 3329,3025,2948,2850,1700,1539,1413,1304,1239,1067,649.'H NMR (CDC13, in ppm): b 7.3 (s, s, 4H), 6.7 (s, m, 2H), 5.7 (s, s, 4H), 4.0 (d, s, 4H), 2.2-1.2 (complex, 14H). Its purity was verified by TLC.

26.2) Synthesis of Phenylene-1, 4-diisocyanate Bis-(3, 4-epoxycyclohexylmethyl) dicarbamate (Uret4)

Following the same procedure as for Uretl, solid Uret4 with yield 81% was obtained and identified by IR and NMR. IR (KBr pellet, in cm') : 3330,2943,1702,1542,1423, 1305,1228,1069,817,853.'HNMR (CDC13, in ppm): b 7.3 (s, s, 4H), 6.5 (s, m, 2H), 3.9 (m, s, 4H), 3.2 (d, s, 4H), 2.2-1.0 (complex, 14H).

EXAMPLE 10 This example discloses the synthesis of Uret5.

27.1) Synthesis of Tolylene-2, 4-diisocyanate Bis- (cyclohex-3-enylmethyl) dicarbamate

Following the same procedure as for phenylene-1, 4-diisocyanate bis- (cyclohex-3- enylmethyl) dicarbamate except that an acetone solution of phenylene-1, 4-diisocyanate was replaced by tolylene-2,4-diisocyanate, solid tolylene-2, 4-diisocyanate bis- (cyclohex-3- enylmethyl) dicarbamate was obtained with 78% yield, and was identified by IR and NMR.

IR (KBr pellet, in cri') : 3329,3015,2900,2813,1702,1542,1413,1304,1230,1067,649.

'H NMR (CDC13, in ppm): 8 7.2-7.0 (complex, 3H), 6.6-6.4 (d, m, 2H), 5.6 (s, s, 4H), 4.0 (m, s, 4H), 2.3-1.2 (complex, 17H). Its purity was verified by TLC.

28.2) Synthesis of Tolylene-2, 4-diisocyanate Bis- (3, 4-epoxycyclohexylmethyl) dicarbamate (UretS)

Following the same procedure as for Uretl, solid Uret5 with yield 85% was obtained and identified by IR and NMR. IR (KBr pellet, in cm'') : 3303,2936,1730,1599,1532, 1416,1224,1056.'H NMR (CDC13, in ppm): 8 7.2-7.0 (complex, 3H), 6.6-6.4 (d, m, 2H), 3.9 (m, s, 4H), 3.1 (s, s, 4H), 2. 3-1.2 (complex, 17H).

EXAMPLE 11 This example discloses the synthesis of Uret6.

29.1) Synthesis of Isophorone diisocyanate Bis-(cyclohex-3-enylmethyl) dicarbamate Isophorone diisocyanate bis- (cyclohex-3-enylmethyl) dicarbamate solid was obtained with 80% yield by following the same procedure as for phenylene-1, 4-diisocyanate bis- (cyclohex-3-enylmethyl) dicarbamate except that the acetone solution of phenylene-1,4-

diisocyanate was replaced by isophorone diisocyanate. IR and NMR spectra confirmed the structure. IR (KBr pellet, in cri') : 3343,3025,2938,1684,1529,1257,1222,1140,643.'H NMR (CDCl3, in ppm): 8 5.6 (s, s, 4H), 4.6 (s, m, 2H), 3.9 (d, s, 4H), 3.1 (s, s, 3H), 2.1-1.2 (complex, 29H). Its purity was verified by TLC.

30. 2) Synthesis of Isophorone diisocyanate Bis- (3, 4-epoxycyclohexylmethyl)

dicarbamate (Uret6) Uret6 solid was obtained with 90% yield by following the same procedure as for Uretl. Its structure was identified by IR and NMR. IR (KBr pellet, in cm'') : 3344,2937, 1683, 1531,1257,1140,1050.'H NMR (CDC13, in ppm): 8 4.6 (s, m, 2H), 3.8 (m, s, 4H), 3.1 (s, s, 7H), 2.1-1.2 (complex, 29H).

EXAMPLE 12

This example discloses the synthesis of Uret7.

