JP5950127B2 - 新規なシアン酸エステル化合物及びその製造方法、並びに該化合物を含む硬化性樹脂組成物及びその硬化物 - Google Patents
新規なシアン酸エステル化合物及びその製造方法、並びに該化合物を含む硬化性樹脂組成物及びその硬化物 Download PDFInfo
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- JP5950127B2 JP5950127B2 JP2013527978A JP2013527978A JP5950127B2 JP 5950127 B2 JP5950127 B2 JP 5950127B2 JP 2013527978 A JP2013527978 A JP 2013527978A JP 2013527978 A JP2013527978 A JP 2013527978A JP 5950127 B2 JP5950127 B2 JP 5950127B2
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- cyanate ester
- ester compound
- resin composition
- phenol
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- 150000001875 compounds Chemical class 0.000 title claims description 94
- 239000004643 cyanate ester Substances 0.000 title claims description 76
- 239000011342 resin composition Substances 0.000 title claims description 56
- 238000004519 manufacturing process Methods 0.000 title claims description 14
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 53
- OIAUFEASXQPCFE-UHFFFAOYSA-N formaldehyde;1,3-xylene Chemical class O=C.CC1=CC=CC(C)=C1 OIAUFEASXQPCFE-UHFFFAOYSA-N 0.000 claims description 43
- 239000003822 epoxy resin Substances 0.000 claims description 38
- -1 methyleneoxymethylene group Chemical group 0.000 claims description 38
- 229920000647 polyepoxide Polymers 0.000 claims description 38
- 239000000463 material Substances 0.000 claims description 26
- 125000003118 aryl group Chemical group 0.000 claims description 22
- 229920005989 resin Polymers 0.000 claims description 22
- 239000011347 resin Substances 0.000 claims description 22
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 21
- 125000000217 alkyl group Chemical group 0.000 claims description 16
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims description 16
- NXXYKOUNUYWIHA-UHFFFAOYSA-N 2,6-Dimethylphenol Chemical compound CC1=CC=CC(C)=C1O NXXYKOUNUYWIHA-UHFFFAOYSA-N 0.000 claims description 14
- 239000000853 adhesive Substances 0.000 claims description 10
- AHHWIHXENZJRFG-UHFFFAOYSA-N oxetane Chemical compound C1COC1 AHHWIHXENZJRFG-UHFFFAOYSA-N 0.000 claims description 10
- 239000000758 substrate Substances 0.000 claims description 10
- 230000001070 adhesive effect Effects 0.000 claims description 9
- 239000003566 sealing material Substances 0.000 claims description 9
- 239000003733 fiber-reinforced composite Substances 0.000 claims description 7
- 125000001570 methylene group Chemical group [H]C([H])([*:1])[*:2] 0.000 claims description 7
