JP2023156243A - Liquid composition, prepreg, metal substrate with resin, wiring board and silica particle - Google Patents

Abstract

To provide a liquid composition which enables formation of a cured product that is excellent in adhesion to a metal substrate layer.SOLUTION: A liquid composition contains a thermosetting resin, and silica particles having a median diameter d50 of 0.5-20.0 μm and a specific surface area of 0.1-3.5 m2/g, and has a viscosity measured at 25°C and a revolution of 1 rpm of 100-10,000 mPa s.SELECTED DRAWING: None

Description

The present disclosure relates to a liquid composition, a prepreg, a resin-coated metal substrate, a wiring board, and silica particles.

A liquid composition containing a thermosetting resin and silica particles is used for manufacturing an electrical insulating layer included in a metal-clad laminate that can be processed into a printed wiring board (see Patent Documents 1 and 2). Specifically, a metal-clad laminate in which a semi-cured product of the liquid composition described above is laminated as an electrical insulating layer on the surface of a metal base layer, a glass cloth impregnated with the liquid composition, etc. as an electrical insulating layer, A metal clad laminate is used, which is laminated on the surface of a metal base layer. In recent years, electrical insulating layers included in printed wiring boards are required to have more advanced characteristics such as low dielectric constant, low dielectric loss tangent, and low coefficient of linear expansion.

JP2013-212956A Japanese Patent Application Publication No. 2015-36357

On the other hand, from the viewpoint of reliability of wiring boards, liquid compositions used to form electrical insulating layers, such as semi-cured products of liquid compositions or glass cloth impregnated with liquid compositions, include Excellent adhesion to the metal base layer is also required. While the silica particles contained in the liquid composition can be expected to have the effect of improving the properties of the electrically insulating layer formed therefrom, the effect they have on the adhesion with the metal base layer is often unclear.
The present inventor believes that depending on the content of silica particles in the liquid composition and the physical properties of the silica particles, the physical properties of the semi-cured product or impregnated state may change and the adhesion to the metal base layer may decrease. I gained knowledge.

A problem to be solved by an embodiment of the present disclosure is to provide a liquid composition and a prepreg that can form a cured product with excellent adhesion to a metal base layer. A problem to be solved by an embodiment of the present disclosure is to provide a resin-coated metal base material and a wiring board that have excellent adhesion between a liquid composition, a cured product, and a metal base layer. A problem to be solved by an embodiment of the present disclosure is to provide silica particles used for adjusting the viscosity of a liquid composition that has excellent adhesion to a metal base layer.

Means for solving the above problems include the following aspects.
<1> Contains a thermosetting resin and silica particles having a median diameter d50 of 0.5 to 20.0 μm and a specific surface area of 0.1 to 3.5 m ² /g, and at 25 ° C. A liquid composition having a viscosity of 100 to 10,000 mPa·s measured at a rotational speed of 1 rpm.
<2> The liquid composition according to <1> above, wherein the silica particles have a median diameter d50 of 1.0 to 10.0 μm.
<3> The liquid composition according to <1> or <2> above, wherein the silica particles have a median diameter d50 of more than 1.0 μm and no more than 5.0 μm.
<4> The liquid composition according to any one of <1> to <3> above, wherein the silica particles have a specific surface area of 0.8 to 2.0 m ² /g.
<5> The liquid composition according to any one of <1> to <4> above, wherein the content of the silica particles is 50 to 400 parts by mass based on 100 parts by mass of the thermosetting resin.
<6> The liquid composition according to any one of <1> to <5> above, wherein the thermosetting resin is an epoxy resin, a polyphenylene ether resin, or an ortho-divinylbenzene resin.
<7> The above <1> to <6>, further comprising a solvent, and the solvent contains at least one selected from the group consisting of toluene, cyclohexanone, methyl ethyl ketone, and N-methyl-2-pyrrolidone. Liquid composition according to any one of the above.
<8> A prepreg comprising the liquid composition or semi-cured product thereof according to any one of <1> to <7> above, and a fibrous base material.
<9> A resin-coated metal base comprising the liquid composition or semi-cured product thereof according to any one of <1> to <7> above, or the prepreg according to <8> above, and a metal base layer. Material.
<10> The resin-coated metal base material according to <9> above, wherein the metal base layer is copper foil.
<11> The resin-coated copper foil according to <9> or <10> above, wherein the maximum height roughness Rz of the surface of the liquid composition, the semi-cured product, or the prepreg side of the copper foil is 2 μm or less. Metal base material.
<12> A wiring board comprising a cured product of the liquid composition according to any one of <1> to <7> above, and metal wiring.
<13> Median diameter d50 is 0.5 to 20.0 μm and specific surface area is 0.1 to 3.5 m ² /g, which is used to adjust the viscosity of a liquid composition containing a thermosetting resin. silica particles.
<14> The silica particles according to <13> above, having a median diameter d50 of more than 1.0 μm and 5.0 μm or less.
<15> The silica particles according to <13> above, having a specific surface area of 0.8 to 2.0 m ² /g.

