WO2010024391A1 - 積層体及び積層体の製造方法 - Google Patents
積層体及び積層体の製造方法 Download PDFInfo
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- WO2010024391A1 WO2010024391A1 PCT/JP2009/065081 JP2009065081W WO2010024391A1 WO 2010024391 A1 WO2010024391 A1 WO 2010024391A1 JP 2009065081 W JP2009065081 W JP 2009065081W WO 2010024391 A1 WO2010024391 A1 WO 2010024391A1
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- resin
- weight
- body layer
- epoxy resin
- cured body
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/46—Manufacturing multilayer circuits
- H05K3/4644—Manufacturing multilayer circuits by building the multilayer layer by layer, i.e. build-up multilayer circuits
- H05K3/4661—Adding a circuit layer by direct wet plating, e.g. electroless plating; insulating materials adapted therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/38—Improvement of the adhesion between the insulating substrate and the metal
- H05K3/381—Improvement of the adhesion between the insulating substrate and the metal by special treatment of the substrate
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/02—Fillers; Particles; Fibers; Reinforcement materials
- H05K2201/0203—Fillers and particles
- H05K2201/0206—Materials
- H05K2201/0209—Inorganic, non-metallic particles
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/02—Fillers; Particles; Fibers; Reinforcement materials
- H05K2201/0203—Fillers and particles
- H05K2201/0206—Materials
- H05K2201/0239—Coupling agent for particles
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/14—Related to the order of processing steps
- H05K2203/1476—Same or similar kind of process performed in phases, e.g. coarse patterning followed by fine patterning
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
Definitions
- the present invention is a laminate in which an insulating cured body layer is formed on a substrate such as a single-layer or multilayer printed wiring board, and more specifically, for example, a metal layer is formed on the surface.
- the present invention relates to a laminate including a cured body layer and a method for producing the laminate.
- the multilayer printed wiring board includes a plurality of laminated insulating layers and a patterned metal wiring disposed between the insulating layers. Conventionally, various thermosetting resin compositions have been used to form this insulating layer.
- Patent Document 1 discloses a thermosetting resin composition containing a thermosetting resin, a curing agent, and a filler surface-treated with imidazole silane.
- An imidazole group exists on the surface of the filler.
- the imidazole group acts as a curing catalyst and a reaction starting point. For this reason, the intensity
- Patent Document 1 describes that the thermosetting resin composition is useful for applications that require adhesion, such as an adhesive, a sealing material, a paint, a laminate, and a molding material.
- Patent Document 2 discloses an epoxy resin composition containing an epoxy resin, a phenol resin, a curing agent, an inorganic filler, and an imidazole silane in which Si atoms and N atoms are not directly bonded. .
- the cured product of the epoxy resin composition has high adhesion to a semiconductor chip and that the cured product has high moisture resistance, so that the cured product is difficult to peel from the semiconductor chip or the like even after IR reflow. ing.
- Patent Document 3 discloses an epoxy resin composition containing an epoxy resin, a curing agent, and silica.
- the silica is treated with imidazole silane, and the average particle size of the silica is 5 ⁇ m or less.
- the silica can be easily detached without etching much of the resin. For this reason, the surface roughness of the surface of hardened
- Metal wiring such as copper may be formed on the surface of the cured body using the thermosetting resin composition as described above.
- the miniaturization of wiring formed on the surface of such a cured body has progressed. That is, L / S indicating the dimension (L) in the width direction of the wiring and the dimension (S) in the width direction of the portion where the wiring is not formed has been further reduced. For this reason, making the linear expansion coefficient of a hardening body still smaller is examined.
- an inorganic filler such as silica is often blended in the thermosetting resin composition.
- the inorganic filler tends to aggregate. Therefore, during the roughening treatment, the agglomerated inorganic fillers may be detached together to increase the surface roughness.
- thermosetting resin compositions described in Patent Documents 1 to 3 contain a substance in which an inorganic filler such as a filler or silica is surface-treated with imidazole silane. Even when such a surface-treated material is used, the surface roughness of the surface of the roughened cured body may not be reduced. Furthermore, even if the surface roughness of the surface of the cured body can be reduced, when the cured body is subjected to metal plating, the roughened adhesive strength between the cured body and the metal plating is not sufficient.
- An object of the present invention is a laminate including a cured body layer, which can reduce the surface roughness of the surface of the cured body layer that has been roughened, and further on the surface of the roughened cured body layer.
- An object of the present invention is to provide a laminate capable of increasing the adhesive strength between a cured body layer and a metal layer when a metal layer such as a metal plating layer is formed, and a method for producing the laminate.
- a laminate comprising a substrate and a cured body layer laminated on the substrate, wherein the cured body layer is formed by laminating a resin film on the substrate, and then the resin film. Is preliminarily cured at 100 to 200 ° C.
- the resin film comprises an epoxy resin and A surface-treating substance in which 100 parts by weight of an inorganic filler having an average particle size of 0.05 to 1.5 ⁇ m is surface-treated with 0.5 to 3.5 parts by weight of a silane coupling agent And the content of the surface treatment substance in a total of 100% by weight of the epoxy resin, the curing agent, the curing accelerator and the surface treatment substance is in the range of 10 to 80% by weight.
- the silane coupling agent has a functional group capable of reacting with the epoxy resin or the curing agent, said functional group is an epoxy group, an imidazole group or an amino group, laminate is provided.
- the curing agent includes a phenol compound having a biphenyl structure, a phenol compound having a naphthalene structure, a phenol compound having a dicyclopentadiene structure, a phenol compound having an aminotriazine structure, activity It is at least one selected from the group consisting of ester compounds and cyanate ester resins.
- the content of the imidazole silane compound in the resin composition is 0.01 to 3 parts by weight with respect to a total of 100 parts by weight of the epoxy resin and the curing agent. Is within the range.
- the arithmetic average roughness Ra of the surface of the cured body layer subjected to the roughening treatment is 300 nm or less, and the ten-point average roughness Rz is 3 ⁇ m or less.
- the resin film is swelled at 50 to 80 ° C. after the preliminary curing and before the roughening treatment.
- a method for manufacturing a laminate comprising a substrate and a cured body layer laminated on the substrate, wherein the resin film for forming the cured body layer is the substrate.
- a step of forming a roughened cured body layer, and the resin film is an epoxy resin, a curing agent, a curing accelerator, and an average particle size of 0.05 to 1.5 ⁇ m.
- 100 parts by weight of an inorganic filler contains a surface treatment substance surface-treated with 0.5 to 3.5 parts by weight of a silane coupling agent, and the epoxy resin, the curing agent, the curing accelerator, and the surface Total processed substances
- the epoxy resin or the curing agent is used as the silane coupling agent by using a resin film formed of a resin composition in which the content of the surface treatment substance in 00% by weight is in the range of 10 to 80% by weight.
- the manufacturing method of a laminated body using the silane coupling agent which has a functional group which can react with this and a functional group is an epoxy group, an imidazole group, or an amino group is provided.
- a phenol compound having a biphenyl structure a phenol compound having a naphthalene structure, a phenol compound having a dicyclopentadiene structure, or a phenol having an aminotriazine structure
- a compound having an active ester compound and a cyanate ester resin is used as the curing agent.
- the resin composition has an imidazole silane compound content of 0.01 to 100 parts by weight with respect to a total of 100 parts by weight of the epoxy resin and the curing agent.
- a resin composition in the range of 3 parts by weight is used.
- the roughening treatment time in the roughening treatment step is 5 to 30 minutes.
- the surface of the precured body layer is swollen at 50 to 80 ° C. after the precuring step and before the roughening treatment step.
- a processing step is further provided.
- the swelling treatment time in the swelling treatment step is 5 to 30 minutes.
- the laminating temperature in the laminating step is 70 to 130 ° C.
- the laminating pressure is 0.1 to 2.0 MPa.
- the inorganic filler having an average particle size of 0.05 to 1.5 ⁇ m contains the above-mentioned specific amount of silane coupling.
- a cured product using a resin composition having the above-mentioned specific functional group that contains a surface-treated substance surface-treated with an agent at the above-mentioned specific content and the silane coupling agent can react with an epoxy resin or a curing agent Since the layer is formed, the precuring temperature when forming the cured body layer is 100 to 200 ° C., and the temperature of the roughening treatment is 55 to 80 ° C. The surface roughness of the surface can be reduced. Furthermore, when a metal layer such as a metal plating layer is formed on the surface of the hardened body layer that has been roughened, the adhesive strength between the hardened body and the metal layer can be increased.
- FIG. 1 is a partially cutaway front sectional view showing a laminated film used for obtaining a laminated body according to an embodiment of the present invention.
- FIG. 2 is a partially cutaway front sectional view schematically showing a multilayer printed wiring board as a laminate according to one embodiment of the present invention.
- FIGS. 3A to 3D are partially cutaway front cross-sectional views for explaining each process for manufacturing a multilayer printed wiring board as a laminate according to an embodiment of the present invention.
- FIG. 4 is a partially cutaway front sectional view schematically showing an enlarged surface of the roughened cured body layer. It is a partial notch front sectional drawing which expands and shows the state in which the metal layer was formed in the surface of the hardening body layer by which the roughening process was carried out.
- the inventors of the present application treated the inorganic filler having the average particle diameter of 0.05 to 1.5 ⁇ m with the specific amount of the silane coupling agent.
- a cured body layer is formed using a resin composition having a composition containing the surface treatment substance having a specific content as described above, and a preliminary curing temperature in forming the cured body layer is set to 100 to 200 ° C.
- the temperature of the heat treatment is set to 55 to 80 ° C., the surface roughness of the surface of the roughened cured body layer can be reduced, and the adhesive strength between the cured body layer and the metal layer can be increased.
- the present inventors have found that the present invention can be accomplished and have completed the present invention.
- the inventors of the present application have a clear correlation between the interfacial area of the resin component-surface treatment substance defined by the average particle diameter of the inorganic filler and the temperature of the roughening treatment, and by having the above-described configuration of the present invention, It has been found that low surface roughness and high adhesive strength can be achieved at a high level.
- the temperature of the roughening treatment is related to the degree of etching with respect to the resin component. By designing the degree of etching and the average particle diameter of the inorganic filler within the optimum range, a small surface roughness, which has been difficult in the past, is difficult. And high adhesive strength.
