TITLE OF THE INVENTION
THERMOSETTING RESIN COMPOSITION FOR HIGH SPEED
TRANSMISSION CIRCUIT BOARD
BACKGROUND OF THE INVENTION
(a) Field of the invention
The present invention relates to a thermosetting resin composition for a
high speed transmission circuit board, more particularly to a thermosetting resin
composition having superior dielectric characteristics with low dielectric constant
and dissipation factor and having superior glass transition temperature, heat
resistance after moisture absorption, dielectric reliability, adhesion to copper film,
workability, dispersibility of inorganic filler, electric characteristics, etc., and thus
being useful for a copper clad laminate for high speed signal transfer.
(b) Description of the Related Art Recently, electronic devices such as computers and communication
devices, etc. are being more highly integrated and multilayered. And, mobile
phones, notebook computers, etc. are becoming more small-sized, light and
capable. As printed circuit boards mounted on these devices are becoming
more integrated and compact, superior heat resistance and dielectric reliability
are required. With the development of high speed communication services,
signal delay and transmission loss of high speed transmission circuit boards
mounted on communication devices are emerging as problem. Because the
signal delay is proportional to the square root of the dielectric constant of an
insulator and the transmission loss is proportional to the dielectric constant of the
insulator and the dissipation factor, a material having low dielectric constant and
dissipation factor is required for a high speed transmission circuit board. In the conventional FR-4 printed circuit board, an epoxy resin
composition comprising a brominated difunctional epoxy resin, a multifunctional
epoxy resin, an amine based curing agent, an imidazole curing accelerator, etc.
is used. The polar groups resultant from the reaction of the epoxy resin and the
amine based curing agent increase the dielectric constant and the dissipation
factor, so that it is impossible to obtain transmission characteristics sufficient for
high speed transmission.
In order to solve this problem, Korea Laid-Open Publication No. 2002-
0044342 discloses a method of using an acid anhydride based epoxy curing
agent and Korea Laid-Open Publication No. 2002-0085475 discloses a method
of using a dicyclopentadiene based epoxy resin, which has low dielectric
constant. However, epoxy resin is limited in offering sufficiently low dielectric
constant and dissipation factor required for high speed and high frequency
transmission.
Thus, use of a thermoplastic resin such as a fluorine based resin,
polyphenylene ether, etc. or a composite resin of polyphenylene ether and epoxy
resin, which have low dielectric constant and dissipation factor, has been
proposed. However, these resins require high temperature and pressure for
processing because of high melting point or softening point and have inferior
processing characteristics and adhesion to copper film.
Use of a cyanate ester resin, which has the lowest dielectric constant
among thermosetting resins, offers low dielectric constant and dissipation factor.
But, the dielectric reliability worsens because triazine, which is included in the
resin, has poor heat resistance after moisture absorption.
In order to solve this problem, Japanese Patent Publication No. 2000-
239496 discloses a method of mixing a cyanate ester resin with a
dicyclopentadiene based epoxy resin, which has low dielectric constant and
dissipation factor, to reduce dielectric constant and dissipation factor and
improve heat resistance after moisture absorption. However, this method does
not offer electric characteristics sufficient for a high speed transmission circuit
board.
In order to improve dielectric characteristics and heat resistance after
moisture absorption of cyanate ester, U.S. Patent No. 6,162,876, U.S. Patent No.
6,245,841 , Japanese Laid-Open Publication No. 1999-21507 and Japanese
Laid-Open Publication No. 1999-21453 disclose a method of decreasing
dielectric constant and dissipation factor by mixing a phenol-modified cyanate
ester oligomer with polyphenylene ether. However, this method is also limited
in that the heat resistance after moisture absorption worsens. Japanese Laid-
Open Publication No. 1999-263940 discloses a method of mixing a phenol-
modified cyanate ester oligomer with a cyclic olefin copolymer and Japanese
Laid-Open Publication No. 2001-214053 discloses a method of mixing a phenol-
modified cyanate ester oligomer with polystyrene. However, these methods are
limited in that the heat resistance after moisture absorption and the adhesion to
copper film is very low because of insufficient compatibility with cyanate ester. Japanese Laid-Open Publication No. Sho 63-33505 discloses a method
of adding an inorganic filler to improve the performance of a clad laminate.
However, as the inorganic filler is mixed with varnish, the filler is slowly
deposited in an impregnation tank during prepreg preparation, and thereby
worsens workability. Also, the appearance of the prepreg becomes poor, the
dispersibility of the inorganic filler becomes non-uniform, so that the interfacial
adhesion of the clad laminate, drilling characteristics and insulating
characteristics worsen.
