TW201615739A - Naphthalene based epoxy for halogen-free and flame retardant compositions - Google Patents

Abstract

A curable composition comprising, consisting of, or consisting essentially of (a) an epoxy component comprising a dinaphthalene epoxy having the structure wherein each R1 group is independently a C1-C20 hydrocarbon; a is an integer in the range of from 0 to 6; m is an integer in the range of 0 to 5; and (b) a hardener component comprising (i) a naphthol novolac which is a reaction product of (I) from 1 to 99 weight percent 1-naphthol and (II) from 1 to 99 weight percent 2-naphthol; (ii) a phosphorus-containing composition which is the reaction product of an etherified resole with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide; and (iii) optionally a phenolic resin selected from the group consisting of a molecule having at least one substituted or unsubstituted naphthalene ring, a high functionality phenolic resin, and combinations thereof, is disclosed. The curable composition can be used to prepare prepregs and electrical laminates.

Description

Naphthalene epoxy resin for halogen-free and flame-retardant compositions Field of invention

This invention relates to an epoxy resin composition. More particularly, the invention relates to a halogen-free or substantially halogen-free formulation.

Background of the invention

Epoxy resin is widely used in coatings, adhesives, printed circuit boards, semiconductor encapsulants, adhesives and aerospace composites. It is responsible for its excellent mechanical strength; resistance to chemicals, moisture and corrosivity; good heat , adhesive and electrical properties.

The integrated circuit and printed circuit board industry requires a low-cost, highly reliable interconnect design that supports fast-increasing input/output (I/O) counts in ASICs and microprocessors. There is an increasing interest in the replacement of standard ceramic wafers for single and multi wafer carrier applications in conventional printed circuit boards. However, the coefficient of thermal expansion (CTE) mismatch between the base material and the turns in the x-axis and the y-axis of the printed wiring board (PWB) plane causes stress to be generated between the member and the PWB. This stress is mainly released by the deformation of the solder balls and PWB. On the other hand, the CTE mismatch between the base material and the copper on the Z-axis of the PWB causes the board to be damaged, although the mechanism is different. Copper plated through hole (PTH) and copper plating The channel will experience cracking in the copper due to the substantially higher PWB expansion. Therefore, a composition is desired which has a lower CTE in the x and y axes facing the crucible and a lower CTE in the z-axis facing the copper and a lower stress between the PWB and its components.

Summary of invention

The present invention is a hardenable composition comprising, consisting of, or consisting essentially of: a) an epoxy resin component comprising a binaphthyl epoxy resin having the following structure: Wherein each R ₁ group is independently a C1-C20 hydrocarbon, a is an integer in the range 0 to 6, m is an integer in the range 0 to 5; b) a hardener component, which comprises i) A naphthol phenolic resin, which is I) from 1 to 99 weight percent of 1-naphthol and II) from 1 to 99 weight percent of 2-naphthol to the following reaction product; ii) a phosphorus-containing composition which is etherified a reaction product of a resol resin with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO); and iii) a selectivity selected from the group consisting of Phenolic resin: a molecule having at least one substituted or unsubstituted naphthalene ring, a highly functional phenol resin, and combinations thereof.

Detailed description of the preferred embodiment

The present invention is a hardenable composition. The present invention is a hardenable composition comprising, consisting of, or consisting essentially of: a) an epoxy resin component comprising a binaphthyl epoxy resin having the following structure: Wherein each R ₁ group is independently a C1-C20 hydrocarbon, a is an integer in the range 0 to 6; m is an integer in the range of 0 to 5; b) a hardener component, which comprises i a naphthol phenolic resin which is a reaction product of 1) 1 to 99 weight percent of 1-naphthol and II) 1 to 99 weight percent of 2-naphthol; ii) a phosphorus-containing composition which is etherified a reaction product of a resol resin with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO); and iii) a selectivity selected from the group consisting of Phenolic resin: a molecule having at least one substituted or unsubstituted naphthalene ring, a highly functional phenol resin, and combinations thereof.

The hardenable composition may further optionally comprise a filler. The hardenable composition may further optionally comprise a catalyst and/or a solvent.

The hardenable composition comprises an epoxy resin component and a hardener component as described in more detail below.