- the roughening liquid penetrates from the interface between the surface treatment substance and the resin component on the surface of the precured body layer, and the resin component in the vicinity of the interface between the surface treatment substance and the resin component is roughened.
- the surface treatment substance is desorbed to form a rough surface.
- the functional group of the silane coupling agent acts on the resin component near the surface of the surface treatment substance, and the resin component near the surface of the surface treatment substance is rougher than necessary. It is suppressed that it becomes. For this reason, it becomes easy to control the surface roughness by using the surface treatment substance.
- the roughening solution permeates from the interface between the surface treatment substance and the resin on the surface of the precured body layer. For this reason, the interfacial area of the surface treatment substance is important.
- an inorganic filler having an average particle size of 0.05 to 1.5 ⁇ m is used, the roughening liquid easily penetrates at the interface between the surface treatment substance and the resin component. Become.
- the swelling treatment is performed, the swelling liquid easily penetrates.
- the resin composition used to form the cured body layer comprises an epoxy resin, a curing agent, a curing accelerator, and 100 parts by weight of an inorganic filler having an average particle size of 0.05 to 1.5 ⁇ m. And a surface treatment substance surface-treated with 0.5 to 3.5 parts by weight of the agent.
- the surface treatment substance is contained in the range of 10 to 80% by weight in a total of 100% by weight of the epoxy resin, the curing agent, the curing accelerator and the surface treatment substance.
- the silane coupling agent has a functional group that can react with the epoxy resin or the curing agent.
- the functional group is an epoxy group, an imidazole group or an amino group.
- Epoxy resin The epoxy resin contained in the resin composition is an organic compound having at least one epoxy group (oxirane ring).
- the number of epoxy groups per molecule of the epoxy resin is 1 or more.
- the number of the epoxy groups is preferably 2 or more.
- a conventionally known epoxy resin can be used as the epoxy resin.
- an epoxy resin only 1 type may be used and 2 or more types may be used together.
- the epoxy resin includes an epoxy resin derivative and an epoxy resin hydrogenated product.
- epoxy resin examples include aromatic epoxy resin (1), alicyclic epoxy resin (2), aliphatic epoxy resin (3), glycidyl ester type epoxy resin (4), and glycidyl amine type epoxy resin (5). And glycidyl acrylic epoxy resin (6) or polyester epoxy resin (7).
- aromatic epoxy resin (1) examples include a bisphenol type epoxy resin or a novolac type epoxy resin.
- bisphenol type epoxy resin examples include bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol AD type epoxy resin, and bisphenol S type epoxy resin.
- novolac type epoxy resin examples include phenol novolac type epoxy resins and cresol novolac type epoxy resins.
- an epoxy resin having an aromatic ring such as naphthalene, naphthylene ether, biphenyl, anthracene, pyrene, xanthene or indole in the main chain can be used.
- indole-phenol co-condensation epoxy resin or phenol aralkyl type epoxy resin can be used.
- an epoxy resin made of an aromatic compound such as trisphenolmethane triglycidyl ether can be used.
- Examples of the alicyclic epoxy resin (2) include 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, 3,4-epoxy-2-methylcyclohexylmethyl-3,4-epoxy-2.
- Examples of commercially available products of the alicyclic epoxy resin (2) include trade name “EHPE-3150” (softening temperature 71 ° C.) manufactured by Daicel Chemical Industries, Ltd.
- Examples of the aliphatic epoxy resin (3) include diglycidyl ether of neopentyl glycol, diglycidyl ether of 1,4-butanediol, diglycidyl ether of 1,6-hexanediol, triglycidyl ether of glycerol, Examples thereof include triglycidyl ether of methylolpropane, diglycidyl ether of polyethylene glycol, diglycidyl ether of polypropylene glycol, or polyglycidyl ether of long-chain polyol.
- the long-chain polyol preferably contains polyoxyalkylene glycol or polytetramethylene ether glycol. Further, the number of carbon atoms of the alkylene group of the polyoxyalkylene glycol is preferably in the range of 2 to 9, and more preferably in the range of 2 to 4.
- Examples of the glycidyl ester type epoxy resin (4) include diglycidyl phthalate, diglycidyl tetrahydrophthalate, diglycidyl hexahydrophthalate, diglycidyl-p-oxybenzoic acid, glycidyl ether-glycidyl ester of salicylic acid. Or dimer acid glycidyl ester etc. are mentioned.
- Examples of the glycidylamine type epoxy resin (5) include triglycidyl isocyanurate, N, N′-diglycidyl derivative of cyclic alkylene urea, N, N, O-triglycidyl derivative of p-aminophenol, or m-amino. Examples thereof include N, N, O-triglycidyl derivatives of phenol.
- Examples of the glycidyl acrylic epoxy resin (6) include a copolymer of glycidyl (meth) acrylate and a radical polymerizable monomer.
- Examples of the radical polymerizable monomer include ethylene, vinyl acetate, and (meth) acrylic acid ester.
- polyester type epoxy resin (7) examples include a polyester resin having an epoxy group.
- the polyester resin preferably has two or more epoxy groups per molecule.
- the following epoxy resins (8) to (11) may be used in addition to the epoxy resins (1) to (7).
- Examples of the epoxy resin (8) include a compound obtained by epoxidizing a carbon-carbon double bond of a (co) polymer mainly composed of a conjugated diene compound, or a (co) polymer mainly composed of a conjugated diene compound. And compounds obtained by epoxidizing a carbon-carbon double bond of a partially hydrogenated product.
- Specific examples of the epoxy resin (8) include epoxidized polybutadiene or epoxidized dicyclopentadiene.
- the epoxy resin (9) includes a polymer block mainly composed of a vinyl aromatic compound and a polymer block mainly composed of a conjugated diene compound or a partially hydrogenated polymer block in the same molecule.
- the copolymer include compounds obtained by epoxidizing a carbon-carbon double bond. Examples of such a compound include epoxidized SBS.
- Examples of the epoxy resin (10) include a urethane-modified epoxy resin in which a urethane bond is introduced or a polycaprolactone-modified epoxy in which a polycaprolactone bond is introduced in the structure of the epoxy resins (1) to (9). Examples thereof include resins.
- Examples of the epoxy resin (11) include an epoxy resin having a bisarylfluorene skeleton.
- a flexible epoxy resin is preferably used as the epoxy resin.
- the use of a flexible epoxy resin can increase the flexibility of the cured body.
- polyester resin having epoxidized carbon-carbon double bond of (co) polymer mainly composed of conjugated diene compound, carbon-carbon of partially hydrogenated product of (co) polymer mainly composed of conjugated diene compound
- polyester resin having epoxidized carbon-carbon double bond of (co) polymer mainly composed of conjugated diene compound, carbon-carbon of partially hydrogenated product of (co) polymer mainly composed of conjugated diene compound
- Examples include a compound in which a double bond is epoxidized, a urethane-modified epoxy resin, or a polycaprolactone-modified epoxy resin.
- the flexible epoxy resin includes a dimer acid-modified epoxy resin in which an epoxy group is introduced into the molecule of a dimer acid or a dimer acid derivative, or a rubber-modified epoxy in which an epoxy group is introduced into a molecule of a rubber component.
- a dimer acid-modified epoxy resin in which an epoxy group is introduced into the molecule of a dimer acid or a dimer acid derivative
- a rubber-modified epoxy in which an epoxy group is introduced into a molecule of a rubber component.
- examples thereof include resins.
- NBR NBR
- CTBN polybutadiene
- acrylic rubber acrylic rubber
- the flexible epoxy resin preferably has a butadiene skeleton.
- a flexible epoxy resin having a butadiene skeleton By using a flexible epoxy resin having a butadiene skeleton, the flexibility of the cured product can be further enhanced. Further, the elongation of the cured product can be increased over a wide temperature range from a low temperature range to a high temperature range.
- biphenyl type epoxy resin examples include compounds in which a part of the hydroxyl group of the phenol compound is substituted with an epoxy group-containing group and the remaining hydroxyl group is substituted with a substituent such as hydrogen other than the hydroxyl group.
- the linear expansion coefficient of the cured product can be lowered.
- the linear expansion coefficient of the cured product can be effectively lowered by using an epoxy resin having a polyfunctional triazine ring such as triglycidyl isocyanurate.
- the epoxy equivalent of the epoxy resin is preferably in the range of 100 to 500.
- the reaction of the epoxy resin is likely to proceed, so that the storage stability of the resin composition and the precured body obtained by precuring the resin composition may be significantly lowered.
- the said epoxy equivalent exceeds 500, reaction of an epoxy resin becomes difficult to advance and hardening of a resin composition may not fully advance.
- 15 to 80% by weight of a total of 100% by weight of the epoxy resin, the curing agent, the curing accelerator and the surface treatment substance is liquid at 25 ° C. More preferably, 25% by weight or more of a total of 100% by weight of the epoxy resin, the curing agent, the curing accelerator and the surface treatment substance is liquid at 25 ° C. More preferably, 20% by weight or more of the total 100% by weight of the components other than the solvent in the resin composition is liquid. If the content of the component that is liquid at 25 ° C. is too small, the resin composition in the B-stage state becomes brittle and cracks when bent.
- the epoxy resin is preferably a liquid epoxy resin that is liquid at 25 ° C.
- Bisphenol A type epoxy resin or bisphenol F type epoxy resin is preferably used as the liquid epoxy resin. Among these, bisphenol A type epoxy resins are more preferable.
- the viscosity of the liquid epoxy resin at 25 ° C. is preferably in the range of 0.1 to 100 Pa ⁇ s.
- the viscosity is less than 0.1 Pa ⁇ s, the resin film tends to be thin at the time of lamination or press molding.
- the viscosity exceeds 100 Pa ⁇ s, the handleability of the resin film may be lowered.
- the content of the epoxy resin is preferably 20% by weight or more in a total of 100% by weight of the components contained in the resin composition.
- the content of the epoxy resin is preferably 20% by weight or more in a total of 100% by weight of the components excluding the solvent contained in the resin composition.
- the handleability of the resin film may be lowered.