According to an embodiment of the present disclosure, a liquid composition and prepreg capable of forming a cured product with excellent adhesion to a metal base layer are provided. According to one embodiment of the present disclosure, a resin-coated metal base material and a wiring board are provided that have excellent adhesion between a liquid composition or a cured product and a metal base layer. According to one embodiment of the present disclosure, silica particles are provided that are used to adjust the viscosity of a liquid composition capable of forming a cured product with excellent adhesion to a metal base layer.

Embodiments of the present disclosure will be described in detail below. However, embodiments of the present disclosure are not limited to the following embodiments. In the following embodiments, the constituent elements (including elemental steps and the like) are not essential unless otherwise specified. The same applies to numerical values and their ranges, and they do not limit the embodiments of the present disclosure.

In the present disclosure, numerical ranges indicated using "~" include the numerical values written before and after "~" as minimum and maximum values, respectively.
In the present disclosure, each component may contain multiple types of corresponding substances. If there are multiple types of substances corresponding to each component in the composition, the content rate or content of each component is the total content rate or content of the multiple types of substances present in the composition, unless otherwise specified. means quantity.
In the present disclosure, a plurality of types of particles corresponding to each component may be included. When a plurality of types of particles corresponding to each component are present in the composition, the particle diameter of each component means a value for a mixture of the plurality of types of particles present in the composition, unless otherwise specified.
In this disclosure, "silica particles" refers to a group of multiple silica particles, unless otherwise specified.
In the present disclosure, "median diameter d50 (hereinafter also simply referred to as "d50")" refers to the volume of particles determined by a laser diffraction particle size distribution measuring device (for example, "MT3300EXII" manufactured by Microtrac Bell Co., Ltd.). This is the reference cumulative 50% diameter. That is, the particle size distribution is measured by a laser diffraction/scattering method, a cumulative curve is obtained with the total volume of the particles as 100%, and the particle diameter is the point on the cumulative curve where the cumulative volume becomes 50%.
In the present disclosure, "10% particle size d10" (hereinafter also simply referred to as "d10") refers to particles determined by a laser diffraction particle size distribution measuring device (for example, "MT3300EXII" manufactured by Microtrac Bell Co., Ltd.). This is the volume-based cumulative 10% diameter of . In other words, the particle size distribution is measured by laser diffraction/scattering method, and a cumulative curve is obtained with the total volume of the particles as 100%.The particle size is the point on the cumulative curve where the cumulative volume from the small particle size side is 10%. be.
In the present disclosure, "particle proportion with a particle diameter of 10 μm or more" is a particle proportion determined from a number-based particle size distribution obtained by the Coulter counter method. Among the 50,000 particles, the number of particles with a particle size of 10 μm or more is calculated, and the ratio (number ppm) of particles with a particle size of 10 μm or more to the total number of measured particles is determined.
In the present disclosure, the "coefficient of variation" (hereinafter also referred to as "CV value") of particle diameter is an index of relative dispersion of particle diameter, and the standard deviation of particle diameter is calculated as the average value (d50 of particle diameter). The value divided by is expressed as a percentage. The standard deviation and average value of the particle size are determined from the volume-based particle size distribution obtained by the Coulter Counter method.
The Coulter counter method is performed using, for example, a precision particle size distribution measuring device Multisizer 4e manufactured by Beckman Coulter.
In the present disclosure, the "specific surface area" is determined by the BET method based on the nitrogen adsorption method using a specific surface area/pore distribution measuring device (for example, "Tristar II" manufactured by Micromeritic Co., Ltd.).
In the present disclosure, "sphericity" refers to the maximum diameter (DL) of any 100 particles in a photographic projection obtained by photographing with a scanning electron microscope (SEM), and the diameter perpendicular to this. The short diameter (DS) is measured, and the ratio of the minimum diameter (DS) to the maximum diameter (DL) (DS/DL) is expressed as an average value.
In the present disclosure, "dielectric loss tangent" and "permittivity" are measured by a perturbation resonator method using a dedicated device (for example, "Vector Network Analyzer E5063A" manufactured by Keycom Co., Ltd.).
In the present disclosure, "viscosity" is measured at 25° C. with a rotary rheometer (for example, Modular Rheometer PhysicaMCR-301 manufactured by Anton Paar) for 30 seconds at a shear rate of 1 rpm, and the obtained 30 seconds Represents the viscosity at the point in time.
In the present disclosure, the "thixotropic ratio" is calculated by dividing the viscosity measured at a rotational speed of 1 rpm by the viscosity measured at a rotational speed of 60 rpm using a rotational rheometer.
In the present disclosure, the "weight average molecular weight" is determined in terms of polystyrene using gel permeation chromatography (GPC).
In the present disclosure, "surface tension" is measured by the Wilhelmy method in a solvent at 25° C. using a surface tension meter.
In the present disclosure, the "boiling point" is the boiling point at normal pressure of 1.013×10 ⁵ Pa.
In the present disclosure, the "evaporation rate" refers to the evaporation rate based on butyl acetate, which is the relative evaporation rate when the evaporation rate of butyl acetate at 23°C is set to 1.
In the present disclosure, "liquid composition" refers to a composition that is liquid at 25°C.
In the present disclosure, the term "semi-cured product" refers to a cured product in which an exothermic peak accompanying curing of the thermosetting resin appears when the cured product of the liquid composition is measured by differential scanning calorimetry. That is, the semi-cured product means a cured product in which uncured thermosetting resin remains.
In the present disclosure, the term "cured product" refers to a cured product in which no exothermic peak associated with curing of the thermosetting resin appears when the cured product of the liquid composition is measured by differential scanning calorimetry. That is, the cured product means a cured product in which no uncured thermosetting resin remains.
In the present disclosure, the maximum height roughness Rz is measured in accordance with JIS B 0601 (2013).