Japanese Laid-Open Publication No. 2001-339130 discloses a method
of improving dispersibility of the inorganic filler, offering the clad laminate
formability and processing characteristics comparable to those of an epoxy resin
and improving heat resistance and dielectric reliability by adding an inorganic
filler treated with a silicon polymer having an hydroxyl group to a cyanate ester
resin and polyphenylene ether. However, this method requires an additional
process of treating the inorganic filler with the silicon polymer. And, the content
of the inorganic filler should be increased to increase heat resistance after
moisture absorption of the clad laminate, which increases the viscosity of varnish
and thus makes the processing difficult.
Accordingly, a thermosetting resin having superior dielectric
characteristics with low dielectric constant and dissipation factor and being
capable of improving heat resistance after moisture absorption and dispersibility
of inorganic filler is necessary.
SUMMARY OF THE INVENTION
It is an aspect of the present invention to provide a thermosetting resin
composition having superior dielectric characteristics with low dielectric constant
and dissipation factor and being capable of greatly improving glass transition
temperature, heat resistance after moisture absorption, dielectric reliability,
adhesion to copper film, workability, dispersibility of inorganic filler, electric
characteristics, etc.
It is another aspect of the present invention to provide a copper clad
laminate for high speed signal transfer capable of reducing dielectric constant
and dissipation factor and offering superior heat resistance after moisture
absorption, dielectric reliability, adhesion to copper film, electric characteristics,
etc. and suitable for multilayering and high speed signal transfer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
To attain the aspects, the present invention provides a thermosetting
resin composition for a high speed transmission circuit board comprising: a) a cyanate ester based resin having at least two cyanate groups in one
molecule; b) a dicyclopentadiene based epoxy resin;
c) a fumed silica; d) a thermoplastic resin; e) a cyanate ester resin curing accelerator; f) an epoxy resin curing accelerator; g) a primary phenolic compound; and h) a flame retardant.
The present invention also provides a copper clad laminate for high
speed signal transfer comprising the thermosetting resin composition.
Hereinafter, the present invention is described in more detail. The present inventors worked on a thermosetting resin having superior
dielectric characteristics with low dielectric constant and dissipation factor and
being capable of improving heat resistance after moisture absorption and
dispersibility of inorganic filler. In doing so, they found out that dielectric
constant and dissipation factor are reduced and glass transition temperature,
heat resistance after moisture absorption, dielectric reliability, adhesion to
copper film, workability, dispersibility of inorganic filler, electric characteristics,
etc. are significantly improved by mixing a cyanate ester based resin having at
least two cyanate groups in one molecule, a dicyclopentadiene based epoxy
resin, a fumed silica and a thermoplastic resin. The present invention is characterized by a thermoplastic resin
composition for a circuit board for high speed signal transfer comprising a
cyanate ester based resin having at least two cyanate groups in one molecule, a
dicyclopentadiene based epoxy resin, a fumed silica, a thermoplastic resin, a
cyanate ester resin curing accelerator, an epoxy resin curing accelerator, a
primary phenolic compound and a flame retardant.
Preferably, the thermosetting resin composition for a high speed
transmission circuit board of the present invention comprises: a) 100 parts by weight of a cyanate ester based resin having at least two
cyanate groups in one molecule; b) 50 to 300 parts by weight of a dicyclopentadiene based epoxy resin; c) 0.5 to 10 parts by weight of a fumed silica per 100 parts by weight of
the cyanate ester based resin and the dicyclopentadiene based epoxy resin; d) 5 to 100 parts by weight of a thermoplastic resin; e) 5 to 300 ppm of a cyanate ester resin curing accelerator; f) 0.05 to 3 parts by weight of an epoxy resin curing accelerator per 100
parts by weight of the dicyclopentadiene based epoxy resin; g) 1 to 30 parts by weight of a primary phenolic compound; and h) 5 to 50 parts by weight of a flame retardant per 100 parts by weight of
the cyanate ester based resin and the dicyclopentadiene based epoxy resin.
Preferably, a) the cyanate ester based resin having at least two cyanate
groups in one molecule is a compound represented by Formula 1 below:
each of R
2, R
3, R
4 and R
5 is hydrogen or CH
3.
Specifically, the cyanate ester based resin having at least two cyanate
groups in one molecule may be 2,2-bis(4-cyanatephenyl)propane, bis(3,5-
dimethyl-4-cyanatephenyl)methane, 2,2-bis(4-cyanatephenyl)-1 , 1 ,1 , 3,3,3-
hexafluoropropane, etc.
