WO2013094606A1 - ドライフィルム及びそれを用いたプリント配線板、プリント配線板の製造方法、及びフリップチップ実装基板 - Google Patents
ドライフィルム及びそれを用いたプリント配線板、プリント配線板の製造方法、及びフリップチップ実装基板 Download PDFInfo
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- WO2013094606A1 WO2013094606A1 PCT/JP2012/082797 JP2012082797W WO2013094606A1 WO 2013094606 A1 WO2013094606 A1 WO 2013094606A1 JP 2012082797 W JP2012082797 W JP 2012082797W WO 2013094606 A1 WO2013094606 A1 WO 2013094606A1
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- WIPO (PCT)
- Prior art keywords
- resin composition
- composition layer
- wiring board
- printed wiring
- photocurable resin
- Prior art date
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- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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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
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0313—Organic insulating material
- H05K1/0353—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B32B27/16—Layered products comprising a layer of synthetic resin specially treated, e.g. irradiated
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
- G03F7/40—Treatment after imagewise removal, e.g. baking
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- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
- H01L21/56—Encapsulations, e.g. encapsulation layers, coatings
- H01L21/563—Encapsulation of active face of flip-chip device, e.g. underfilling or underencapsulation of flip-chip, encapsulation preform on chip or mounting substrate
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- H—ELECTRICITY
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/48—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
- H01L23/488—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of soldered or bonded constructions
- H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
- H01L23/49811—Additional leads joined to the metallisation on the insulating substrate, e.g. pins, bumps, wires, flat leads
- H01L23/49816—Spherical bumps on the substrate for external connection, e.g. ball grid arrays [BGA]
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/48—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
- H01L23/488—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of soldered or bonded constructions
- H01L23/498—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers
- H01L23/49866—Leads, i.e. metallisations or lead-frames on insulating substrates, e.g. chip carriers characterised by the materials
- H01L23/49894—Materials of the insulating layers or coatings
-
- 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
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0313—Organic insulating material
- H05K1/0353—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
- H05K1/036—Multilayers with layers of different types
-
- 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
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0313—Organic insulating material
- H05K1/0353—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
- H05K1/0373—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement containing additives, e.g. fillers
-
- 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
- H05K3/0073—Masks not provided for in groups H05K3/02 - H05K3/46, e.g. for photomechanical production of patterned surfaces
- H05K3/0082—Masks not provided for in groups H05K3/02 - H05K3/46, e.g. for photomechanical production of patterned surfaces characterised by the exposure method of radiation-sensitive masks
-
- 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
- H05K3/22—Secondary treatment of printed circuits
- H05K3/28—Applying non-metallic protective coatings
- H05K3/281—Applying non-metallic protective coatings by means of a preformed insulating foil
-
- 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
- H05K3/4611—Manufacturing multilayer circuits by laminating two or more circuit boards
-
- 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
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/102—Oxide or hydroxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
- B32B2307/202—Conductive
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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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
- B32B2307/206—Insulating
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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
- B32B2457/00—Electrical equipment
- B32B2457/08—PCBs, i.e. printed circuit boards
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/73—Means for bonding being of different types provided for in two or more of groups H01L2224/10, H01L2224/18, H01L2224/26, H01L2224/34, H01L2224/42, H01L2224/50, H01L2224/63, H01L2224/71
- H01L2224/732—Location after the connecting process
- H01L2224/73201—Location after the connecting process on the same surface
- H01L2224/73203—Bump and layer connectors
- H01L2224/73204—Bump and layer connectors the bump connector being embedded into the layer connector
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/91—Methods for connecting semiconductor or solid state bodies including different methods provided for in two or more of groups H01L2224/80 - H01L2224/90
- H01L2224/92—Specific sequence of method steps
- H01L2224/921—Connecting a surface with connectors of different types
- H01L2224/9212—Sequential connecting processes
- H01L2224/92122—Sequential connecting processes the first connecting process involving a bump connector
- H01L2224/92125—Sequential connecting processes the first connecting process involving a bump connector the second connecting process involving a layer connector
-
- 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
- H05K2201/01—Dielectrics
- H05K2201/0183—Dielectric layers
- H05K2201/0195—Dielectric or adhesive layers comprising a plurality of layers, e.g. in a multilayer structure
-
- 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
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10613—Details of electrical connections of non-printed components, e.g. special leads
- H05K2201/10621—Components characterised by their electrical contacts
- H05K2201/10674—Flip chip
-
- 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
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10613—Details of electrical connections of non-printed components, e.g. special leads
- H05K2201/10954—Other details of electrical connections
- H05K2201/10977—Encapsulated connections
-
- 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
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
- H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
- H05K3/341—Surface mounted components
- H05K3/3431—Leadless components
- H05K3/3436—Leadless components having an array of bottom contacts, e.g. pad grid array or ball grid array components
-
- 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.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/2495—Thickness [relative or absolute]
- Y10T428/24967—Absolute thicknesses specified
- Y10T428/24975—No layer or component greater than 5 mils thick
-
- 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
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31511—Of epoxy ether
- Y10T428/31515—As intermediate layer
Definitions
- the present invention relates to a dry film and a printed wiring board using the same, and more particularly to a dry film capable of forming a cured film excellent in laser processability and desmear resistance and a printed wiring board using the dry film.