The liquid composition of the present disclosure (hereinafter also referred to as the present composition) comprises a thermosetting resin and silica having a d50 of 0.5 to 20 μm and a specific surface area of 0.1 to 3.5 m ² /g. particles, and has a viscosity of 100 to 10,000 mPa·s measured at a rotation speed of 1 rpm at 25°C. In other words, the present composition is a liquid thermosetting composition.
The viscosity of the present composition measured at a rotation speed of 1 rpm is 100 to 10,000 mPa·s, preferably 130 to 5,000 mPa·s, more preferably 150 to 3,000 mPa·s, even more preferably 180 to 1,500 mPa·s, and even more preferably 200 to 1,500 mPa·s. Particularly preferred is 1000 mPa·s.
From the viewpoint of ease of storage of the present composition, fluidity during use, etc., the thixotropic ratio of the present composition is preferably 3.0 or less, more preferably 2.5 or less, and even more preferably 2.0 or less. The lower limit of the thixotropic ratio is not particularly limited, and can be set to 0.5 or more.

This composition has excellent adhesion to the metal base layer. Although its mechanism of action is not clear, it is generally estimated as follows. The composition includes silica particles having a specific range of d50 and specific surface area. This improves the wettability of the silica particles contained in the composition and suppresses their aggregation, thereby improving the uniform dispersibility of the silica particles in the composition and keeping the viscosity of the composition within a predetermined range. It is converging. By using the present composition containing silica particles in such a state, the formation of a cured product in which uneven distribution of silica particles is suppressed, in other words, the formation of a cured product in which silica particles are not excessively exposed on the surface is promoted. it is conceivable that. As a result, it is thought that the adhesiveness of the cured product obtained from the present composition to the metal base layer improves. Hereinafter, the adhesion to the metal base layer will be simply referred to as "adhesion".

The composition contains a thermosetting resin. One type of thermosetting resin may be used, or two or more types may be used. Examples of thermosetting resins include epoxy resins, polyphenylene ether resins, polyimide resins, phenol resins, and ortho-divinylbenzene resins. From the viewpoints of adhesion, heat resistance, etc., the thermosetting resin is preferably an epoxy resin, a polyphenylene ether resin, or an orthodivinylbenzene resin.

Epoxy resins include bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin, alicyclic epoxy resin, phenol novolac epoxy resin, cresol novolak epoxy resin, bisphenol A novolac epoxy resin, and polyfunctional epoxy resin. Examples include diglycidyl etherified products of phenol and diglycidyl etherified products of polyfunctional alcohols.
The polyphenylene ether resin may be modified polyphenylene ether or unmodified polyphenylene ether, but from the viewpoint of adhesiveness, modified polyphenylene ether is preferable. The modified polyphenylene ether has a polyphenylene ether chain or a substituent bonded to the terminal of the polyphenylene ether chain. The substituent is preferably a group having a reactive group, more preferably a group having a vinyl group, (meth)acryloyloxy group, or epoxy group.

The hydrogen atom of the phenylene group in the polyphenylene ether chain may be substituted with an alkyl group, an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group, or an alkynylcarbonyl group.

From the viewpoint of adhesion, dielectric properties, etc., the weight average molecular weight of the thermosetting resin is preferably from 1,000 to 7,000, more preferably from 1,000 to 5,000, and even more preferably from 1,000 to 3,000.

From the viewpoint of adhesion, etc., the content of the thermosetting resin based on the total mass of the composition is preferably 10 to 40% by mass, more preferably 15 to 35% by mass, and even more preferably 20 to 30% by mass.

