JP4797536B2 - Manufacturing method of prepreg for printed wiring board, manufacturing apparatus for prepreg for printed wiring board, prepreg for printed wiring board and laminated board - Google Patents

Description

The present invention relates to a printed wiring board prepreg manufacturing method, a printed wiring board prepreg manufacturing apparatus, a printed wiring board prepreg, and a laminated board.

A prepreg used for the production of laminated boards and multilayer printed wiring boards for printed wiring boards is generally produced by impregnating a long fiber base material with a liquid resin, followed by heat drying and semi-curing it. .
Laminates are usually manufactured by stacking one or many prepregs, and then stacking copper foils on both sides of the laminate. In addition, the multilayer printed wiring board is manufactured by using a circuit board on the front and back of the laminated board as an inner circuit board, and superposing a prepreg on the circuit board, followed by heat and pressure molding.
Insulating layer parts of laminated boards and multilayer printed wiring boards obtained by the above method (parts where the prepreg is heated and pressurized and cured and molded) have good moldability and thickness accuracy to ensure insulation reliability. In addition, mechanical properties such as warpage characteristics and dimensional stability are required to be good for accuracy and workability during circuit processing and component mounting.

In the case of molding a laminated board or multilayer printed wiring board, means for improving the moldability include a method of molding at a high pressure or increasing the fluidity of the resin used for the prepreg.
However, these methods tend to cause internal strain in the base material used for the prepreg during molding, which may affect the mechanical properties. Further, if the resin flow is excessive, the thickness accuracy may be lowered.
For this reason, it is considered that one of effective means is to use a prepreg having excellent impregnation properties.

Examples of the method for impregnating the fiber base material with the liquid resin include a method of immersing the fiber base material in the liquid resin, a method using a kiss roll, and the like (for example, see Patent Document 1).
The method of immersing the fiber substrate in the liquid resin replaces the air inside the fiber substrate and the liquid resin in the liquid resin, and the method using a kiss roll pushes the liquid resin from one side of the fiber substrate. This is a method for promoting the replacement of the air inside the fiber base material with the liquid resin.
In addition, as a method of improving the impregnation property, there is a method of using an impregnation roll having a large number of holes capable of flowing a liquid resin. This is because when the impregnation roll is immersed in the liquid resin and the fiber base material is transferred along the surface of the impregnation roll, the liquid resin is caused to flow through the hole by a suction means or the like, and air remains inside the fiber base material. (For example, refer to Patent Documents 2 and 3).
JP 60-165213 A JP 2003-159706 A JP 2003-025328 A

By the way, in the above method in which the fiber base material is immersed in the liquid resin, the prepreg can be manufactured with a simple apparatus. However, since the air inside the fiber base material is trapped and remains, the prepreg having an unimpregnated portion is left. It is easy to become.
In addition, the above method using a kiss roll usually has a short contact distance between the fiber base material and the kiss roll, so that the time during which the fiber base material can be impregnated with the liquid resin is short. For this reason, even if these methods were combined, there was a problem that the impregnation property was not sufficiently improved.
Further, in the method using the impregnating roll, the liquid resin flows only in the holes provided in the impregnating roll, so that the flow of the liquid resin is localized, and the effect of improving the impregnation property is sufficiently expressed in the entire fiber base material. It was difficult.
In view of such a background, the present invention provides a method for producing a prepreg for a printed wiring board that can exhibit excellent impregnation properties with high uniformity, and a prepreg for a printed wiring board that can implement this production method. The present invention provides a manufacturing apparatus, a prepreg for a printed wiring board obtained by the above manufacturing method, and a laminated board formed by molding the prepreg.

Such an object is achieved by the following present inventions (1) to (10).
(1) A method for producing a prepreg for a printed wiring board in which a glass fiber cloth is impregnated with a liquid resin containing at least an epoxy resin ,
While contact with the liquid surface of the liquid resin, or while immersed in the liquid resin, and conveys the glass fiber cloth,
During the transport, and wherein the upper surface side of the glass fiber cloth sucks the liquid resin in the thickness direction of the glass fiber cloth, a step, contacting supporting the glass fiber cloth in the direction of the suction The manufacturing method of the prepreg for printed wiring boards .
(2) In the above process, when sucking the liquid resin, to rectify the flow of the liquid resin, the manufacturing method of the printed wiring board prepreg according to the above (1).
(3) In the above process, while contact with the liquid surface of the liquid resin, the glass fiber cloth is conveyed to horizontal direction, the (1) or the method of manufacturing a prepreg for a printed wiring board according to (2) .
(4) In the above process, the while immersed in a liquid resin, the glass fiber cloth is conveyed to horizontal direction, the (1) A process for producing a prepreg for a printed wiring board according to (2).
(5) The manufacturing method of the prepreg for printed wiring boards in any one of said (1) thru | or (4) whose said glass fiber cloth is a glass woven cloth in the said process.
(6) A method for producing a prepreg in which a glass fiber cloth is impregnated with a liquid resin,
The manufacturing method of the prepreg for printed wiring boards which has an impregnation process including the process in any one of said (1) thru | or (5).
(7) A prepreg for a printed wiring board, which is obtained by the production method according to any one of (1) to (6) above.
(8) A laminated board obtained by heating and pressing the prepreg for printed wiring board according to (7).
(9) A printed wiring board prepreg manufacturing apparatus for impregnating a glass fiber cloth with a liquid resin containing at least an epoxy resin ,
(A) a reservoir means for storing the liquid resin,
(B) a transport means for the liquid resin to the glass fiber cloth conveying the glass fiber cloth to be impregnated,
(C) from the upper surface side of the glass fiber cloth and a suction means for sucking the liquid resin in the thickness direction of the glass fiber cloth,
And (d) contacting the support means, wherein for glass fiber fabric contact support in a direction to suck the liquid resin,
An apparatus for producing a prepreg for a printed wiring board, comprising:
(10) Furthermore,
(E) a suction means, between the glass fiber cloth, a rectifying means for rectifying the flow of the liquid resin,
The manufacturing apparatus of the prepreg for printed wiring boards as described in said (9) which has these.