Preferably, the cyanate ester based resin having at least two cyanate
groups in one molecule is prepolymerized from a monomer. If the monomer is
treated with varnish, impregnation may become impossible due to
recrystallization. Thus, the content of the monomer is preferably 10 to 70 mol%,
more preferably 30 to 60 mol%. If the content of the monomer is below 10
mol%, recrystallization may occur. Otherwise, if it exceeds 70 mol%, the
varnish becomes too viscous, so that impregnation becomes difficult and storage
stability of the varnish worsens. b) The dicyclopentadiene based epoxy resin, which is represented by
Formula 2 below, has a hydrophobic bicyclic hydrocarbon group with less
polarization, and thus has superior dielectric characteristics.
In Formula 2, n is 0 or a positive integer.
Preferably, the dicyclopentadiene based epoxy resin is comprised in 50
to 300 parts by weight per 100 parts by weight of the cyanate ester based resin.
If the content is below 50 parts by weight, heat resistance may worsen after
moisture absorption. Otherwise, if it exceeds 300 parts by weight, dielectric
characteristics may worsen. c) The fumed silica, a porous nano-sized silica particle, solves the
dispersibility problem of the micro-sized silica.
Preferably, the fumed silica has an average diameter ranging from 1 to
100 nm.
Preferably, the fumed silica is comprised in 0.5 to 10 parts by weight per
100 parts by weight of the cyanate ester based resin and the dicyclopentadiene
based epoxy resin. If the content is below 0.5 part by weight, heat resistance
after moisture absorption may worsen. Otherwise, if it exceeds 10 parts by
weight, the varnish becomes too viscous, so that impregnation becomes difficult.
For d) the thermoplastic resin, polystyrene, cyclic olefin copolymer,
polyphenylene ether, polyphenylene ether having an epoxy group, etc., which
has superior dielectric characteristics, may be used.
Preferably, the thermoplastic resin is comprised in 5 to 100 parts by
weight per 100 parts by weight of the cyanate ester based resin. If the content
is below 5 parts by weight of, it is impossible to obtain ideal dielectric
characteristics. Otherwise, if it exceeds 100 parts by weight, heat resistance
after moisture absorption is significantly reduced and adhesion to metal film also
worsens. e) The cyanate ester resin curing accelerator acts as a catalyst
promoting curing of the cyanate ester based resin.
For the cyanate ester resin curing accelerator, an organometal or an
organometallic complex, specifically with iron, copper, zinc, cobalt, nickel,
manganese, tin, etc. may be used. For the organometal, iron naphthenate,
copper naphthenate, zinc naphthenate, cobalt naphthenate, iron octanoate,
copper octanoate, zinc octanoate, cobalt octanoate, etc. may be used. And, for
the organometallic complex, lead acetylacetonate, cobalt acetylacetonate, etc.
may be used.
Preferably, the cyanate ester resin curing accelerator is comprised in 5
to 300 ppm, more preferably in 10 to 200 ppm, per 100 parts by weight of the
cyanate ester based resin, based on the metal concentration. If the content is
below 5 ppm, reactivity and curing characteristics may be insufficient.
Otherwise, if it exceeds 300 ppm, reaction control becomes difficult, so that
curing happens too fast or forming characteristics may worsen.
For g) the epoxy resin curing accelerator, imidazole derivatives such as
1-methylimidazole, 2-methylimidazole, 2-ethyl-4-methylimidazole, 2-
phenylimidazole, 2-cyclohexyl-4-methylimidazole, 4-butyl-5-ethylimidazole, 2-
methyl-5-ethylimidazole, 2-octyl-4-hexylimidazole, 2,5-chloro-4-ethylimidazole,
etc. may be used. Preferably, the epoxy resin curing accelerator is comprised in 0.05 to 3
parts by weight per 100 parts by weight of the dicyclopentadiene based epoxy
resin. If the content is below 0.05 part by weight, catalytic activity decreases,
so that curing time increases. Otherwise, if it exceeds 3 parts by weight,
storage stability of varnish or prepreg may worsen significantly. f) The primary phenolic compound functions as cocatalyst in the curing
of the cyanate ester based resin and reduces dielectric constant and dissipation
factor. As the cyanate ester based resin is cured, a triazine is formed and
unreacted cyanate reacts with the primary phenolic compound to form imide
carbonate, thereby reducing polarity and thus reducing dielectric constant and
dissipation factor.