The hardenable composition may further comprise one or more fillers selected from the group consisting of natural cerium oxide, molten cerium oxide, aluminum oxide, hydrated alumina, talc, alumina trihydrate, hydrogen Magnesium oxide and combinations thereof. The hardenable composition may comprise from 10 to 80 weight percent One or more fillers. All individual values and sub-ranges of 10 to 80 weight percent are included herein and disclosed herein, for example, the weight percentage of the filler may be from a lower limit of 10, 12, 15, 20 or 25 weight percent to an upper limit of 62, 65, 70, 75 or 80 weight percent. For example, the hardenable composition can comprise from 15 to 75 weight percent of one or more fillers; or in an alternative embodiment, the hardenable composition can comprise from 20 to 70 weight percent of one or more fillers. Such fillers include, but are not limited to, natural ceria, molten ceria, alumina, hydrated alumina, talc, alumina trihydrate, magnesium hydroxide, and combinations thereof.

The hardenable composition may further comprise one or more catalysts. The hardenable composition may comprise from 0.01 to 10 weight percent of one or more catalysts. All individual values and sub-ranges of 0.01 to 10 weight percent are included and disclosed herein, for example, the weight percentage of the catalyst may be from a lower limit of 0.01, 0.03, 0.05, 0.07 or 1 weight percent to an upper limit of 2. 6 or 10 weight percent. For example, the hardenable composition can comprise from 0.05 to 10 weight percent of one or more catalysts; or in an alternative embodiment, the hardenable composition can comprise from 0.05 to 2 weight percent of one or more catalysts. Such catalysts include, but are not limited to, 2-methylimidazole (2MI), 2-phenylimidazole (2PI), 2-ethyl-4-methylimidazole (2E4MI), 1-benzyl-2-phenylimidazole ( 1B2PZ), boric acid, triphenylphosphine (TPP), tetraphenylphosphonium tetraphenylborate (TPP-k), and combinations thereof.

The hardenable composition may further comprise one or more toughening agents. The hardenable composition may comprise from 0.01 to 70 weight percent of one or more toughening agents. Included in this document and disclosed herein are 0.01 to 70 weights All individual values and sub-ranges of percentages, for example, the weight percentage of the toughening agent may range from a lower limit of 0.01, 0.05, 1, 1.5 or 2 weight percent to an upper limit of 15, 30, 50, 60 or 70 weight percent. For example, the hardenable composition can comprise from 1 to 50 weight percent of one or more toughening agents; or in an alternative embodiment, the hardenable composition can comprise from 2 to 30 weight percent of one or more toughening agents.

Such toughening agents include, but are not limited to, core-shell rubbers. The core-shell type rubber is a polymer comprising a rubber particle core formed of an elastomer-containing polymer or a rubber-like polymer as a main component, and a polymer polymerized by grafting on the core. The outer shell layer formed. The outer shell layer partially or completely covers the surface of the rubber particle core by graft polymerizing a monomer to the core. Generally, the rubber particle core is composed of an acrylic or methacrylic ester monomer, or a diene (conjugated diene) monomer, or a vinyl monomer, or a decyloxy type monomer, and combinations thereof. The toughening agent can be selected from commercially available products, for example, Paraloid EXL 2650A, EXL 2655, EXL 2691 A, each of which is available from The Dow Chemical Company; or Kane Ace® MX series from Kaneka Corporation. Such as MX 120, MX 125, MX 130, MX 136, MX 551; or METABLEN SX-006, available from Mitsubishi Rayon.

The hardenable composition may further comprise one or more solvents. A solvent can be used to dissolve the epoxy resin and hardener component or to adjust the viscosity of the final varnish. The hardenable composition may comprise from 0.01 to 50 weight percent of one or more solvents. All individual values and sub-ranges of 0.01 to 50 weight percent are included and disclosed herein, for example, the weight percentage of the catalyst may be from a lower limit of 0.01, 0.03, 0.05, 0.07 or 1 weight percent to an upper limit of 2. 6, 10, 15, 30 or 50 weight percent. For example, the hardenable composition can comprise from 1 to 50 weight percent of one or more solvents; or in an alternative embodiment, the hardenable composition can comprise from 2 to 30 weight percent of one or more solvents. Such solvents include, but are not limited to, methanol, acetone, n-butanol, methyl ethyl ketone (MEK), benzene, toluene, xylene, cyclohexanone, dimethylformamide (DMF), ethanol (EtOH), propylene glycol. methyl ether (PM), propylene glycol methyl ether acetate ester (DOWANOL ^TM PMA) and mixtures thereof.