1) Synthesis of Hexylene-1, 6-diisocyanate Bis- (cyclohex-3-enylmethyl) dicarbamate Following the same procedure as for phenylene-1, 4-diisocyanate bis- (cyclohex-3- enylmethyl) dicarbamate except that the acetone solution of phenylene-1, 4-diisocyanate was replaced by hexylene-1, 6-diisocyanate, hexylene-1, 6-diisocyanate bis- (cyclohex-3-

enylmethyl) dicarbamate, in the form of a semi-solid, was obtained with 87% yield, and was identified by IR and NMR. IR (neat, in cri') : 3328, 2925,2840,1701,1542,1355,1024, 780,653.'H NMR (CDC13, in ppm): 8 5.6 (s, s, 4H), 4.7-4.4 (d, w, 2H), 3.9 (d, s, 4H), 2.9 (d, m, 2H), 2.1-0.8 (complex, 24H). Its purity was verified by TLC.

31.2) Synthesis of Hexylene-1, 6-diisocyanate Bis- (3, 4-epoxycyclohexylmethyl)

dicarbamate (Uret7) A Semi-solid Uret7 was obtained with 88% yield by following the same procedure as for Uretl. Its structure was identified by IR and NMR. IR (neat, in cm'') : 3347,2918,1704, 1532, 1309,1247,1146,1041,792.'H NMR (CDCl3, in ppm): b 4.7-4.4 (d, w, 2H), 3.8 (d, s, 4H), 3.1 (d, s, 4H), 2.9 (d, m, 2H), 2.1-0.8 (complex, 24H). The synthesis scheme for Uret4 through Uret7 is diagrammed below: OCM-R-NCO-) -<=ON i- '-"td§ 0 cm DaseWju PVTdine 0 . L_- S. i Yt "3-S3 jEbr UKt5 , n for., Uret6 <cEr< bF Unt7 9 EXAMPLE 13 This example discloses Epoxide Equivalent Weights (EEWs) of Uretl through Uret7.

The Epoxide Equivalent Weights (EEWs) of these diepoxides were measured according to ASTM titration procedure D1652-90. Table 2 shows their theoretical and measured EEW values. It can be seen that the measured values are in good agreement with the theoretical values.

Table 2 EEWs of Uretl through Uret7

Sample EEW (g/mol.) Theoretical Measured Uretl 133. 5 141 Uret2 147. 5 164 Uret3 147. 5 186 Uret4 208 222 UretS 215 284 Uret6 212 232 Uret7 239 268

EXAMPLE 14 This example discloses structure of other chemicals used in the study.

Table 3 lists the chemical structures of a commercial epoxy resin, hardener and catalyst used in the experiments. The commercial epoxy resin, 3,4-epoxy cyclohexyl methyl- 3,4-epoxy cyclohexyl carboxylate, was provided by Union Carbide under the Trade Name ERL4221 and used as received. Its Epoxide Equivalent Weight (EEW) is 133 g/mol. The hardener, hexahydro-4-methylphthalic anhydride (HMPA), was purchased from Aldrich Chemical Company, Inc. and used as received. The catalyst, imidazole, was also purchased from Aldrich Chemical Company, Inc. and used as received.

One of ordinary skill in the art will recognize that a number of other compounds may be suitable for use with the cycloaliphatic epoxies of the present invention. For example, and not limitation, the organic hardener may also comprise any organic carboxylic acid anhydride hardener and in particular: hexahydrophthalic anhydride, methyl hexahydrophthalic anhydride, methyl-5-norbornene-2, 3-dicarboxylic anhydride, tetrahydrophthalic anhydride, methyl tetrahydrophthalic anhydride, and nadic methyl anhydride. Other curing accelerators which may be suitable for use in accordance with the present invention include: triphenylphosphine, 2-ethyl-4-methyl imidazole, 1-(2-cyanoethyl)-2-ethyl-4- methylimidazole, imidazole, 1-methylimidazole, 1-benylimidazole, 1,2-dimethylimidazole, 1-benzyl-2-methylimidazole, 4-methyl-2-phenylimidazole, benzyldimethylamine, triethylamine, pyridine, dimethylaminopyridine, 1, 4-diazabicyclo [2.2.2.] octane, 1,8- diazabicyclo [5.4.0] undec-7-ene, and 1, 5-diazabicyclot4. 3.0] non-5-ene. Finally, the filler may selected from silica fillers with a variety of different particle sizes and particle size distributions.

Table 3 Chemical Ingredients Used for Reworkable Epoxy Sample Preparation Name of chemicals 1 Structure of 1 ERL4221 OCH HHMPA 9 HHMPAQ H3 N zu Imidazole 4

EXAMPLE 15 An electro-magnetic stirrer was used to mix the epoxy resin, hardener, and catalyst.

