Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • 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
  • C08G59/20—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 epoxy compounds used
  • C08G59/32—Epoxy compounds containing three or more epoxy groups
  • C08G59/3218—Carbocyclic compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • 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
  • C08G59/68—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 catalysts used
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • 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
  • C08G59/68—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 catalysts used
  • C08G59/686—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 catalysts used containing nitrogen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/20—Oxides; Hydroxides
  • C08K3/22—Oxides; Hydroxides of metals
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
  • C08K3/36—Silica
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K9/00—Use of pretreated ingredients
  • C08K9/04—Ingredients treated with organic substances
  • C08K9/06—Ingredients treated with organic substances with silicon-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
  • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
  • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
  • H01B3/40—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes epoxy resins
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
  • C08K3/20—Oxides; Hydroxides
  • C08K3/22—Oxides; Hydroxides of metals
  • C08K2003/2265—Oxides; Hydroxides of metals of iron
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K2201/00—Specific properties of additives
  • C08K2201/002—Physical properties
  • C08K2201/005—Additives being defined by their particle size in general
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K2201/00—Specific properties of additives
  • C08K2201/011—Nanostructured additives
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K2201/00—Specific properties of additives
  • C08K2201/014—Additives containing two or more different additives of the same subgroup in C08K

Definitions

• the present invention relates to a curable composition
• a curable composition comprising an epoxy resin and a filler composition, a cured product obtained by curing said curable composition as well as the use of the curable composition as insulating material for electrical and electronic components, in particular as encapsulation system for printed circuit boards.
• Customary encapsulating materials are often based on epoxy resins in combination with anhydride hardeners. Some anhydrides, however, have been classified as “respiratory sensitizers” (hazard label: R42) according to REACH legislation.
• the invention relates to a composition
• a composition comprising
• epoxy resins suitable as component (a) are those customary in epoxy resin technology.
• examples of epoxy resins are:
• Aliphatic polycarboxylic acids may be used as the compound having at least two carboxyl groups in the molecule.
• examples of such polycarboxylic acids are oxalic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid or dimerised or trimerised linoleic acid.
• cycloaliphatic polycarboxylic acids for example hexahydrophthalic acid or 4-methylhexahydrophthalic acid.
• Aromatic polycarboxylic acids for example phthalic acid, isophthalic acid or terephthalic acid, may also be used as well as partly hydrogenated aromatic polycarboxylic acids such as tetrahydrophthalic acid or 4-methyltetrahydrophthalic acid.
• Polyglycidyl or poly( ⁇ -methylglycidyl) ethers obtainable by reaction of a compound having at least two free alcoholic hydroxy groups and/or phenolic hydroxy groups with epichlorohydrin or ⁇ -methylepichlorohydrin under alkaline conditions or in the presence of an acid catalyst with subsequent alkali treatment.
• the glycidyl ethers of this kind are derived, for example, from acyclic alcohols, e.g. from ethylene glycol, diethylene glycol or higher poly(oxyethylene) glycols, propane-1,2-diol or poly(oxypropylene) glycols, propane-1,3-diol, butane-1,4-diol, poly(oxytetramethylene) glycols, pentane-1,5-diol, hexane-1,6-diol, hexane-2,4,6-triol, glycerol, 1,1,1-trimethylol-propane, pentaerythritol, sorbitol, and also from polyepichlorohydrins.
• acyclic alcohols e.g. from ethylene glycol, diethylene glycol or higher poly(oxyethylene) glycols, propane-1,2-diol or poly(oxypropylene) glycols, propane-1,
• glycidyl ethers of this kind are derived from cycloaliphatic alcohols, such as 1,4-cyclohexanedimethanol, bis(4-hydroxycyclohexyl) methane or 2,2-bis(4-hydroxycyclo-hexyl)propane, or from alcohols that contain aromatic groups and/or further functional groups, such as N,N-bis(2-hydroxyethyl)aniline or p,p′-bis(2-hydroxyethylamino)diphenyl-methane.
