JP2005281513A - Resin composition, prepreg and laminate sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin composition capable of producing a laminate sheet superior in hardenability, low thermal expansion coefficient, low dielectric constant and heat resistance, a prepreg using the same and a laminate sheet. <P>SOLUTION: This resin composition is used for use in formation of the prepreg in a sheet form by impregnation of the resin composition into a substrate. The resin composition comprises a cyanate resin and/or its prepolymer, an epoxy resin containing substantially no halogen atom, an imidazole compound of 15% or less weight loss by sublimation or decomposition at 200°C and an inorganic filler. The prepreg produced by impregnation of the resin composition into the substrate and the laminate sheet produced by molding the prepreg are provided. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a resin composition, a prepreg, and a laminate.

In the semiconductor field, the trend of shifting from conventional surface mounting to area mounting has progressed due to advances in high-density mounting technology, and new packages such as BGA (ball grid array) and CSP (chip scale package) are increasing. is there. The speed of information transmission is also increasing.
For this reason, the rigid substrate for interposers has been attracting more attention than ever before, and the demand for high heat resistance, low thermal expansion, and low dielectric substrate is increasing.

  Furthermore, in recent years, with the demand for higher functionality of electronic devices, etc., the integration of electronic components has been increased, and further, the mounting of high density has been progressing. More than ever, miniaturization and higher density are progressing. Many build-up multilayer wiring boards have been adopted as a countermeasure for increasing the density of such printed wiring boards.

  However, in the method using the build-up multilayer wiring board, since the interlayer connection is made by fine vias, the connection strength is lowered, so that it is difficult to maintain the mechanical and electrical connection reliability in a high temperature and high humidity atmosphere. There was a problem.

In order to achieve such an object, high heat resistance and low linear expansion of the resin used for the substrate are effective means, and cyanate resin is used as a resin having excellent heat resistance. An imidazole compound is used to accelerate the reaction. Thereby, the low thermal expansion property, the low dielectric property, and the low water absorption of the insulating layer obtained can be expressed (for example, refer patent document 1).
However, since imidazole compounds generally have a low sublimation temperature, they tend to sublime when a prepreg is produced by impregnating and drying a resin composition on a base material, and a curing reaction such as cyanate resin cannot be promoted. was there.

JP 2003-253018 A

  The present invention provides a resin composition that is excellent in curability and can produce a laminate having a low coefficient of thermal expansion, a low dielectric constant, and heat resistance, and a prepreg and laminate using the resin composition.

Such an object is achieved by the present invention described in the following (1) to (6).
(1) A resin composition used for impregnating a base material to form a sheet-like prepreg, which is a cyanate resin and / or a prepolymer thereof, an epoxy resin substantially free of halogen atoms, and 200 ° C. A resin composition characterized by containing an imidazole compound having a weight loss of 15% or less due to sublimation and decomposition, and an inorganic filler.
(2) The said cyanate resin is a resin composition as described in said (1) which is a novolak-type cyanate.
(3) The said epoxy resin is a resin composition as described in said (1) or (2) which is an aryl alkylene type epoxy resin.
(4) The resin composition according to any one of (1) to (3), wherein the content of the imidazole compound is 0.05 to 5% by weight with respect to the total weight of the cyanate resin and the epoxy resin.
(5) A prepreg obtained by impregnating a base material with the resin composition according to any one of (1) to (4).
(6) A laminate obtained by molding the prepreg as described in (5) above.

  According to the present invention, it is possible to obtain a resin composition that can produce a laminate having excellent curability, low expansion coefficient, low dielectric constant, and high heat resistance, and a prepreg and laminate using the same. it can.

Hereinafter, the resin composition, prepreg and laminate of the present invention will be described in detail.
The resin composition of the present invention is a resin composition used for impregnating a base material to form a sheet-like prepreg, and is an epoxy substantially free of a halogen atom and a cyanate resin and / or a prepolymer thereof. It contains a resin, an imidazole compound whose weight loss due to sublimation and decomposition at 200 ° C. is 15% or less, and an inorganic filler.
Moreover, the prepreg of the present invention is characterized in that a base material is impregnated with the resin composition of the present invention.
And the laminated board of this invention shape | molds the said prepreg of this invention, It is characterized by the above-mentioned.