The composition contains silica particles with a d50 of 0.5 to 20.0 μm.
The d50 of the silica particles is determined from the viewpoint of achieving a high balance between the physical properties of the composition itself, such as dispersion stability and fluidity, and the physical properties of the molded product formed from the composition, such as adhesion and low dielectric loss tangent. The thickness is preferably 1.0 to 10.0 μm, more preferably more than 1.0 μm and 5.0 μm or less.
The d10 of the silica particles is preferably 0.5 to 5.0 μm, and preferably 1.0 to 3.0 μm, from the viewpoint of improving the uniform dispersibility in the present composition and enhancing the interaction between the silica particles and the thermosetting resin. is more preferable.

The specific surface area of the silica particles is determined from the viewpoint of achieving a higher balance between the physical properties of the composition itself, such as dispersion stability and fluidity, and the physical properties of the molded product formed from the composition, such as adhesion and low dielectric loss tangent. Therefore, 0.3 to 3.0 m ² /g is preferable, and 0.8 to 2.0 m ² /g is more preferable.

The ratio of d50 to d10 (d50/d10) is preferably more than 1.0 and not more than 5.0 from the viewpoint of improving the uniform dispersibility in the present composition and increasing the interaction between the silica particles and the thermosetting resin. 1.3 to 4.0 is more preferable, and 1.5 to 3.0 is even more preferable.
From the viewpoint of reducing the water absorption rate of the present composition and its cured product, the product A between the specific surface area of the silica particles and the d50 of the silica particles is preferably 2.7 to 5.0 μm·m ² /g; More preferably 9 to 4.5 μm·m ² /g.
The particle size distribution of the silica particles contained in the present composition is preferably unimodal. The fact that the particle size distribution of the silica particles is unimodal can be confirmed from the fact that there is one peak in the particle size distribution determined by the laser diffraction/scattering method described above.

The CV value of the particle diameter of the silica particles in the present composition is preferably 30 to 80%, more preferably 30 to 70%, from the viewpoint of suppressing agglomeration of silica particles and improving the surface smoothness of molded products. 60% is more preferred, and 35 to 55% is particularly preferred.

In the silica particles in the present composition, the proportion of particles with a particle size of 30 μm or more is preferably 500 ppm or less, more preferably 300 ppm or less, and even more preferably 200 ppm or less, especially from the viewpoint of excellent surface smoothness of the molded product. It is preferably 100 ppm or less, particularly preferably 100 ppm or less.

The shape of each silica particle contained in the silica particles depends on the physical properties of the composition itself, such as dispersion stability and fluidity, and the physical properties of the molded product formed from the composition, such as adhesion and low dielectric loss tangent. From the viewpoint of achieving a high degree of balance, a spherical shape is preferable. From the same viewpoint, the sphericity of the spherical silica particles is preferably 0.75 or more, more preferably 0.90 or more, even more preferably 0.93 or more, and particularly preferably 1.00. Further, from the same viewpoint, the silica particles are preferably non-porous particles.

From the viewpoint of reducing transmission loss in a circuit when a resin-coated metal base material is used as a printed wiring board, the dielectric loss tangent of silica particles is preferably 0.0020 or less, more preferably 0.0010 or less, and 0.0010 or less at a frequency of 1 GHz. More preferably, it is .0008 or less.
From the same viewpoint, the dielectric constant of the silica particles is preferably 5.0 or less, more preferably 4.5 or less, and even more preferably 4.1 or less at a frequency of 1 GHz.

Individual silica particles may be treated with a silane coupling agent. By treating the surface of the silica particles with a silane coupling agent, the amount of residual silanol groups on the surface is reduced, making the surface hydrophobic, suppressing moisture adsorption, and improving dielectric loss. The affinity with the thermosetting resin is improved, and the dispersibility and strength after resin film formation can be improved.
Examples of the silane coupling agent include aminosilane coupling agents, epoxysilane coupling agents, mercaptosilane coupling agents, silane coupling agents, organosilazane compounds, and the like. One type of silane coupling agent may be used, or two or more types may be used in combination.
The amount of the silane coupling agent deposited is preferably 0.01 to 5 parts by mass, more preferably 0.10 to 2 parts by mass, per 100 parts by mass of silica particles.
It can be confirmed that the surface of the silica particles has been treated with the silane coupling agent by detecting a peak due to the substituent of the silane coupling agent using IR. Further, the amount of attached silane coupling agent can be measured by the amount of carbon.