• cycloaliphatic alcohols such as 1,4-cyclohexanedimethanol, bis(4-hydroxycyclohexyl) methane or 2,2-bis(4-hydroxycyclo-hexyl)propane
• alcohols that contain aromatic groups and/or further functional groups such as N,N-bis(2-hydroxyethyl)aniline or p,p′-bis(2-hydroxyethylamino)diphenyl-methane.
• the glycidyl ethers can also be based on mononuclear phenols, for example resorcinol or hydroquinone, or on polynuclear phenols, for example bis(4-hydroxyphenyl)methane, 4,4′-dihydroxybiphenyl, bis(4-hydroxyphenyl)sulfone, 1,1,2,2-tetrakis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane or 2,2-bis(3,5-dibromo-4-hydroxyphenyl) propane.
• mononuclear phenols for example resorcinol or hydroquinone
• polynuclear phenols for example bis(4-hydroxyphenyl)methane, 4,4′-dihydroxybiphenyl, bis(4-hydroxyphenyl)sulfone, 1,1,2,2-tetrakis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxypheny
• aldehydes such as formaldehyde, acetaldehyde, chloral or furfuraldehyde
• phenols or bisphenols that are unsubstituted or substituted by chlorine atoms or by C 1 -C 9 alkyl groups, e.g. phenol, 4-chlorophenol, 2-methylphenol or 4-tert-butylphenol.
• Poly(N-glycidyl) compounds obtainable by dehydrochlorination of the reaction products of epichlorohydrin with amines containing at least two amine hydrogen atoms.
• amines are, for example, aniline, n-butylamine, bis(4-aminophenyl)methane, m-xylylenediamine or bis(4-methylaminophenyl)methane.
• the poly(N-glycidyl) compounds also include, however, triglycidyl isocyanurate, N,N′-diglycidyl derivatives of cycloalkyleneureas, such as ethyleneurea or 1,3-propyleneurea, and diglycidyl derivatives of hydantoins, such as of 5,5-dimethylhydantoin.
• Poly(S-glycidyl) compounds for example di-S-glycidyl derivatives, derived from dithiols, e.g. ethane-1,2-dithiol or bis(4-mercaptomethylphenyl)ether.
• Cycloaliphatic epoxy resins e.g. bis(2,3-epoxycyclopentyl)ether, 2,3-epoxycyclopentylglycidyl ether, 1,2-bis(2,3-epoxycyclopentyloxy) ethane or 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexanecarboxylate.
• epoxy resins wherein the 1,2-epoxy groups are bonded to different hetero atoms or functional groups; such compounds include, for example, the N,N,O-triglycidyl derivative of 4-aminophenol, the glycidyl ether glycidyl ester of salicylic acid, N-glycidyl-N′-(2-glycidyloxypropyl)-5,5-dimethylhydantoin and 2-glycidyloxy-1,3-bis(5,5-dimethyl-1-glycidylhydantoin-3-yl)propane.
• such compounds include, for example, the N,N,O-triglycidyl derivative of 4-aminophenol, the glycidyl ether glycidyl ester of salicylic acid, N-glycidyl-N′-(2-glycidyloxypropyl)-5,5-dimethylhydantoin and 2-glycidyloxy-1,3-bis(
• component (a) is a cycloaliphatic epoxy resin.
• cycloaliphatic epoxy resin in the context of this invention denotes any epoxy resin having cycloaliphatic structural units, that is to say it includes both cycloaliphatic glycidyl compounds and ⁇ -methylglycidyl compounds as well as epoxy resins based on cycloalkylene oxides.
• Suitable cycloaliphatic glycidyl compounds and ⁇ -methylglycidyl compounds are the glycidyl esters and ⁇ -methylglycidyl esters of cycloaliphatic polycarboxylic acids, such as tetrahydrophthalic acid, 4-methyltetrahydrophthalic acid, hexahydrophthalic acid, 3-methylhexahydrophthalic acid and 4-methylhexahydrophthalic acid.