First, the resin composition of the present invention will be described.
In the resin composition of the present invention, a cyanate resin is used. Thereby, low dielectric properties and low thermal expansion can be improved.
The cyanate resin is not particularly limited as long as it has a cyanate group, and examples thereof include novolak type cyanate resin, bisphenol A type cyanate resin, bisphenol E type cyanate resin, and bisphenol F type cyanate resin. It is done. Among these, it is preferable that the novolak cyanate resin shown by the following general formula (I) is included. Thereby, a glass transition temperature can be made high and the resin characteristic and flame retardance after hardening can be improved more.

The weight average molecular weight of the novolak cyanate resin represented by the general formula (I) is not particularly limited, but is preferably 500 to 4,500, and particularly preferably 600 to 3,000. When the weight average molecular weight of the novolak-type cyanate resin is less than the lower limit, the mechanical strength may be lowered, and when the upper limit is exceeded, the curing rate of the resin composition is high and the storage stability may be lowered.
The novolak-type cyanate resin can be obtained, for example, by reacting a novolak resin with a compound such as cyanogen chloride or cyanogen bromide. Moreover, the commercial item prepared in this way can also be used.

Moreover, what prepolymerized the said cyanate resin is preferably used in order to adjust a moldability and fluidity | liquidity, and is contained in the cyanate resin of this invention.
The prepolymerization is usually performed by heating and melting. In the present invention, the prepolymer refers to one having a trimerization rate of 20 to 50%, for example.
The trimerization rate can be determined using, for example, an infrared spectroscopic analyzer. In addition, you may use together cyanate resin and what prepolymerized the said cyanate resin.

  Although content of the said cyanate resin is not specifically limited, 5-70 weight% is preferable with respect to the whole resin composition, and 10-60 weight% is especially preferable. If the content is less than the lower limit, the effect of improving the low dielectric properties may be reduced. If the content exceeds the upper limit, it may be difficult to control the reaction and formability may be reduced.

In the resin composition of the present invention, an epoxy resin containing substantially no halogen atom is used. Thereby, a water absorption rate can be reduced. Here, the phrase “substantially free of halogen atoms” means, for example, that the content of halogen atoms in the epoxy resin is 1% by weight or less.
Examples of the epoxy resin include phenol novolac type epoxy resin, bisphenol type epoxy resin, naphthalene type epoxy resin, arylalkylene type epoxy resin and the like. Among these, aryl alkylene type epoxy resins are preferable. Thereby, a flame retardance and moisture absorption solder heat resistance can be improved.

  The aryl alkylene type epoxy resin refers to an epoxy resin having one or more aryl alkylene groups in a repeating unit. For example, a xylylene type epoxy resin, a biphenyl dimethylene type epoxy resin, etc. are mentioned. Among these, a biphenyl dimethylene type epoxy resin is preferable. As the biphenyldimethylene type epoxy resin, for example, those represented by the following general formula (II) can be used.

  Although n of the biphenyl dimethylene type epoxy resin represented by the general formula (II) is not particularly limited, 1 to 10 is preferable, and 2 to 5 is particularly preferable. If the amount is less than this, the biphenyldimethylene type epoxy resin is easily crystallized, and the solubility in a general-purpose solvent is relatively lowered, which may make handling difficult. Moreover, when more than this, the fluidity | liquidity of resin will fall and it may become a cause of a molding defect.

  Although content of the said epoxy resin is not specifically limited, 5 to 60 weight% is preferable with respect to the whole resin composition, and 15 to 55 weight% is especially preferable. If the content is less than the above lower limit, the effect of improving adhesion may be reduced, and if it exceeds the upper limit, low thermal expansion may not be sufficiently imparted.

  The weight average molecular weight of the epoxy resin is not particularly limited, but the weight average molecular weight is preferably 4,000 or less, more preferably 500 to 4,000, and particularly preferably 600 to 3,000. When the weight average molecular weight is less than the above lower limit value, tackiness may occur in the prepreg, and when the upper limit value is exceeded, solder heat resistance may be reduced.