According to the method for producing a prepreg for a printed wiring board of the present invention, a prepreg capable of expressing excellent impregnation properties with high uniformity can be produced. Moreover, according to the manufacturing apparatus of the prepreg for printed wiring boards of this invention, the said manufacturing method can be implemented simply. And the prepreg for printed wiring boards obtained by this invention is excellent in impregnation property, and the laminated board using this is excellent in moldability.

Hereinafter, the present invention will be described in detail.
First, the manufacturing apparatus of the prepreg of this invention and the manufacturing method of the prepreg of this invention are demonstrated.

The prepreg manufacturing apparatus of the present invention (hereinafter sometimes simply referred to as “manufacturing apparatus”)
A prepreg manufacturing apparatus for impregnating a fiber base material with a liquid resin,
(A) storage means for storing liquid resin;
(B) a transport means for transporting the fiber base material so that the liquid base material is impregnated with the liquid resin;
(C) suction means for sucking liquid resin from the upper surface side of the fiber base material in the thickness direction of the fiber base material;
(D) contact support means for contacting and supporting the fiber substrate in the direction of sucking the liquid resin;
It is characterized by having.

Further, the method for producing the prepreg of the present invention (hereinafter sometimes simply referred to as “manufacturing method”)
A method for producing a prepreg in which a fiber base material is impregnated with a liquid resin,
While contacting the liquid surface of the liquid resin, or while immersing in the liquid resin, transport the fiber substrate,
During the conveyance, the liquid resin is sucked in the thickness direction of the fiber base material from the upper surface side of the fiber base material, and the fiber base material is contacted and supported in the suction direction (hereinafter simply referred to as “process of the present invention”). And the like.).
And the manufacturing method of this invention can be implemented with the manufacturing apparatus of the said invention.

FIG. 1 (1) shows a first embodiment (hereinafter sometimes simply referred to as “embodiment [1]”) according to the manufacturing apparatus of the present invention.
The embodiment [1] includes a transport roll 2 as a transport means for the fiber substrate 1 a, a storage means 4 for the liquid resin 5, and an impregnation device 3.
The impregnation apparatus 3 has contact support means 6 for supporting and supporting the fiber base material 1 a and suction means 9 for sucking the liquid resin 5, and further rectifies between the fiber base material 1 a and the suction means 9. Means 7 are provided.
The fiber base material 1a can be supplied by continuously unwinding a sheet-like fiber base material in the form of a scroll, for example.
The liquid resin 5 is stored in the storage unit 4.
The two transport rolls 2 and 2 are configured to transport the fiber base material 1 a along the impregnation apparatus 3 while being in contact with the liquid surface of the liquid resin 5.

In the form shown in FIG. 1 (1), a total of five units 10 constituting one unit of the impregnation apparatus 3 are installed between the two transport rolls 2 and 2. However, the present invention is limited to this form. Instead, the number of units can be appropriately set depending on the properties of the fiber base material and the liquid resin, the transport speed of the fiber base material, the magnitude of the negative pressure applied by the suction means, and the like.
Here, the unit 10 includes two contact support means 6, one suction means 9, and one rectifying means 7.

FIG. 1B is an enlarged view of the unit 10 and will be described.
The fiber substrate 1a is conveyed on the liquid surface of the liquid resin 5 while the upper surface side is contact-supported by the contact support means 6.
The liquid resin 5 is sucked in the thickness direction from the upper surface side of the fiber base 1a by a suction means 9 such as a vacuum pump (not shown), and a flow 8 of the liquid resin is generated. Thereby, the liquid resin 5 moves so that it may ooze out to the upper surface side of the fiber base material 1a.
The rectifying means 7 is provided between the fiber base 1 a and the suction means 9. The rectifying means 7 has a rectifying hole 7a through which air can pass.