The hardenable composition comprises a) an epoxy resin component; b) a hardener component comprising i) a naphthol phenolic resin, wherein I) from 1 to 99 weight percent of 1-naphthol and II) a reaction product of 1 to 99% by weight of 2-naphthol; and ii) an oligomeric compound comprising a phosphorus composition which is a reaction product of an etherified resol resin and DOPO; and iii) selective selection A phenolic resin from the group consisting of: a molecule having at least one substituted or unsubstituted naphthalene ring, a highly functional phenol resin, and combinations thereof.

In various embodiments, the epoxy resin component is a naphthyl epoxy resin. An example of the epoxy resin component is depicted in Formula 1.

In Formula 1, each of the R ₁ groups is independently a hydrocarbon having 1 to 20 carbon atoms per molecule. All individual values and sub-ranges of 1 to 20 are included herein and disclosed herein. For example, R ₁ may be 1, 2, 3, 4, 5, 6, 7, 8, 9, per molecule. A hydrocarbon of 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms. a is an integer between 0 and 6. All individual values and sub-ranges from 0 to 6 are included and disclosed herein, for example, a may be 0, 1, 2, 3, 4, 5 or 6. m is an integer in the range 0 to 5. All individual values and sub-ranges from 0 to 5 are included and disclosed herein, for example, m can be 0, 1, 2, 3, 4 or 5.

In a specific example, the binaphthyl epoxy resin is prepared by contacting dihydroxybinaphthalene with an epihalohydrin. The dihydroxybinaphthyl can be a trans isomer or a cis isomer or a mixture of cis and trans isomers. In various embodiments, the epihalohydrin is epichlorohydrin (EPI). An embodiment of the reaction method is depicted in Formula 2 below.

The hardenable composition may comprise from 1 to 99 weight percent of the epoxy resin component. All individual values and sub-ranges of from 1 to 99 weight percent are included herein and disclosed herein, for example, the weight percent of the epoxy resin may range from a lower limit of 12, 17, 20, 30 or 35 weight percent to an upper limit of 55. , 70, 86, 90 or 98 weight percent. For example, the hardenable composition can comprise from 20 to 98 weight percent of one or more epoxy resins; or in an alternative embodiment, the hardenable composition can comprise from 30 to 90 weight percent of one or more epoxy resins.

The hardenable composition may comprise from 1 to 99 weight percent of one or more naphthol phenolic resins. This ensures that the naphthol novolac epoxy resin composition to a temperature in the range of equal or greater than T _g of the hardened state at room temperature having a low coefficient of linear expansion and a high T _g. All individual values and sub-ranges of from 1 to 99 weight percent are included herein and disclosed herein, for example, the weight percentage of the naphthol phenolic resin may range from a lower limit of 1, 1.2, 1.5, 12 or 20 weight percent to an upper limit. 45, 50, 54, 60 or 70 weight percent.

In various embodiments, the naphthol phenolic resin is formed by contacting a naphthol component with an aldehyde. An example of the reaction method is depicted in the following formula 3.

The naphthol phenolic resin is a reaction product of 1 to 99% by weight of 1-naphthol and II) 1 to 99% by weight of 2-naphthol. All individual values and sub-ranges of from 1 to 99 weight percent are included herein and disclosed herein, for example, the weight percentage of the 1-naphthol can be from the lower limits 1, 10, 14, 25, 33, 50, 66 , 71 or 80 weight percent to an upper limit of 25, 33, 55, 66, 75, 82 or 95 weight percent. Likewise, the weight percentage of the 2-naphthol can range from a lower limit of 1, 10, 14, 33, 50, 66, 71 or 80 weight percent to an upper limit of 25, 33, 55, 66, 82 or 95 weight percent.