- 125000004432 carbon atom Chemical group C* 0.000 claims description 6
- 125000001424 substituent group Chemical group 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 125000005699 methyleneoxy group Chemical group [H]C([H])([*:1])O[*:2] 0.000 claims description 5
- 125000005704 oxymethylene group Chemical group [H]C([H])([*:2])O[*:1] 0.000 claims description 5
- 239000011888 foil Substances 0.000 claims description 3
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- 238000010438 heat treatment Methods 0.000 claims description 2
- 238000000034 method Methods 0.000 description 39
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- 239000002904 solvent Substances 0.000 description 26
- 239000000835 fiber Substances 0.000 description 22
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 21
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 21
- 238000006243 chemical reaction Methods 0.000 description 18
- 229920003986 novolac Polymers 0.000 description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 16
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 13
- 238000001723 curing Methods 0.000 description 13
- ZMANZCXQSJIPKH-UHFFFAOYSA-N Triethylamine Chemical compound CCN(CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-N 0.000 description 12
- 239000002585 base Substances 0.000 description 12
- 239000000203 mixture Substances 0.000 description 12
- 239000000243 solution Substances 0.000 description 11
- 239000003054 catalyst Substances 0.000 description 10
- XLJMAIOERFSOGZ-UHFFFAOYSA-M cyanate Chemical compound [O-]C#N XLJMAIOERFSOGZ-UHFFFAOYSA-M 0.000 description 10
- 150000002989 phenols Chemical class 0.000 description 10
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 9
- 239000003795 chemical substances by application Substances 0.000 description 8
- 238000002156 mixing Methods 0.000 description 8
- 230000000704 physical effect Effects 0.000 description 8
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical class [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 7
- 239000000654 additive Substances 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 7
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical class C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 7
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 description 7
- 229910052794 bromium Inorganic materials 0.000 description 7
- 239000003063 flame retardant Substances 0.000 description 7