• cycloaliphatic epoxy resins are the diglycidyl ethers and ⁇ -methylglycidyl ethers of cycloaliphatic alcohols, such as 1,2-dihydroxycyclohexane, 1,3-dihydroxycyclohexane and 1,4-dihydroxycyclohexane, 1,4-cyclohexanedimethanol, 1,1-bis(hydroxymethyl) cyclohex-3-ene, bis(4-hydroxycyclohexyl)methane, 2,2-bis(4-hydroxycyclohexyl)propane and bis(4-hydroxycyclohexyl)sulfone.
• cycloaliphatic alcohols such as 1,2-dihydroxycyclohexane, 1,3-dihydroxycyclohexane and 1,4-dihydroxycyclohexane, 1,4-cyclohexanedimethanol, 1,1-bis(hydroxymethyl) cyclohex-3-ene, bis(4-hydroxycyclohex
• epoxy resins having cycloalkylene oxide structures are bis(2,3-epoxycyclopentyl)ether, 2,3-epoxycyclopentylglycidyl ether, 1,2-bis(2,3-epoxycyclopentyl)ethane, vinyl cyclohexene dioxide, 3,4-epoxycyclohexylmethyl 3′,4′-epoxycyclohexanecarboxylate, 3,4-epoxy-6-methylcyclohexylmethyl-3′,4′-epoxy-6′-methylcyclohexanecarboxylate, bis(3,4-epoxycyclohexylmethyl)adipate and bis(3,4-epoxy-6-methylcyclohexylmethyl)adipate.
• the composition according to the invention contains as component (a) a cycloaliphatic epoxy resin selected from bis(4-hydroxycyclohexyl)methane-diglycidyl ether, 2,2-bis(4-hydroxycyclohexyl)propanediglycidyl ether, tetrahydrophthalic acid diglycidyl ester, 4-methyltetrahydrophthalic acid diglycidyl ester, 4-methylhexahydrophthalic acid diglycidyl ester and, in particular, 3,4-epoxycyclohexylmethyl3′,4′-epoxycyclohexanecarboxylate.
• a cycloaliphatic epoxy resin selected from bis(4-hydroxycyclohexyl)methane-diglycidyl ether, 2,2-bis(4-hydroxycyclohexyl)propanediglycidyl ether, tetrahydrophthalic acid diglycidyl ester, 4-methyltetrahydrophthalic acid dig
• initiator system for the cationic polymerisation of the epoxy resin there are used, for example, thermally activatable onium salts, oxonium salts, iodonium salts, sulfonium salts, phosphonium salts or quaternary ammonium salts that do not contain nucleophilic anions.
• thermally activatable onium salts for example, thermally activatable onium salts, oxonium salts, iodonium salts, sulfonium salts, phosphonium salts or quaternary ammonium salts that do not contain nucleophilic anions.
• Such initiators and their use are known.
• U.S. Pat. No. 4,336,363, EP-A 379 464 and EP-A 145 580 552 disclose specific sulfonium salts as curing agents for epoxy resins.
• U.S. Pat. No. 4,058,401 in addition to describing specific sulfonium salts, also describes the
• Quaternary ammonium salts as thermally activatable initiators are disclosed, for example, in EP-A 66 543 and EP-A 673 104. They are salts of aromatic-heterocyclic nitrogen bases with non-nucleophilic anions, for example complex halideanions such as BF 4 ⁇ , PF 6 ⁇ , SbF 6 ⁇ , SbF 5 OH ⁇ and AsF 6 ⁇ .
• thermal free-radical former for example pinacols and their ethers, esters or silyl derivatives.
• thermal free-radical former for example pinacols and their ethers, esters or silyl derivatives.