Although it does not specifically limit as liquid resin 5 used in embodiment [1], Usually, if it is used for manufacture of a laminated board, it can be used without being specifically limited.
Examples of the resin component that can be used for the liquid resin 5 include thermosetting resins such as epoxy resins, phenol resins, cyanate resins, dicyclopentadiene resins, and polyimide resins.
Furthermore, if necessary, additives such as a coupling agent can be appropriately blended in addition to a curing agent, a curing accelerator, a thermoplastic resin, an inorganic filler, an organic filler, and the like.
As the liquid resin 5, it is possible to suitably use a liquid form obtained by dissolving and / or dispersing solids such as the above resin components with an organic solvent or the like.

  The storage means 4 for storing the liquid resin 5 may be any one that can store a predetermined amount of the liquid resin 5 and has a size that can store the means constituting the manufacturing apparatus of the present invention. For example, a bat shape having a wide opening can be suitably used.

Although it does not specifically limit as a kind of fiber base material 1a used in embodiment [1], For example, glass fiber cloths, such as a glass fiber cloth and a glass non-woven cloth, and a fiber cloth or a non-woven cloth which uses inorganic compounds other than glass as a component Examples thereof include inorganic fiber cloths, aromatic polyamide resins, polyamide resins, aromatic polyester resins, polyester resins, polyimide resins, organic fiber cloths composed of organic fibers such as fluorine resins, and the like.
Among these, when a glass woven fabric which is a glass fiber fabric is used, a prepreg suitable for a laminated board requiring high formability can be obtained.

In FIG. 1 (1), although the structure using the conveyance roll 2 was shown as a conveyance means which conveys the fiber base material 1a, it is not limited to this, If it has the same function, it is applicable. can do.
As the transport roll 2, a drive roll or a guide roll can be used.
Here, the drive roll itself has a function of guiding the fiber base material 1a to a predetermined position while conveying the fiber base material 1a with a driving force. Further, the guide roll itself has only a function of guiding the fiber substrate 1a to a predetermined position without having a driving force. When a guide roll is used, other driving means can be applied.

The suction means 9 sucks the liquid resin 5 in the thickness direction of the fiber substrate 1a from the upper surface side of the fiber substrate 1a. Specifically, the liquid resin 5 on the lower surface side of the fiber substrate 1a is caused to flow to the upper surface side of the fiber substrate 1a. Thereby, impregnation property can be improved without applying a large stress to the fiber substrate 1a.
Here, when the direction in which the liquid resin 5 is sucked is the surface direction of the fiber base material 1a (the direction perpendicular to the thickness direction), the resistance of the fiber base material 1a to the flow of the liquid resin 5 becomes relatively large, and the fiber base Since the stress acting on the material 1a increases, depending on the flow rate of the liquid resin 5, it is difficult to bend the fiber bundle constituting the fiber substrate 1a or to convey the fiber substrate 1a continuously and stably. Sometimes it becomes.

As the suction means 9, for example, a configuration in which suction is directly performed using a vacuum pump, a configuration in which suction is performed indirectly through a decompression tank decompressed by a vacuum pump or the like can be suitably used.
The negative pressure applied by the suction means 9 varies depending on the viscosity of the liquid resin 5 and the basis weight (weight per unit area) of the fiber substrate 1a. For example, the negative pressure is reduced by 100 to 500 Torr from the atmospheric pressure. Pressure. Thereby, an impregnation improvement effect can be heightened, without making an excessive stress act on the fiber base material 1a.

The contact support means 6 contacts and supports the fiber substrate 1a in the direction in which the liquid resin 5 is sucked, and the configuration thereof is not particularly limited. For example, a square such as a square or a rectangle, or a circle such as a circle or an ellipse. A long rod-shaped contact support having a cross-sectional shape of the above and having a dimension equal to or greater than the width-direction dimension of the fiber substrate 1a (here, the width direction indicates a direction orthogonal to the conveyance direction of the fiber substrate 1a) A configuration using the means 6 can be preferably applied.
As a method of contacting and supporting the fiber substrate 1a using the contact support means 6, for example, the contact support means 6 having a quadrangular cross-sectional shape is installed horizontally with respect to the conveying direction of the fiber substrate 1a, and the fiber The base material 1a and the contact support means 6 are brought into contact with each other on the surface, or the contact support means 6 having a circular cross-sectional shape is provided so that the fiber base material 1a and the contact support means 6 come in contact with a gentle curved surface. It is preferable to do so.
Thereby, excessive stress does not act on the portion where the fiber base 1a and the contact support means 6 are in contact with each other, and it is possible to prevent the fiber bundle constituting the fiber base 1a from being bent.

In the embodiment [1], the rectifying means 7 is provided between the suction means 9 and the fiber substrate 1a.
The rectifying means 7 rectifies the flow of the liquid resin 5. Specifically, the flow of the liquid resin 5 from the lower surface side to the upper surface side of the fiber base material 1a by adjusting the flow of air that sucks the liquid resin 5 present on the upper surface side of the fiber base material 1a in the surface direction. And the uniformity of the impregnation improving effect in the surface direction of the fiber base 1a can be enhanced. Moreover, the fiber base material 1a can also be conveyed stably.