The primary phenolic compound is a compound represented by Formula
3 below:
where each of R6 and R7 is hydrogen or CH3 independently; and
n is 1 or 2.
For the primary phenolic compound, nonylphenol, dinonylphenol,
octylphenol, 4-cumylphenol, etc., which has superior heat resistance, may be
used.
The primary phenolic compound is preferably comprised in 1 to 30 parts
by weight, more preferably in 5 to 25 parts by weight, per 100 parts by weight of
the cyanate ester based resin. If the content is below 1 part by weight,
dielectric characteristics may worsen. Otherwise, if it exceeds 30 parts by
weight, heat resistance may worsen.
For h) the flame retardant, a hydrocarbon based less polar compound
not inhibiting curing of the cyanate ester based resin and not reducing dielectric
characteristics, such as 1 ,2-dibromo-4-(1 ,2-dibromoethyl)cyclohexane,
tetrabromocyclohexane, hexabromocyclodecane, etc., may be used.
Particularly, it is preferable to use 2,4,6-tris(tribromophenoxy)-1 ,3,5-
triazine represented by Formula 4 below, which is highly compatible with a
structure similar to that of the cyanate ester based resin, for the flame retardant.
Preferably, the flame retardant is comprised in 5 to 50 parts by weight
per 100 parts by weight of the cyanate ester based resin and the
dicyclopentadiene based epoxy resin, in the range of having a flame retardance
of UL-V0 level. If the content is below 5 parts by weight, flame retardance may
be insufficient. Otherwise, if it exceeds 50 parts by weight, heat resistance may
be insufficient.
The thermosetting resin composition of the present invention can reduce
dielectric constant and dissipation factor and improve heat resistance after
moisture absorption, adhesion to copper film and dispersibility of inorganic filler
by adding the fumed silica and the thermoplastic resin to the cyanate ester
based resin and the dicyclopentadiene based epoxy resin.
The present invention also provides a copper clad laminate for high
speed signal transfer comprising the thermosetting resin composition by
dissolving or dispersing the thermosetting resin composition in a solvent,
impregnating the composition in a substrate and drying it at 80 to 200 °C for a
given time to prepare a prepreg for a printed circuit board without B stage
adhesivity. For the substrate, the common woven or nonwoven fiber substrate
can be used. For the fiber substrate, an inorganic fiber such as glass, alumina,
asbestos, boron, silica alumina glass, silica glass, silicon carbide, silicon nitride,
etc. or an organic fiber such as aramid, polyether ketone, polyether imide,
cellulose, etc. may be used. Especially, a glass woven fiber is preferable. The
prepreg is laminated to at least one layer and then a metal film is formed on one
or both sides. Then, it is heated, pressed and molded into a copper clad
laminate for high speed signal transfer.
Hereinafter, the present invention is described in more detail through
examples. However, the following examples are only for the understanding of
the present invention and they do not limit the present invention.
EXAMPLES
Example 1
(Preparation of epoxy resin composition) 40 phr of polyphenylene ether (HPP820, GE) was added to 200 phr of
toluene contained in a beaker and was completely dissolved. Then, 7 phr of
fumed silica (Aerosil R972, Degussa) was added to the solution. After stirring
for about 1 hour, 60 phr of 2,4,6-tris(tribromophenoxy)-1 ,3,5-triazine (SR-245H,
Dai-lchi Kogyo Seiyaku) and 20 phr of 4-cumylphenol were added as flame
retardant and primary phenolic compound, respectively, and dissolved. Then,
100 phr of 2,2-bis(4-cyanatephenyl)propane prepolymer (BA230S, Lonza) was
added as cyanate ester based resin and dissolved, and then 100 phr of
dicyclopentadiene epoxy resin (XD-1000L, Nippon Chemicals) was dissolved.
After the constituents were completely dissolved, 0.01 phr of cobalt
acetylacetonate and 0.5 phr of 2-ethyl-4-methylimidazole were added as cyanate
ester based resin curing accelerator and epoxy resin curing accelerator,
respectively. The solution was stirred until the constituents were completely
dissolved to obtain a thermoplastic resin composition.
(Preparation of copper clad laminate for high speed signal transfer) The resultant thermoplastic resin composition was impregnated in a
glass fiber and dried at 80 to 200 °C to obtain a prepreg for a printed circuit
board without B stage adhesivity. The prepreg was placed on each side of a 35
m-thick copper film and heated and pressed with a vacuum press to prepare a
copper clad laminate for high speed signal transfer.