- curing agent contained in the said resin composition is not specifically limited.
- the curing agent include dicyandiamide, amine compounds, compounds synthesized from amine compounds, hydrazide compounds, melamine compounds, acid anhydrides, phenol compounds (phenol curing agents), active ester compounds, benzoxazine compounds, maleimide compounds, Examples thereof include a heat latent cationic polymerization catalyst, a photolatent cationic polymerization initiator, a cyanate ester resin, and the like. Derivatives of these curing agents may be used.
- curing agent only 1 type may be used and 2 or more types may be used together.
- Examples of the amine compound include a chain aliphatic amine compound, a cyclic aliphatic amine compound, and an aromatic amine compound.
- chain aliphatic amine compound examples include ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, polyoxypropylenediamine, and polyoxypropylenetriamine.
- cycloaliphatic amine compound examples include mensendiamine, isophoronediamine, bis (4-amino-3-methylcyclohexyl) methane, diaminodicyclohexylmethane, bis (aminomethyl) cyclohexane, N-aminoethylpiperazine, or 3,9-bis (3-aminopropyl) -2,4,8,10-tetraoxaspiro (5,5) undecane and the like.
- aromatic amine compound examples include m-xylenediamine, ⁇ - (m / p-aminophenyl) ethylamine, m-phenylenediamine, diaminodiphenylmethane, diaminodiphenylsulfone, or ⁇ , ⁇ -bis (4-aminophenyl). ) -P-diisopropylbenzene.
- a tertiary amine compound may be used as the amine compound.
- the tertiary amine compound include N, N-dimethylpiperazine, pyridine, picoline, benzyldimethylamine, 2- (dimethylaminomethyl) phenol, 2,4,6-tris (dimethylaminomethyl) phenol or 1,8. -Diazabiscyclo (5,4,0) undecene-1 and the like.
- Specific examples of compounds synthesized from the above amine compounds include polyaminoamide compounds, polyaminoimide compounds, ketimine compounds, and the like.
- polyaminoamide compound examples include compounds synthesized from the above amine compounds and carboxylic acids.
- carboxylic acid examples include succinic acid, adipic acid, azelaic acid, sebacic acid, dodecadioic acid, isophthalic acid, terephthalic acid, dihydroisophthalic acid, tetrahydroisophthalic acid, and hexahydroisophthalic acid.
- polyaminoimide compound examples include compounds synthesized from the amine compounds and maleimide compounds.
- maleimide compound examples include diaminodiphenylmethane bismaleimide.
- Examples of the ketimine compound include a compound synthesized from the amine compound and a ketone compound.
- the compound synthesized from the amine compound include compounds synthesized from the amine compound and an epoxy compound, a urea compound, a thiourea compound, an aldehyde compound, a phenol compound, or an acrylic compound.
- the hydrazide compound include 1,3-bis (hydrazinocarboethyl) -5-isopropylhydantoin, 7,11-octadecadien-1,18-dicarbohydrazide, eicosanedioic acid dihydrazide, and adipic acid dihydrazide. Is mentioned.
- Examples of the melamine compound include 2,4-diamino-6-vinyl-1,3,5-triazine.
- the acid anhydride examples include phthalic anhydride, trimellitic anhydride, pyromellitic anhydride, benzophenone tetracarboxylic anhydride, ethylene glycol bisanhydro trimellitate, glycerol tris anhydro trimellitate, Methyltetrahydrophthalic anhydride, tetrahydrophthalic anhydride, nadic anhydride, methylnadic anhydride, trialkyltetrahydrophthalic anhydride, hexahydrophthalic anhydride, methylhexahydrophthalic anhydride, 5- (2,5-dioxo Tetrahydrofuryl) -3-methyl-3-cyclohexene-1,2-dicarboxylic acid anhydride, trialkyltetrahydrophthalic anhydride-maleic anhydride adduct, dodecenyl succinic anhydride, polyazelinic anhydride, polydodecanedioic
- thermal latent cationic polymerization catalyst examples include an ionic thermal latent cationic polymerization catalyst and a nonionic thermal latent cationic polymerization catalyst.
- Examples of the ionic thermal latent cationic polymerization catalyst include benzylsulfonium salt, benzylammonium salt, benzylpyridinium salt or benzylsulfonium salt having antimony hexafluoride, phosphorus hexafluoride or boron tetrafluoride as a counter anion. Can be mentioned.
- nonionic thermal latent cationic polymerization catalyst examples include N-benzylphthalimide or aromatic sulfonic acid ester.
- photolatent cationic polymerization catalyst examples include ionic photolatent cationic polymerization initiators and nonionic photolatent cationic polymerization initiators.
- the ionic photolatent cationic polymerization initiator include onium salts and organometallic complexes.
- the onium salts include aromatic diazonium salts, aromatic halonium salts, and aromatic sulfonium salts using antimony hexafluoride, phosphorus hexafluoride, boron tetrafluoride, or the like as a counter anion.
- the organometallic complexes include iron-allene complexes, titanocene complexes, and arylsilanol-aluminum complexes.
- nonionic photolatent cationic polymerization initiator examples include nitrobenzyl ester, sulfonic acid derivative, phosphoric acid ester, phenol sulfonic acid ester, diazonaphthoquinone, N-hydroxyimide sulfonate, and the like.
- phenol compound examples include phenol novolak, o-cresol novolak, p-cresol novolak, t-butylphenol novolak, dicyclopentadiene cresol, phenol aralkyl resin, ⁇ -naphthol aralkyl resin, ⁇ -naphthol aralkyl resin, or aminotriazine novolak.
- resins examples include resins. These derivatives may be used as the phenol compound.
- a phenol compound only 1 type may be used and 2 or more types may be used together.
- the phenol compound (phenol curing agent) is preferably used as the curing agent.
- the heat resistance and dimensional stability of the cured body can be increased, and the water absorption of the cured body can be lowered.
- the surface roughness of the roughened cured body can be further reduced. Specifically, the arithmetic average roughness Ra and the ten-point average roughness Rz of the surface of the roughened cured body can be further reduced.
- a phenol compound represented by any one of the following formula (1), the following formula (2), and the following formula (3) is more preferably used.
- the surface roughness of the surface of the cured body can be further reduced.
- R1 represents a methyl group or an ethyl group
- R2 represents hydrogen or a hydrocarbon group
- n represents an integer of 2 to 4.
- m represents an integer of 0 to 5.
- R3 represents a group represented by the following formula (4a) or the following formula (4b)
- R4 is represented by the following formula (5a), the following formula (5b) or the following formula (5c)
- R5 represents a group represented by the following formula (6a) or the following formula (6b)
- R6 represents hydrogen or an organic group having 1 to 20 carbon atoms
- p represents an integer of 1 to 6
- Q represents an integer of 1 to 6
- r represents an integer of 1 to 11.
- a phenol compound represented by the above formula (3), wherein R4 in the above formula (3) is a group represented by the above formula (5c), is preferred.
- the electrical properties and heat resistance of the cured body can be further increased, and the linear expansion coefficient and water absorption of the cured body can be further decreased.
- the dimensional stability of the cured body when a thermal history is given can be further enhanced.
- the curing agent is particularly preferably a phenol compound having a structure represented by the following formula (7).
- the electrical characteristics and heat resistance of the cured body can be further increased, and the linear expansion coefficient and water absorption of the cured body can be further decreased.
- the dimensional stability of the cured body when a thermal history is given can be further enhanced.
- s represents an integer of 1 to 11.
- the active ester compound examples include aromatic polyvalent ester compounds. When an active ester compound is used, no OH group is generated during the reaction between the active ester group and the epoxy resin, so that a cured product having excellent dielectric constant and dielectric loss tangent can be obtained. Specific examples of the active ester compound are disclosed in, for example, JP-A-2002-12650.
- Examples of commercially available active ester compounds include trade names “EPICLON EXB9451-65T” and “EPICLON EXB9460S-65T” manufactured by DIC.
- benzoxazine compound examples include aliphatic benzoxazine resins and aromatic benzoxazine resins.
- Examples of commercially available products of the benzoxazine compound include trade names “Pd-type benzoxazine” and “Fa-type benzoxazine” manufactured by Shikoku Kasei Kogyo Co., Ltd.
- cyanate ester resin for example, a novolak type sinate ester resin, a bisphenol type cyanate ester resin, a prepolymer partially triazineated, or the like can be used.
- the cyanate ester resin By using the cyanate ester resin, the linear expansion coefficient of the cured product can be further reduced.
- the maleimide compounds include N, N′-4,4-diphenylmethane bismaleimide, N, N′-1,3-phenylene dimaleimide, N, N′-1,4-phenylene dimaleimide, 1,2-bis ( Maleimide) ethane, 1,6-bismaleimide hexane, bis (3-ethyl-5-methyl-4-maleimidophenyl) methane, polyphenylmethanemaleimide, bisphenol A diphenyl ether bismaleimide, 4-methyl-1,3-phenylenebis It is preferably at least one selected from the group consisting of maleimide, 1,6-bismaleimide- (2,2,4-trimethyl) hexane and oligomers thereof, and a maleimide skeleton-containing diamine condensate.
- the said oligomer is an oligomer obtained by condensing the maleimide compound which is a monomer in the maleimide compound mentioned above.
- the maleimide compound is more preferably at least one of polyphenylmethane maleimide and bismaleimide oligomer.
- the bismaleimide oligomer is preferably an oligomer obtained by condensation of phenylmethane bismaleimide and 4,4-diaminodiphenylmethane.
- maleimide compounds examples include polyphenylmethane maleimide (manufactured by Daiwa Kasei Co., Ltd., trade name “BMI-2300”) and bismaleimide oligomer (manufactured by Daiwa Kasei Co., Ltd., trade name “DAIMAID-100H”).
- BMI-2300 manufactured by Daiwa Kasei Co., Ltd. is a low molecular weight oligomer.
- DAIMAID-100H manufactured by Daiwa Kasei Co., Ltd. is a condensate using diaminodiphenylmethane as an amine curing agent and has a high molecular weight.
- the breaking strength and elongation at break of the cured product can be increased.
- the curing agent at least one of a phenol curing agent, an active ester compound, and a cyanate ester resin is preferably used.