In the resin composition of the present invention, an imidazole compound having a weight loss by sublimation and decomposition at 200 ° C. of 15% or less is used. Thereby, the reaction of the cyanate resin or the epoxy resin can be promoted without deteriorating various properties of the resin composition, and the curability can be improved. For this purpose, it is more preferable that the weight reduction is 10% or less.
Examples of imidazole compounds that sublimate at 200 ° C. and have a weight loss of 15% or less due to decomposition include 1-benzyl-2-phenylimidazole, 2,4-diamino-6- (2′-undecylimidazolyl) -ethyl-s -Triazine, 2-phenylimidazole, 2-phenyl-4-methyl-5-hydroxymethylimidazole and the like can be mentioned.
Among these, 1-benzyl-2-phenylimidazole is particularly preferable. Thereby, when the resin composition is impregnated and dried, sublimation of imidazole can be suppressed, the heat resistance of the resin composition can be improved, and the thermal expansion coefficient and dielectric constant of the resulting insulating layer can be reduced. it can.

Here, the amount of weight loss due to sublimation and decomposition at 200 ° C. is the weight loss at 200 ° C. when the temperature of the sample is raised at 10 ° C./min using TGA (thermogravimetry) as a reference. Is measured.
When measured by the above method, the weight loss rates of the imidazole compounds are 1-benzyl-2-phenylimidazole (7.3 wt%) and 2,4-diamino-6- (2′-undecylimidazolyl)-, respectively. Ethyl-s-triazine (12.0% by weight), 2-phenylimidazole (7.1% by weight), 2-phenyl-4-methyl-5-hydroxymethylimidazole (2.8% by weight).

  Although content of the said imidazole compound is not specifically limited, 0.05 to 5 weight% is preferable with respect to the total weight of cyanate resin and an epoxy resin, and 0.5 to 2 weight% is especially preferable. If the content is less than the above lower limit, the effect of promoting the curing reaction of cyanate resin or epoxy resin may be reduced, and if the content exceeds the upper limit, the reaction cannot be controlled and molding may be difficult. is there.

The resin composition of the present invention contains an inorganic filler. Thereby, low thermal expansibility and an improvement of a flame retardance can be aimed at.
Moreover, an elastic modulus can be improved by the combination of the said cyanate resin and / or its prepolymer (especially novolak-type cyanate resin) and an inorganic filler.
Although it does not specifically limit as said inorganic filler, For example, a talc, an alumina, glass, a silica, mica etc. can be mentioned. Among these, silica is preferable, and fused silica is preferable in that it has excellent low expansibility. The shape is crushed and spherical, but in order to reduce the melt viscosity of the resin composition in order to ensure the impregnation property to the glass substrate, a usage method adapted to the purpose such as using spherical silica is adopted. .

The average particle size of the inorganic filler is not particularly limited, but is preferably 0.01 to 5 μm, particularly preferably 0.2 to 2 μm. If the particle size of the inorganic filler is less than the lower limit, the viscosity of the varnish increases, which may affect the workability when producing the resin-coated metal foil. When the upper limit is exceeded, phenomena such as sedimentation of the inorganic filler may occur in the varnish.
In the resin composition of the present invention, it is particularly preferable to use spherical fused silica having the above average particle diameter. Thereby, the filling property of an inorganic filler can be improved.

  The content of the inorganic filler is preferably 5 to 70% by weight, particularly preferably 15 to 60% by weight, based on the entire resin composition. If the content is less than the above lower limit, low thermal expansion and adhesion may not be sufficient, and if it exceeds the upper limit, moldability may be reduced due to a decrease in fluidity.

  Although it does not specifically limit in the resin composition of this invention, It is preferable to contain a coupling agent further. This improves the wettability of the interface between the resin and the inorganic filler, thereby uniformly fixing the resin and the filler to the base material, and improving the heat resistance, particularly the solder heat resistance after moisture absorption. it can.

  As the coupling agent, any of those usually used can be used, and among these, one kind selected from an epoxy silane coupling agent, a titanate coupling agent, an aminosilane coupling agent, and a silicone oil type coupling agent. It is preferable to use the above coupling agent. Thereby, wettability with the interface of an inorganic filler can be made high, and heat resistance can be improved more.