Example 2
A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for using 100 phr of tetra-o-m ethyl bisphenol F dicyanate prepolymer (ME240S,
Lonza) as cyanate ester based resin.
Example 3
A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for using 80 phr of 2,2-bis(4-cyanatephenyl)propane prepolymer as cyanate
ester resin, 120 phr of dicyclopentadiene epoxy resin, 10 phr of fumed silica,
0.008 phr of cyanate ester resin curing accelerator, 0.6 phr of epoxy resin curing
accelerator and 15 phr of primary phenolic compound.
Example 4 A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for using 40 phr of polystyrene (15NFI, LG) instead of polyphenylene ether.
Comparative Example 1
A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for not using a fumed silica.
Comparative Example 2
A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for using 10 phr of a spherical silica (SFP-30M, Denka) instead of a fumed silica.
Comparative Example 3 A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for using 10 phr of a planar silica (MN-U-SIL5, US Silica) instead of a fumed
silica.
Comparative Example 4 A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for using 100 phr of a cresol novolak epoxy resin (N673, Bakelite) instead of a
dicyclopentadiene based epoxy resin.
Comparative Example 5 A thermoplastic resin composition and a copper clad laminate for high
speed signal transfer were prepared in the same manner of Example 1 , except
for using 15 phr of a fumed silica and 150 phr of polyphenylene ether.
For each copper clad laminate for high speed signal transfer prepared in
Examples 1 to 4 and Comparative Examples 1 to 5, glass transition temperature,
heat resistance after moisture absorption, dielectric characteristics, and
adhesion to copper film were measured as follows. The result is given in Table
2 below. a) Glass transition temperature (Tg, °C) - Copper film was removed from
each copper clad laminate for high speed signal transfer prepared in Examples 1
to 4 and Comparative Examples 1 to 5 using an etching solution. The sample
was heated to 250 °C at a rate of 10 °C/min using a DSC (differential scanning
calorimeter). It was cooled to 30 °C and then heated to 300 °C at a rate of
10 °C/min to measure the glass transition temperature. b) Heat resistance after moisture absorption - Each copper clad
laminate for high speed signal transfer prepared in Examples 1 to 4 and
Comparative Examples 1 to 5 was cut to a size of 5 cm * 5 cm and wetted for 2
hours under a PCT (pressure cooker test, 121 °C) condition. After keeping in a
lead bath of 288 °C for 10 seconds, the surface status was observed with eyes.
The sample in which delamination was observed was evaluated as X and the
one with no delamination was evaluated as O. c) Dielectric characteristics - Dielectric constant and dissipation factor
were measured at 1 MHz according to JIS C6481 , the Japanese standard for
copper clad laminate for high speed signal transfer, using an impedance
analyzer. d) Adhesion to copper film (peel strength, kg/cm) - Each copper clad
laminate for high speed signal transfer prepared in Examples 1 to 4 and
Comparative Examples 1 to 5 was cut to a size of 10 cm x 1 cm. Adhesion
strength of the clad laminate to the copper film was measured at 0.8 mm/sec
using a UTM (universal testing machine).
[Table 1]
As seen in Table 2, the thermoplastic resin compositions and the copper
clad laminate for high speed signal transfer of Examples 1 to 4, which had been
prepared according to the present invention, were superior in all of glass
transition temperature (Tg), heat resistance after moisture absorption, dielectric
constant, dissipation factor and adhesion to copper film to those of Comparatives
Example 1 to 5.
Especially, that of Comparative Example 1 , in which the fumed silica had
not been used, and those of Comparative Example 2 and Comparative Example
3, in which a spherical silica and a planar silica had been used respectively
instead of the fumed silica, showed less heat resistance after moisture
absorption. And, that of Comparative Example 4, in which a phenol novolak
epoxy resin had been used instead of the dicyclopentadiene epoxy resin,
showed low dielectric constant, dissipation factor and heat resistance after
moisture absorption were poor. Also, that of Comparative Example 5, in which
15 phr of fumed silica and 150 phr of polyphenylene ether resin had been used,
showed poor heat resistance after moisture absorption and adhesion to copper
film.
As described above, the thermosetting resin of the present invention has
superior dielectric characteristics with low dielectric constant and dissipation
factor and is capable of significantly improving glass transition temperature, heat
resistance after moisture absorption, dielectric reliability, adhesion to copper film,
workability, dispersibility of inorganic filler, electric characteristics, etc., and thus
it is useful for a copper clad laminate for multilayering and high speed signal
transfer.