Rapid spray method for improving Cu-epoxy interface strength

A simple spray method using a plain orifice atomizer has been developed for depositing γ- aminopropyltriethoxysilane (APS) from solutions in water and in methanol onto copper surfaces. The peel strengths between copper foil and epoxy resin were measured with and without APS deposition. In all cases, a higher concentration of APS gives higher peel strength. APS applied from 1 wt% solution in methanol resulted in higher peel strength than when applied from a 1 wt% aqueous solution; the opposite was true with 0.2 wt% APS solutions, indicating a trade-off between deposited APS film thickness and surface coverage. APS was very effective when chemisorption occurred at the surface but much less effective when there was only physisorption. A study of the fracture surfaces showed that the failure is cohesive, inside the epoxy layer, and that the deposited APS on the copper surfaces had a long-range effect which was seen deep in the epoxy layer, well away from the copper surface.