- the present invention also relates to a method for manufacturing a printed wiring board, a printed wiring board obtained by the manufacturing method, and a flip chip mounting substrate, and more specifically, a print capable of easily forming a dam that prevents the underfill from spreading.
- the present invention relates to a method of manufacturing a wiring board, a printed wiring board manufactured by the method, and a flip-chip mounting substrate in which a chip is flip-chip mounted on the printed wiring board.
- solder resist layer is formed in a region excluding connection holes on the substrate on which the circuit pattern is formed.
- solder resists there are two types of solder resists, which are mainly used, that are formed using a photo-curable resin composition and those that are formed using a thermosetting resin composition.
- a photocurable resin composition a portion irradiated with light is cured, and other uncured portions are removed with a dilute alkali solution or an organic solvent, thereby forming a fine solder resist pattern.
- solder resist pattern formation using a thermosetting resin composition and fabrication of a via hole for mounting are generally performed by laser light irradiation.
- a carbon dioxide gas laser, a UV-YAG laser, an excimer laser, or the like is used.
- a wet method is generally used in which a smear is decomposed and removed by a permanganate solution after swelling with a concentrated alkaline solution.
- flip chip mounting has been adopted as a connection form between a chip and a printed wiring board, which enables higher-density mounting and lower height of a semiconductor package than wire bonding.
- a method for joining electrodes using solder balls is widely known.
- the bonding using the solder ball is performed by placing the solder ball on one of the electrodes of the wiring board or chip, aligning with the other connection electrode, and then reflowing.
- Connection reliability is improved by pouring underfill (sealing resin) into the gap and curing it.
- the underfill is filled so as to overflow slightly from the gap between the chip and the substrate so as to form a mountain skirt that spreads with the chip as the top for reinforcing the connection portion.
- the underfill has a property of easily spreading on the solder resist because it is designed to have high fluidity in order to reliably fill the gap between the chip and the substrate.
- the spread of the underfill is prevented so that the overflowed underfill reaches them and does not adversely affect the electrical operation. There was a need.
- Patent Document 2 proposes forming a step by scraping a solder resist near the outside of the outer edge of the chip with an NC milling cutter or the like, but it is insufficient for forming a high-definition dam. Was the way.
- Patent Document 2 also proposes a method of providing a groove around the chip by removing the uncured portion of the photocurable resist, but when the amount of underfill reaching the groove is insufficient, There was a problem that the conductor pattern located in the dam groove was unnecessarily exposed. Further, Patent Document 2 proposes a method of forming a protrusion (projection piece) by applying a resist on a solder resist layer by silk printing or the like. It was difficult to form a rough protrusion. In addition, it is described that alkali-developing or UV-curable resist can be used for such protrusions. However, specific aspects and implementations such as advantages, solder resist layer composition, patterning method, etc. are described. There is no description of an example, and no concrete implementation method has been proposed.
- Patent Document 3 a method of forming a protrusion by printing ink on a solder resist has also been proposed (for example, Patent Document 3).
- an object of the present invention is to provide a dry film capable of forming a cured film excellent in laser processability and desmear resistance and a printed wiring board using the dry film.
- Patent Document 3 proposes a method of forming a groove by laser processing using a carbon dioxide laser, but the processing time increases in proportion to the processing area, and is suitable for forming a wide range of grooves. It wasn't.
- an object of the present invention is to provide a method for manufacturing a printed wiring board for a flip-chip mounting substrate, in which a dam for preventing the spread of underfill can be easily formed, a printed wiring board manufactured by the method, and the printed wiring board.
- An object of the present invention is to provide a flip chip mounting substrate on which a chip is flip chip mounted.
- the present inventors have found that the above problems can be solved by making a dry film comprising a photocurable resin composition layer and a thermosetting resin composition layer.