In various embodiments, paraformaldehyde can be used as the aldehyde. Other aldehydes may be used including, but not limited to, formaldehyde, aliphatic aldehydes, and aromatic aldehydes.

In various embodiments, the naphthalene can be contacted prior to contact with the aldehyde The phenol component is added to the solvent. Any suitable solvent may be used such as, for example, toluene and xylene.

A phenol resin may be selectively added to the hardenable composition. The phenol resin may be selected from the group consisting of molecules having at least one substituted or unsubstituted naphthalene ring, high functional phenol resins, and combinations thereof.

Phenolic resins which may be used include, but are not limited to, novolak type phenol resins (for example, phenol novolac resins, cresol novolac resins), triphenol alkane type phenol resins (for example, trisphenol methane phenol resin, trisphenol propenol resin) , phenol aralkyl type phenol resin, biphenyl aralkyl type phenol resin, biphenyl type phenol resin. In a specific example, the phenol resin is a naphthalene type phenol resin. These phenol resins may be used singly or in combination of two or more.

The hardenable composition may comprise from 1 to 70 weight percent of one or more selective phenolic resins. All individual values and sub-ranges of from 1 to 99 weight percent are included herein and disclosed herein, for example, the weight percentage of the phenolic resin may range from a lower limit of 1, 1.2, 1.5, 12 or 20 weight percent to an upper limit of 45, 50, 54, 60 or 70 weight percent.

The hardenable composition may comprise from 1 to 80 weight percent of one or more oligomeric compounds comprising a phosphorus composition which is the reaction product of an etherified resol resin and DOPO. All individual values and sub-ranges of from 1 to 80 weight percent are included and disclosed herein, for example, the weight percentage of the DOPO compound can be from a lower limit of 1.5, 2, 3, 5 or 10 weight percent to an upper limit of 20, 40, 55, 60 or 70 weight percent. For example, the hardenable composition may comprise from 2 to 60 weight percent of one or more DOPO compounds; or in an alternative example, the hardenable composition may comprise Up to 40% by weight of one or more DOPO compounds.

In a specific example, the DOPO-containing compound is an oligomeric composition comprising a phosphorus-containing compound which is the reaction product of an etherified resol resin and DOPO. This reaction product is depicted in the following formula 4.

Further information regarding this composition and its preparation can be found in U.S. Patent No. 8,124,716.

The composition can be made by any suitable method known to those skilled in the art. These components are prepared by any suitable method. In a specific example, in a reaction zone, the dihydroxybinaphthalene is contacted with an epihalohydrin under a reaction condition to form a binaphthyl epoxy resin; and in a reaction zone, under a reaction condition, 1-naphthol is contacted with 2-naphthol to form a naphthol phenolic resin composition. In a specific example, the epoxy resin component, the naphthol phenolic resin, and the solution of the phosphorus-containing composition are mixed together. Any other desired components, such as the optional components described above, are then added to the mixture.

A specific example of the present disclosure provides a prepreg comprising a reinforcing component and a hardenable composition as discussed herein. The prepreg can be obtained by a method comprising impregnating a matrix component into the reinforcing component. The matrix component surrounds and/or supports the reinforcing component. The disclosed hardenable composition can be used in the matrix component. The matrix component of the prepreg provides synergy with the reinforcing component. This synergy provides the prepreg and/or the product obtained by hardening the prepreg with mechanical and/or physical properties that are not achievable with the individual components. The prepreg can be used to produce an electric laminate for a printed circuit board.

The reinforcing component can be a fiber. Examples of such fibers include, but are not limited to, glass, aromatic polyamides, carbon, polyester, polyethylene, quartz, metals, ceramics, biomass, and combinations thereof. The fiber can be coated. Examples of such fiber coatings include, but are not limited to, boron.

Examples of such glass fibers include, but are not limited to, A-glass fibers, E-glass fibers, C-glass fibers, R-glass fibers, S-glass fibers, T-glass fibers, and combinations thereof. The aromatic polyamine-based organic polymers, examples of which include, but are not limited to, Kevlar®, Twaron®, and combinations thereof. Examples of such carbon fibers include, but are not limited to, those formed from polyacrylonitrile, asphalt, fluorene, cellulose, and combinations thereof. Examples of such metal fibers include, but are not limited to, stainless steel, chromium, nickel, platinum, titanium, copper, aluminum, tantalum, tungsten, and combinations thereof. Examples of such ceramic fibers include, but are not limited to, those formed from alumina, ceria, zirconia, tantalum nitride, niobium carbide, boron carbide, boron nitride, tantalum boride, and combinations thereof. Examples of such biomass fibers include, but are not limited to, those formed from wood, non-wood, and combinations thereof.

