Patents by Inventor Steven A. Castaldi

Steven A. Castaldi has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 8518281
    Abstract: A composition for providing acid resistance to copper surfaces in the production of multilayered printed circuit boards. The composition comprises an acid, an oxidizer, a five-membered heterocyclic compound and a thiophosphate or a phosphorous sulfide compound. In a preferred embodiment, the phosphorous compound is phosphorus pentasulfide. The composition is applied to a copper or copper alloy substrate and the copper substrate is thereafter bonded to a polymeric material.
    Type: Grant
    Filed: June 3, 2008
    Date of Patent: August 27, 2013
    Inventors: Kesheng Feng, Ming De Wang, Colleen Mckirryher, Steven A. Castaldi
  • Patent number: 8512504
    Abstract: A process for treating metal surfaces that includes first contacting the metal surface with a particular acidic peroxide adhesion promoting composition, followed by contacting that metal surface with an aqueous acid post-dip composition to provide a micro-roughened surface. This treatment is particularly suitable for treating metal surfaces used in printed circuit multilayer construction.
    Type: Grant
    Filed: May 6, 2009
    Date of Patent: August 20, 2013
    Inventors: Steven A. Castaldi, Kesheng Feng
  • Patent number: 8486281
    Abstract: A nickel-chromium alloy etching composition comprising sulfuric acid, a source of chloride ions, including hydrochloric acid or sodium, potassium or ammonium chloride, and a sulfur compound comprising a sulfur atom with an oxidation state between ?2 to +5, such as thiosulfate, sulfide, sulfite, bisulfite, metabisulfite and phosphorus pentasulfide that can efficiently remove nickel-chromium alloy in the presence of copper circuits is disclosed.
    Type: Grant
    Filed: October 5, 2009
    Date of Patent: July 16, 2013
    Inventors: Kesheng Feng, Nilesh Kapadia, Steven A. Castaldi, John Ganjei
  • Patent number: 8308893
    Abstract: A method of increasing adhesion between a copper or copper alloy layer and a polymeric resin. The method includes the steps of a) applying a pre-dip composition to the copper layer; b) applying a nano-oxide composition to the treated copper layer, c) applying a post-dip composition to the nano-oxide treated surface, and d) bonding a resin to the treated copper surface. The nano-oxide composition comprises (i) a chlorite; (ii) a caustic; (iii) a phosphate salt; (iv) an organic nitro compound; and (v) a thio compound. The post-dip composition is an alkaline solution that comprises (i) a phosphate salt; (ii) a source of molybdenum ions; and (iii) a thiazole. The process of the invention is useful for improving the bond between copper and a resin, including high Tg resins, halogen-free resins, and high speed/lost resins.
    Type: Grant
    Filed: February 1, 2010
    Date of Patent: November 13, 2012
    Inventors: Ming De Wang, Steven A. Castaldi, Kesheng Feng
  • Patent number: 8088246
    Abstract: An adhesion promoting composition and a process for treating metal surfaces with the adhesion promoting composition is described. The adhesion promoting composition comprises an oxidizer, an acid, a corrosion inhibitor, a source of halide ions and a material selected from a mercapto propane sulfonate, mercapto propane sulfonic acid, and bis-sodium sulfopropyl disulfide. The adhesion promoting composition increases the adhesion of polymeric materials to the metal surfaces and also provides increased acid resistance.
    Type: Grant
    Filed: January 8, 2009
    Date of Patent: January 3, 2012
    Inventors: John L. Cordani, Jr., Kesheng Feng, Steven A. Castaldi, Colleen Mckirryher
  • Publication number: 20110186221
    Abstract: A method of increasing adhesion between a copper or copper alloy layer and a polymeric resin. The method includes the steps of a) applying a pre-dip composition to the copper layer; b) applying a nano-oxide composition to the treated copper layer, c) applying a post-dip composition to the nano-oxide treated surface, and d) bonding a resin to the treated copper surface. The nano-oxide composition comprises (i) a chlorite; (ii) a caustic; (iii) a phosphate salt; (iv) an organic nitro compound; and (v) a thio compound. The post-dip composition is an alkaline solution that comprises (i) a phosphate salt; (ii) a source of molybdenum ions; and (iii) a thiazole. The process of the invention is useful for improving the bond between copper and a resin, including high Tg resins, halogen-free resins, and high speed/lost resins.