The silica particles preferably contain titanium (Ti) in an amount of 30 to 1500 ppm by mass, more preferably 100 to 1000 ppm by mass, and even more preferably 100 to 500 ppm by mass. Ti is a component that is optionally included in the production of silica particles. During production of silica particles, generation of fine powder due to cracking of silica particles increases the specific surface area of the particles. By including Ti during the production of silica particles, it is possible to facilitate heat compaction during firing and suppress cracking of the particles. As a result, the generation of fine powder can be suppressed, and the number of particles adhering to the surface of the base particle of the silica particles can be reduced, making it easier to adjust the specific surface area of the silica particles. Containing Ti in an amount of 30 mass ppm or more facilitates thermal compaction during firing, thereby suppressing the generation of fine powder due to cracking, and a Ti content of 1500 mass ppm or less provides the above effects and suppresses an increase in the amount of silanol groups. and can increase the dielectric loss tangent.

The silica particles may contain impurity elements other than titanium (Ti) within a range that does not impede the effects of the present disclosure. In addition to Ti, impurity elements include, for example, Na, K, Mg, Ca, Al, Fe, and the like. The total content of alkali metals and alkaline earth metals among the impurity elements is preferably 2000 mass ppm or less, more preferably 1000 mass ppm or less, and even more preferably 200 mass ppm or less.

Preferably, the silica particles are silica particles produced by a wet process. The wet method refers to a method that includes a step of using a liquid silica source and gelling it to obtain a raw material for silica particles. By using the wet method, it is easier to adjust the shape of silica particles, especially spherical silica particles, and there is no need to adjust the shape of the particles by grinding, etc., and as a result, particles with a small specific surface area can be obtained. Cheap. In addition, in the wet method, it is difficult to produce particles that are significantly smaller than the average particle size, and the specific surface area tends to become small after firing. Furthermore, in the wet method, by adjusting the impurities in the silica source, the amount of impurity elements such as titanium can be adjusted, and the impurity elements described above can be uniformly dispersed in the particles.

Examples of the wet method include a spray method, an emulsion gelling method, and the like. As an emulsion gelling method, for example, a dispersed phase containing a silica precursor and a continuous phase are emulsified, and the resulting emulsion is gelled to obtain a spherical silica precursor. As the emulsification method, it is preferable to prepare an emulsion by supplying a dispersed phase containing a silica precursor to a continuous phase through micropores or a porous membrane. In this way, an emulsion with a uniform droplet size is produced, and as a result, spherical silica particles with a uniform particle size are obtained. Examples of such emulsification methods include a micromixer method and a membrane emulsification method. For example, the micromixer method is disclosed in International Publication No. 2013/062105.

Silica particles are obtained by heat-treating the silica precursor. The heat treatment has the effect of sintering the spherical silica precursor to densify the shell, as well as reducing the amount of silanol groups on the surface and lowering the dielectric loss tangent. The temperature of the heat treatment is preferably 700°C or higher. Further, from the viewpoint of suppressing particle aggregation, the temperature is preferably 1600°C or lower. Moreover, the obtained silica particles may be surface-treated with a silane coupling agent.

The content of silica particles per 100 parts by mass of the thermosetting resin in the present composition is preferably 50 parts by mass or more, more preferably 70 parts by mass or more, even more preferably 90 parts by mass or more, and even if it is 100 parts by mass or more. good. Further, the content is preferably 600 parts by mass or less, more preferably 400 parts by mass or less, even more preferably 300 parts by mass or less, and particularly preferably 250 parts by mass or less.
Due to the above-described mechanism of action, the silica particles in this composition are sufficiently wetted and uniformly dispersed, and are highly likely to interact with the thermosetting resin. Therefore, even in the present composition in which the content is within this range, that is, in the present composition in which the thermosetting resin is filled with a large amount of silica particles, both components are easily stabilized, and the adhesion to the metal base layer is improved. Excellent molded products can be formed.

The composition may contain one or more curing agents. A curing agent is an agent that initiates a curing reaction of a thermosetting resin by the action of heat, and specifically, α,α'-bis(t-butylperoxy-m-isopropyl)benzene, 2,5- Dimethyl-2,5-di(t-butylperoxy)-3-hexyne, benzoyl peroxide, 3,3',5,5'-tetramethyl-1,4-diphenoquinone, chloranil, 2,4,6- Examples include tri-t-butylphenoxyl, t-butylperoxyisopropyl monocarbonate, azobisisobutyronitrile, and the like. The content of the curing agent per 100 parts by mass of the thermosetting resin is preferably 0.1 to 5 parts by mass.

The composition may contain one or more curing accelerators. Examples of curing accelerators include trialkenyl isocyanurate compounds such as triallyl isocyanurate, polyfunctional acrylic compounds having two or more acryloyl or methacryloyl groups in the molecule, and polyfunctional vinyl having two or more vinyl groups in the molecule. Compounds include vinylbenzyl compounds such as styrene having a vinylbenzyl group in the molecule. The content of the curing accelerator relative to 100 parts by mass of the thermosetting resin is preferably 10 to 100 parts by mass.