• Such compounds are known and can be prepared in accordance with known procedures.
• Such initiator systems are described, for example, in WO 00/04075.
• the invention further relates to a composition as defined above containing as component (b) a mixture comprising
• X denotes halogen or hydroxyl
• Y represents phenyl or naphthyl which are unsubstituted or substituted by fluoro, trifluoromethyl, trifluoromethoxy, nitro or cyano,
• n is 0 or an integer from 1 to 17, and
• compositions according to the invention contain as component (b1) a quaternary ammonium salt with an aromatic heterocyclic cation of formula (1), (2) or (3)
• R 1 is C 1 -C 12 alkyl, C 7 -C 36 aralkyl, C 3 -C 15 alkoxyalkyl or benzoylmethyl
• R 2 , R 3 , R 4 , R 5 and R 6 independently of the other are hydrogen, C 1 -C 4 alkyl or phenyl or R 2 and R 3 or R 3 and R 4 or R 4 and R 5 or R 5 and R 6 together with the carbon atoms to which they are attached form a benzene, naphthalene, pyridine or quinoline ring.
• radicals R 1 -R 6 When any of the radicals R 1 -R 6 is alkyl, that radical or those radicals may be straight-chain or branched.
• alkyl groups are methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, neopentyl, n-hexyl, n-heptyl, n-octyl, isooctyl, n-decyl and n-dodecyl.
• Aralkyl groups as R 1 have preferably from 7 to 30 carbon atoms, especially from 7 to 12 carbon atoms.
• Suitable aralkyl groups are benzyl, 2-phenylethyl, tolylmethyl, mesitylmethyl and 4-chlorophenylmethyl.
• alkoxyalkyl groups are 2-methoxyethyl, 3-methoxypropyl, 4-methoxybutyl, 6-methoxyhexyl, 2-ethoxyethyl, 3-ethoxypropyl, 4-ethoxybutyl and 6-methoxyhexyl.
• compositions contain as component (b 1) a quaternary ammonium salt of formula (4)
• R 7 denotes methyl, ethyl, n-butyl, benzyl or benzoylmethyl
• Z ⁇ is hexafluorophosphate, hexafluoroarsenate, hexafluoroantimonate, pentafluorohydroxyantimonate, tetrafluoroborate, tetrakis[3,5-bis(trifluoromethyl)-phenyl]borate and tetrakis(pentafluorophenyl)borate.
• suitable compounds of the formula (4) are N-methylquinolinium hexafluorophosphate, N-methylquinolinium hexafluoroarsenate, N-methylquinolinium hexafluoroantimonate, N-methylquinolinium pentafluorohydroxyantimonate, N-methylquinolinium tetrafluoroborate, N-methylquinolinium tetrakis[3,5-bis(trifluoromethyl)phenyl]borate, N-methylquinolinium tetrakis(pentafluorophenyl)borate, N-ethylquinolinium hexafluorophosphate, N-ethylquinolinium hexafluoroarsenate, N-ethylquinolinium hexafluoroantimonate, N-ethylquinolinium pentafluorohydroxyantimonate, N-ethylquinolinium tetrafluoroborate, N-ethylquinolini
• the most preferred compound of the formula (4) is N-benzylquinolinium hexafluoroantimonate.
• compositions according to the invention contain as component (b2) a compound of formula (5)
• R 8 , R 9 , R 10 and R 11 independently of the other are phenyl that is unsubstituted or substituted by C 1 -C 12 alkyl, C 1 -C 12 alkoxy, C 7 -C 36 aralkyl, C 6 -C 36 aryl, C 3 -C 15 alkoxyalkyl, C 1 -C 12 alkylthio, C 1 -C 12 alkylcarbonyl, halogen, nitro or cyano, and R 12 and R 13 independently of the other are hydrogen or C 1 -C 12 alkyl.