- the above phenol curing agent shows high reaction activity with respect to epoxy groups. Moreover, when the said phenol hardening
- the active ester compound is preferably an aromatic polyvalent ester compound.
- aromatic polyvalent ester compound By using the aromatic polyvalent ester compound, it is possible to obtain a cured product that is further excellent in dielectric constant and dielectric loss tangent.
- the curing agent was selected from the group consisting of a phenolic compound having a biphenyl structure, a phenolic compound having a naphthalene structure, a phenolic compound having a dicyclopentadiene structure, a phenolic compound having an aminotriazine structure, an active ester compound, and a cyanate ester resin. It is preferable that there is at least one.
- the curing agent is more preferably at least one selected from the group consisting of a biphenyl type phenol curing agent, a naphthol curing agent and an active ester compound, and particularly preferably a biphenyl type phenol curing agent.
- the resin component is more unlikely to be adversely affected during the roughening treatment.
- fine pores can be formed by selectively desorbing the surface treatment substance without making the surface of the cured body too rough. For this reason, the fine unevenness
- the phenol curing agent preferably has two or more hydroxyl groups in one molecule. In this case, the strength and heat resistance of the cured body can be increased.
- the weight average molecular weight of the curing agent is preferably in the range of 1000 to 20000.
- curing agent becomes high, and the heat resistance and intensity
- the above weight average molecular weight is a weight average molecular weight in terms of polystyrene measured by gel permeation chromatography (GPC).
- the softening point of the curing agent is preferably 50 ° C. or higher.
- the softening point is less than 50 ° C., the molecular weight of the curing agent tends to be small, and the performance of the cured body may not be sufficiently improved.
- a preferable upper limit of the softening point is 100 ° C. When the softening point exceeds 100 ° C., the curing agent may not be dissolved in the solvent when producing the resin composition.
- the preferable lower limit of the total content of the epoxy resin and the curing agent is 40% by weight or more in a total of 100% by weight of the epoxy resin, the curing agent, the curing accelerator, and the surface treatment substance. If the total content of the epoxy resin and the curing agent is too small, the handleability of the resin film is lowered when the resin composition is coated on the base film to form a resin film. When the handling property of the resin film is lowered, the resin film is easily broken when the resin film is curved, and the resin film chips are likely to adhere to the manufacturing apparatus or the like.
- a more preferable lower limit of the total content of the epoxy resin and the phenol curing agent is 50% by weight, and a more preferable lower limit. Is 55% by weight, a particularly preferred lower limit is 60% by weight, a preferred upper limit is 90% by weight, and a more preferred upper limit is 80% by weight.
- the compounding ratio of the epoxy resin to the curing agent is preferably in the range of 1.0 to 2.5 by weight.
- the blending ratio is less than 1.0, the content of the epoxy resin is too small, and the flatness of the surface of the cured body may be lowered. If the blending ratio exceeds 2.5, the content of the curing agent is too small, and unreacted epoxy resin tends to remain after curing, and the glass transition temperature and linear expansion coefficient performance of the cured product may be reduced. is there.
- the preferable lower limit of the blending ratio is 1.3, the more preferable lower limit is 1.6, the preferable upper limit is 2.4, and the more preferable upper limit is 2.2.
- the curing accelerator contained in the resin composition is not particularly limited. As for a hardening accelerator, only 1 type may be used and 2 or more types may be used together.
- the curing accelerator is preferably an imidazole compound.
- the curing accelerator is 2-undecylimidazole, 2-heptadecylimidazole, 2-methylimidazole, 2-ethyl-4-methylimidazole, 2-phenylimidazole, 2-phenyl-4-methylimidazole, 1-benzyl- 2-methylimidazole, 1-benzyl-2-phenylimidazole, 1,2-dimethylimidazole, 1-cyanoethyl-2-methylimidazole, 1-cyanoethyl-2-ethyl-4-methylimidazole, 1-cyanoethyl-2-un Decylimidazole, 1-cyanoethyl-2-phenylimidazole, 1-cyanoethyl-2-undecylimidazolium trimellitate, 1-cyanoethyl-2-phenylimidazolium trimellitate, 2,4-diamino-6- [2 ' -Met
- phosphine compounds such as triphenylphosphine, diazabicycloundecene (DBU), diazabicyclononene (DBN), DBU phenol salt, DBN phenol salt, octylate, p- Examples include toluene sulfonate, formate, orthophthalate, and phenol novolac resin salt.
- a preferable lower limit of the content of the curing accelerator is 0.01% by weight, and a more preferable lower limit is 0.1% by weight.
- a more preferred lower limit is 0.2% by weight, a preferred upper limit is 10% by weight, a more preferred upper limit is 5% by weight, and a still more preferred upper limit is 3% by weight.
- the content of the curing accelerator is too large, the reaction start point increases, and therefore the molecular weight does not increase sufficiently even when the resin composition is cured, or the epoxy resin may not be uniformly crosslinked. There is. Moreover, the storage stability of the resin composition may be reduced.
- the said resin composition contains the surface treatment substance by which the inorganic filler is surface-treated with the silane coupling agent. Only one type of surface treatment substance may be used, or two or more types may be used in combination.
- the average particle diameter of the inorganic filler is in the range of 0.05 to 1.5 ⁇ m.
- the surface treatment substance tends to aggregate and unevenness of the rough surface may occur in the cured product. Accordingly, the adhesive strength between the roughened cured body and the metal layer is likely to decrease. Moreover, the viscosity of a resin composition may become high and the filling property of the resin composition to a through hole or a via hole may fall.
- the average particle diameter exceeds 1.5 ⁇ m the surface roughness of the surface of the roughened cured body tends to increase. Further, it becomes difficult for the surface treatment substance to be detached during the roughening treatment.
- the plating solution may sink into the gap between the surface treatment substance and the resin component that have not been detached. For this reason, there exists a possibility that a malfunction may arise in the metal layer formed in the surface of the hardening body.
- the average particle diameter of the inorganic filler is preferably in the range of 0.2 to 1.5 ⁇ m. When the average particle diameter is within the above range, a finer rough surface can be formed on the surface of the roughened cured body.
- the inorganic filler examples include aluminum nitride, alumina, boron nitrite, titanium oxide, mica, mica powder, clay, talc, silica, silicon nitride, and the like.
- the silica examples include fused silica or crystalline silica.
- the maximum particle size of the inorganic filler is preferably 10 ⁇ m or less.
- the maximum particle diameter exceeds 10 ⁇ m, when a patterned metal layer is formed on the surface of the cured body, a rough surface (recessed portion) based on the desorption of one surface treatment substance is close to both of the adjacent metal layers. Sometimes. For this reason, variations occur in the electrical characteristics between the wirings, causing malfunctions or reducing reliability.
- the inorganic filler is preferably silica.
- Silica is easily available industrially and is inexpensive. By using silica, the linear expansion coefficient of the cured product can be lowered, and the heat dissipation property can be increased.
- the silica is preferably fused silica.
- the median diameter (d50) value of 50% can be adopted as the average particle diameter.
- the average particle size can be measured using a laser diffraction / scattering particle size distribution measuring apparatus.
- the specific surface area of the inorganic filler is preferably in the range of 10 to 70 m 2 / g.
- the specific surface area is less than 10 m 2 / g, the adhesive strength between the roughened cured body and the metal layer tends to decrease.
- the roughening liquid does not easily penetrate into the interface between the surface treatment substance and the resin component and the surface treatment substance is roughened to such an extent that the surface treatment substance is detached, the surface roughness of the cured body tends to increase.
- the specific surface area exceeds 70 m 2 / g, the surface roughness of the surface of the roughened cured body tends to increase. Furthermore, the surface treatment substance tends to aggregate and unevenness is likely to occur in the cured body.
- the inorganic filler is surface-treated with a silane coupling agent.
- the silane coupling agent has a functional group that can react with the epoxy resin or the curing agent. Therefore, when the resin composition is cured, the surface treatment substance reacts with the epoxy resin or the curing agent, and the surface treatment substance is appropriately adhered to the resin component in the precured body. For this reason, the surface roughness of the surface of the roughened cured body can be reduced by roughening the surface of the preliminary-cured body. Furthermore, the adhesive strength between the cured body and the metal layer can be increased.
- the functional group of the silane coupling agent is an epoxy group, an imidazole group, or an amino group. Since the silane coupling agent has such a functional group, the surface roughness of the roughened cured body surface can be reduced. Furthermore, the adhesive strength between the cured body and the metal layer can be further increased.
- the surface treatment material used in the present invention 100 parts by weight of the inorganic filler is surface-treated with 0.5 to 3.5 parts by weight of a silane coupling agent. If the amount of the silane coupling agent is too small, the surface treatment substance tends to aggregate in the resin composition, and the surface roughness of the cured body tends to increase. When there is too much quantity of the said silane coupling agent, hardening will advance easily and storage stability will worsen. Moreover, the surface roughness of the surface of the cured body tends to increase.
- a preferable lower limit of the amount of the silane coupling agent for surface-treating 100 parts by weight of the inorganic filler is 1.0 part by weight, a preferable upper limit is 3.0 parts by weight, and a more preferable upper limit is 2.5 parts by weight.
- the content of the surface treatment substance in the total of 100% by weight of the epoxy resin, the curing agent, the curing accelerator and the surface treatment substance is in the range of 5 to 80% by weight.
- a preferred lower limit of the content of the surface treatment substance is 10% by weight, a more preferred lower limit is 15% by weight, and a preferred upper limit is 50% by weight, and a more preferable upper limit is 40% by weight.
- the resin composition preferably contains an imidazole silane compound.
- the imidazole silane compound By using the imidazole silane compound, the surface roughness of the surface of the roughened cured body can be further reduced.
- the imidazole silane compound is contained within a range of 0.01 to 3 parts by weight with respect to a total of 100 parts by weight of the epoxy resin and the curing agent.
- the content of the imidazole silane compound is within the above range, the surface roughness of the surface of the roughened cured body can be further reduced, and the roughened adhesive strength between the cured body and the metal layer can be further increased. It can be made even higher.
- the minimum with more preferable content of the said imidazole silane compound is 0.03 weight part, A more preferable upper limit is 2 weight part, Furthermore, a preferable upper limit is 1 weight part.