    Type: Application
    Filed: February 1, 2010
    Publication date: August 4, 2011
    Inventors: Ming De Wang, Steven A. Castaldi, Kesheng Feng
  • Patent number: 7989346
    Abstract: A method of forming a resist pattern on a silicon semiconductor substrate having an anti-reflective layer thereon is described. The method includes the steps of a) modifying surface energy of the anti-reflective surface with a chemical treatment composition, b) applying a UV etch resist to the treated anti-reflective surface, and c) exposing the anti-reflective surface to a wet chemical etchant composition to remove exposed areas of the anti-reflective surface. Thereafter, the substrate can be metallized to provide a conductor pattern. The method may be used to produce silicon solar cells.
    Type: Grant
    Filed: July 27, 2009
    Date of Patent: August 2, 2011
    Inventors: Adam Letize, Andrew M. Krol, Ernest Long, Steven A. Castaldi
  • Publication number: 20110079578
    Abstract: A nickel-chromium alloy etching composition comprising sulfuric acid, a source of chloride ions, including hydrochloric acid or sodium, potassium or ammonium chloride, and a sulfur compound comprising a sulfur atom with an oxidation state between ?2 to +5, such as thiosulfate, sulfide, sulfite, bisulfite, metabisulfite and phosphorus pentasulfide that can efficiently remove nickel-chromium alloy in the presence of copper circuits is disclosed.
    Type: Application
    Filed: October 5, 2009
    Publication date: April 7, 2011
    Inventors: Kesheng Feng, Nilesh Kapadia, Steven A. Castaldi, John Ganjei
  • Publication number: 20110021023
    Abstract: A method of forming a resist pattern on a silicon semiconductor substrate having an anti-reflective layer thereon is described. The method includes the steps of a) modifying surface energy of the anti-reflective surface with a chemical treatment composition, b) applying a UV etch resist to the treated anti-reflective surface, and c) exposing the anti-reflective surface to a wet chemical etchant composition to remove exposed areas of the anti-reflective surface. Thereafter, the substrate can be metallized to provide a conductor pattern. The method may be used to produce silicon solar cells.
    Type: Application
    Filed: July 27, 2009
    Publication date: January 27, 2011
    Inventors: Adam Letize, Andrew M. Krol, Ernest Long, Steven A. Castaldi
  • Patent number: 7875558
    Abstract: The present invention is directed to a microetching composition comprising a source of cupric ions, acid, a nitrile compound, and a source of halide ions. Other additive, including organic solvents, a source of molybdenum ions, amines, polyamines, and acrylamides may also be included in the composition of the invention. The present invention is also directed to a method of microetching copper or copper alloy surfaces to increase the adhesion of the copper surface to a polymeric material, comprising the steps of contacting a copper or copper alloy surface with the composition of the invention, and thereafter bonding the polymeric material to the copper or copper alloy surface.
    Type: Grant
    Filed: August 14, 2007
    Date of Patent: January 25, 2011
    Inventors: Kesheng Feng, Nilesh Kapadia, Steven A. Castaldi
  • Publication number: 20100282393
    Abstract: A process for treating metal surfaces that includes first contacting the metal surface with a particular acidic peroxide adhesion promoting composition, followed by contacting that metal surface with an aqueous acid post-dip composition to provide a micro-roughened surface. This treatment is particularly suitable for treating metal surfaces used in printed circuit multilayer construction.
    Type: Application
    Filed: May 6, 2009
    Publication date: November 11, 2010
    Inventors: STEVEN A. CASTALDI, KESHENG FENG
  • Publication number: 20100170638
    Abstract: An adhesion promoting composition and a process for treating metal surfaces with the adhesion promoting composition is described. The adhesion promoting composition comprises an oxidizer, an acid, a corrosion inhibitor, a source of halide ions and a material selected from a mercapto propane sulfonate, mercapto propane sulfonic acid, and bis-sodium sulfopropyl disulfide. The adhesion promoting composition increases the adhesion of polymeric materials to the metal surfaces and also provides increased acid resistance.
    Type: Application
    Filed: January 8, 2009
    Publication date: July 8, 2010
    Inventors: John L. Cordani, JR., Kesheng Feng, Steven A. Castaldi, Colleen Mckirryher
  • Patent number: 7645393
    Abstract: A process is described for treating metal surfaces with roughening compositions that use poly(ethyleneamino propionitrile) polymer as an additive in the composition to improve adhesion of polymeric materials to the metal surfaces and to improve peel strength for thermal stability. The polymer of the invention may be added to compositions containing for example, cupric chloride and hydrochloric acid and is also usable in compositions containing an oxidizer/acid/azole mixture. Other additives, such as adiponitrile may also be beneficially added to compositions of the invention.
    Type: Grant
    Filed: April 27, 2007
    Date of Patent: January 12, 2010
    Inventors: Kesheng Feng, Ming De Wang, Steven A. Castaldi
  • Patent number: 7631798
    Abstract: A method for enhancing the solderability of a metallic surface is disclosed where the metallic surface is plated with a silver plate prior to soldering, which immersion silver plate is treated with an additive comprising a mercapto substituted or thio substituted silane compound. Preferred post treatments comprise 3-mercapto propyl trimethoxysilane and/or 3-oxtanoylthio-1-propyltriethoxy silane.
