JP6841839B2 - 熱硬化性樹脂用の活性エステル硬化剤化合物、それを含む難燃性組成物、およびそれから製造される物品 - Google Patents
熱硬化性樹脂用の活性エステル硬化剤化合物、それを含む難燃性組成物、およびそれから製造される物品 Download PDFInfo
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- JP6841839B2 JP6841839B2 JP2018544762A JP2018544762A JP6841839B2 JP 6841839 B2 JP6841839 B2 JP 6841839B2 JP 2018544762 A JP2018544762 A JP 2018544762A JP 2018544762 A JP2018544762 A JP 2018544762A JP 6841839 B2 JP6841839 B2 JP 6841839B2
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Images
Classifications
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
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- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/4007—Curing agents not provided for by the groups C08G59/42 - C08G59/66
- C08G59/4071—Curing agents not provided for by the groups C08G59/42 - C08G59/66 phosphorus containing compounds
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- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
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- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
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Description
本発明の一実施形態において、本明細書および一実施形態において説明される一般式(I)の化合物およびその組み合わせは、硬化性(架橋性)リン含有難燃性エポキシ樹脂組成物の一成分として使用されうる。この実施形態において、硬化性リン含有難燃性エポキシ樹脂組成物は、(i)本明細書において説明される一般式(I)の化合物、(ii)少なくとも一種のエポキシ樹脂(たとえば、非ハロゲン系エポキシ樹脂、非リン系エポキシ樹脂、および、リン含有エポキシ樹脂、および、それらの混合物、から選択されるもの)であって、非限定的な例として、DEN 438、DER 330、Epon 164(DENおよびEDRは、ダウ・ケミカル社の商標である。)、エポキシ官能性ポリオキサゾリドン含有化合物、脂環式エポキシ樹脂、GMA/スチレン共重合体、および、DEN438とDOPO樹脂との反応生成物など、ならびに、任意選択により(iii)少なくとも一種の共架橋剤、ならびに、任意選択により一種または複数種の、硬化触媒、ルイス酸、抑制剤、および、ベンゾオキサジン含有化合物、を含む。当該硬化性リン含有難燃性エポキシ樹脂組成物は、任意選択により、上記の成分(ii)とは異なる少なくとも一種の追加の架橋性エポキシ樹脂または2種以上のエポキシ樹脂の混合物を含有しうる。当該硬化性リン含有難燃性エポキシ樹脂組成物は、任意選択により、少なくとも一種の硬化触媒および少なくとも一種の抑制剤も含有しうる。上記の成分の全ては、当該硬化性リン含有難燃性エポキシ樹脂組成物を形成するために、任意の順番においてブレンドまたは混合することができる。
本発明の別の実施形態において、本明細書において説明される一般式(I)の化合物は、リン含有耐発火性熱硬化性組成物を作製するために使用され、その場合、たとえば、非限定的な一実施形態において、当該熱硬化性樹脂は、エポキシに加えて使用され、または、エポキシと別に使用される。
−−−−−−−−−−−−−−−−−−−−−−−−
0 90 10
3 90 10
30 10 90
35 10 90
37 90 10
40 90 10
酢酸カリウムまたは酢酸ナトリウムなどの触媒を使用することにより、より温和な条件、たとえば、より低い温度およびより高い減圧度(1mbarの代わりに30mbar)の条件下で、触媒を用いない場合と同様の結果を達成することが可能となり、そのような温和な条件は、スケールアップにとってより好適である。