• Examples for suitable compounds of formula (5) are 1,2-bis(2-methylphenyl)-1,2-diphenyl-1,2-ethanediol, 1,2-bis(2-ethylphenyl)-1,2-diphenyl-1,2-ethanediol, 1,2-bis(2-fluorophenyl)-1,2-diphenyl-1,2-ethanediol, 1,2-bis(2,6-difluorophenyl)-1,2-diphenyl-1,2-ethanediol and, in particular, 1,1,2,2-tetraphenyl-1,2-ethanediol.
• compositions according to the invention optionally comprise a curing accelerator as additional component.
• Suitable accelerators are known to the person skilled in the art. Examples that may be mentioned are:
• tertiary amines such as benzyldimethylamine
• urea derivatives such as N-4-chlorophenyl-N,N′-dimethylurea (monuron);
• unsubstituted or substituted imidazoles such as imidazole or 2-phenylimidazole.
• Preferred accelerators are imidazoles, in particular N-methylimidazole.
• An essential component of the curable composition according to the present invention is a filler composition comprising a microparticle filler and a nanoparticle filler.
• the microparticle filler is preferably selected from globular or angular metal or semi-metal oxides, nitrides, carbides and hydroxides, especially from the group consisting of silica flour, amorphous silica (natural amorphous silica or fused silica), aluminium oxide, silicon carbide, boron nitride, aluminium nitride, aluminium hydroxide and magnesium hydroxide.
• the microparticles have an average particle size (d 50 ) of 1 to 100 ⁇ m, more preferably from 2 to 50 ⁇ m and most preferably from 5 to 25 ⁇ m determined according to ISO 13320-1:1999.
• Component (c) of the compositions according to the invention is preferably amorphous silica.
• the amorphous silica is natural amorphous silica or fused silica.
• Fused silica with an average particle size (d 50 ) of 10.5 ⁇ m is commercially available under the name TECOSIL® from CE Minerals, Greenville, Tenn., USA.
• Natural amorphous silica is available under the name AMOSIL® from Quarzwerke, Germany.
• the amorphous silica has an average particle size d 50 of 1 to 100 ⁇ m, more preferably from 2 to 50 ⁇ m and most preferably from 5 to 25 ⁇ m determined according to ISO 13320-1:1999.
• the amorphous silica is surface treated.
• the amorphous silica is surface treated with a silane, more preferably selected from the group consisting of amino silane, epoxy silane, (meth)acrylic silane, methyl silane and vinyl silane.
• silane is a compound of the following formula:
• R denotes methyl or ethyl
• the nanoparticle fillers are preferably selected from oxides, carbonates, nitrides and silicates of magnesium, calcium, boron, aluminium and silicon.
• nanoparticle fillers essentially consist of calcium carbonate, boron nitride, montmorillonite or silicon dioxide.
• Silica nanoparticles are particularly preferred.
• silicon dioxide nanoparticles The preparation of silicon dioxide nanoparticles is disclosed, for example, in WO 02/083776.
• the preferred silicon dixide nanoparticles are substantially spherical and have only slight, if any, agglomeration and/or aggregation.
• the nanoparticles are preferably surface-modified in order to prevent or reduce their agglomeration.
• a preferred surface modification is silanization with appropriate silanes, for examples the silanes mentioned above as surface modification agents for silica microparticles.
• nanoparticle fillers are known and to some extent commercially available, for example under the designation NANOPDX® (supplied by Evonik).
• a preferred nanop architecture filler is NANOPDX® E 601, which is a dispersion of silica nanoparticles in a cycloaliphatic epoxy resin.
• the average particle size of the silica nanoparticles d 50 is usually between 2 and 100 nm, preferably between 6 and 40 nm, more preferably between 8 and 80 nm and in particular between 10 and 25 nm.
• D 50 is known as the medium value of particle diameter. This means that a powder comprises 50% of particles having a larger particle size and 50% of particles having a smaller particle size than the d 50 value.