The four synthesized diepoxides were mixed with HHMPA, respectively, in a mole ratio 1: 0.8 and 1% in weight of catalyst imidazole, and were called Epocarbl through Epocarb4.

ERL4221 was also mixed with HHMPA and imidazole in the same ratio and was called EpoO (see Table 4). The mixture was stirred until a homogeneous phase was formed.

Table 4 Composition of EpoO and Epocarbl Through Epocarb4 Sample Epoxide/Anhydride Catalyst (1/0.8 mol) (1 wt %) EpoO ERL4221/HHMPA Imidazole Epocarbl Carbl/BIBPA Imidazole Epocarb2 Carb2/HHMPA Imidazole Epocarb3 Carb3/HHMPA Imidazole Epocarb4 Carb4/HHMPA Imidazole

EXAMPLE 16 It was found that carbonate linkage inside the epoxide structure did not react with epoxy composition and was inert to epoxy curing due to the fact that carbonate linkage was a fairly chemically stable group. Figure 1 shows the curing profiles of four formulations based on these four epoxides as compared to EpoO. It can be seen that they all cured similarly

compared to EpoO. Endothermic peaks for Epocarb3 and Epocarb4 around 200°C were caused by decomposition.

EXAMPLE 17 Time-resolved FT-IR proved to be a useful tool to monitor the curing and degradation of epoxy system. IR spectra of Epocarb4 were collected at different temperatures at a heating rate of 10°C/min and analyzed. The curing process was easily monitored by a decrease in absorbance at 1864 and 1789 crri' (HHMPA anhydride C=O stretching) and at 901 cm- 1 (epoxide C-O-C ring deformation). Furthermore, the increase of the absorbance at 1155 crri' (ester C-O stretching) and 1736 cm-' (ester C=O stretching) is the clear sign of ester formation during the epoxy-anhydride curing. The absorbance at 1266 cm'' (carbonate C-O stretching) was used as an internal standard to normalize the baseline and film thickness change of the sample during reaction. Figure 2 shows the normalized FT-IR absorbance of Epocarb2 from room temperature to 250°C.

EXAMPLE 18 Degradation of Epocarb2 was studied by analyzing its IR spectra from 250°C to 350°C. While the absorbance at 1736 and 1155 cm''decreased slightly which was probably caused by the film thickness change, the absorbance at 1266 cm''decreased much faster.

Figure 3 shows the normalized FT-IR absorbance (by 1155 cm~') of Epocarb2 from 250°C to 350°C. The decrease of 1266 cm-l was caused by the thermal cleavage of carbonate linkage, which is the mechanism for Epocarb2 degradation. Other samples were also studied by time- resolved FT-IR and similar results were obtained.

EXAMPLE 19 Figure 4 shows the TGA curves of the cured samples at a heating rate of 10°C/min. It is clear that all these samples based on carbonate-containing epoxides degraded at lower temperature than that based on ERL4221. In addition, it can be drawn from the figure that thermal stability of these epoxides in very general terms goes in the following order: tertiary carbonate < secondary carbonate < primary carbonate.

EXAMPLE 20

Degradation kinetics of epoxy can be described by the following equation: ln R = ln (da/dt) = F + ln A-E/RT where R is reaction rate, a is conversion, t is time, F is a constant, A is the pre- exponential factor and E is activation energy. Degradation kinetics of EpoO, Epocarbl and Epocarb2 was studied by using TGA at four different heating rates. At different degree of conversion and temperature, the degradation kinetics may be different and can be influenced by many factors including sample shape, volatility, local atmosphere and thermal transfer. So all samples were tested under the same TGA conditions. The activation energy of the thermal decomposition as calculated above (see Table 5) is the average activation energy at low conversion, a = 0.01-0.10, which is due to the initial decomposition of the weak linkages.

EpoO (primary ester linkage) had higher activation energy than Epocarbl (primary carbonate linkage), and Epocarbl had higher activation energy than Epocarb2 (secondary carbonate linkage). It can be seen that these calculated activation energy results are in good accordance with the onset decomposition temperatures of these three materials.

Table 5 Thermal Decomposition Activation Energies of EpoO, Epocarbl and Epocarb2 Calculated from TGA Kinetics Sample Activation Energy Ea (kJ/mol) EpoO 152. 7 Epocarbl 124. 8 Epocarb2 112. 3 EXAMPLE 21 TGA results show that Epocarbl and Epocarb2 started weight loss around 250°C, which is much higher than the targeted rework temperature, 220°C. However, TGA is not a very good tool to determine network break-down temperature because it can only measure weight loss vs. temperature, but the network may have already partially broken down even though the products are not volatile enough to produce any detectable mass change.