As this rectification | straightening means 7, the plate-shaped thing which has the rectification | straightening hole 7a can be used suitably.
Although it does not specifically limit as a shape of the rectification | straightening hole 7a, For example, a slit shape and a circular shape (a circle | round | yen and an ellipse are included) can be used suitably.
In this case, the area ratio of the portion of the rectifying hole 7s can be set to, for example, 20 to 70 area% with respect to the total area where the liquid resin 5 can flow when no rectifying plate is provided.

  When the rectifying means 7 is provided, it is preferable that the rectifying means 7 is provided between the suction means 9 and the fiber base 1a so as not to contact the fiber base 1a. Thereby, the said effect | action can be expressed effectively, without receiving the influence which the air which passes the rectification | straightening hole 7a, and the liquid resin 5 temporarily localize.

In the manufacturing method of the present invention according to the embodiment [1], the fiber substrate 1a is conveyed while being in contact with the liquid surface of the liquid resin 5. Thereby, the liquid resin 5 can be impregnated from the side in contact with the fiber substrate 1a. And since the upper surface side of the fiber base material 1a on the side not in contact with the liquid resin 5 is open to the atmosphere, the liquid resin in the thickness direction of the fiber base material 1a from the upper surface side of the fiber base material 1a by the suction means 9 By sucking 5, the replacement of the air remaining in the fiber substrate 1 a with the liquid resin 5 can be promoted, and the impregnation improving effect can be enhanced.
In the manufacturing method according to the embodiment [1], the sucked liquid resin 5 is at a position where it can be impregnated into the fiber substrate 1a, that is, a level slightly raised from the upper surface of the fiber substrate 1a. It is preferable to adjust the negative pressure by the suction means so as to be in the position. Thereby, the said effect | action can be expressed effectively.

In the manufacturing method according to the embodiment [1], by controlling the transport position of the fiber substrate 1a and the liquid surface position of the liquid resin 5, the fiber substrate 1a and the liquid resin 5 are always in contact with each other, The effect of improving the impregnation property can be expressed highly.
For this reason, it is preferable to convey the fiber base material 1a in a substantially horizontal direction parallel to the liquid surface of the liquid resin 5. Thereby, the said control can be performed easily.

In the manufacturing method according to the embodiment [1], the fiber substrate 1a is contact-supported in the direction in which the liquid resin 5 is sucked. Thereby, the stress which acts on the thickness direction of the fiber base material 1a by the suction | inhalation of the liquid resin 5 can be disperse | distributed, and the deformation | transformation of the fiber base material 1a can be prevented. And even when the air discharged to the upper surface side of the fiber base material 1a by the flow of the liquid resin 5 adheres to the upper surface side of the fiber base material 1a, it can be efficiently removed by the contact support. The impregnation improvement effect can be enhanced.

FIG. 2 (1) shows a second embodiment (hereinafter sometimes simply referred to as “embodiment [2]”) according to the manufacturing apparatus of the present invention.
The embodiment [2] includes a transport roll 12 as a transport means for the fiber substrate 1b, a storage means 14 for the liquid resin 15, and an impregnation device 13.
The impregnation apparatus 13 has a contact support means 16 for supporting and supporting the fiber base material 1 b and a suction means 19 for sucking the liquid resin 15, and further rectifies between the fiber base material 1 b and the suction means 19. Means 17 are provided.
The fiber base material 1b can be supplied by continuously unwinding a sheet-like fiber base material in the form of a roll, for example.
The liquid resin 15 is stored in the storage unit 14.
The two transport rolls 12 and 12 are configured to transport the fiber base material 1 b along the impregnation device 13 while being immersed in the liquid resin 15.

In the form shown in FIG. 2 (1), a total of five units 20 constituting one unit of the impregnation apparatus 13 are installed between the two transport rolls 12 and 12, but the present invention is limited to this form. Instead, the number of units can be appropriately set depending on the properties of the fiber base material and the liquid resin, the transport speed of the fiber base material, the magnitude of the negative pressure applied by the suction means, and the like.
Here, the unit 20 includes two contact support means 16, one suction means 19, and one rectifying means 17.

FIG. 2B is an enlarged view of the unit 20 and will be described.
The fiber base 1 b is conveyed in the liquid resin 15 while the upper surface side is contact-supported by the contact support means 16.
The liquid resin 15 is sucked in the thickness direction from the upper surface side of the fiber substrate 1b by a suction means 19 such as a vacuum pump (not shown), and a liquid resin flow 18 is generated. Thereby, the liquid resin 15 moves from the lower surface side of the fiber base material 1b to the upper surface side.
The rectifying means 17 is provided between the fiber base 1 b and the suction means 19. The rectifying means 17 has a rectifying hole 17a through which the liquid resin 15 can pass.