  Although content of the said coupling agent is not specifically limited, It is preferable that it is 0.05-3 weight part with respect to 100 weight part of inorganic fillers. If the content is less than the above lower limit value, the inorganic filler cannot be sufficiently coated and the effect of improving heat resistance may be reduced, and if the content exceeds the upper limit value, the bending strength of the laminate may be reduced.

  In addition to the components described above, the resin composition of the present invention can use various additives as necessary within a range that does not impair the objects and effects of the present invention. Examples of the additive include an antifoaming material and a leveling material.

Next, the prepreg of the present invention will be described.
The prepreg of the present invention is obtained by impregnating a base material with the resin composition of the present invention. Thereby, a prepreg excellent in various characteristics such as dielectric characteristics, mechanical characteristics under high temperature and high humidity, and electrical connection reliability can be obtained.

  Although it does not specifically limit as a base material used with the prepreg of this invention, For example, inorganic fiber base materials, such as glass fiber base materials, such as a glass fiber cloth and a glass non-woven cloth, or a fiber cloth or non-fiber cloth which uses inorganic compounds other than glass as a component And organic fiber base materials composed of organic fibers such as aromatic polyamide resin, polyamide resin, aromatic polyester resin, polyester resin, polyimide resin, and fluororesin. Among these base materials, glass fiber base materials represented by glass woven fabric are preferable in terms of mechanical strength and water absorption.

The method for impregnating the resin composition obtained in the present invention into the substrate is not particularly limited. For example, a resin varnish in which the resin composition of the present invention is dissolved and dispersed in a solvent is prepared, and the substrate is used as the resin varnish. Examples include a dipping method, a method of applying a resin varnish to a substrate with various coater devices, and a method of spraying the resin varnish onto a substrate with a spray device.
Among these, the method of immersing the base material in the resin varnish is preferable. Thereby, the impregnation property of the resin composition with respect to a base material can be improved. In addition, when a base material is immersed in a resin varnish, a normal impregnation coating equipment can be used.

The solvent used for the preparation of the resin varnish desirably has good solubility in the resin component in the resin composition, but a poor solvent may be used as long as it does not adversely affect the resin varnish. Examples of the solvent exhibiting good solubility include methyl ethyl ketone and cyclohexanone.
The solid content in the resin varnish is not particularly limited, but is preferably 40 to 80% by weight, and particularly preferably 50 to 65% by weight. Thereby, the impregnation property to the base material of the resin varnish can further be improved.
The prepreg of the present invention can be obtained by impregnating the base material with the resin varnish and drying it at a predetermined temperature, for example, 80 to 200 ° C.

Next, the laminated board of this invention is demonstrated.
The laminate of the present invention is formed by molding at least one prepreg of the present invention. As a result, it is possible to obtain a laminate having low dielectric properties, mechanical properties under high temperature and high humidity, and excellent electrical connection reliability.
When one prepreg is used, a metal foil or film is stacked on both upper and lower surfaces or one surface. Also, two or more prepregs can be laminated and used. When two or more prepregs are used, a metal foil or film is laminated on the outermost upper and lower surfaces or one surface of the laminated prepreg. Next, a laminate can be obtained by heating and pressurizing a laminate of a prepreg and a metal foil.
Although the temperature to heat is not specifically limited, 120-220 degreeC is preferable and especially 150-200 degreeC is preferable. Moreover, the pressure to pressurize is not particularly limited, but is preferably 2 to 5 MPa, and particularly preferably 2.5 to 4 MPa.

  Examples of the metal constituting the metal foil include copper and copper-based alloys, aluminum and aluminum-based alloys, iron and iron-based alloys, and the like. Examples of the film include polyethylene and polypropylene.

  Hereinafter, although an example and a comparative example explain the present invention, the present invention is not limited to this.