The reinforcing component can be a fabric. As discussed herein, the fabric can be formed from fibers. Examples of such fabrics include, but are not limited to, stitched fabrics, woven fabrics, and combinations thereof. The fabric can be unidirectional, multi-axial, and combinations thereof. The reinforcing component can be a combination of fibers and fabric.

The prepreg can be obtained by impregnating the matrix component into the reinforcing component. The matrix component can be impregnated into the reinforcing component by a variety of methods. The prepreg can be formed by contacting the reinforcing component with the matrix component via roll coating, dipping, spraying or other such procedure. After the prepreg reinforcing component has been contacted with the prepreg matrix component, the solvent can be removed via volatilization. Simultaneously and/or after evaporation of the solvent, the prepreg matrix component can be hardened, for example, partially. Volatilization and/or partial hardening of the solvent may be referred to as B-staged. The B-staged product can be referred to as a prepreg.

For some applications, the B-stage can occur via exposure to a temperature of 60 ° C to 250 ° C; for example, the B-stage can occur via exposure to temperatures between 65 ° C and 240 ° C, or 70 ° C to 230 ° C. For some applications, the B-stage can occur for a period of 1 minute (min) to 60 minutes; for example, the B-stage can occur for a period of 2 minutes to 50 minutes, or 5 minutes to 40 minutes. However, for some applications, the B-stage can occur at another temperature and/or for another period of time.

One or more of the prepregs can be hardened (e.g., more completely cured) to obtain a hardened product. The prepreg can be laminated and/or formed into a shape before further hardening. For some applications (eg, when manufacturing an electrical laminate), the prepreg layer can be placed alternately with the layer of electrically conductive material. Conductive Examples of materials include, but are not limited to, copper foil. The prepreg layer can then be exposed to conditions where the matrix component will become more fully hardened.

An example of a method for obtaining the more fully cured product is pressurization. One or more prepregs can be placed in a press, where they are subjected to a hardening force for a predetermined period of hardening to obtain the more fully hardened product. The press has a hardening temperature in the hardening temperature range stated above. For one or more specific examples, the press has a hardening temperature that jumps from a lower hardening temperature to a higher hardening temperature during a jump time interval.

The one or more prepregs may receive a hardening force via a press during pressurization. The value of the hardening force may be from 10 thousand Bass (kPa) to 350 thousand Bass; for example, the hardening force may be from 20 thousand Bass to 300 thousand Bass, or 30 thousand Bass to 275 thousand Baska. The predetermined hardening time interval may range from 5 seconds to 500 seconds; for example, the predetermined hardening time interval may range from 25 seconds to 540 seconds, or 45 seconds to 520 seconds. Other hardening temperatures, hardening force values, and/or predetermined hardening time intervals are possible for other methods of obtaining the hardened product. Additionally, the method can be repeated to further harden the prepreg and obtain the hardened product.

The prepreg can be used to make composites, laminates and coatings. Printed circuit boards prepared from the laminated sheets can be used in a variety of applications. In a specific example, the printed circuit board is used in smart phones and tablets. In various embodiments, the laminated sheet has a copper stripping strength in the range of 4 lbs/inch to 12 lbs/inch.

Example Synthesis of naphthol phenolic resin hardener (mNPN)

Unless otherwise mentioned, all materials used in the synthesis of naphthol phenolic resins were from Sinopharm Co. (Shanghai, China).