- 238000003786 synthesis reaction Methods 0.000 description 7
- JOXIMZWYDAKGHI-UHFFFAOYSA-N toluene-4-sulfonic acid Chemical compound CC1=CC=C(S(O)(=O)=O)C=C1 JOXIMZWYDAKGHI-UHFFFAOYSA-N 0.000 description 7
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical group C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 6
- 102100023849 Glycophorin-C Human genes 0.000 description 6
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 6
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 6
- 238000010521 absorption reaction Methods 0.000 description 6
- PXKLMJQFEQBVLD-UHFFFAOYSA-N bisphenol F Chemical compound C1=CC(O)=CC=C1CC1=CC=C(O)C=C1 PXKLMJQFEQBVLD-UHFFFAOYSA-N 0.000 description 6
- 238000004821 distillation Methods 0.000 description 6
- IVSZLXZYQVIEFR-UHFFFAOYSA-N m-xylene Chemical group CC1=CC=CC(C)=C1 IVSZLXZYQVIEFR-UHFFFAOYSA-N 0.000 description 6
- 239000003505 polymerization initiator Substances 0.000 description 6
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- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 5
- 230000002378 acidificating effect Effects 0.000 description 5
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- ZUOUZKKEUPVFJK-UHFFFAOYSA-N diphenyl Chemical compound C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 5
- JMANVNJQNLATNU-UHFFFAOYSA-N glycolonitrile Natural products N#CC#N JMANVNJQNLATNU-UHFFFAOYSA-N 0.000 description 5
- 239000011256 inorganic filler Substances 0.000 description 5
- 229910003475 inorganic filler Inorganic materials 0.000 description 5
- 229910052698 phosphorus Inorganic materials 0.000 description 5
- 239000011574 phosphorus Substances 0.000 description 5
- 239000012783 reinforcing fiber Substances 0.000 description 5
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 4
- 101100229307 Homo sapiens GYPC gene Proteins 0.000 description 4
- XYFCBTPGUUZFHI-UHFFFAOYSA-N Phosphine Chemical compound P XYFCBTPGUUZFHI-UHFFFAOYSA-N 0.000 description 4
- LZCLXQDLBQLTDK-UHFFFAOYSA-N ethyl 2-hydroxypropanoate Chemical compound CCOC(=O)C(C)O LZCLXQDLBQLTDK-UHFFFAOYSA-N 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 229920001002 functional polymer Polymers 0.000 description 4
- 239000003365 glass fiber Substances 0.000 description 4
- 230000009477 glass transition Effects 0.000 description 4
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 4
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 4
- 229920001225 polyester resin Polymers 0.000 description 4