- the imidazole silane compound is 0.01 to 2% by weight with respect to 100 parts by weight in total of the epoxy resin and the curing agent. It is particularly preferred that it is contained within the range of parts.
- the resin composition may contain a solvent.
- a solvent having good resin component solubility is appropriately selected and used.
- the said solvent only 1 type may be used and 2 or more types may be used together.
- the solvent examples include acetone, methyl ethyl ketone, toluene, xylene, n-hexane, methanol, ethanol, methyl cellosolve, ethyl cellosolve, butyl cellosolve, methoxypropanol, cyclohexanone, N-methylpyrrolidone, dimethylformamide, dimethylacetamide, propylene glycol monomethyl Examples include ether, propylene glycol monomethyl ether acetate, and ethylene glycol monomethyl ether acetate.
- the solvent is preferably dimethylformamide, methyl ethyl ketone, cyclohexanone, hexane or propylene glycol monomethyl ether.
- the blending amount of the solvent is appropriately selected so that, for example, the resin composition can be applied to a uniform thickness when the resin composition is applied onto the base film to form the resin composition.
- the preferable lower limit of the content of the solvent is 30 parts by weight with respect to 100 parts by weight of the total components other than the solvent in the resin composition containing the epoxy resin, the curing agent, the curing accelerator, and the surface treatment substance.
- a more preferred lower limit is 40 parts by weight, a still more preferred lower limit is 50 parts by weight, a preferred upper limit is 200 parts by weight, a more preferred upper limit is 150 parts by weight, a still more preferred upper limit is 70 parts by weight, and a particularly preferred upper limit is 60 parts by weight.
- liquidity of a resin composition is too low, and it may be unable to apply a resin composition to uniform thickness.
- liquidity of a resin composition will be too high, and when a resin composition is applied, it may spread out more than necessary.
- the resin composition may contain a resin copolymerizable with the epoxy resin, if necessary, in addition to the epoxy resin.
- the above copolymerizable resin is not particularly limited.
- examples of the copolymerizable resin include phenoxy resin, thermosetting modified polyphenylene ether resin, or benzoxazine resin.
- the copolymerizable resin only one type may be used, or two or more types may be used in combination.
- thermosetting modified polyphenylene ether resin examples include resins obtained by modifying a polyphenylene ether resin with a functional group such as an epoxy group, an isocyanate group, or an amino group.
- a functional group such as an epoxy group, an isocyanate group, or an amino group.
- the said thermosetting modified polyphenylene ether resin only 1 type may be used and 2 or more types may be used together.
- the benzoxazine resin is not particularly limited.
- Specific examples of the benzoxazine resin include a resin in which a substituent having an aryl group skeleton such as a methyl group, an ethyl group, a phenyl group, a biphenyl group, or a cyclohexyl group is bonded to nitrogen of the oxazine ring, or a methylene group, an ethylene group And a resin in which a substituent having an arylene skeleton such as a phenylene group, a biphenylene group, a naphthalene group, or a cyclohexylene group is bonded between nitrogen atoms of two oxazine rings.
- the said benzoxazine resin only 1 type may be used and 2 or more types may be used together.
- the heat resistance of the cured product can be increased, and the water absorption and the linear expansion coefficient can be decreased.
- a benzoxazine monomer or oligomer, or a resin in which a benzoxazine monomer or oligomer is polymerized by ring-opening polymerization of an oxazine ring is included in the benzoxazine resin.
- additives such as a stabilizer, an ultraviolet absorber, a lubricant, a pigment, a flame retardant, an antioxidant, or a plasticizer may be further added.
- An agent or the like may be appropriately added to the resin composition.
- a coupling agent may be added to the resin composition as necessary.
- Examples of the coupling agent include silane coupling agents, titanate coupling agents, and aluminum coupling agents. Of these, a silane coupling agent is preferable.
- Examples of the silane coupling agent include silane compounds having amino groups, silane compounds having mercapto groups, silane compounds having isocyanate groups, silane compounds having acid anhydride groups, and silane compounds having isocyanuric acid groups.
- the silane coupling agent is selected from the group consisting of a silane compound having an amino group, a silane compound having a mercapto group, a silane compound having an isocyanate group, a silane compound having an acid anhydride group, and a silane compound having an isocyanuric acid group.
- at least one kind is used.
- a polymer resin may be added to the resin composition.
- the polymer resin include phenoxy resin, polysulfone resin, polyphenylene ether resin, and the like.
- the manufacturing method of the said resin composition is not specifically limited.
- a method for producing the resin composition for example, the epoxy resin, the curing agent, the curing accelerator, the surface treatment substance, and other components blended as necessary are added to a solvent. Thereafter, a method of drying and removing the solvent may be used.
- the resin composition is, for example, a substrate material for forming a core layer or a buildup layer of a multilayer substrate, an adhesive sheet, a laminate, a copper foil with resin, a copper clad laminate, a TAB tape, a printed board, a prepreg, or It is suitably used for varnishes and the like.
- the resin composition is suitably used for applications requiring insulation such as a copper foil with resin, a copper clad laminate, a printed board, a prepreg, an adhesive sheet, or a TAB tape.
- Additive method for forming circuit after forming conductive plating layer on the surface of cured body, build-up substrate etc. where multiple cured body and conductive plating layer are laminated by semi-additive method etc. Preferably used.
- the bonding reliability between the conductive plating layer and the cured body can be increased.
- the insulation reliability between patterns can be improved.
- the depth of the hole from which the surface treatment material is detached is shallow, the insulation reliability between the layers and between the wirings can be improved. Therefore, highly reliable fine wiring can be formed.
- the resin composition can also be used as a sealing material or a solder resist.
- the resin composition is also applied to a passive component or a component-embedded substrate in which an active component is required. Can be used.
- the above resin composition may be impregnated into a porous substrate and used as a prepreg.
- the porous substrate is not particularly limited as long as it can be impregnated with the resin composition.
- the porous substrate include organic fibers or glass fibers.
- the organic fiber include carbon fiber, polyamide fiber, polyaramid fiber, and polyester fiber.
- the form of textiles such as a plain weave or a twill, or the form of a nonwoven fabric, etc. are mentioned.
- the porous substrate is preferably a glass fiber nonwoven fabric.
- FIG. 1 the laminated
- the laminated film 1 includes a base film 2 and a resin film 3 laminated on the upper surface 2 a of the base film 2.
- the resin film 3 is formed of the resin composition.
- the substrate film 2 examples include resin-coated paper, polyester film, polyethylene terephthalate (PET) film, polypropylene (PP) film, and metal foil such as copper foil.
- PET polyethylene terephthalate
- PP polypropylene
- the flatness of the surface of the cured body can be improved. Is preferably high.
- the substrate having a high elastic modulus include copper foil.
- the upper surface 2 a of the base film 2 is in contact with the lower surface of the resin film 3. For this reason, the surface roughness of the upper surface 2a of the base film 2 affects the surface roughness of the surface of the roughened cured body. Therefore, it is preferable that the surface roughness of the upper surface 2a of the base film 2 is small. For this reason, a plastic film such as a PET film is preferably used as the base film 2. Further, a copper foil having a relatively small surface roughness is also suitably used as the base film 2.
- the base film 2 may be subjected to mold release treatment.
- the method for releasing the base film 2 includes a method of containing a silicon compound, a fluorine compound or a surfactant in the substrate, a method of imparting irregularities to the surface of the substrate, and a silicon compound, a fluorine compound or Examples thereof include a method of applying a releasable substance such as a surfactant to the surface of the substrate. Examples of the method for imparting unevenness to the surface of the substrate include a method of embossing the surface of the substrate.
- the base film 2 may be added with additives such as a stabilizer, an ultraviolet absorber, a lubricant, a pigment, an antioxidant, a leveling agent, or a plasticizer.
- additives such as a stabilizer, an ultraviolet absorber, a lubricant, a pigment, an antioxidant, a leveling agent, or a plasticizer.
- the thickness of the base film 2 is not particularly limited.
- the thickness of the base film 2 is preferably in the range of 10 to 200 ⁇ m. If the thickness of the base film 2 is thin, the base film 2 is easily stretched by tension, so that wrinkles are likely to occur or dimensional changes of the resin film 3 are likely to occur. For this reason, the thickness of the base film 2 is more preferably 20 ⁇ m or more.
- the resin film 3 does not contain a solvent or contains a solvent in a content of 5% by weight or less.
- the content of the solvent exceeds 5% by weight, the adhesive force between the base film 2 and the resin film 3 becomes strong, and it may be difficult to peel the resin film 3 from the base film 2.
- the smaller the solvent content the easier it is to obtain flatness after lamination of the resin film 3.
- the resin film 3 contains a solvent in the range of 0.1 to 3% by weight.
- the resin film 3 since a part or all of a solvent is removed by drying the resin composition containing a solvent, the resin film 3 which does not contain a solvent or contains a solvent with content of 5 weight% or less is obtained. .
- the thickness of the resin film 3 is preferably in the range of 10 to 200 ⁇ m. When the thickness of the resin film 3 is within the above range, the resin film 3 can be suitably used for forming an insulating layer such as a printed wiring board.
- the laminated film 1 can be manufactured as follows, for example.
- the above resin composition is applied to the upper surface 2a of the base film 2.
- the resin composition applied to the upper surface 2a of the base film 2 is dried at about 80 to 150 ° C. as necessary to remove a part or all of the solvent.
- the resin film 3 can be formed on the upper surface 2 a of the base film 2.
- the drying temperature is about 100 ° C.
- the drying time is about 30 seconds to 10 minutes.
- a resin film having no base material may be formed using the resin composition.
- Other production methods of the resin film 3 include an extrusion molding method or a conventionally known film molding method other than the extrusion molding method.
- the epoxy resin, the curing agent, the curing accelerator, the surface treatment substance, and a material to be blended as necessary are melt-kneaded in an extruder, and then extruded, T-die or circular die. Etc. to form a film. Thereby, a resin film can be obtained.
- the laminated film 1 is used to form, for example, an insulating layer of a single layer or multilayer printed wiring board.
- FIG. 2 is a front sectional view schematically showing a multilayer printed wiring board as a laminate according to an embodiment of the present invention.