メカニカルスターラー、温度計、および、窒素導入口、を備える0.25Lの四つ口フラスコにDOPO(21.6g.0.1mol)、ベンゾキノン(10.3g、0.095mol)、および、ジメトキシエタン(50mL)、を装入した。フラスコを還流するまで加熱し、その温度を3時間維持することにより、溶媒中においてDOPO−HQのスラリーを得た。続いて、無水酢酸(30.6g、0.3mol)を導入し、その後、140℃に加熱した。加熱工程の間に、ジメトキシエタンを蒸留除去した。140℃で30分保持した後、初期スラリーは透明になり、溶液を還流においてさらに2時間加熱した。次いで、イソフタル酸(10g、0.06mol)および酢酸カリウム0.01gを加え、反応混合物を220℃に加熱した。この時点において、過剰な無水酢酸および生成した酢酸の両方を反応領域からより効率的に除去するために、30mbarに減圧した。結果として得られた非常に粘性の高い液体生成物を、アルミニウムプレート上に注いだ。定量的収率で得られた最終固体生成物は、茶色を呈し、3%のDOPO−HQ−モノアセテートおよびDOPO−HQ−アセテート−イソフタレート、6%の未反応のDOPO−HQ−ジアセテート、ならびに、91%のオリゴマー、を含有した(各成分の含有率%はHPLC面積基準)。生成物におけるリン含有量は6.7%であった。
実施例1〜4および8において調製したDOPO−HQ−誘導体の試料を、エポキシおよびノボラックと組み合わせて、小スケールにおいて硬化させた(全ての材料情報は表4に一覧されている)。試料は、1:1の比のDEN438:EPON164、共硬化剤としてSD1708、および、触媒として0.2重量%の2−メチルイミダゾール、を使用して硬化させた。総P%は2.4〜2.7%であった。エポキシを、2時間にわたって165〜195℃で硬化させ、1時間にわたって180〜210℃で後硬化させた。試料の熱安定性を、DSCおよびTGAを使用して調査した。DkおよびDf測定のためのワニスキャスティングを調製するために、組成物Aを、1:1の比のDEN438:EPON164、共硬化剤SD1708、および、触媒2−メチルイミダゾール、と混合して、当該エポキシ混和物試料を使用して10インチ×10インチのアルミニウム箔の片面をコーティングした。コーティング後、アルミニウム箔を空気乾燥させ、その後、165℃において「B」ステージ化した(3分50秒)。当該エポキシをアルミニウム箔から剥がし、成形して、200℃で2〜3時間にわたって硬化させ、210〜220℃で1時間にわたって後硬化させた。結果を表3に示す。
実施例2において合成した組成物Aについて、エポキシラミネート用途のための共硬化剤として使用することについて検討した。フェノール性ノボラックと一緒に組成物Aを使用して、多官能性エポキシ樹脂DEN 438およびEPON 164を硬化させた。全ての材料情報を表4に一覧する。MEK/ダウアノール(80/20)溶媒混合物を加えることによって、固体含有量を66.67%に維持した。それらから、2.7%のリン含有量を有するワニス配合物を調製した。各組成物の含有量を表5に示す。
実施例8において合成した組成物Aについて、エポキシラミネート用途のための共硬化剤として使用することについて検討した。フェノール性ノボラックと一緒に組成物Aを使用して、多官能性エポキシ樹脂DEN 438およびEPON 164を硬化させた。全ての材料情報を表4に一覧する。MEK/ダウアノール(80/20)溶媒混合物を加えることによって、固体含有量を65〜66%に維持した。それらから、2.4%のリン含有量を有するワニス配合物を調製した。各組成物の含有量を表7に示す。
Claims (22)
- 熱硬化性樹脂と、難燃剤であると同時に活性エステル硬化剤でもある式(I)のリン含有芳香族ポリエステルとを含むエポキシ樹脂組成物。
Xは、1〜8個の炭素原子を有する二価の直鎖状アルキレン基もしくは分岐鎖状アルキレン基、または、2個〜8個の炭素原子を有する二価の直鎖状アルケニレン基もしくは分岐鎖状アルケニレン基、であり、
Yは、
ここで、Zは、共有結合、−SO2−、−C(CH3)2−、−CH(CH3)−、および、−CH2−、からなる群から選択され、a=0〜2であり、b=0〜2であり、かつ、aとbとは同時に0ではなく、
Yの各構造における波線部は、一般式(I)においてYが接続するO原子への結合を示し、
R1は、H、1個〜4個の炭素原子を有するアルキル基、フェニル基、ナフチル基、
R2は、Hまたは−C(=O)R3であり、ここで、R3は、1〜4個の炭素原子を有するアルキル基、フェニル基、ナフチル基、ならびに、フェノール基、o−クレゾール基、m−クレゾール基、p−クレゾール基、α−ナフトール基、および、β−ナフトール基、のうちの1つから選択される芳香族フェノール基、から選択され、ならびに、
R2がHである場合、R1は、フェニル基またはナフチル基ではありえず、かつ、n≧1である。 - R1が、1個〜4個の炭素原子を有するアルキル基であり、Xが、6個までの炭素原子を有するアルキル基またはアルコキシ基で置換されていてもよい6〜12個の炭素原子を有する二価の芳香族炭化水素基、である請求項1に記載の組成物。
- R1が、H、1個〜4個の炭素原子を有するアルキル基であり、Xが、1〜8個の炭素原子を有する二価の直鎖状アルキレン基もしくは分岐鎖状アルキレン基、または、2個〜8個の炭素原子を有する二価の直鎖状アルケニレン基もしくは分岐鎖状アルケニレン基、である請求項1に記載の組成物。
- Xが、6個までの炭素原子を有するアルキル基またはアルコキシ基で置換されていてもよい6〜12個の炭素原子を有する二価の芳香族炭化水素基、である請求項1に記載の組成物。