1-naphthol (24 g, 0.17 mol) and 2-naphthol (12 g, 0.083 mol) were dissolved in toluene (75 ml) at 50 ° C (using 250 ml equipped with a stirrer, condenser) And a 3-neck round bottom flask for introducing a tube of N ₂ ). After the solid disappeared, oxalic acid (300 mg, 5 mmol) was added followed by trioxane (6.75 g, 0.225 mol). The reaction mixture was slowly heated to 90 ° C and revealed many bubbles. After the mixture was settled, it was refluxed with stirring for 6.5 hours. Then, it was cooled to 50 ° C and the upper toluene solution was removed. Then, the residue was dissolved in cyclohexanone (30 ml) at 80 ° C for 1 hour. This solution can be used without further purification. The small portion was removed and dried in a vacuum oven at 80 ° C for 3 hours to calculate the concentration of mNPN in cyclohexanone.

Synthesis of binaphthyl epoxy resin (EN-1)

Unless otherwise mentioned, all materials used in the synthesis of the binaphthyl epoxy resin were from Sinopharm Co. (Shanghai, China).

Add 2,2'-hydroxy-1,1'-binaphthyl (14.32 g, 50 mmol), poly(ethylene glycol) (PEG-400) (1 g) and epichlorohydrin (110 ml) to 250 ml three-necked bottle. The bottle is equipped with a modified Dean-Stark trap with a condenser and a vacuum controller. The reaction system was heated to 65 °C. Then, via a metering pump, 8.6 grams of 48% by weight sodium hydroxide water over a 6 hour period The solution was added to the above solution while maintaining the temperature at 65 ° C under reduced pressure. During the reaction, water produced by the reaction and water contained in the aqueous sodium hydroxide solution are continuously removed from the reaction system by azeotropic distillation, and the distilled epichlorohydrin is returned to the reaction system. After the reaction was over, the reaction mixture was filtered and subsequently distilled to remove salts and excess epichlorohydrin. 100 ml of ethyl acetate was added to dissolve the crude resin product produced. The obtained solution was washed several times with water to remove PEG-400. Then, ethyl acetate was evaporated to give the final product.

Varnish formulation

Ingredients

Epoxy EN-1 (binaphthyl epoxy resin, 60% in methyl ethyl ketone) from the above method

Epoxy D.E.N. 438 (3.6 functional epoxy resin, 60% in methyl ethyl ketone) from The Dow Chemical Company

eBPAN (bisphenol A type phenolic novolac epoxy resin, EEW = 200) from The Dow Chemical Company

mNPN (5-functional naphthol phenolic resin), a synthetic compound derived from the above method

The reaction product of an etherified resol resin with DOPO (60% in methyl ethyl ketone) from The Dow Chemical Company

HF-1M (phenolic phenolic resin, HEW=106) from Meiwa Plastic Industries LTD

X.Z.92535 (phenolic phenolic resin, 50% in propylene glycol monomethyl ether) from The Dow Chemical Company

MEH7000 (cresol/naphthol/aldehyde type resin, HEW=143) from Meiwa Plastic Industries LTD

MEH7500 (triphenylmethane type phenolic resin, HEW=97) from Meiwa Plastic Industries LTD

MEH7600-4H (highly functional phenolic resin, HEW=100) from Meiwa Plastic Industries LTD

BPAN (bisphenol A type phenolic phenolic resin, HEW = 125) from The Dow Chemical Company

2-methylimidazole (2-MI): hardening catalyst (10% in propylene glycol monomethyl ether) from Sinopharm Chemical and Reagent Company

The above ingredients were mixed according to the respective formulations and shaken on a shaker to form a homogeneous solution. Then, the catalyst was added to the varnish, and the gel time of the varnish was tested on a hot plate maintained at 171 °C. The gelled material was recovered from the surface of the hot plate and hardened in an oven at 220 ° C for 2 hours. Then, the thermal properties of the hardened material were measured by DSC and the CTE was measured by TMA. The formulations and results are shown in Tables 1 and 2.

The results in Tables 1 and 2 show that, from the comparison between Inventive Examples 1-11 and Comparative Examples A-L, it was found that EN-1 is a good construction component for reducing the CTE value of the hardened resin. Similarly, higher EN-1 content (higher EEW/HEW) is produced in the formulation. Lower CTE. For the conventional high functionality epoxy resin D.E.N. 438, the EEW/HEW ratio provided minimal impact on the CTE (Comparative Example B-I).