- a plurality of cured body layers 3 ⁇ / b> A are laminated on the upper surface 12 a of the substrate 12.
- the cured body layer 3A is an insulating layer.
- the cured body layer 3A is formed by subjecting a precured body layer obtained by heating and precuring the resin film 3 to a roughening treatment.
- a metal layer 13 is formed in a part of the upper surface 3a of the cured body layer 3A other than the uppermost cured body layer 3A. Metal layers 13 are disposed between the respective layers of the cured body layer 3A. The lower metal layer 13 and the upper metal layer 13 are connected by at least one of via hole connection and through hole connection (not shown).
- the resin film 3 is laminated on the upper surface 12a of the substrate 12 while being laminated. Moreover, the resin film 3 laminated
- the laminator or press used for the laminate is not particularly limited.
- Examples of the laminator or press machine include a vacuum pressurization laminator manufactured by Meiki Seisakusho, a vacuum press machine manufactured by Kitagawa Seiki Co., Ltd., and a quick vacuum press machine manufactured by Mikado Technos.
- the temperature of the laminate is preferably in the range of 70 to 130 ° C.
- substrate 12 will fall, and it will become easy to produce delamination.
- the flatness of the upper surface 3a of the resin film 3 will fall, the embedding of the resin film will become inadequate, and a void etc. may generate
- the thickness of the resin film 3 may reduce or the flatness of the upper surface 3a of the resin film 3 may fall.
- the filling property of the resin film 3 to the irregularities may be lowered.
- the minimum with the preferable temperature of the said laminate is 80 degreeC, a preferable upper limit is 120 degreeC, and a more preferable upper limit is 100 degreeC.
- the pressure of the laminate is preferably in the range of 0.1 to 2.0 MPa. If the pressure of the laminate is too low, the adhesion between the resin film 3 and the upper surface 12a of the substrate 12 is lowered, and delamination is likely to occur. Moreover, when the said pressure is too low, when the upper surface 3a of the resin film 3 cannot fully be made flat, or the surface where the resin film 3 is laminated
- corrugation tends to differ greatly partially. For this reason, unevenness in thickness tends to occur in the resin film 3, and the upper surface 3a of the resin film 3 may not be sufficiently flat.
- the preferable lower limit of the pressure is 0.3 MPa
- the preferable upper limit is 1.0 MPa
- the more preferable upper limit is 0.8 MPa.
- the time for pressing is not particularly limited. Since the working efficiency can be improved, the pressing time is preferably in the range of 6 seconds to 6 hours. Furthermore, when the surface on which the resin film 3 is laminated has irregularities, the irregularities can be sufficiently filled with the resin film 3, and the flatness of the upper surface 3a of the resin film 3 can be ensured.
- the resin film 3 is heated and pre-cured.
- An oven or the like is used for heating.
- a precured body layer in which the resin film 3 is cured is formed on the upper surface 12 a of the substrate 12.
- the heating temperature in the curing process is in the range of 100 to 200 ° C. If the heating temperature is too low, the resin film 3 may not be sufficiently cured. In addition, if the heating temperature is too low, the surface roughness of the surface of the hardened body layer that has been roughened may increase, or the adhesive strength between the hardened body layer and the metal layer may decrease. . If the heating temperature is too high, the resin film 3 tends to shrink by heat. For this reason, the flatness of the upper surface of the precured body layer may not be sufficiently secured. Moreover, when the said heating temperature is too high, the hardening reaction of a resin composition will advance rapidly. For this reason, the degree of curing tends to be partially different, and a rough portion and a dense portion are likely to be formed.
- the minimum with said preferable heating temperature is 130 degreeC, and a preferable upper limit is 200 degreeC.
- a preferable heating temperature is too high, there exists a possibility that the roughening process mentioned later may become difficult.
- the heating time in the curing process is preferably in the range of 3 to 120 minutes. If the heating time is too short, the resin film 3 may not be sufficiently cured. When the said heating time is too long, there exists a possibility that the roughening process mentioned later may become difficult.
- a step cure method or the like that raises the temperature stepwise may be used.
- the surface of the pre-cured body layer is subjected to swelling treatment and roughening treatment.
- the preliminary-cured body layer may be subjected only to the roughening treatment without being subjected to the swelling treatment.
- the precured body layer is preferably subjected to a roughening treatment after being subjected to a swelling treatment.
- the method for swelling the precured body layer is not particularly limited.
- the swelling treatment is performed by a conventionally known method.
- a method of treating the precured body layer with an aqueous solution or an organic solvent dispersion containing ethylene glycol, dimethylformamide, dimethyl sulfoxide, N-methyl-2-pyrrolidone, pyridine, sulfuric acid, sulfonic acid, or the like as a main component can be used. .
- the method of processing a precured body layer in the aqueous solution containing ethylene glycol is preferable.
- the temperature of the swelling treatment is preferably in the range of 50 to 80 ° C. A more preferable lower limit of the swelling temperature is 60 ° C.
- the adhesive strength between the cured body layer and the metal layer after the roughening treatment may be lowered. If the temperature of the swelling treatment is too high, the surface roughness of the surface of the roughened cured body layer tends to increase.
- the swelling treatment time is preferably 1 to 40 minutes, more preferably 5 to 30 minutes, and further preferably 5 to 20 minutes. If the swelling treatment time is too short, the adhesive strength between the roughened cured body layer and the metal layer may be lowered. When the time for the swelling treatment is too long, the surface roughness of the roughened cured body layer tends to increase.
- the method for roughening the precured body layer is not particularly limited.
- the roughening process is performed by a conventionally known method. Examples thereof include a method of treating the precured body layer with a roughening treatment liquid such as an aqueous solution of a chemical oxidant containing a manganese compound, a chromium compound or a persulfuric acid compound as a main component, or an organic solvent dispersion.
- a roughening treatment liquid such as an aqueous solution of a chemical oxidant containing a manganese compound, a chromium compound or a persulfuric acid compound as a main component, or an organic solvent dispersion.
- Examples of the manganese compound include potassium permanganate and sodium permanganate.
- Examples of the chromium compound include potassium dichromate and anhydrous potassium chromate.
- Examples of the persulfate compound include sodium persulfate, potassium persulfate, and ammonium persulfate.
- the temperature of the roughening treatment is in the range of 55 to 80 ° C.
- a preferable lower limit of the temperature of the roughening treatment is 60 ° C. If the temperature of the roughening treatment is too low, the adhesive strength between the roughened cured body layer and the metal layer may be lowered. If the temperature of the roughening treatment is too high, the surface roughness of the surface of the hardened body layer subjected to the roughening treatment may increase, or the adhesive strength between the hardened body layer and the metal layer may be reduced.
- the time for the roughening treatment is preferably 1 to 30 minutes, more preferably 5 to 30 minutes. If the roughening treatment time is too short, the adhesive strength between the roughened cured body layer and the metal layer may be lowered. When the time for the roughening treatment is too long, the surface roughness of the surface of the cured body layer subjected to the roughening treatment tends to increase. Furthermore, there exists a tendency for the adhesive strength of a hardening body layer and a metal layer to fall.
- the roughening treatment may be performed only once or multiple times. When the number of roughening treatments is large, the roughening effect is large. However, when the number of times of roughening treatment exceeds 3, the roughening effect may be saturated, or the resin component on the surface of the cured body is scraped more than necessary, and the surface treatment substance is formed on the surface of the cured body layer. It is difficult to form a hole with a shape from which the is detached.
- a 30 to 90 g / L permanganate solution a 30 to 90 g / L permanganate solution, or a 30 to 90 g / L sodium hydroxide solution is preferably used. It is preferable to immerse and swing the precured body layer in these roughening treatment liquids.
- the roughened cured body layer 3 ⁇ / b> A can be formed on the upper surface 12 a of the substrate 12.
- a plurality of roughened cured body layers 3A are formed on the upper surface 3a by desorption of the surface treatment substance.
- a hole 3b is formed.
- the resin composition contains a surface treatment substance in which the inorganic filler is surface-treated with the specific amount of the silane coupling agent. For this reason, it is excellent in the dispersibility of the surface treatment substance in a resin composition. Accordingly, it is difficult to form a large hole in the upper surface 3a of the cured body layer 3A due to the removal of the aggregate of the surface treatment substance. Therefore, the strength of the cured body layer 3A is hardly locally reduced, and the adhesive strength between the cured body layer 3A and the metal layer can be increased. Moreover, in order to lower the linear expansion coefficient of the cured body layer 3A, a large amount of a surface treatment substance can be added to the resin composition.
- the holes 3b may be holes from which about several surface treatment substances, for example, about 2 to 10 are removed.
- the resin component in the portion indicated by the arrow X in FIG. For this reason, the strength of the cured body layer 3A can be increased.
- the arithmetic average roughness Ra of the surface of the roughened cured body layer 3A (cured body) obtained as described above is 300 nm or less, and the ten-point average roughness Rz is 3.0 ⁇ m or less. Is preferred.
- the arithmetic average roughness Ra of the surface of the cured body layer 3A is more preferably 200 nm or less, and further preferably 150 nm or less.
- the ten-point average roughness Rz of the surface of the cured body layer 3A is more preferably 2 ⁇ m or less, and further preferably 1.5 ⁇ m or less.
- the arithmetic average roughness Ra and the ten-point average roughness Rz can be obtained by a measuring method based on JIS B0601-1994.
- a metal layer 13 is formed on the upper surface 3a of the roughened cured body layer 3A.
- the method for forming the metal layer 13 is not particularly limited.
- the metal layer 13 can be formed by performing electroless plating on the upper surface 3a of the cured body layer 3A, or further performing electroplating after performing electroless plating.
- the top surface 3a of the cured body layer 3A may be subjected to plasma treatment or chemical treatment to form fine irregularities on the top surface 3a.
- Examples of the plating material include gold, silver, copper, rhodium, palladium, nickel, and tin. Two or more kinds of these alloys may be used. A plurality of metal layers may be formed of two or more kinds of plating materials.
- the adhesive strength (roughened adhesive strength) between the cured body layer 3A and the metal layer 13 is preferably 4.9 N / cm or more.