• the relative amounts of components (a), (b), (c) and (d) may vary within wide ranges.
• the total amount of filler (c)+(d) is 60 to 90% by weight, preferably 65 to 85% by weight and in particular 70-80% by weight based on the total composition (a)+(b)+(c)+(d).
• the amount of microparticle filler (c) is 55 to 80% by weight, more preferably 60 to 75% by weight and in particular 65 to 70% by weight. based on the total composition (a)+(b)+(c)+(d).
• the amount of nanoparticle filler (d) is 2 to 20% by weight, more preferably 5 to 15% by weight and in particular 7 to 12% by weight. based on the total composition (a)+(b)+(c)+(d).
• the amount of cationically polymerisable epoxy resin (a) is preferably 10 to 40% by weight, more preferably 15 to 30% by weight and in particular 20 to 25% by weight. based on the total composition (a)+(b)+(c)+(d).
• the amount of initiator for the cationic polymerisation initiator (b) is preferably 0.05 to 1.0% by weight, more preferably 0.1 to 0.7% by weight and in particular 0.2 to 0.5% by weight. based on the total composition (a)+(b)+(c)+(d).
• the curable composition according to the present invention can additionally comprise further additives, such as flexibilizers, thixotropic agents, wetting agents, antisettling agents, colour agents, defoamers, light stabilizers, mold release agents, toughening agents, adhesion promoters, flame retardants, curing accelerators, etc.
• further additives such as flexibilizers, thixotropic agents, wetting agents, antisettling agents, colour agents, defoamers, light stabilizers, mold release agents, toughening agents, adhesion promoters, flame retardants, curing accelerators, etc.
• compositions according to the present invention are heat-curable mixtures.
• the cationically polymerisable epoxy resin (a) is mixed with the required amount of the initiator for the cationic polymerisation (b).
• These mixtures are stable at room temperature and can be handled without hazard. In general, it is not necessary to add any additional activating component prior to initiation of polymerisation, so that the mixtures are one-component systems which can be cured at any time.
• the polymerisation is initiated by heating the the mixture to temperatures of 60-220° C., preferably 80-200° C. and in particular 100.-190° C., depending on the material used and the desired polymerisation time.
• the cured products demonstrate surprisingly excellent mechanical properties, in particular with respect to thermal stability and crack resistance.
• a further embodiment of the present invention is a cured product which is obtainable by curing a curable composition according to the present invention.
• the cured products according to the present invention are preferably used as electrically insulating construction material for electrical or electronic components.
• curable compositions according to the invention can specifically be applied as casting system for medium to high voltage applications, e.g for insulators, bushings, transformers, instrument transformers and switchgears, in all cases for indoor as well as outdoor applications, especially as encapsulation systems for printed circuit boards.
• medium to high voltage applications e.g for insulators, bushings, transformers, instrument transformers and switchgears
• the curable compositions according to the invention may be used as encapsulation material for stators and rotors of electrical machines such as motors or generators. They may be used either as full encapsulation systems or only for impregnation of the end turns of the windings.
• a further embodiment of the present invention is a method for the manufacturing of electrical insulation equipment comprising the steps:
• the invention further relates to the use of the composition according to the invention as insulating material for electrical and electronic components.
• composition according to the invention is used as encapsulation system for printed circuit boards.
• a further embodiment of the present invention is the use of the curable compositions as adhesives.
• K IC critical stress intensity factor
• G IC specific break energy
• T g glass transition temperature
• Masterbatch B 90 g of ARALDITE® CY 179-1 and 10 g of Initiator 1 are mixed at 60° C. for 30 min. The resulting clear solution is cooled to RT.
• AEROSIL® R 972 are put into an Esco mixer of sufficient size. The content of the mixer is then stirred with a disperser stirrer with 100 rpm while heating up to 50° C.