The type of phenolic novolac hardener affects _Tg performance. Comparative Inventive Examples 5-6 and Inventive Examples 7-11 show the use of a highly functional hardener to produce a higher _Tg while maintaining comparable CTE performance.

The nature of the laminate

The invention and two comparative laminates were prepared. Table 3 lists the detailed varnish formulations. First, the polymer components were mixed to form a uniform 60% solution in MEK and shaken for 1 hour. Then, the varnish was coated on a glass flake (Hexcel 2116) and partially hardened in a 171 ° C ventilating oven to prepare a prepreg. Finally, 8 prepregs were thermally pressed at 220 ° C for two hours with copper to prepare a laminate. Then, the properties and detailed results of testing the laminates are shown in Table 4.

The results in Table 4 show that Inventive Example 12 shows a lower z-axis thermal expansion coefficient, a higher _Tg , a lower water absorption, and a better comparison with a comparative laminate prepared with a highly functional epoxy resin. Flame retardant properties.

testing method

The reactivity of the different varnish formulations is determined by the time required for the material to gel. The gel point is the point at which the resin returns from the viscous liquid to the elastomer. Use approximately 0.7 ml of liquid and feed it at 171 ° C On a hot plate, after 60 seconds, the liquid was tapped back and forth on the hot plate until it gelled to measure and record the gel time.

Manual layup technique

The hand lay-up technique was developed to produce prepregs quickly and easily on a small scale. A single piece of glass fabric sheet of approximately twelve square feet was nailed to the wooden frame. The frame containing the e-glass fabric is placed on a flat surface covered with a disposable plastic sheet. About 25-35 grams of varnish was poured onto the e-glass fabric and then evenly coated with a paint brush to a width of two inches. Subsequently, the frame containing the wet glass fabric was suspended in an air circulating oven at a temperature of 171 ° C to remove the solvent. After one minute, the frame was removed and allowed to cool to room temperature. The prepreg was crushed to obtain a powder for further testing.

Thermogravimetric analysis (TGA) of the hardened resin was carried out with an Instrument TGA Q5000 V3.10 Build 258. The test temperature ranged from room temperature to 600 ° C; the heating rate was 20 ° C / min, nitrogen flow protection. The decomposition temperature (T _d ) is determined by selecting the corresponding temperature at 5% weight loss (95% residual weight) of the material.

The glass transition temperature (T _g ) of the hardened resin is determined by both DSC and DMTA.

The DSC test conditions are as follows:

N ₂ environment

Cycle one:

Initial temperature: room temperature

Final temperature: 180 ° C

Jump rate = 20 ° C / min

Cycle 2:

Initial temperature: 180 ° C

Final temperature: room temperature

Jump rate = -20 ° C / min

Cycle three:

Initial temperature: 23 ° C

Final temperature: 200 ° C

Jump rate = 10 ° C / min

RSA III using dynamic mechanical thermal analyzer (DMTA) to determine the cured resin DMTA T _g. The sample was heated from -50 to 250 °C at a heating rate of 3 °C/min. The test frequency is 6.28 radians/second. T _g of the obtained epoxy resin cured from the tangent δ peak.

CTE test

According to IPC-TM-650 2.4.41, samples for CTE testing were prepared and tested by the following steps: 1:10.00 ° C / min jump to T _g ; 2: isothermal 5.00 min; 3: 10.00 ° C / min jump to 30.00 ° C; 4: 5.00 ° C / min jump to greater than T _g 20 ° C; 5: jump to 30.00 ° C

UL 94 test

The prepreg sheet was molded into a laminate and hardened at 220 ° C for 3 hours by a general hot press. Cut the last laminate into Standard sample for UL-94 FR testing. The UL 94 vertical flame test was conducted in a CZF-2 vertical/horizontal combustion tester manufactured by Nanjing Jiangning Analytical Equipment Company. The cabin is 720 mm x 370 mm x 500 mm and uses natural gas as a burner gas resource. The pod is open throughout the testing process in which air is prohibited from flowing around the test device. Each sample was burned twice and the afterflame time (AFT) t1 and t2 were recorded. AFT t1 and t2 were obtained as follows: A test flame was applied to the sample for 10 seconds and then removed. This length of time (t1) is the period between the time the flame is removed and the flame on the sample is extinguished. Once the flame has extinguished, apply a test flame for another 10 seconds and then remove. The burning period (t2) of the sample was recorded again.