(Example 1)
(1) Preparation of resin varnish 30 parts by weight of novolak-type cyanate resin (Lonza Japan KK, Primaset PT-30, weight average molecular weight 700), novolak-type cyanate resin (Lonza Japan KK, Primaset PT-60) , Weight average molecular weight of about 2600) 5 parts by weight, biphenyl dimethylene type epoxy resin (Nippon Kayaku Co., Ltd., NC-3000H, epoxy equivalent 275) 35 parts by weight, and epoxy silane type coupling agent (manufactured by Nippon Unicar Co., Ltd.) A187) 0.2 part by weight is dissolved in methyl ethyl ketone at room temperature, 30 parts by weight of spherical fused silica (manufactured by Admatechs Co., Ltd., spherical fused silica SO-32R, average particle size 1.5 μm) is added, and a high-speed stirrer is added. And stirred for 10 minutes. As an imidazole compound, 1.0 part by weight of 1-benzyl-2-phenylimidazole (manufactured by Shikoku Kasei Kogyo Co., Ltd., Curesol “1B2PZ”) is added to 100 parts by weight of the total of the cyanate resin and the epoxy resin, The mixture was stirred for 10 minutes using a high-speed stirrer to obtain a resin varnish having a solid content of 65% by weight.

(2) Manufacture of prepreg The above resin varnish is impregnated into a glass woven fabric (manufactured by Nitto Boseki Co., Ltd., WEA-2319), dried in a heating furnace at 150 ° C. for 3.5 minutes, and solid content in the resin varnish in the prepreg Yielded 50% by weight of prepreg.

(3) Manufacture of laminated plate 4 and 8 prepregs as described above, 18 μm copper foils are stacked on each side, and the thickness is determined by heating and pressing at a pressure of 4 MPa and a temperature of 200 ° C. for 2 hours. 0.4 mm and 0.8 mm double-sided copper clad laminates were obtained.

(Example 2)
A resin composition, a prepreg, and a laminate were obtained in the same manner as in Example 1 except that the composition of the resin varnish was as follows.
As the imidazole compound, 0.7 part by weight of 1-benzyl-2-phenylimidazole was used with respect to 100 parts by weight of the total of the cyanate resin and the epoxy resin. Others were the same as in Example 1.

(Example 3)
A resin composition, a prepreg, and a laminate were obtained in the same manner as in Example 1 except that the composition of the resin varnish was as follows.
As the imidazole compound, 0.4 part by weight of 1-benzyl-2-phenylimidazole was used with respect to 100 parts by weight of the total of the cyanate resin and the epoxy resin. Others were the same as in Example 1.

Example 4
A resin composition, a prepreg, and a laminate were obtained in the same manner as in Example 1 except that the composition of the resin varnish was as follows.
As an imidazole compound, 1-benzyl-2-phenylimidazole was used in an amount of 2.0 parts by weight based on 100 parts by weight of the total of the cyanate resin and the epoxy resin. Others were the same as in Example 1.

(Comparative Example 1)
A resin composition, a prepreg, and a laminate were obtained in the same manner as in Example 1 except that the composition of the resin varnish was as follows.
As an imidazole compound, 2-phenyl-4-methyl-imidazole (manufactured by Shikoku Kasei Kogyo Co., Ltd., Curesol “2P4MZ”, 21% weight reduction at 200 ° C.) is used with respect to a total of 100 parts by weight of cyanate resin and epoxy resin. 1.0 part by weight was used. Others were the same as in Example 1.

(Comparative Example 2)
A resin composition, a prepreg, and a laminate were obtained in the same manner as in Example 1 except that the composition of the resin varnish was as follows.
As an imidazole compound, 2.0 parts by weight of 2-phenyl-4-methyl-imidazole was used with respect to 100 parts by weight of the total of the cyanate resin and the epoxy resin. Others were the same as in Example 1.

(Comparative Example 3)
A resin composition, a prepreg, and a laminate were obtained in the same manner as in Example 1 except that the composition of the resin varnish was as follows.
17 parts by weight of PT-30 as a novolak type cyanate resin, 3 parts by weight of PT-60, 11 parts by weight of NC-3000H as a biphenyl dimethylene type epoxy resin, biphenyl dimethylene type phenol resin (MEH Kasei Co., Ltd., MEH- 7851-HHH), 9 parts by weight,
In addition, 0.2 parts by weight of A187 was used as an epoxy silane type coupling agent, and 60 parts by weight of SO-32R was used as spherical fused silica. Others were the same as in Example 1.