In the embodiment [2], as the liquid resin, the fiber base material, the storage means, the transport means, the suction means, the contact support means, and the rectifying means, the same configuration as that used in the embodiment [1] is preferably used. be able to.
The rectifying means 17 used in the embodiment [2] adjusts the flow of the liquid resin 15 existing on the upper surface side of the fiber base material 1b in the surface direction, so that the upper surface side from the lower surface side of the fiber base material 1b. The flow of the liquid resin 15 to the rectifier can be rectified, and the uniformity of the impregnation improvement effect in the surface direction of the fiber substrate 1b can be enhanced. Moreover, the fiber base material 1b can also be conveyed stably.

In the manufacturing method of the present invention according to the embodiment [2], the fiber substrate 1b is conveyed while being immersed in the liquid resin 15.
Thereby, the liquid resin 15 can be impregnated from both sides of the fiber substrate 1b. Then, by sucking the liquid resin 15 in the thickness direction of the fiber base material 1b from the upper surface side of the fiber base material 1b by the suction means 19, the replacement of the air remaining in the fiber base material 1b with the liquid resin 15 is promoted. Thus, the effect of improving the impregnation property can be enhanced.
In the manufacturing method according to the embodiment [2], it is preferable that the liquid surface of the liquid resin 15 in the unit 20 is positioned higher than the rectifying means 17. Thereby, the impregnation improvement effect by rectifying the liquid resin 15 can be effectively expressed.
Moreover, it is preferable that the liquid resin 15 provided with the flow by the suction means 19 is circulated and used. Thereby, in the unit 20, it can suppress that the solid content density | concentration in the liquid resin 15 fluctuates by volatilizing the organic solvent etc. in the liquid resin 15, and can maintain the viscosity of the liquid resin 15 to a predetermined level. Therefore, the impregnation improvement effect can be maintained over time.

  When implemented in this form, the transport position of the fiber substrate 1b may be controlled within a range in which the fiber substrate 1b is immersed in the liquid resin 15. The transport direction of the fiber base material 1b is not particularly limited. However, if it is substantially horizontal, the drive shaft portion of the drive roll is in the liquid resin 15 even when the drive roll is used as the transport means for the fiber base material 1b. Since it is easy to install so as not to immerse, it can be simplified in terms of the device configuration, and is also preferable in terms of the quality of the prepreg.

The production method of the present invention includes an impregnation step including at least one of the steps of the present invention described above.
Specifically, in addition to a method for producing a prepreg by an impregnation step composed only of the steps of the present invention, a prepreg is produced by an impregnation step having a plurality of steps and at least a part of the steps of the present invention. It can also be implemented by a method.

Below, the form which has a some process and manufactures a prepreg by the impregnation process which has the process of this invention in at least one is demonstrated.
The third form of the production method of the present invention (hereinafter sometimes simply referred to as “embodiment [3]”) is an impregnation step (hereinafter referred to as a method different from the step of the present invention) in the previous stage of the process of the present invention. , Sometimes simply referred to as “other process”).
Examples of such other steps include a step of impregnating a fiber base material with a kiss roll, a step of immersing the fiber base material in a liquid resin, and a step of impregnating the liquid base material with a coater. The process etc. of apply | coating etc. are mentioned.
And as an example of embodiment [3], after using the process which impregnates a liquid resin to a fiber base material using a kiss roll in a front stage, the method of using the process of this invention in a back stage, etc. are mentioned.

In addition, the fourth embodiment (hereinafter sometimes simply referred to as “embodiment [4]”) in the production method of the present invention is provided in addition to the above-mentioned other steps at a later stage of the process of the present invention. .
And as an example of Embodiment [4], after using the process of this invention in the front | former stage, the method etc. which use the process of immersing a fiber base material in a liquid resin in a back | latter stage, etc. are mentioned.

  In addition, the manufacturing method of the present invention is also carried out by a method using only two or more processes of the present invention, or a method of providing other processes in combination before and after the process of the present invention. can do.

FIG. 3 illustrates another process that can be applied in combination with the process of the present invention.
FIG. 3A is an example of an embodiment in which a step of impregnating a fiber base material with a liquid resin using a kiss roll is performed.
In FIG. 3A, the fiber base material 1c is in contact with the upper surface side circumferential portion of the kiss roll 25 between the roll 23 and the roll 24. The lower part of the kiss roll 25 is immersed in the liquid resin 22 stored in the storage device 21, and the liquid resin 22 comes into contact with the fiber base material 1 c by the rotation of the kiss roll 25 and is impregnated.
FIG. 3B is an example of an embodiment in which a step of immersing and impregnating a fiber base material in a liquid resin is performed.
In FIG. 3 (B), the fiber base material 1d is immersed in the liquid resin 32 stored in the storage device 31 by the guide roll 33 and the guide roll 34, and is impregnated with the liquid resin 32.

Next, the prepreg of the present invention will be described.
The prepreg of the present invention is obtained by the production method of the present invention.