• AMOSIL® 510 and 894.6 g of AMOSIL® 520 are added slowly in several portions while mixing at 100 rpm. After 5 min the mixer is stopped and the walls are scratched and the material is put into the mixture. Then the mixture is stirred for another 70 min under vacuum at 50° C. After 30 min. of mixing the walls are scratched again and the material is put into the mixture.
• ARALDITE® XB 5992 100 g of ARALDITE® XB 5992 are mixed with 90 g of ARALDITE XB 5993 and the mixture is heated while slightly stirring with a propeller stirrer to about 60° C. for about 5 minutes. Then the mixer is stopped and 2 g of BAYFERROX® 225 is added and the mixer is started again for about 1 min. Subsequently, while stirring, 51.3 g of TREMIN® 283-600 EST and 290.7 g of AMOSIL® 520 are added in portions and the mixture is heated up to 60° C. under stirring for about 10 minutes. Then the mixer is stopped and the vessel is degassed carefully by applying a vacuum for about 1 minute.
• the mixture is poured into a 140° C. hot steel mold to prepare plates for the determination of the properties (4 mm thickness).
• the mold is then put to an oven for 30 minutes at 140° C. After thermally curing the mold, the mold is taken out of the oven and the plates are cooled down to ambient temperature (25° C.).
• 950 g NANOPDX® E 601, 3.75 g SILFOAM® SH, 5.0 g BYK W 955, 6.25 g BYK 070, 12.5 g SILAN A-187 and 22.5 g AEROSIL® R 972 are put to a Esco mixer of sufficient size. The content of the mixer is then heated up 60° C. and stirred with a dissolver stirrer with 300 rpm under vacuum at 60° C. for 3 min. Then the vacuum is broken and 500 g of AMOSIL® 510 and 1000 g of AMOSIL® 520 are added slowly in several portions while mixing at 300 rpm at 60-65° C. under vacuum.
• metal molds are preheated to about 80° C. in an oven. Then the degassed resin/hardener mixture is poured into the mold. The mold is then put to an oven at 100° C. for one hour, then for 1.5 hours at 140° C. and finally for 1.5 hours at 210° C. Then the mold is taken out of the oven and opened after cooling down to room temperature. The cured plate is subjected to various tests the results of which are given in Table 1.
• compositions A1, C1 and C2 are given in parts by weight Composition A1 C1 C2 ARALDITE ® CY 179-1 9.60 ARALDITE ® XB 5992 18.73 INITIATOR 1 0.13 CO-INITIATOR 1 0.17 ARALDITE ® XB 5993 16.85 ARADUR ® HY 906 17.33 ACCELERATOR 1 0.15 NANOPOX ® E 601 22.50 23.03 AEROSIL ® R 972 0.20 0.55 AMOSIL ® 510 21.75 33.65 AMOSIL ® 520 44.73 54.44 24.24 TREMIN ® 283-600 9.61 BYK W 940 0.50 0.20 BYK W 995 0.12 BYK 070 0.21 0.15 SILFOAM ® SH 0.21 0.09 SILAN A-187 0.50 BAYFERROX ® 225 0.37 Viscosity at 60° C./Pa ⁇ s 15 8.6 5 Curing conditions 1
• the inventive composition A1 provides a cured product that fulfills all the requirements of a single-component encapsulation system for high temperature stable insulations:
• the viscosity of the curable composition is sufficient low for applications as encapsulation system for printed circuit boards.
• the product obtained from Comparative Example Cl has a quite low, but yet insufficient SCT of ⁇ 131 at a T g of 105° C. (which is far too low) and a CTE of 25.7 (which is too high).
• the properties of the cured product according to Comparative Example C2 are satisfactory with respect to T g and CTE, but completely insufficient with respect to SCT. It is not a solution to the problem because it is R42-labelled, but mainly because the SCT is far too high ( ⁇ 84° C. vs. target of ⁇ 200° C.).
• Composition C2 suffers from the classification as hazardous substance (label R42, “respiratory sensitizer”)

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