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- 239000000377 silicon dioxide Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 239000002759 woven fabric Substances 0.000 description 4
- HECLRDQVFMWTQS-RGOKHQFPSA-N 1755-01-7 Chemical compound C1[C@H]2[C@@H]3CC=C[C@@H]3[C@@H]1C=C2 HECLRDQVFMWTQS-RGOKHQFPSA-N 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 3
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 3
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- NTIZESTWPVYFNL-UHFFFAOYSA-N Methyl isobutyl ketone Chemical compound CC(C)CC(C)=O NTIZESTWPVYFNL-UHFFFAOYSA-N 0.000 description 3
- UIHCLUNTQKBZGK-UHFFFAOYSA-N Methyl isobutyl ketone Natural products CCC(C)C(C)=O UIHCLUNTQKBZGK-UHFFFAOYSA-N 0.000 description 3
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 3
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- AHZMUXQJTGRNHT-UHFFFAOYSA-N [4-[2-(4-cyanatophenyl)propan-2-yl]phenyl] cyanate Chemical compound C=1C=C(OC#N)C=CC=1C(C)(C)C1=CC=C(OC#N)C=C1 AHZMUXQJTGRNHT-UHFFFAOYSA-N 0.000 description 3
- 239000002253 acid Substances 0.000 description 3
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- 125000003710 aryl alkyl group Chemical group 0.000 description 3
- 239000004305 biphenyl Substances 0.000 description 3
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- 238000010538 cationic polymerization reaction Methods 0.000 description 3
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- QPJDMGCKMHUXFD-UHFFFAOYSA-N cyanogen chloride Chemical compound ClC#N QPJDMGCKMHUXFD-UHFFFAOYSA-N 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 3
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- 150000003512 tertiary amines Chemical class 0.000 description 3
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- HCNHNBLSNVSJTJ-UHFFFAOYSA-N 1,1-Bis(4-hydroxyphenyl)ethane Chemical compound C=1C=C(O)C=CC=1C(C)C1=CC=C(O)C=C1 HCNHNBLSNVSJTJ-UHFFFAOYSA-N 0.000 description 2
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- QTWJRLJHJPIABL-UHFFFAOYSA-N 2-methylphenol;3-methylphenol;4-methylphenol Chemical compound CC1=CC=C(O)C=C1.CC1=CC=CC(O)=C1.CC1=CC=CC=C1O QTWJRLJHJPIABL-UHFFFAOYSA-N 0.000 description 2
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- 235000012211 aluminium silicate Nutrition 0.000 description 2
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- WTEOIRVLGSZEPR-UHFFFAOYSA-N boron trifluoride Chemical compound FB(F)F WTEOIRVLGSZEPR-UHFFFAOYSA-N 0.000 description 2