    Type: Grant
    Filed: October 2, 2008
    Date of Patent: December 15, 2009
    Inventors: Ernest Long, Lenora M. Toscano, Paul Romaine, Colleen McKirryher, Donna M. Kologe, Steven A. Castaldi, Carl P. Steinecker
  • Publication number: 20090294294
    Abstract: A composition for providing acid resistance to copper surfaces in the production of multilayered printed circuit boards. The composition comprises an acid, an oxidizer, a five-membered heterocyclic compound and a thiophosphate or a phosphorous sulfide compound. In a preferred embodiment, the phosphorous compound is phosphorus pentasulfide. The composition is applied to a copper or copper alloy substrate and the copper substrate is thereafter bonded to a polymeric material.
    Type: Application
    Filed: June 3, 2008
    Publication date: December 3, 2009
    Inventors: Kesheng Feng, Ming de Wang, Colleen Mckirryher, Steven A. Castaldi
  • Publication number: 20090123656
    Abstract: A composition for inhibiting the galvanic corrosion of printed circuit boards. The corrosion resistant coating composition may be applied to the printed circuit board to reduce corrosion and to shut down the chemical mechanism for galvanic corrosion so that corrosion protection of the product is achieved. The corrosion resistant coating composition comprises a) a mercaptan; b) an ethoxylated alcohol; and c) at least one metal species selected from the group consisting of molybdates, tungstates, vanadataes, zirconium, cobalt.
    Type: Application
    Filed: November 13, 2007
    Publication date: May 14, 2009
    Inventors: Ernest Long, Andrew Krol, Lenora M. Toscano, Steven A. Castaldi
  • Patent number: 7456114
    Abstract: The present invention is directed to a microetching composition comprising a source of cupric ions, acid, a nitrile compound, and a source of halide ions. Other additive, including organic solvents, a source of molybdenum ions, amines, polyamines, and acrylamides may also be included in the composition of the invention. The present invention is also directed to a method of microetching copper or copper alloy surfaces to increase the adhesion of the copper surface to a polymeric material, comprising the steps of contacting a copper or copper alloy surface with the composition of the invention, and thereafter bonding the polymeric material to the copper or copper alloy surface.
    Type: Grant
    Filed: December 21, 2005
    Date of Patent: November 25, 2008
    Inventors: Kesheng Feng, Nilesh Kapadia, Steven A. Castaldi
  • Publication number: 20080264900
    Abstract: A process is described for treating metal surfaces with roughening compositions that use poly(ethyleneamino propionitrile)polymer as an additive in the composition to improve adhesion of polymeric materials to the metal surfaces and to improve peel strength for thermal stability. The polymer of the invention may be added to compositions containing for example, cupric chloride and hydrochloric acid and is also usable in compositions containing an oxidizer/acid/azole mixture. Other additives, such as adiponitrile may also be beneficially added to compositions of the invention.
    Type: Application
    Filed: April 27, 2007
    Publication date: October 30, 2008
    Inventors: Kesheng Feng, Ming De Wang, Steven A. Castaldi
  • Publication number: 20080041824
    Abstract: The present invention is directed to a microetching composition comprising a source of cupric ions, acid, a nitrile compound, and a source of halide ions. Other additive, including organic solvents, a source of molybdenum ions, amines, polyamines, and acrylamides may also be included in the composition of the invention. The present invention is also directed to a method of microetching copper or copper alloy surfaces to increase the adhesion of the copper surface to a polymeric material, comprising the steps of contacting a copper or copper alloy surface with the composition of the invention, and thereafter bonding the polymeric material to the copper or copper alloy surface.
    Type: Application
    Filed: August 14, 2007
    Publication date: February 21, 2008
    Inventors: Kesheng Feng, Nilesh Kapadia, Steven Castaldi
  • Publication number: 20080003351
    Abstract: A process is revealed whereby resistors can be manufactured integral with a printed circuit board by plating the resistors onto the insulative substrate. Uniformization of the insulative substrate through etching and oxidation of the plated resistor are discussed as techniques for improving the uniformity and consistency of the plated resistors. Trimming and baking are also disclosed as methods for adjusting and stabilizing the resistance of the plated resistors.
    Type: Application
    Filed: September 4, 2007
    Publication date: January 3, 2008
    Applicant: MacDermid, Incorporated
    Inventors: Peter Kukanskis, Dennis Fritz, Frank Durso, Steven Castaldi, David Sawoska