Water absorption

Water absorption was carried out by exposing 4 or 5 samples to steam (121 ° C, 2 atm) for 1 hour in a pressure cooker. Remove the sample and bake quickly, then weigh to determine water absorption.

Copper stripping strength test

The copper stripping strength was tested by the IMASS SP-2000 Slip/Peel Tester according to the method described in IPC TM-650 2.4.8.1. A 35 micron standard copper foil was used to prepare the laminate.

D _k and D _f measurements

Samples were analyzed at room temperature using an Agilent 4991A Impendence/Material Analyzer equipped with an Agilent 16453A test fixture. Calibration was performed using Agilent Teflon standard plaque using Dk/Df parameters provided by the supplier. Measuring Teflon standard plaques with a micrometer The thickness of all samples.

Transparent ingot or plate pressurization method:

a) increase the temperature to 220 ° C

b) Use 24,000 pounds of force at 220 ° C, repeat several times to discharge bubbles

c) Maintain a fixed pressure at 220 ° C for 2 hours

d) cooling to room temperature

Claims (14)

A hardenable composition comprising: a) an epoxy resin component comprising a naphthalene epoxy resin having the following structure Wherein each R ₁ group is independently a C1-C20 hydrocarbon; a is an integer in the range 0 to 6; m is an integer in the range 0 to 5; and b) a hardener component comprising: i) a naphthol phenolic resin which is the following reaction product: I) 1 to 99 weight percent of 1-naphthol; and II) 1 to 99 weight percent of 2-naphthol; ii) a phosphorus-containing composition, It is a reaction product of an etherified resol resin and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide; and iii) a selective phenol resin selected from the group consisting of The group consisting of: a molecule having at least one substituted or unsubstituted naphthalene ring, a highly functional phenol resin, and combinations thereof. The hardenable composition of claim 1, further comprising a filler selected from the group consisting of natural cerium oxide, molten cerium oxide, aluminum oxide, hydrated alumina, talc, alumina trihydrate. , magnesium hydroxide and combinations thereof. The hardenable composition of claim 1 or 2, wherein the phosphorus composition has the following structure: The hardenable composition according to any one of claims 1 to 3, further comprising a catalyst. The hardenable composition according to any one of claims 1 to 4, further comprising a toughening agent. The hardenable composition according to any one of claims 1 to 5, wherein the epoxy resin component is present in an amount ranging from 20% by weight to 80% by weight based on the total weight of the hardenable composition, The naphthol phenolic resin is present in an amount ranging from 1 weight percent to 60 weight percent, and the phosphorus-containing compound is present in an amount ranging from 1 weight percent to 60 weight percent. The hardenable composition according to any one of claims 1 to 6, wherein the phenol resin is present in an amount ranging from 1% by weight to 60% by weight. The hardenable composition of any one of claims 2 to 7, wherein the filler is present in an amount ranging from 10 weight percent to 80 weight percent. The hardenable composition of any one of claims 4 to 8, wherein the catalyst is present in an amount ranging from 0.01 weight percent to 10 weight percent. The hardenable composition according to any one of claims 5 to 9, wherein the toughening agent is present in an amount ranging from 0.01% by weight to 70% by weight. A method for producing a hardenable composition according to any one of claims 1 to 10, which comprises: a) contacting dihydroxybinaphthalene with epihalohydrin in a reaction zone under a reaction condition Forming a naphthyl epoxy resin; b) contacting I) from 1 to 99 weight percent of 1-naphthol in a reaction zone under a reaction condition; and contacting II) from 1 to 99 weight percent of 2-naphthol To form a naphthol phenolic resin composition; and c) to mix i) the naphthyl epoxy resin: ii) the naphthol phenolic resin composition; and iii) an oligomeric compound comprising a phosphorus composition, The reaction product of an etherified resol resin and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide. A prepreg prepared by the hardenable composition according to any one of claims 1 to 10. An electrodeposited sheet prepared from the hardenable composition according to any one of claims 1 to 10. A printed circuit board prepared from an electrical laminate as claimed in claim 13.