The composition may contain one or more solvents. From the viewpoint of reducing the water absorption of the present composition and its cured product, the surface tension of the solvent is preferably 45 mN/m or less, more preferably 40 mN/m or less, even more preferably 35 mN/m or less, and 30 mN/m or less. Particularly preferred. The lower limit of the surface tension is not particularly limited, and can be 5 mN/m or more. From the viewpoint of handling properties when thermosetting the present composition to form a molded article such as a prepreg, the boiling point of the solvent is preferably 75°C or higher, more preferably 80°C or higher, and even more preferably 90°C or higher. The upper limit of the boiling point is not particularly limited, and can be 200°C or less. When the evaporation rate of butyl acetate is 1, the evaporation rate of the solvent is preferably 0.3 to 3.0 from the viewpoint of handling properties when thermosetting the present composition to form a molded article such as prepreg. , 0.4 to 2.0 are more preferable.
Solvents include acetone, methanol, ethanol, butanol, 2-propanol, 2-methoxyethanol, 2-ethoxyethanol, toluene, xylene, methyl ethyl ketone, N,N-dimethylformamide, methyl isobutyl ketone, N-methyl-2-pyrrolidone. , n-hexane, cyclohexane and the like. From the viewpoint of adhesion, etc., the solvents were toluene (110°C, 28mN/cm, 0.58), cyclohexanone (156°C, 35mN/cm, 0.32), methyl ethyl ketone (80°C, 24.6mN/cm, 3 .7) and N-methyl-2-pyrrolidone (202° C., 42 mN/m, 0.3 to 4.0). Note that the numbers in parentheses indicate boiling point, surface tension, and evaporation rate in that order.
The content of the solvent with respect to the total mass of the present composition is not particularly limited, and can be 10 to 60% by mass.

The content of silica particles per 100 parts by mass of the solvent in the present composition is preferably 50 to 550 parts by mass, may be 100 to 500 parts by mass, may be 125 to 400 parts by mass, and may be 150 to 300 parts by mass. It may be a department.

The composition may contain one or more plasticizers. Examples of the plasticizer include butadiene-styrene copolymer. The content of the plasticizer per 100 parts by mass of the thermosetting resin is preferably 10 to 50 parts by mass, more preferably 20 to 40 parts by mass.

In addition to the above-mentioned ingredients, this composition also contains a surfactant, a thixotropy agent, a pH adjuster, a pH buffer, a viscosity adjuster, an antifoaming agent, a silane coupling agent, and a dehydrating agent within the range that does not impair its effects. Other components such as agents, weathering agents, antioxidants, heat stabilizers, lubricants, antistatic agents, brighteners, colorants, conductive materials, mold release agents, surface treatment agents, flame retardants, and various organic or inorganic fillers. may further include.

The prepreg of the present disclosure includes the present composition or a semi-cured product thereof, and a fibrous base material. Examples of the fibrous base material include glass cloth, aramid cloth, polyester cloth, glass nonwoven fabric, aramid nonwoven fabric, polyester nonwoven fabric, and pulp paper. The thickness of the fibrous base material is not particularly limited, and can be 3 to 10 μm. Note that since the present composition has been described above, the description will be omitted here.

The prepreg of the present disclosure can be produced by coating or impregnating a fibrous base material with the present composition. After coating or impregnating the present composition, the liquid composition may be heated and semi-cured.

The resin-coated metal base material of the present disclosure includes the present composition, the semi-cured product thereof, or the above prepreg, and a metal base layer. The metal base layer may be provided on one surface of the present composition, its semi-cured product, or the prepreg, or may be provided on both surfaces.
The type of the metal base layer is not particularly limited, and examples of metals constituting the metal base layer include copper, copper alloy, stainless steel, nickel, nickel alloy (including 42 alloy), aluminum, and aluminum alloy. , titanium, titanium alloys, etc. The metal base layer is preferably a metal foil, more preferably a copper foil such as rolled copper foil or electrolytic copper foil. The surface of the metal foil may be subjected to anti-corrosion treatment (eg, an oxide film such as chromate) or roughening treatment. As the metal foil, a metal foil with a carrier consisting of a carrier copper foil (thickness: 10 to 35 μm) and an ultra-thin copper foil (thickness: 2 to 5 μm) laminated on the surface of the carrier copper foil via a release layer is used. May be used. The surface of the metal base layer may be treated with a silane coupling agent. In this case, the entire surface of the metal base layer may be treated with a silane coupling agent, or a part of the surface of the metal base layer may be treated with a silane coupling agent. As the silane coupling agent, those mentioned above can be used.