  The following evaluation was performed about the laminated board obtained by the Example and the comparative example. The obtained results are shown in Table 1.

Evaluation was performed by the following method.
(1) Presence / absence of sublimation of imidazole compound during prepreg production (coating and drying) Whether or not white smoke due to sublimation of imidazole is observed in the drying apparatus when the resin composition is impregnated into a substrate and dried. It was confirmed visually.

(2) Curing reaction start temperature The resin composition in the prepreg was sampled, and this was heated at 10 ° C./min using a DSC (differential scanning calorimeter), and the temperature at the start of the reaction was measured. Read in 5 ° C units.

(3) Curing reaction temperature The resin composition in a prepreg was extract | collected, this was heated up at 10 degrees C / min using DSC (differential scanning calorimetry), and the temperature of the reaction peak was measured.

(4) Formability The resin flow rate at the time of manufacturing the laminated plate was measured by measuring the resin flow amount from the end of the laminated plate to confirm the fluidity of the resin. Moreover, the double-sided laminate was etched on both sides, and formability was confirmed. The symbols are as follows.
A: The flow amount during press molding is 1 mm or more and 5 mm or less, and the moldability is good. ○: The flow amount during press molding is less than 1 mm, and the moldability is good.

(5) Linear expansion coefficient A 0.8 mm-thick double-sided copper-clad laminate is etched all over, a 5 mm × 5 mm test piece is cut out from the obtained laminate, and the thickness direction is measured using TMA (thermomechanical analyzer). The linear expansion coefficient in the (Z direction) was measured at 10 ° C./min.

(6) Dielectric properties A double-sided copper-clad laminate with a thickness of 0.4 mm is etched all over, a test piece of 60 mm x 60 mm is cut out from the obtained laminate, and the dielectric constant and dielectric loss tangent are measured in accordance with JIS C 6481. I went.

(7) Glass transition temperature A double-sided copper-clad laminate having a thickness of 0.8 mm was entirely etched, and a 5 mm × 5 mm test piece was cut out from the obtained laminate and measured at 10 ° C./min using TMA.

Examples 1-4 are a cyanate resin and / or a prepolymer thereof, an epoxy resin substantially free of halogen atoms, an imidazole compound having a weight loss of not more than 15% by sublimation and decomposition at 200 ° C., and inorganic filling Prepreg and laminate using the resin composition of the present invention containing a material, compared with Comparative Examples 1 and 2 using an imidazole compound with a large weight loss due to sublimation and decomposition at 200 ° C. While suppressing the sublimation of the imidazole compound, the curing promoting action of the imidazole compound could be effectively expressed, and the curability could be improved.
Moreover, although the comparative example 3 uses phenol resin instead of an imidazole compound as a hardening | curing agent, and increased the compounding quantity of the inorganic filler, all the Examples were able to improve a dielectric constant from this. .

  ADVANTAGE OF THE INVENTION According to this invention, the resin composition which can manufacture the laminated board which is excellent in sclerosis | hardenability, and has low thermal expansibility, low dielectric property, and high heat resistance, and a prepreg and laminated board using this can be obtained. . The laminated board of this invention is used suitably for the printed wiring board use etc. corresponding to high-density mounting.

Claims (6)

A resin composition used for impregnating a base material to form a sheet-like prepreg, which is a cyanate resin and / or a prepolymer thereof, an epoxy resin substantially free of halogen atoms, and sublimation at 200 ° C. A resin composition comprising an imidazole compound whose weight loss due to decomposition is 15% or less and an inorganic filler. The resin composition according to claim 1, wherein the cyanate resin is a novolak cyanate. The resin composition according to claim 1, wherein the epoxy resin is an aryl alkylene type epoxy resin. The resin composition according to any one of claims 1 to 3, wherein a content of the imidazole compound is 0.05 to 5% by weight with respect to a total weight of the cyanate resin and the epoxy resin. A prepreg obtained by impregnating a base material with the resin composition according to claim 1. A laminate obtained by molding the prepreg according to claim 5.