Therefore, it was decided to use Tg change of the epoxy network to represent the network break-down. First, ten specimens of each epoxy formulation were prepared by curing at 175°C for 30 minutes. Among these specimens, nine were then exposed to different temperatures by staying in a preheated oven for 5 minutes. The temperature ranged from 200 to 280°C for every 10°C increment. Then the Tgs of these nine high temperature treated

specimens and the non-treated specimen were determined by DSC. Figure 5 shows the Tg vs. exposure temperature curve for Epocarbl and Epocarb2. It shows that both formulations had network-break down temperature around 220°C, which is just the temperature we need. It also shows that Epocarb2 had network break-down much faster than Epocarbl, which can be explained by the less thermal stability of secondary carbonate linkage than primary carbonate linkage.

EXAMPLE 22 Various properties of Epocarbl and Epocarb2 were measured and compared to those of EpoO. Table 6 lists the Tg, CTE, Storage Modulus, and room temperature viscosity of Epocarbl and Epocarb2 as compared to EpoO. It is clear that both Epocarbl and Epocarb2 were comparable to EpoO in any of these categories.

Table 6 Properties of EpoO, Epocarbl, and Epocarb2 Sample EpoO Epocarbl Epocarb2 Tg (°C) 175 176 176 CTE (ppm/°C, 50-100°C) 75 76 85 Storage Modulus (GPa, at 25°C) 2. 6 2. 8 2. 5 Viscosity(Pa. S, At25°c) 0. 24 0. 30 0. 34 EXAMPLE 23 The adhesion of Epocarbl and Epocarb2 was also studied. Figure 6 shows the adhesion data of Epocarbl, Epocarb2 and EpoO, which shows both Epocarbl and Epocarb2 had comparable adhesion compared to EpoO.

EXAMPLE 24 Moisture uptake of Epocarbl and Epocarb2 was measured and compared to that of EpoO. Figure 7 shows the results from moisture uptake measurements. The moisture uptake of Epocarbl and Epocarb2 was lower than EpoO, which can be explained by the less hydrophilicity of carbonate group than ester group. The fact that Epocarb2 picked up less moisture than Epocarbl could be explained by the less hydrophilicity of Carb2 than Carbl with the additional methyl group.

EXAMPLE 25 This example discloses the chemicals and formulations used to study Uretl through Uret7.

ERL4221 was used as the epoxy resin while HHMPA was used as the hardener. The catalyst, l-cyanoethyl-2-ethyl-4-methylimidazole (EMZCN), was provided by Shikoku company and used as received.

An electro-magnetic stirrer was used to mix the epoxy resin, hardener, and catalyst.

The seven synthesized diepoxides were mixed with HHMPA, respectively, in a mole ratio 1: 0.8 and 4 wt% of catalyst EMZCN, and were called Epouretl through Epouret7. ERL4221 was also mixed with HHMPA and EMZCN in the same ratio and was called EpoxyO (see Table 7). The mixture was stirred until a homogeneous phase was formed.

Table 7 Composition of EpoxyO and Epouretl Through Epouret7 Sample Epoxide/Anhydride Catalyst (1/0.8 mol) (4 wt %) EpoxyO ERL4221/HHMPA EMZCN Epouretl UretlEPA EMZCN Epouret2 Uret2/HHMPA EMZCN Epouret3 Uret3/HHMPA EMZCN Epouret4 Uret4/HHMPA EMZCN Epouret5 UretStHHM PA EMZCN Epouret6 Uret6/EIHMPA EMZCN Epouret7 Uret7/EEMPA EMZCN EXAMPLE 26 Figure 8 shows the curing profiles of formulations EpoxyO through Epouret3. Figure 9 shows the curing profiles of Epouret4 through Epouret7. It is clear that EpoxyO cured at a higher temperature region than the other formulations. This indicated that there might be some interactions between the carbamate linkage and epoxy curing, causing the peak of epoxy curing to shift to a lower temperature region.

EXAMPLE 27 Figure 10 shows the TGA curves of cured samples EpoxyO through Epouret3. It

clearly shows that the sample from ERL4221 was quite thermally stable. It did not start losing weight until after 350°C. For the three cured samples from liquid formulations, Epouretl through Epouret3, decomposition started at much lower temperatures. By comparing the curve of Epouretl, which showed its onset decomposition temperature around 280°C, to the curve of Epouret2, which showed its onset decomposition temperature around 220°C, it is clear that the carbamate group from a tertiary alcohol degraded at a much lower temperature than the one from a primary alcohol.