The thickness of the metal base layer is preferably 1 to 40 μm, more preferably 2 to 15 μm. From the viewpoint of reducing transmission loss when a resin-coated metal base material is used as a printed wiring board, the maximum height roughness (Rz) of the metal base layer (for example, copper foil) is preferably 2 μm or less, and 1.2 μm. The following are more preferred. It is preferable that the Rz of the surface of the metal base layer (for example, copper foil) on the liquid composition, semi-cured product, or prepreg side is within the above range. When a resin-coated metal base material is used as a printed wiring board, transmission loss can generally be reduced, but the adhesion between the metal base layer and prepreg etc. generally tends to decrease. According to the prepreg using the present composition of the present disclosure, it is possible to suppress the above-mentioned decrease in adhesion and reduce transmission loss.

In one embodiment, the resin-coated metal base material of the present disclosure can be manufactured by applying the present composition to the surface of a metal base layer. After applying the present composition, the liquid composition may be heated and semi-cured.
In other embodiments, the resin-coated metal base material of the present disclosure can be manufactured by laminating a metal base layer and a prepreg. Examples of the method for laminating the metal base material layer and the prepreg include a method of thermocompression bonding them together.

The wiring board of the present disclosure includes a cured product of the present composition and metal wiring. As the metal wiring, one manufactured by etching or the like the above metal base layer can be used.

The wiring board of the present disclosure includes a method of etching the metal base layer included in the resin-coated metal base material, an electrolytic plating method (semi-additive method (SAP method), a modified semi-additive method (MSAP method), etc.) on the surface of the cured product of the present composition. It can be manufactured by a method of forming a pattern circuit by a method such as a method (method), etc.).

In one embodiment, the silica particles are used to adjust the viscosity of a liquid composition containing a thermosetting resin, have a d50 of 0.5 to 20.0 μm, and a specific surface area of 0.1 to 3.0 μm. 5 m ² /g.
Preferable numerical ranges of d50, d10, specific surface area, d50/d10, sphericity, dielectric loss tangent, etc. of the silica particles have been described above, and therefore will not be described here. Further, as described above, the silica particles may contain titanium and an impurity element.

Hereinafter, embodiments of the present disclosure will be described in detail using Examples, but the embodiments of the present disclosure are not limited thereto.

(Method for measuring d50 of silica particles)
The d50 of the following silica particles was measured by a laser diffraction/scattering method using a particle size distribution analyzer (MT3300EXII, manufactured by Microtrac Bell). Specifically, the measurement was performed after the silica particles were dispersed by performing ultrasonic irradiation three times for 60 seconds in the device. The d50 was measured twice for 60 seconds, and the average value was taken as the average value. Table 1 summarizes the d50 of the silica particles contained in silica particles A to D.

(Method for measuring specific surface area of silica particles)
The following silica particles A to D were dried under reduced pressure at 230° C. to completely remove moisture and used as samples. Regarding this sample, the specific surface area was determined by the multi-point BET method using nitrogen gas using an automatic specific surface area/pore distribution measuring device "Tristar II" manufactured by Micromeritic Co., Ltd., and the results are summarized in Table 1.

1. Preparation of each component for producing liquid composition [thermosetting resin]
Polyphenylene ether resin: Modified polyphenylene ether in which the terminal hydroxyl group of polyphenylene ether is modified with a methacryloyloxy group (manufactured by SABIC: Noryl SA9000, Mw: 1700, number of functional groups per molecule: 2)
[Silica particles]
Silica particles A: As a spherical silica precursor, 15 g of silica powder 1 (manufactured by AGC SI Tech Co., Ltd.: H-31, d50: 3.5 μm) manufactured by a wet method was filled into an alumina crucible, and the temperature inside the electric furnace was set to 1200. Silica particles obtained by heat treatment at ℃ for 1 hour, cooling to 25 ℃, and crushing in an agate mortar.
Silica particles B: As a spherical silica precursor, 15 g of silica powder 2 (manufactured by Suzuki Yushi Co., Ltd., E-2C, d50: 2.5 μm) manufactured by a wet method was filled into an alumina crucible, and the temperature inside the electric furnace was set at 1200°C. The silica particles were heat-treated for 1 hour, cooled to 25°C, and crushed in an agate mortar.
Silica particles C: Silica particles manufactured by VMC (Vaporized Metal Combustion) method (manufactured by Admatex: SC5500-SQ).
Silica particles D: Silica particles manufactured by a dry method (manufactured by Micron Corporation: SPH516).
Silica particles E: Silica particles manufactured by a wet method (manufactured by AGC SI Tech Co., Ltd.: H-201, d50: 20.0 μm).
Silica particles F: Silica powder manufactured by a wet method (manufactured by Suzuki Yushi Co., Ltd., E-2C, d50: 2.5 μm).
Silica particles G: Silica particles manufactured by the VMC method (manufactured by Admatex: SO-C1).