- Xが、1〜8個の炭素原子を有する二価の直鎖状アルキレン基もしくは分岐鎖状アルキレン基であるか、または、2個〜8個の炭素原子を有する二価の直鎖状アルケニレン基もしくは分岐鎖状アルケニレン基、である請求項1に記載の組成物。
- nが1〜100である請求項1に記載の組成物。
- 前記熱硬化性樹脂がエポキシ樹脂である請求項1に記載の組成物。
- 前記熱硬化性樹脂が、非ハロゲン系エポキシ樹脂、非リン系エポキシ樹脂、および、リン含有エポキシ樹脂、ならびに、それらの混合物、からなる該群より選択されるエポキシ樹脂である請求項1に記載の組成物。
- 式(I)のリン含有芳香族ポリエステルを、前記熱硬化性樹脂100重量部あたり10重量部〜150重量部含む請求項1に記載の組成物。
- 請求項1に記載の組成物を含む、コーティング配合物、封入材、複合材、接着剤、成形物、ボンディングシート、または、積層プレート。
- 請求項1に記載の組成物を含む物品。
- 鉛フリーはんだ付けおよび電子デバイスにおいて使用することができる、請求項13に記載の物品。
- さらに銅箔を含む請求項13に記載の物品。
- プリント回路基板である請求項13に記載の物品。
- 請求項1に記載の組成物を含むプリプレグ。
- 請求項1に記載の組成物を含むラミネートまたはボンディングシート。
- 請求項17に記載のプリプレグを含むプリント回路基板。
- 請求項18に記載のラミネートを含むプリント回路基板。
- 請求項18に記載のラミネートを製造する方法であって、
前記組成物を充填材料中に染み込ませてプリプレグを形成する工程と、
前記プリプレグを高温において処理することにより、B−ステージへの部分硬化を促進する工程と、
前記プリプレグを高圧および高温において積層することによってラミネートを形成する工程と、を含む方法。 - 請求項21に記載の方法によってラミネートを製造することを含むプリント回路基板を製造する方法。
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WO2018031103A1 (en) * | 2016-08-11 | 2018-02-15 | Icl-Ip America Inc. | Curable epoxy composition |
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KR102340799B1 (ko) * | 2018-09-20 | 2021-12-16 | 주식회사 엘지화학 | 금속 박막 코팅용 열경화성 수지 조성물, 이를 이용한 수지 코팅 금속 박막 및 금속박 적층판 |
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US20150189745A1 (en) | 2012-09-14 | 2015-07-02 | Shengyi Technology Co., Ltd. | Epoxy resin composition, and, prepreg and copper clad laminate manufactured using the composition |
CN103694642B (zh) * | 2013-12-27 | 2015-11-25 | 广东生益科技股份有限公司 | 一种热固性树脂组合物及其用途 |
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- 2016-11-01 JP JP2018544762A patent/JP6841839B2/ja active Active
- 2016-11-01 EP EP16791799.6A patent/EP3374414B1/en active Active
- 2016-11-01 US US15/772,848 patent/US10500823B2/en active Active
- 2016-11-01 CN CN201680065750.4A patent/CN108350157B/zh active Active
- 2016-11-01 WO PCT/US2016/059878 patent/WO2017083136A1/en active Application Filing
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CN108350157A (zh) | 2018-07-31 |
KR20180084778A (ko) | 2018-07-25 |
CN108350157B (zh) | 2020-06-09 |
JP2019502011A (ja) | 2019-01-24 |
TWI721024B (zh) | 2021-03-11 |
WO2017083136A1 (en) | 2017-05-18 |
TW201728613A (zh) | 2017-08-16 |
US20180326708A1 (en) | 2018-11-15 |
EP3374414A1 (en) | 2018-09-19 |
US10500823B2 (en) | 2019-12-10 |
EP3374414B1 (en) | 2020-04-22 |
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