Figure 11 shows the TGA curves of the formulations from the four solid diepoxides, Epouret4 through Epouret7. The formulations using solid diepoxides started to decompose at temperatures below 300°C. Moreover, the two formulations from Uret6 and Uret7-Epouret6 and Epouret7 had higher onset decomposition temperatures than Epouret4 and Epouret5.

EXAMPLE 28 This example discloses the composition of a thermally reworkable underfill formulation based on Carbl as shown in Table 8. This formulation is named GT-1".

Table 8 Composition of GT-1" SampleEpoxide/Anhydride Imidazole Filler Silane Tougher (1/0.8 mol) (1 wt %) Loading (1 wt %) (10 mole %) GT-1"Carbl/HH1VIPA Y 50% Y Y EXAMPLE 29 This example discloses a developed rework process.

Chip Removal Chip removal test was conducted on the rework station using assembled and underfilled flip chip test boards. Temperature profile of the board site during chip removal was obtained by monitoring the actual temperature inside the board during chip removal through a buried thermal couple. Through adjusting various machine parameters and checking the subsequent temperature profiles of the board site, a chip removal profile allowing the board site to reach desired rework temperature without damaging the board was obtained. This chip removal profile was found to loosen the reworkable underfill at peak temperature. The major steps of the profile is listed as follows: 1. Preheat

Top and bottom heater was set at 200°C. The board was heated until 25 seconds had passed since the preset temperature was reached.

2. Activate Top and bottom heater was set at 270°C. The board was heated until 20 seconds had passed since the preset temperature was reached.

3. Adjust Head Position 4. Reflow Top heater was set at 380°C while the bottom heater was set to 400°C. The board was heated until 30 seconds had passed since the preset temperature was reached.

5. Remove Part Figure 12 shows the temperature profile of the board using the established chip removal profile.

By using this rework profile, non-underfilled chips were found to be easily removed by the vacuum force applied through the nozzle. However, the nozzle could not remove the underfilled chips from the board because the vacuum force was not strong enough. An accessory was then designed, manufactured, and mounted onto the small nozzle for flip chip rework. The schematic of this design is shown in Figure 13. The idea was to have the accessory holding the chip during the rework. This would allow shear or twisting force to be applied to the chip.

This accessory was put to test. After the nozzle touched the chip, the frame that held the board was slowly moved in both X and Y directions in order to apply a shear force on the chip. This was found to not only apply the shear force to the chip, but also help remove part of the underfill fillet, which helped the subsequent site-cleaning step as the underfill fillet was the most difficult part to remove. After that, the chip was lifted up by the nozzle and removed from the board.

Site-Cleaning After chip removal, the underfill residue and solder residue had to be cleaned and the site prepared to accept a new chip. Different cleaning methods were tried and the combination of a gentle mechanical process with solvent cleaning worked best. The mechanical cleaning was done by using a horsehair brush which was attached to a Dremel tool to slowly and carefully sweep away the underfill residue. The debris generated during the mechanical cleaning was then removed by isopropyl alcohol (IPA). This cleaning method was found to clean the underfill residue and the solder residue simultaneously with minimum

damage to the solder mask and bump pads on the FR-4 board. Figure 14 shows the comparison of the IR spectrum of a board after clean vs. a clean board. Both spectra matched well, indicating that the board was clean after the cleaning step.

Chip Replacement New chips were assembled on the reworked sites following the same procedure for test vehicle assembly : Inspecting replaced chips using continuity test and x-ray machine found that good solder interconnects were formed. High yield chip replacement was achieved on the replaced chips, which indicated that the cleaning process maintained the integrity of the bond pads.

EXAMPLE 30 This example discloses the rework test results of GT-1". Flip chips underfilled with GT-1"could be reworked using the above rework process. Underfill and solder residue were removed during the cleaning process. The bond pads at the rework site kept their integrity.

New chips were placed on the reworked sites and good electrical continuity was achieved.

EXAMPLE 31 This example discloses a reliability test for GT-1".

Reliability of underfilled flip chips was measured by subjecting the boards to liquid- to-liquid thermal shock (LLTS) test using an ESPEC Thermal Shock Chamber. The test condition was 10-minute cycle from-55 to 125°C, with 5 minutes cold and 5 minutes hot.

EXAMPLE 32 This example discloses reliability test results for GT-1". Average number of cycles a flip chip underfilled with GT-1"could withstand is 1500 cycles, which is comparable to a high performance commercial non-reworkable underfill.