The prepreg of the present invention has an impregnation process according to the process of the present invention as described above, or a plurality of processes, at least one of which undergoes the impregnation process of the present invention, and then as necessary. The fiber base material can be produced by adjusting the amount of liquid resin impregnated and heating and drying it.
The conditions for the heat drying are not particularly limited because they vary depending on the components of the liquid resin, the amount of impregnation, and the like. However, for example, the temperature can be 150 to 190 ° C. and the time can be 1 to 10 minutes.

Next, the laminated board of this invention is demonstrated.
The laminate of the present invention is characterized by being formed by heating and pressing the prepreg of the present invention.
The laminate of the present invention can be produced by stacking one or a plurality of the above prepregs and heating and pressing them. Moreover, a metal foil-clad laminate can be produced by stacking a metal foil such as a copper foil on one or both sides of one or a plurality of prepregs which are stacked and heating and pressing.
Although it does not specifically limit as a method to heat-press-mold, If an example is given, it can implement in temperature 150-200 degreeC, pressure 1-4 MPa, and time 60-120 minutes.

  As described above, in the present invention, when impregnating the fiber base material with the liquid resin, the fiber base material is conveyed while being in contact with the liquid surface of the liquid resin or being immersed in the liquid resin. And a step of sucking the liquid resin from the upper surface side of the fiber base material in the thickness direction of the fiber base material during the conveyance and contacting and supporting the fiber base material in the suction direction. It is a method, and the prepreg and laminated board obtained by this method, and can provide the prepreg which has high impregnation property compared with the conventional one, and the laminated board which has favorable moldability.

  EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention, this invention is not limited to this Example.

1. Raw materials The raw materials used in the following examples and comparative examples are as follows.
(1) Tetrabromobisphenol A type epoxy resin:
“Epicoat 5047” manufactured by Japan Epoxy Resin Co., Epoxy Equivalent 550
(2) Cresol novolac-type epoxy resin Dainippon Ink & Chemicals, Inc. “Epicron N-690”, epoxy equivalent 210
(3) Fiber substrate Nittobo “WEA-7628”, long glass woven fabric with a thickness of 0.18 mm and a width of 1000 mm (4) electrolytic copper foil Furukawa Circuit Foil “GTS-MP 18” , Thickness 18μm

2. Preparation of Liquid Resin (1) Preparation of Liquid Resin a 85 parts by weight of tetrabromobisphenol A type epoxy resin, 15 parts by weight of cresol novolac type epoxy resin, 2.3 parts by weight of dicyandiamide, 2-ethyl-4-methylimidazole 0.1 A part by weight was dissolved in N, N-dimethylformamide to prepare a liquid resin a having a solid content concentration of 30% by weight.

(2) Preparation of liquid resin b 85 parts by weight of tetrabromobisphenol A type epoxy resin, 15 parts by weight of cresol novolac type epoxy resin, 2.3 parts by weight of dicyandiamide, 0.1 part by weight of 2-ethyl-4-methylimidazole , N-dimethylformamide was dissolved to prepare a liquid resin b having a solid concentration of 55% by weight.

3. Manufacture of prepreg
<Example 1>
The pre-impregnation is performed using the manufacturing apparatus of the form shown in FIG. 2, and then the post-impregnation is performed using the manufacturing apparatus of the form shown in FIG. 3 (B), and then a squeeze (not shown) is performed. After adjusting the amount of impregnation of the liquid resin into the fiber base material with a roll, the prepreg having a resin composition content of 51% by weight was manufactured by heat drying for 2 minutes with a 180 ° C. heat drying apparatus. The specifications of the apparatus, operating conditions, and the liquid resin used in each impregnation step are as follows.

[1] Impregnation in the previous stage (1) Liquid resin Liquid resin a was used.
(2) Fiber base material conveying means / guide roll: diameter 150 mm, width 1200 mm (The fiber base material was transferred by a driving means (not shown)).
・ Distance between two guide rolls: 2000 mm
-Conveyance speed of the fiber substrate: 5 m / min (3) Contact support means-A rectangular member having a cross-sectional shape of 100 mm x 200 mm and a width of 1200 mm was used, and the 100 mm side was contacted and supported by the fiber substrate.
・ Distance between contact support means: 200 mm
(4) A depressurized tank whose pressure was reduced by 100 Torr from the atmospheric pressure by a suction means / vacuum pump was used.
(5) Rectifying means A plate-shaped rectifying plate in which slit-shaped rectifying holes of 10 mm × 1100 mm were formed at intervals of 10 mm was used.
(6) Number of units of impregnation apparatus In FIG. 2, as the unit 20 constituting one unit of the impregnation apparatus 13, a unit composed of five units was used.