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- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 2
- JIAARYAFYJHUJI-UHFFFAOYSA-L zinc dichloride Chemical compound [Cl-].[Cl-].[Zn+2] JIAARYAFYJHUJI-UHFFFAOYSA-L 0.000 description 2
- CHJMFFKHPHCQIJ-UHFFFAOYSA-L zinc;octanoate Chemical compound [Zn+2].CCCCCCCC([O-])=O.CCCCCCCC([O-])=O CHJMFFKHPHCQIJ-UHFFFAOYSA-L 0.000 description 2
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- OWICEWMBIBPFAH-UHFFFAOYSA-N (3-diphenoxyphosphoryloxyphenyl) diphenyl phosphate Chemical compound C=1C=CC=CC=1OP(OC=1C=C(OP(=O)(OC=2C=CC=CC=2)OC=2C=CC=CC=2)C=CC=1)(=O)OC1=CC=CC=C1 OWICEWMBIBPFAH-UHFFFAOYSA-N 0.000 description 1
- UNMJLQGKEDTEKJ-UHFFFAOYSA-N (3-ethyloxetan-3-yl)methanol Chemical compound CCC1(CO)COC1 UNMJLQGKEDTEKJ-UHFFFAOYSA-N 0.000 description 1
- OXYKVVLTXXXVRT-UHFFFAOYSA-N (4-chlorobenzoyl) 4-chlorobenzenecarboperoxoate Chemical compound C1=CC(Cl)=CC=C1C(=O)OOC(=O)C1=CC=C(Cl)C=C1 OXYKVVLTXXXVRT-UHFFFAOYSA-N 0.000 description 1
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- DVQHRBFGRZHMSR-UHFFFAOYSA-N sodium methyl 2,2-dimethyl-4,6-dioxo-5-(N-prop-2-enoxy-C-propylcarbonimidoyl)cyclohexane-1-carboxylate Chemical compound [Na+].C=CCON=C(CCC)[C-]1C(=O)CC(C)(C)C(C(=O)OC)C1=O DVQHRBFGRZHMSR-UHFFFAOYSA-N 0.000 description 1
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- ITMCEJHCFYSIIV-UHFFFAOYSA-N triflic acid Chemical compound OS(=O)(=O)C(F)(F)F ITMCEJHCFYSIIV-UHFFFAOYSA-N 0.000 description 1
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- XZZNDPSIHUTMOC-UHFFFAOYSA-N triphenyl phosphate Chemical compound C=1C=CC=CC=1OP(OC=1C=CC=CC=1)(=O)OC1=CC=CC=C1 XZZNDPSIHUTMOC-UHFFFAOYSA-N 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
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- XAEWLETZEZXLHR-UHFFFAOYSA-N zinc;dioxido(dioxo)molybdenum Chemical compound [Zn+2].[O-][Mo]([O-])(=O)=O XAEWLETZEZXLHR-UHFFFAOYSA-N 0.000 description 1
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Landscapes
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- Macromolecular Compounds Obtained By Forming Nitrogen-Containing Linkages In General (AREA)
Description
しかしながら、これらの臭素化合物は高い難燃性を有するものの、熱分解により腐食性の臭素や臭化水素を形成させ得るのみならず、酸素存在下で分解した場合には近年のダイオキシン問題に関連した毒性の強い臭素化合物を形成させ得るおそれがある。そのため、これらの臭素系難燃剤を含まない材料が求められている。
しかしながら、これらのリン含有化合物を樹脂組成物中に大量に配合すると、樹脂組成物の耐熱性、耐湿性、吸水性等を低下させる場合が多い。それを改良するために、フェノール性水酸基を有するリン含有化合物を二価のシアネートエステル化合物と併用することも検討されているが(例えば、特許文献6、特許文献7、特許文献8参照)、リン含有化合物の使用は、上記臭素化合物と同様に、毒性の問題が懸念される。しかも、リン含有化合物は埋め立て処分が困難な場合が多く、燃焼時にホスフィンガスの発生も懸念される。また、窒素含有化合物としては、メラミンやグアニジン等が知られているが、単独使用では難燃性が不十分である。