- the metal layer 13 reaches the hole 3b. Therefore, the adhesive strength between the cured body layer 3A and the metal layer 13 can be increased by the physical anchor effect. Further, in the vicinity of the hole 3b formed by the detachment of the surface treatment substance, the resin component is not removed more than necessary, so that the adhesive strength between the cured body layer 3A and the metal layer 13 can be increased.
- Epoxy resin Bisphenol A type epoxy resin (1) (trade name “Epicoat 828”, epoxy equivalent 189, viscosity 12-25 Pa ⁇ s at 25 ° C., manufactured by JER)
- Biphenyl type phenol curing agent (1) (trade name “MEH7851-4H”, OH equivalent 243, softening point 130 ° C., manufactured by Meiwa Kasei Co., Ltd.)
- Naphthol curing agent (2) (trade name “SN485”, OH equivalent 213, softening point 86 ° C., manufactured by Tohto Kasei Co., Ltd.)
- Active ester curing agent active ester compound, manufactured by DIC, trade name “EPICLON EXB9460S-65T”, toluene solution with a solid content of 65%
- Silica 50 wt% DMF dispersion (1) 100 parts by weight of silica particles having an average particle size of 0.3 ⁇ m and a specific surface area of 18 m 2 / g are aminosilane coupling agents (trade name “KBE-903”, manufactured by Shin-Etsu Chemical Co., Ltd.) Dispersion containing 50% by weight of a surface-treated substance surface-treated with 1.0 part by weight and 50% by weight of DMF (N, N-dimethylformamide)
- Silica 50 wt% DMF dispersion (2) 100 parts by weight of silica particles having an average particle size of 0.3 ⁇ m and a specific surface area of 18 m 2 / g are aminosilane coupling agents (trade name “KBE-903”, manufactured by Shin-Etsu Chemical Co., Ltd.) Dispersion containing 50% by weight of a surface-treated substance surface-treated by 2.5 parts by weight and 50% by weight of DMF
- Silica 50 wt% DMF dispersion (3) 100 parts by weight of silica particles having an average particle size of 1.5 ⁇ m and a specific surface area of 3 m 2 / g are aminosilane coupling agents (trade name “KBE-903”, manufactured by Shin-Etsu Chemical Co., Ltd.) Dispersion containing 50% by weight of a surface-treated substance surface-treated with 1.0 part by weight and 50% by weight of DMF
- Silica 50 wt% DMF dispersion (4) 100 parts by weight of silica particles having an average particle size of 0.3 ⁇ m and a specific surface area of 18 m 2 / g are epoxy silane coupling agents (trade name “KBE-403”, manufactured by Shin-Etsu Chemical Co., Ltd.) )
- Silica 50 wt% DMF dispersion (5) 100 parts by weight of silica particles having an average particle diameter of 0.3 ⁇ m and a specific surface area of 18 m 2 / g are imidazole silane coupling agents (trade name “IM-1000”, manufactured by Nikko Metals) Dispersion containing 50% by weight of a surface-treated substance surface-treated with 1.0 part by weight and 50% by weight of DMF
- Silica 50 wt% DMF dispersion (6) 100 parts by weight of silica particles having an average particle size of 0.3 ⁇ m and a specific surface area of 18 m 2 / g are aminosilane coupling agents (trade name “KBE-903”, manufactured by Shin-Etsu Chemical Co., Ltd.) Dispersion containing 50% by weight of a surface-treated substance surface-treated with 4.0 parts by weight and 50% by weight of DMF
- Silica 50 wt% DMF dispersion (7) 100 parts by weight of silica particles having an average particle diameter of 0.01 ⁇ m and a specific surface area of 150 m 2 / g are aminosilane coupling agents (trade name “KBE-903”, manufactured by Shin-Etsu Chemical Co., Ltd.) Dispersion containing 50% by weight of a surface-treated substance surface-treated with 1.0 part by weight and 50% by weight of DMF
- Silica 50 wt% DMF dispersion (8) 100 parts by weight of silica particles having an average particle diameter of 4.5 ⁇ m and a specific surface area of 2 m 2 / g are aminosilane coupling agents (trade name “KBE-903”, manufactured by Shin-Etsu Chemical Co., Ltd.) Dispersion containing 50% by weight of a surface-treated substance surface-treated with 1.0 part by weight and 50% by weight of DMF
- Imidazolesilane compound Imidazolesilane (product name “IM-1000”, manufactured by Nikko Metals)
- Example 1 Preparation of Resin Composition 19.71 g of bisphenol A type epoxy resin (1), 0.45 g of accelerator (1), and 39.00 g of silica 50% by weight DMF dispersion (1) N, N -Added to 15.50 g of dimethylformamide, mixed well, and stirred at room temperature until a uniform solution was obtained.
- a substrate having a 75 ⁇ m-interval copper pattern (one copper pattern: 40 ⁇ m long ⁇ 40 ⁇ m wide ⁇ 1 cm thick) formed on the upper surface was prepared.
- a parallel plate type vacuum pressurization type laminator (Meiki Seisakusho) put the laminated film on the substrate so that the resin film in the B stage state is on the substrate side, the conditions of laminating temperature 100 ° C and laminating pressure 0.6MPa And heated and pressed for 1 minute to laminate. Thereafter, the PET film was peeled off and removed.
- the substrate on which the B-stage resin film was laminated was placed in a gear oven so that the main surface of the substrate was located in a plane parallel to the vertical direction. Then, it heated at the curing temperature of 150 degreeC for 1 hour, the B-stage resin film was hardened, the precured body layer was formed on the board
- the cured body layer is formed by performing the following (b) permanganate treatment, that is, roughening treatment, and further curing.
- the body layer was subjected to the following (c) copper plating treatment.
- (B) Permanganate treatment The above laminated sample is put into a roughened aqueous solution of potassium permanganate (Concentrate Compact CP, manufactured by Atotech Japan) at 70 ° C., and the hardened body layer subjected to the roughening treatment is shaken at a roughening temperature of 70 ° C. for 15 minutes. Formed on a substrate. The obtained cured body layer was washed for 2 minutes using a washing solution (Reduction Securigant P, manufactured by Atotech Japan Co., Ltd.) at 25 ° C., and further washed purely.
- a washing solution Reduction Securigant P, manufactured by Atotech Japan Co., Ltd.
- the surface of the cured body layer was treated with an alkali cleaner (cleaner securigant 902) at 60 ° C. for 5 minutes and degreased and washed. After washing, the cured body layer was treated with a 25 ° C. pre-dip solution (Pre-dip Neogant B) for 2 minutes. Thereafter, the cured body layer was treated with an activator solution (activator Neogant 834) at 40 ° C. for 5 minutes to attach a palladium catalyst. Next, the cured body was treated for 5 minutes using a 30 ° C. reducing solution (reducer Neogant WA).
- the cured body layer was placed in a chemical copper solution (basic print Gantt MSK-DK, copper print Gantt MSK, stabilizer print Gantt MSK), and electroless plating was performed until the plating thickness reached about 0.5 ⁇ m.
- a chemical copper solution basic print Gantt MSK-DK, copper print Gantt MSK, stabilizer print Gantt MSK
- electroless plating was performed until the plating thickness reached about 0.5 ⁇ m.
- annealing was performed at a temperature of 120 ° C. for 30 minutes in order to remove the remaining hydrogen gas. All the steps up to the electroless plating step were performed while using a beaker scale with a treatment liquid of 1 L and rocking the cured body.
- electrolytic plating was performed on the cured body layer that had been subjected to electroless plating until the plating thickness reached 20 ⁇ m.
- An electric current of 0.6 A / cm 2 was passed using copper sulfate (reducer Cu) as the electrolytic copper plating.
- the cured body layer was heated at 180 ° C. for 1 hour and cured to obtain a cured body layer on which the copper plating layer was formed. In this way, a printed wiring board as a laminate was obtained.
- Examples 2 to 9, Examples 16, 17 and Comparative Examples 5 to 8 Using the laminated film obtained in Example 1, Example 1 except that the laminating temperature, laminating pressure, curing temperature, swelling temperature or roughening temperature were changed as shown in Tables 1, 2 and 4 below. Similarly, a printed wiring board was produced.
- Examples 10 to 15, 18 to 24 and Comparative Examples 1 to 4 A resin composition was prepared in the same manner as in Example 1 except that the materials used and the blending amounts thereof were as shown in Tables 2 to 4 below. A laminated film was produced and a printed wiring board was produced in the same manner as in Example 1 except that the obtained resin composition was used. When the resin composition contains imidazole silane, the imidazole silane was added together with a curing agent.
- Arithmetic average roughness Ra and ten-point average roughness Rz When obtaining the cured body layer on which the plating layer was formed, a roughened cured body layer before the plating layer was formed was prepared. Arithmetic average roughness Ra and ten-point average roughness of the roughened surface of the cured body in a measurement area of 100 ⁇ m 2 using a non-contact three-dimensional surface shape measuring device (product number “WYKO NT1100”, manufactured by Veeco) Rz was measured.