[2] Subsequent impregnation (1) Liquid resin Liquid resin b was used.
(2) Specification and operating conditions of immersion impregnation apparatus and guide roll: diameter 100 mm, width 1200 mm (The fiber substrate was transferred by a driving means not shown).
・ Distance between two guide rolls: 300mm
・ Conveying speed of fiber base material: 5m / min

<Example 2>
In Example 1, the prepreg was prepared in the same manner as in Example 1 except that a vacuum tank with a pressure reduced by 300 Torr from the atmospheric pressure was used as the suction means in the previous impregnation, and the number of units of the impregnation apparatus was three. Manufactured.

<Example 3>
In Example 1, a prepreg was prepared in the same manner as in Example 1 except that a vacuum tank with a pressure reduced by 500 Torr from atmospheric pressure was used as the suction means in the previous impregnation, and the number of units of the impregnation apparatus was one. Manufactured.

<Example 4>
The pre-impregnation is performed using the manufacturing apparatus of the form shown in FIG. 1, and then the post-impregnation is performed using the manufacturing apparatus of the form shown in FIG. 3 (B), and then a squeeze (not shown) is performed. After adjusting the amount of impregnation of the liquid resin into the fiber base material with a roll, the prepreg having a resin composition content of 51% by weight was manufactured by heat drying for 2 minutes with a 180 ° C. heat drying apparatus. The specifications of the apparatus, operating conditions, and the liquid resin used in each impregnation step are as follows.

[1] Impregnation in the previous stage (1) Liquid resin Liquid resin a was used.
(2) Fiber base material conveying means / guide roll: diameter 150 mm, width 1200 mm (The fiber base material was transferred by a driving means (not shown)).
・ Distance between two guide rolls: 2000 mm
-Conveyance speed of the fiber base material: 5 m / min.
(3) Contact support means A rod-shaped member having a cross-sectional shape of a rectangle of 100 mm × 200 mm and a width of 1200 mm was used to contact and support the 100 mm side on the fiber substrate.
・ Distance between contact support means: 200 mm
(4) A depressurized tank whose pressure was reduced by 100 Torr from the atmospheric pressure by a suction means / vacuum pump was used.
(5) Rectifying means A plate-shaped rectifying plate in which slit-shaped rectifying holes of 10 mm × 1100 mm were formed at intervals of 10 mm was used.
(6) Number of units of impregnation apparatus In FIG. 1, as the unit 10 constituting one unit of the impregnation apparatus 3, a unit composed of five units was used.

[2] Subsequent impregnation The liquid resin b was used under the same apparatus specifications and operating conditions as the post-impregnation in Example 1.

<Example 5>
The pre-impregnation is performed using the manufacturing apparatus of the form shown in FIG. 3A, and then the post-impregnation is performed using the manufacturing apparatus of the form shown in FIG. 2, and then a squeeze (not shown) is performed. After adjusting the amount of impregnation of the liquid resin into the fiber base material with a roll, the prepreg having a resin composition content of 51% by weight was manufactured by heat drying for 2 minutes with a 180 ° C. heat drying apparatus. The specifications of the apparatus, operating conditions, and the liquid resin used in each impregnation step are as follows.

[1] Impregnation in the previous stage (1) Liquid resin Liquid resin a was used.
(2) Specifications and operating conditions of kiss roll impregnation device / kiss roll: 200 mm in diameter, 1200 mm in width
・ Distance at which the kiss roll and the fiber base material come into contact (base material transfer direction): 100 mm
-Number of rotations of kiss roll: 10 rpm
・ Transfer speed of fiber substrate: 5m / min

[2] Subsequent impregnation (1) Liquid resin Liquid resin b was used.
Except for this, the same specifications and operating conditions were used as in the first impregnation apparatus in Example 1.

<Comparative Example 1>
The impregnation in the previous stage is performed using the manufacturing apparatus of the form shown in FIG. 3A, and then the impregnation in the subsequent stage is performed using the manufacturing apparatus of the form shown in FIG. 3B. After adjusting the amount of impregnation of the liquid resin into the fiber substrate with a squeeze roll (not shown), the prepreg having a resin composition content of 51 wt% was manufactured by heating and drying for 2 minutes with a 180 ° C. heating and drying apparatus. . The specifications of the apparatus, operating conditions, and the liquid resin used in each impregnation step are as follows.
[1] Impregnation in the previous stage The liquid resin a was used under the same apparatus specifications and operating conditions as in the previous stage of impregnation in Example 5.
[2] Subsequent impregnation The liquid resin b was used under the same apparatus specifications and operating conditions as the post-impregnation in Example 1.

4). Manufacture of laminates Each of the prepregs obtained in Examples 1 to 5 and Comparative Example 1 was laminated, and further, electrolytic copper foils were laminated on both front and back surfaces. A double-sided copper-clad laminate having a thickness of about 1.0 mm was manufactured by heating and pressing at 190 ° C. for 100 minutes.