以上のような見地から、樹脂組成物に配合する機能性高分子材料自体の難燃性の向上が、これまで以上に求められている。
また、ハロゲンを含有した単官能シアン酸エステル化合物を添加することにより、低誘電率化及び低誘電正接化を図りながら、吸湿性が低い難燃性シアン酸エステル硬化樹脂組成物を製造する方法が知られている(特許文献4参照)。この特許文献4には、種々のシアン酸エステル化合物が記載されているものの、難燃性を保つためには臭素を官能基として有する芳香族単官能シアン酸エステル化合物の使用が必須であり、臭素を用いないで難燃性を向上させることには成功していない。
しかしながら、これら方法では、誘電特性、難燃性、耐熱性のすべての性能を高次元で備える実用的なシアン酸エステル化合物単体の硬化物は得られていない。
また、本発明の他の課題は、かかる新規なシアン酸エステル化合物を含む硬化性樹脂組成物、プリプレグ、積層板、封止用材料、繊維強化複合材料、及び接着剤等を提供することにあり、さらには、誘電率及び誘電正接が低く、優れた難燃性及び耐熱性を有し、取扱性にも優れる、硬化物を提供することにある。
すなわち、本発明は、以下<1>〜<15>を提供する。
下記一般式(Ic)で表される構造を有する、シアン酸エステル化合物。
<2> 前記フェノール変性キシレンホルムアルデヒド樹脂は、キシレンホルムアルデヒド樹脂を下記一般式(1)で表されるフェノール類を用いて変性させたものである、
上記<1>に記載のシアン酸エステル化合物。
<3> 前記一般式(1)で表されるフェノール類が、フェノール及び/又は2,6−キシレノールである、
上記<2>に記載のシアン酸エステル化合物。
<4> 重量平均分子量Mwが250〜10,000である、
上記<1>〜<3>のいずれか一項に記載のシアン酸エステル化合物。
シアン酸エステル化合物。
<6> 重量平均分子量Mwが250〜10,000である、
上記<5>に記載のシアン酸エステル化合物。
得られたフェノール変性キシレンホルムアルデヒド樹脂が有するフェノール性水酸基をシアネート化する工程と、を有する、
上記<1>〜<4>のいずれか一項に記載のシアン酸エステル化合物の製造方法。
硬化性樹脂組成物。
<9> 上記<1>〜<6>のいずれか一項に記載のシアン酸エステル化合物以外のシアン酸エステル化合物、エポキシ樹脂、オキセタン樹脂及び重合可能な不飽和基を有する化合物からなる群から選択される少なくとも1種以上をさらに含む、
上記<8>に記載の硬化性樹脂組成物。
硬化物。
<11> 上記<8>又は<9>に記載の硬化性樹脂組成物を繊維基材に含浸または塗布し、乾燥させてなる、
プリプレグ。
<12> 上記<11>に記載のプリプレグに金属箔を積層し、加熱加圧成形してなる、
積層板。
封止用材料。
<14> 上記<8>又は<9>に記載の硬化性樹脂組成物を含む、
繊維強化複合材料。
<15> 上記<8>又は<9>に記載の硬化性樹脂組成物を含む、
接着剤。
例えばキシレン、ホルマリン水溶液、2,6−キシレノール及び濃硫酸を窒素気流中、水溶媒を7時間還流させた後、酸を中和し、有機溶媒で抽出して得られるフェノール変性キシレンホルムアルデヒド樹脂は、下記式(2)〜(5)で示される化合物を代表組成とする混合物となる。
例えば、IAN HAMERTON,“Chemistry and Technology of Cyanate Ester Resins”,BLACKIE ACADEMIC & PROFESSIONALに記載された方法により、フェノールをシアネート化してシアン酸エステル化合物を得ることができる。また、溶媒中、塩基の存在下で、ハロゲン化シアンが常に塩基より過剰に存在するようにして反応させる方法(米国特許第3553244号)や、塩基として3級アミンを用い、これをハロゲン化シアンよりも過剰に用いながら合成する方法(特開平7−53497号公報)、連続プラグフロー方式で、トリアルキルアミンとハロゲン化シアンを反応させる方法(特表2000−501138号公報)、フェノールとハロゲン化シアンとを、tert−アミンの存在下、非水溶液中で反応させる際に副生するtert−アンモニウムハライドを、カチオン及びアニオン交換対で処理する方法(特表2001−504835号公報)、フェノール化合物を、水と分液可能な溶媒の存在下で、3級アミンとハロゲン化シアンとを同時に添加して反応させた後、水洗分液し、得られた溶液から2級または3級アルコール類もしくは炭化水素の貧溶媒を用いて沈殿精製する方法(特許第2991054号)、さらには、ナフトール類、ハロゲン化シアン及び3級アミンを、水と有機溶媒との二相系溶媒中で、酸性条件下で反応させる方法(特開2007−277102号公報)等が知られており、これら公知の方法を好適に使用して、本実施形態のシアン酸エステル化合物を得ることができる。なお、得られたシアン酸エステル化合物は、NMR等の公知の方法により同定することができる。
本実施形態の硬化性樹脂組成物は、上述したシアン酸エステル化合物を含むものである。この硬化性樹脂組成物は、所期の特性が損なわれない範囲において、上述したシアン酸エステル化合物以外のシアン酸エステル化合物(以下、「他のシアン酸エステル化合物」という。)、エポキシ樹脂、オキセタン樹脂、及び/又は重合可能な不飽和基を有する化合物等を含有していてもよい。