Abstract
Description
上記樹脂組成物に含まれているエポキシ樹脂は、少なくとも1個のエポキシ基(オキシラン環)を有する有機化合物である。上記エポキシ樹脂の1分子当たりのエポキシ基の数は、1以上である。該エポキシ基の数は、2以上であることが好ましい。
上記樹脂組成物に含まれている上記硬化剤は特に限定されない。上記硬化剤としては、例えば、ジシアンジアミド、アミン化合物、アミン化合物から合成される化合物、ヒドラジド化合物、メラミン化合物、酸無水物、フェノール化合物(フェノール硬化剤)、活性エステル化合物、ベンゾオキサジン化合物、マレイミド化合物、熱潜在性カチオン重合触媒、光潜在性カチオン重合開始剤又はシアネートエステル樹脂等が挙げられる。これらの硬化剤の誘導体を用いてもよい。上記硬化剤は1種のみが用いられてもよく、2種以上が併用されてもよい。
上記ヒドラジド化合物としては、例えば、1,3-ビス(ヒドラジノカルボエチル)-5-イソプロピルヒダントイン、7,11-オクタデカジエン-1,18-ジカルボヒドラジド、エイコサン二酸ジヒドラジド又はアジピン酸ジヒドラジド等が挙げられる。
上記樹脂組成物に含まれている硬化促進剤は特に限定されない。硬化促進剤は、1種のみが用いられてもよく、2種以上が併用されてもよい。
上記樹脂組成物は、無機充填材がシランカップリング剤により表面処理されている表面処理物質を含有する。表面処理物質は1種のみが用いられてもよく、2種以上が併用されてもよい。
上記樹脂組成物は、イミダゾールシラン化合物を含有することが好ましい。イミダゾールシラン化合物の使用により、粗化処理された硬化体の表面の表面粗さをより一層小さくすることができる。
上記樹脂組成物の製造方法は特に限定されない。該樹脂組成物の製造方法としては、例えば上記エポキシ樹脂と、上記硬化剤と、上記硬化促進剤と、上記表面処理物質と、必要に応じて配合される他の成分とを、溶剤に添加した後、乾燥し、溶剤を除去する方法などが挙げられる。
図1に、本発明の一実施形態に係る積層体を得るために用いられる積層フィルムを部分切欠正面断面図で示す。
積層フィルム1は、例えば、単層又は多層のプリント配線板の絶縁層等を形成するのに用いられる。
ビスフェノールA型エポキシ樹脂(1)(商品名「エピコート828」、エポキシ当量189、25℃での粘度12~15Pa・s、JER社製)
ビフェニル型フェノール硬化剤(1)(商品名「MEH7851-4H」、OH当量243、軟化点130℃、明和化成社製)
ナフトール硬化剤(2)(商品名「SN485」、OH当量213、軟化点86℃、東都化成社製)
活性エステル硬化剤(活性エステル化合物、DIC社製、商品名「EPICLON EXB9460S-65T」、固形分65%のトルエン溶液)
促進剤(1)(商品名「2PZ-CN」、1-シアノエチル-2-フェニルイミダゾール、四国化成社製)
シリカ50重量%DMF分散液(1):平均粒子径0.3μm及び比表面積18m2/gのシリカ粒子100重量部がアミノシランカップリング剤(商品名「KBE-903」、信越化学工業社製)1.0重量部により表面処理されている表面処理物質50重量%と、DMF(N,N-ジメチルホルムアミド)50重量%とを含む分散液
DMF:N,N-ジメチルホルムアミド(特級試薬、和光純薬工業社製)
イミダゾールシラン(日鉱金属社製、商品名「IM-1000」)
(1)樹脂組成物の調製
ビスフェノールA型エポキシ樹脂(1)19.71gと、促進剤(1)0.45gと、シリカ50重量%DMF分散液(1)39.00gとを、N,N-ジメチルホルムアミド15.50g中に加え、よく混合し、均一な溶液となるまで常温で攪拌した。
離型処理されたPETフィルム上に、アプリケーターを用いて、乾燥後の厚みが40μmとなるように得られた樹脂組成物を塗工した。次に、100℃のギアオーブン内で1分間乾燥し、半硬化したBステージ状態の樹脂フィルムをPETフィルム上に形成した。このようにして、PETフィルム上に樹脂フィルムが積層されている積層フィルムを作製した。
得られた積層フィルムを用いて、以下のようにして、プリント配線板を作製した。
70℃の膨潤液(スウェリングディップセキュリガントP、アトテックジャパン社製)に上記積層サンプルを入れ、膨潤温度70℃で15分間揺動させた。その後、純水で洗浄した。
70℃の過マンガン酸カリウム(コンセントレートコンパクトCP、アトテックジャパン社製)粗化水溶液に上記積層サンプルを入れて、粗化温度70℃で15分間揺動させ、粗化処理された硬化体層を基板上に形成した。25℃の洗浄液(リダクションセキュリガントP、アトテックジャパン社製)を用いて、得られた硬化体層を2分間洗浄した後、純粋でさらに洗浄した。
次に、基板上に形成された硬化体層に、無電解銅めっき及び電解銅めっき処理を以下の手順で行った。
実施例1で得られた積層フィルムを用いて、ラミネート温度、ラミネート圧力、キュア温度、膨潤温度又は粗化温度を下記の表1,2,4に示すように変更したこと以外は実施例1と同様にして、プリント配線板を作製した。
使用した材料及びその配合量を下記の表2~4に示すようにしたこと以外は実施例1と同様にして、樹脂組成物を調製した。得られた樹脂組成物を用いたこと以外は実施例1と同様にして、積層フィルムを作製し、かつプリント配線板を作製した。なお、樹脂組成物がイミダゾールシランを含有する場合には、該イミダゾールシランは硬化剤とともに添加した。
(1)粗化接着強度
上記銅めっき層が形成された硬化体層の銅めっき層の表面に、10mm幅に切り欠きを入れた。その後、引張試験機(商品名「オートグラフ」、島津製作所社製)を用いて、クロスヘッド速度5mm/分の条件で、銅めっき層と硬化体層との接着強度を測定し、得られた測定値を粗化接着強度とした。
上記めっき層が形成された硬化体層を得る際に、めっき層が形成される前の粗化処理された硬化体層を用意した。非接触3次元表面形状測定装置(品番「WYKO NT1100」、Veeco社製)を用いて、100μm2の測定領域における硬化体の粗化処理された表面の算術平均粗さRa及び十点平均粗さRzを測定した。
2…基材フィルム
2a…上面
3…樹脂フィルム
3A…硬化体層
3a…上面
3b…孔
11…多層プリント配線板
12…基板
12a…上面
13…金属層
Claims (12)
- 基板と、該基板上に積層された硬化体層とを備える積層体であって、
前記硬化体層は、樹脂フィルムを基板上にラミネートした後、前記樹脂フィルムを100~200℃で予備硬化させて予備硬化体層を形成し、該予備硬化体層の表面を55~80℃で粗化処理することにより形成されており、
前記樹脂フィルムは、エポキシ樹脂と、硬化剤と、硬化促進剤と、平均粒子径0.05~1.5μmの無機充填材100重量部がシランカップリング剤0.5~3.5重量部により表面処理されている表面処理物質とを含有し、かつ前記エポキシ樹脂、前記硬化剤、前記硬化促進剤及び前記表面処理物質の合計100重量%中の前記表面処理物質の含有量が10~80重量%の範囲内である樹脂組成物により形成されており、
前記シランカップリング剤が、前記エポキシ樹脂又は前記硬化剤と反応しうる官能基を有し、該官能基がエポキシ基、イミダゾール基又はアミノ基である、積層体。 - 前記硬化剤が、ビフェニル構造を有するフェノール化合物、ナフタレン構造を有するフェノール化合物、ジシクロペンタジエン構造を有するフェノール化合物、アミノトリアジン構造を有するフェノール化合物、活性エステル化合物及びシアネートエステル樹脂からなる群から選択された少なくとも1種である、請求項1に記載の積層体。
- 前記樹脂組成物におけるイミダゾールシラン化合物の含有量が、前記エポキシ樹脂及び前記硬化剤の合計100重量部に対して、0.01~3重量部の範囲内である、請求項1又は2に記載の積層体。
- 粗化処理された前記硬化体層の表面の算術平均粗さRaが300nm以下であり、かつ十点平均粗さRzが3μm以下である、請求項1~3のいずれか1項に記載の積層体。
- 前記予備硬化の後、かつ前記粗化処理の前に、前記予備硬化体層が50~80℃で膨潤処理されている、請求項1~4のいずれか1項に記載の積層体。
- 基板と、該基板上に積層された硬化体層とを備える積層体の製造方法であって、
前記硬化体層を形成するための樹脂フィルムを前記基板上にラミネートする工程と、
前記基板上にラミネートされた前記樹脂フィルムを100~200℃で予備硬化させて予備硬化体層を形成する工程と、
前記予備硬化体層の表面を55~80℃で粗化処理し、粗化処理された硬化体層を形成する工程とを備え、
前記樹脂フィルムとして、エポキシ樹脂と、硬化剤と、硬化促進剤と、平均粒子径0.05~1.5μmの無機充填材100重量部がシランカップリング剤0.5~3.5重量部により表面処理されている表面処理物質とを含有し、かつ前記エポキシ樹脂、前記硬化剤、前記硬化促進剤及び前記表面処理物質の合計100重量%中の前記表面処理物質の含有量が10~80重量%の範囲内である樹脂組成物により形成された樹脂フィルムを用いて、
前記シランカップリング剤として、前記エポキシ樹脂又は前記硬化剤と反応しうる官能基を有し、該官能基がエポキシ基、イミダゾール基又はアミノ基であるシランカップリング剤を用いる、積層体の製造方法。 - 前記硬化剤として、ビフェニル構造を有するフェノール化合物、ナフタレン構造を有するフェノール化合物、ジシクロペンタジエン構造を有するフェノール化合物、アミノトリアジン構造を有するフェノール化合物、活性エステル化合物及びシアネートエステル樹脂からなる群から選択された少なくとも1種を用いる、請求項6に記載の積層体の製造方法。
- 前記樹脂組成物として、前記エポキシ樹脂及び前記硬化剤の合計100重量部に対して、イミダゾールシラン化合物の含有量が0.01~3重量部の範囲内である樹脂組成物を用いる、請求項6又は7に記載の積層体の製造方法。
- 前記粗化処理の工程における粗化処理の時間が、5~30分間である、請求項6~8のいずれか1項に記載の積層体の製造方法。
- 前記予備硬化の工程の後、かつ前記粗化処理の工程の前に、
前記予備硬化体層の表面を50~80℃で膨潤処理する工程をさらに備える、請求項6~9のいずれか1項に記載の積層体の製造方法。 - 前記膨潤処理の工程における膨潤処理の時間が、5~30分間である、請求項10に記載の積層体の製造方法。
- 前記ラミネートの工程におけるラミネート温度が70~130℃であり、かつラミネート圧力が0.1~2.0MPaである、請求項6~11のいずれか1項に記載の積層体の製造方法。
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CN102137758A (zh) | 2011-07-27 |
TW201012652A (en) | 2010-04-01 |
JPWO2010024391A1 (ja) | 2012-01-26 |
JP4911795B2 (ja) | 2012-04-04 |
KR101148225B1 (ko) | 2012-05-21 |
KR20110055587A (ko) | 2011-05-25 |
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