5. Evaluation of prepreg After the prepregs obtained in Examples 1 to 5 and Comparative Example 1 were cut into a size of 100 × 100 mm, they were suspended in a drying apparatus at 150 ° C. for 15 minutes and then heated, and then cooled. About what was, the presence or absence of the void which is not impregnated with resin was visually observed and evaluated. The obtained results are shown below.
(1) Example 1: No void (2) Example 2: No void (3) Example 3: No void (4) Example 4: No void (5) Example 5: No void (6) Comparative example 1: There is a void

6). Evaluation of Laminate Plate The laminate plates obtained in Examples 1 to 5 and Comparative Example 1 were evaluated by visually observing the presence or absence of voids and voids on the substrate surface by etching away the double-sided copper foil. . The obtained results are shown below.
(1) Example 1: No sag and void (2) Example 2: Smudge and no void (3) Example 3: Smudge and no void (4) Example 4: Smudge and no void (5) Example 5 : No blurring or void (6) Comparative Example 1: With blurring or void

Examples 1 to 5 are prepregs produced by applying the production method of the present invention, which had no voids and had excellent impregnation properties. And also about the laminated board obtained using this prepreg, there was no void and blur and the moldability was favorable.
In contrast, Comparative Example 1 is manufactured by applying a method in which a step of impregnating a fiber base material with a kiss roll is impregnated with a liquid resin and a step of immersing and impregnating the fiber base material in the liquid resin. When the obtained prepreg was observed after the treatment, voids were observed. And the laminated board obtained using this prepreg showed the burr and void which are the unmolded parts on the surface.

FIG. 1 (1) is a schematic sectional side view of an example of an embodiment (Embodiment [1]) in the production apparatus of the present invention, and FIG. 1 (2) is an enlargement of the impregnation apparatus unit in Embodiment [1]. FIG. FIG. 2 (1) is a schematic side sectional view of an example of the embodiment of the manufacturing apparatus of the present invention (embodiment [2]), and FIG. 2 (2) is an enlarged view of the impregnation apparatus unit in the embodiment [2]. FIG. FIG. 3A is a schematic side cross-sectional view of an example of a mode in which a fiber base material is impregnated with a kiss roll, and FIG. 3B is an impregnation by immersing the fiber base material in the liquid resin. It is a schematic sectional side view of an example of the form made to do.

Explanation of symbols

1a, 1b, 1c, 1d Fiber substrate 2, 12 Transport roll 3, 13 Impregnation device 4, 14 Storage means 5, 15 Liquid resin 6, 16 Contact support means 7, 17 Rectification means 7a, 17a Rectification holes 8, 18 Liquid Resin flow 9, 19 Suction means 10, 20 Impregnation unit 21, 31 Storage device 22, 32 Liquid resin 23, 24 Roll 25 Kiss roll 33, 34 Guide roll

Claims (10)

A method for producing a prepreg for a printed wiring board in which a glass fiber cloth is impregnated with a liquid resin containing at least an epoxy resin ,
While contact with the liquid surface of the liquid resin, or while immersed in the liquid resin, and conveys the glass fiber cloth,
During the transport, and wherein the upper surface side of the glass fiber cloth sucks the liquid resin in the thickness direction of the glass fiber cloth, a step, contacting supporting the glass fiber cloth in the direction of the suction The manufacturing method of the prepreg for printed wiring boards . In the process, when sucking the liquid resin, to rectify the flow of the liquid resin, the manufacturing method of the printed wiring board prepreg according to claim 1. In the step, the while contacting on the liquid surface of the liquid resin, the glass fiber cloth is conveyed to horizontal direction, the manufacturing method of the printed wiring board prepreg according to claim 1 or 2. In the step, the while immersed in a liquid resin, the glass fiber cloth is conveyed to horizontal direction, the manufacturing method of the printed wiring board prepreg according to claim 1 or 2. In the step, the glass fiber cloth is a glass woven fabric, a method for manufacturing a printed wiring board prepreg according to any one of claims 1 to 4. A method for producing a prepreg in which a glass fiber cloth is impregnated with a liquid resin,
The manufacturing method of the prepreg for printed wiring boards which has an impregnation process including the process of any one of Claim 1 thru | or 5. Printed wiring board prepreg wherein the claims 1 to those obtained by the process according to any one of 6. A laminated board obtained by heat-pressing the prepreg for printed wiring board according to claim 7. An apparatus for producing a prepreg for a printed wiring board in which a glass fiber cloth is impregnated with a liquid resin containing at least an epoxy resin ,
(A) a reservoir means for storing the liquid resin,
(B) a transport means for the liquid resin to the glass fiber cloth conveying the glass fiber cloth to be impregnated,
(C) from the upper surface side of the glass fiber cloth and a suction means for sucking the liquid resin in the thickness direction of the glass fiber cloth,
And (d) contacting the support means, wherein for glass fiber fabric contact support in a direction to suck the liquid resin,
An apparatus for producing a prepreg for a printed wiring board, comprising: further,
(E) a suction means, between the glass fiber cloth, a rectifying means for rectifying the flow of the liquid resin,
The manufacturing apparatus of the prepreg for printed wiring boards of Claim 9 which has these.

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