無機充填材としては、一般に公知のものが使用でき、特に限定されないが、例えば、天然シリカ、合成シリカ、溶融シリカ、アモルファスシリカ、中空シリカ等のシリカ類、ベーマイト、酸化モリブデン、モリブデン酸亜鉛等のモリブデン化合物、ホワイトカーボン、チタンホワイト、アエロジル、シリコーン複合パウダー、シリコーンレジンパウダー、ホウ酸亜鉛、錫酸亜鉛、アルミナ、タルク、天然マイカ、合成マイカ、カオリン、クレー、焼成クレー、焼成カオリン、焼成タルク、酸化亜鉛、酸化マグネシウム、酸化ジルコニウム、水酸化アルミニウム、窒化ホウ素、硫酸バリウム、E−ガラス、A−ガラス、NE−ガラス、C−ガラス、L−ガラス、D−ガラス、S−ガラス、M−ガラスG20、ガラス短繊維(EガラスやTガラス、Dガラス、Sガラス、Qガラスなどのガラス微粉末類を含む。)、中空ガラス、球状ガラス等が挙げられる。これらの無機充填材は、1種を単独で或いは2種以上組み合わせて用いることができる。
また、硬化触媒としては、一般に公知のものが使用でき、特に限定されないが、例えば、オクチル酸亜鉛、ナフテン酸亜鉛、ナフテン酸コバルト、ナフテン酸銅、アセチルアセトン鉄等の金属塩、フェノール、アルコール、アミン等の活性水酸基を有する化合物等が挙げられる。これらの硬化触媒は、1種を単独で或いは2種以上組み合わせて用いることができる。
溶媒としては、一般に公知のものが使用でき、特に限定されないが、アセトン、メチルエチルケトン、メチルイソブチルケトン、シクロヘキサノン等のケトン系溶媒、プロピレングリコールモノメチルエーテル、プロピレングリコールモノメチルエーテルアセテート等のセロソルブ系溶媒、乳酸エチル、酢酸メチル、酢酸エチル、酢酸ブチル、酢酸イソアミル、乳酸エチル、メトキシプロピオン酸メチル、ヒドロキシイソ酪酸メチル等のエステル系溶媒、メタノール、エタノール、イソプロパノール、1−エトキシ−2−プロパノール等のアルコール系溶媒、トルエン、キシレン、アニソール等の芳香族系炭化水素等が挙げられるが、これらに特に限定されない。これらの溶媒は、1種を単独で或いは2種以上組み合わせて用いることができる。
上記の硬化性樹脂組成物を基材に含浸または塗布し、乾燥することにより、プリプレグを製造することができる。ここで使用する基材としては、一般に公知のものが使用でき、例えば、無機繊維基材や有機繊維基材など、特に限定されはない。
2,6−キシレノール変性キシレンホルムアルデヒド樹脂のシアン酸エステル(下記式(Ia)のシアン酸エステル(代表組成として下記式(9)を有する):NXDCと略す)の合成
2,6−キシレノール486.8g(3.99mol)及び触媒のPTSA(パラトルエンスルホン酸)6.3gを仕込み攪拌昇温し、液温125℃になった時点でキシレンホルムアルデヒド樹脂(ニカノールGL16、フドー(株)製)144gを1時間かけて滴下した。滴下中、昇温を続け、150℃、3時間で反応を完結させた。反応後120℃以下に冷却し、反応液にメタキシレン160gを添加し、次にメチルイソブチルケトン240gを添加して反応液を希釈した。次いで、希釈した反応液を、70〜80℃の温水400gで3回繰り返し洗浄した。
る。)
得られた2,6−キシレノール変性キシレンホルムアルデヒド樹脂のOH価をJISK1557−1に基づき求めたところ、318mgKOH/gであった。
上記方法で得られた式(Ia’)で表される2,6−キシレノール変性キシレンホルムアルデヒド樹脂の精製品256g(OH基として1.45mol)及び1.6molトリエチルアミンを3−メチルテトラヒドロフラン600mLに溶解させた(溶液1)。その後、2.8molの塩化シアンの塩化メチレン溶液500gに−10℃で溶液1を1.5時間かけて滴下した。30分撹拌した後、0.8molのトリエチルアミンと塩化メチレン115gの混合溶液を滴下し、さらに30分撹拌して反応を完結させた。そして、反応液からトリエチルアミンの塩酸塩をろ別し、得られたろ液を0.1N塩酸1,000mLにより洗浄した後、さらにNaCl水溶液1,000mLで3回洗浄し、最後に水1,000mLによる洗浄を行った。塩化メチレン溶液を硫酸ナトリウムにより乾燥し、蒸留操作により溶媒を留去することにより、目的とする上記式(Ia)で表される2,6−キシレノール変性キシレンホルムアルデヒド樹脂のシアン酸エステル(NXDC)240gを黄赤色粘性物として得た。
該化合物は、メチルエチルケトンに対し、25℃で30質量%以上溶解することが可能であった。また、ティー・エー・インスツルメント製レオメータAR2000EXを用いて粘度を測定したところ、該化合物の粘度は100℃で0.3Pa・sであった。GPCで測定したところ、該化合物の重量平均分子量(Mw)は650であった。
硬化性樹脂組成物の調製と硬化物の作製
実施例1で得られたシアン酸エステルNXDC100質量部をナス型フラスコに入れ、150℃で加熱溶融させて真空ポンプで脱気した。その後、オクチル酸亜鉛を0.05質量部加え1分間振とうさせて混合することで、硬化性樹脂組成物を調製した。
得られた硬化性樹脂組成物を、ガラス板(120mm×120mm×5mmt)、ポリイミドフィルム(カプトン200H:東レデュポン)、フッ素ゴム製Oリング(S−100:モリセイ)を用いて作製した型内に流し込み、オーブンを用いて170℃で1時間、その後さらに230℃で9時間加熱して硬化させて、硬化物を注型成形した。冷却後、ポリイミドフィルムを研磨により除去して、硬化物を取り出した。
ガラス転移温度(Tg):動的粘弾性測定(DMA)により求めた。振動周波数10GHzで測定を行った。
誘電率、誘電正接:Agilent社製HP8722ESを用い、空洞共振摂動法により求めた。