2. Production of liquid composition, prepreg and resin-coated metal substrate <Example 1>
59 parts by mass of polyphenylene ether resin, 16 parts by mass of butadiene-styrene random copolymer (manufactured by Cray Valley, Ricon 100), 25 parts by mass of triallyl isocyanurate (curing accelerator, manufactured by Mitsubishi Chemical Corporation, TAIC), α, α '-ji(t
-Butylperoxy) diisopropylbenzene (curing agent, manufactured by NOF Corporation, Perbutyl (registered trademark) P)
1 part by mass of silica particles A, 55 parts by mass of silica particles A, and 80 parts by mass of toluene were placed in a polyethylene bottle, and alumina balls with a diameter of 20 mm were added thereto and mixed at 30 rpm for 12 hours. The alumina balls were removed to obtain a liquid composition. The liquid composition contains 68.75 parts by mass of silica particles A per 100 parts by mass of toluene, and 93 parts by mass of silica particles A per 100 parts by mass of polyphenylene ether resin.
The liquid composition was impregnated and coated on a glass cloth of IPC spec 2116, and heated and dried at 160° C. for 4 minutes to obtain a prepreg.
Copper foil with a carrier having a thickness of 18 μm (copper foil thickness: 3 μm, maximum height roughness Rz: 2 μm, manufactured by Mitsui Kinzoku Co., Ltd., MT18E) was laminated on both sides of the prepreg, and the temperature was 230° C. and the pressure was 30 kg/cm ² The resin was heat-molded for 120 minutes to obtain a resin-coated metal base material.

<Examples 2 to 7>
A liquid composition, a prepreg, and a resin-coated metal base material were produced in the same manner as in Example 1, except that silica particles A were changed to the silica particles listed in Table 1.

<Examples 8-9>
A liquid composition of Example 8 containing 137.5 parts by mass of silica particles A based on 100 parts by mass of toluene was obtained in the same manner as in Example 1 except that the amount of toluene was changed to 40 parts by mass. Further, a liquid composition of Example 9 containing 137.5 parts by mass of silica particles C per 100 parts by mass of toluene was obtained in the same manner as in Example 3 except that the amount of toluene was changed to 40 parts by mass. Using the obtained liquid composition, a prepreg and a resin-coated metal base material were manufactured in the same manner as in Example 1.

<Measurement of peel strength>
In accordance with IPC-TM650-2.4.8, the peel strength between the prepreg and the carrier-attached copper foil was measured using a Tensilon universal testing machine (manufactured by A&D, RTC-1250A). The measurement results are summarized in Table 1.
Note that Examples 1 to 3, 8, and 9 are examples, and Examples 4 to 7 are comparative examples.

Table 1 shows that the prepreg using this composition has excellent adhesion to the metal base layer.

Claims (15)

Contains a thermosetting resin and silica particles having a median diameter d50 of 0.5 to 20.0 μm and a specific surface area of 0.1 to 3.5 m ² /g, and a rotation speed of 1 rpm at 25° C. A liquid composition having a viscosity of 100 to 10,000 mPa·s as measured by The liquid composition according to claim 1, wherein the silica particles have a median diameter d50 of 1.0 to 10.0 μm. The liquid composition according to claim 1, wherein the silica particles have a median diameter d50 of more than 1.0 μm and 5.0 μm or less. The liquid composition according to claim 1, wherein the silica particles have a specific surface area of 0.8 to 2.0 m ² /g. The liquid composition according to claim 1, wherein the content of the silica particles is 50 to 400 parts by mass based on 100 parts by mass of the thermosetting resin. The liquid composition according to claim 1, wherein the thermosetting resin is an epoxy resin, a polyphenylene ether resin, or an orthodivinylbenzene resin. The liquid composition according to claim 1, further comprising a solvent, and the solvent includes at least one selected from the group consisting of toluene, cyclohexanone, methyl ethyl ketone, and N-methyl-2-pyrrolidone. A prepreg comprising the liquid composition according to claim 1 or a semi-cured product thereof, and a fibrous base material. A resin-coated metal base material comprising the liquid composition or semi-cured product thereof according to any one of claims 1 to 7, or the prepreg according to claim 8, and a metal base material layer. The resin-coated metal base material according to claim 9, wherein the metal base layer is copper foil. The resin-coated metal base material according to claim 10, wherein the copper foil has a maximum height roughness Rz of a surface on the side of the liquid composition, the semi-cured product, or the prepreg of 2 μm or less. A wiring board comprising a cured product of the liquid composition according to claim 1 and metal wiring. Silica having a median diameter d50 of 0.5 to 20.0 μm and a specific surface area of 0.1 to 3.5 m ² /g, which is used to adjust the viscosity of a liquid composition containing a thermosetting resin. particle. The silica particles according to claim 13, having a median diameter d50 of more than 1.0 μm and less than or equal to 5.0 μm. The silica particles according to claim 13, having a specific surface area of 0.8 to 2.0 m ² /g.