難燃性:UL94に基づき耐燃性試験を実施した。なお、サンプルサイズは10mm×70mm×1.5mmとした。
評価結果を表1に示す。
フェノール変性キシレンホルムアルデヒド樹脂のシアン酸エステル(下記式(Ib)のシアン酸エステル(代表組成として下記式(10)を有する):GLPCと略す)の合成
フェノール800g(8.5mol)及び触媒のPTSA(パラトルエンスルホン酸)0.43gを仕込み攪拌昇温し、液温130℃にてキシレンホルムアルデヒド樹脂(ニカノールG、フドー(株)製)670gを1時間かけて滴下した。滴下中、還流温度は150℃から105℃に低下した。滴下後1時間で反応を完結させた。反応後、脱フェノールするため水蒸気蒸留を170℃で2.5時間実施した。その後冷却しながら徐々にメチルイソブチルケトン1700gを添加し希釈した。次いで、希釈した反応液を、70〜80℃の温水850gで3回繰り返し洗浄した。
得られたフェノール変性キシレンホルムアルデヒド樹脂のOH価をJISK1557−1に基づき求めたところ、314mgKOH/gであった。
上記方法で得られた式(Ib’)で表されるフェノール変性キシレンホルムアルデヒド樹脂20g(OH基として0.112mol)及びトリエチルアミン17.13g(0.168mol)を塩化メチレン120gに溶解させた(溶液2)。0.249molの塩化シアンの塩化メチレン溶液48.1gと36%塩酸23.76g(0.235mol)と水147.3gとを撹拌混合した溶液へ、−5〜+5℃で溶液2を10分かけて滴下した。30分撹拌した後、トリエチルアミン11.42g(0.112mol)と塩化メチレン11.4gの混合溶液を滴下し、さらに30分撹拌して反応を完結させた。反応液を分液し、有機相を分取した。得られた有機相を水100gで4回洗浄した後、蒸留により塩化メチレンを留去し、目的とする上記式(Ib)で表されるフェノール変性キシレンホルムアルデヒド樹脂のシアン酸エステル(GLPC)23.1gを黄赤色粘性物として得た。
該化合物は、メチルエチルケトンに対し、25℃で30質量%以上溶解することが可能であった。また、ティー・エー・インスツルメント製レオメータAR2000EXを用いて粘度を測定したところ、該化合物の粘度は100℃で0.4Pa・sであった。
GPCで測定したところ、該化合物の重量平均分子量(Mw)は1050であった。
NXDCの代わりに実施例3で得られたGLPCを用いること以外は、実施例2と同様に行って、硬化性樹脂組成物を調製し、硬化物を作製した。
得られた硬化物の物性の評価結果を表1に示す。
NXDCの代わりにビスフェノールAジシアネートskylex(三菱ガス化学(株)製)を単独で用いること以外は、実施例2と同様に行って、硬化性樹脂組成物を調製し、硬化物を作製した。
なお、上記のビスフェノールAジシアネートskylexは、メチルエチルケトンに対し、25℃で30質量%以上溶解することが可能であった。また、ティー・エー・インスツルメント製レオメータAR2000EXを用いて粘度を測定したところ、その粘度は100℃で0.02Pa・sであった。
得られた硬化物の物性の評価結果を表1に示す。
NXDCの代わりにフェノールノボラックシアネートPT30(ロンザ社製)を用いること以外は、実施例2と同様に行って、硬化性樹脂組成物を調製し、硬化物を作製した。
なお、上記のフェノールノボラックシアネートPT30は、メチルエチルケトンに対し、25℃で30質量%以上溶解することが可能であった。また、ティー・エー・インスツルメント製レオメータAR2000EXを用いて粘度を測定したところ、その粘度は100℃で0.5Pa・sであった。
得られた硬化物の物性の評価結果を表1に示す。
Claims (15)
- フェノール変性キシレンホルムアルデヒド樹脂のシアン酸エステルであって、
下記一般式(Ic)で表される構造を有する、シアン酸エステル化合物。
- 前記一般式(1)で表されるフェノール類が、フェノール及び/又は2,6−キシレノールである、
請求項2に記載のシアン酸エステル化合物。 - 重量平均分子量Mwが250〜10,000である、
請求項1〜3のいずれか一項に記載のシアン酸エステル化合物。 - 下記一般式(Ic)で表される構造を有する、
シアン酸エステル化合物。 - 重量平均分子量Mwが250〜10,000である、
請求項5に記載のシアン酸エステル化合物。 - キシレンホルムアルデヒド樹脂をフェノール変性する工程と、
得られたフェノール変性キシレンホルムアルデヒド樹脂が有するフェノール性水酸基をシアネート化する工程と、を有する、
請求項1〜4のいずれか一項に記載のシアン酸エステル化合物の製造方法。 - 請求項1〜6のいずれか一項に記載のシアン酸エステル化合物を含む、
硬化性樹脂組成物。 - 請求項1〜6のいずれか一項に記載のシアン酸エステル化合物以外のシアン酸エステル化合物、エポキシ樹脂、オキセタン樹脂及び重合可能な不飽和基を有する化合物からなる群から選択される少なくとも1種以上をさらに含む、
請求項8に記載の硬化性樹脂組成物。 - 請求項8又は9に記載の硬化性樹脂組成物を硬化させてなる、
硬化物。 - 請求項8又は9に記載の硬化性樹脂組成物を基材に含浸または塗布し、乾燥させてなる、
プリプレグ。 - 請求項11に記載のプリプレグに金属箔を積層し、加熱加圧成形してなる、
積層板。 - 請求項8又は9に記載の硬化性樹脂組成物を含む、
封止用材料。 - 請求項8又は9に記載の硬化性樹脂組成物を含む、
繊維強化複合材料。 - 請求項8又は9に記載の硬化性樹脂組成物を含む、
接着剤。
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