- the present invention has been completed. Furthermore, by using together the patterning by a photolithographic method and the patterning by laser processing with respect to the resin insulating layer which has a thermosetting resin composition layer and a photocurable resin composition layer in an order from the substrate surface side. The present inventors have found that the above problems can be solved, and have completed the present invention.
- the dry film of the present invention includes a carrier film and a photocurable resin composition layer (L1) formed by applying and drying a photocurable resin composition, and the photocurable resin composition layer (L1). ) And the carrier film, at least a thermosetting resin composition layer (L2) formed by applying and drying the thermosetting resin composition is provided.
- another dry film of the present invention includes a carrier film and a thermosetting resin composition layer (L2), and is photocured between the thermosetting resin composition layer (L2) and the carrier film.
- the resin composition layer (L1) is provided at least.
- the photocurable resin composition layer (L1) has a thickness of 1 to 20 ⁇ m
- the thermosetting resin composition layer (L2) has a thickness of 1 to 100 ⁇ m. preferable.
- the content of the inorganic filler in the photocurable resin composition layer (L1) is 0 to 40 wt% based on the total solid content of the photocurable resin composition forming L1. It is preferable that
- thermosetting resin composition layer (L2) contains (A) an epoxy resin, (B) an epoxy curing agent, and (C) an inorganic filler. It is preferable that a product is applied and dried.
- thermosetting resin composition layer (L2) further includes (D) a thermoplastic resin.
- the dry film of the present invention preferably has a weight average molecular weight (Mw) of the thermoplastic resin (D) of 5000 or more.
- the photocurable resin composition layer (L1) is a light containing (E) a carboxyl group-containing resin, (F) a photopolymerization initiator, and (G) a photosensitive monomer. It is preferable that the curable resin composition is applied and dried.
- the printed wiring board of the present invention is a printed wiring board provided with a cured film obtained by using any one of the above dry films on a substrate on which a circuit pattern is formed, and a photocurable resin composition layer on the surface layer side (L1) is cured, and the thermosetting resin composition layer (L2) is cured between the substrate and the cured film derived from the photocurable resin composition layer (L1). It is characterized by having at least a cured film.
- the method for producing a printed wiring board according to the present invention includes a resin insulating layer having a thermosetting resin composition layer (L2) and a photocurable resin composition layer (L1) in order from the substrate surface side on the surface of the substrate.
- the recess formed in the patterning process by the photolithography method is a dam.
- the dam is preferably formed in at least one of a groove shape and a projecting shape.
- the resin insulating layer is formed by laminating a dry film in which a photocurable resin composition layer and a thermosetting resin composition layer are laminated on a film on the substrate. It is preferable that it is formed by this.
- the resin insulating layer is formed by directly applying and drying a thermosetting resin composition and a photocurable resin composition on the substrate in order. Preferably there is.
- the photocurable resin composition layer is patterned by the step of patterning by the photolithography method, and the thermosetting resin composition layer is formed by the step of patterning by the laser processing. Is preferably patterned.
- the printed wiring board of the present invention is manufactured by the method for manufacturing a printed wiring board.
- the flip chip mounting substrate of the present invention is characterized in that a chip is flip chip mounted on the printed wiring board.
- a dry film capable of forming a cured film excellent in laser processability and desmear resistance and a printed wiring board using the dry film.
- a printed wiring board manufacturing method capable of easily forming a dam that prevents the spread of underfill, a printed wiring board manufactured by the method, and a flip in which a chip is flip-chip mounted on the printed wiring board It is possible to provide a chip mounting substrate.
- the dry film of the present invention comprises a carrier film, a photocurable resin composition layer (L1) formed by applying and drying a photocurable resin composition, and a heat formed by applying and drying a thermosetting resin composition. It comprises at least a curable resin composition layer (L2).
- the curable resin composition layers may be laminated in the order of the carrier film, L2, and L1, and the curable resin composition layers may be laminated in the order of the carrier film, L1, and L2. In any of the embodiments, it is used by laminating on the substrate so that L1 is located on the surface layer and L2 is located on the substrate side.
- solder resist having excellent desmear resistance can be obtained. Moreover, it can be set as the soldering resist excellent in the electrical property by providing the cured film derived from a thermosetting resin composition layer (L2) between L1 and a board
- the resin composition in the dry film of the present invention can be used.
- Two or more physical layers may be used. That is, when it is laminated in the order of the carrier film, L2, L1, it may have a layer other than L2 between the carrier film and L1, and it is laminated in the order of the carrier film, L1, L2. If present, another resin composition layer may be provided between L1 and L2 or on L2.
- a plastic film As the carrier film, a plastic film is used, and a plastic film such as a polyester film such as polyethylene terephthalate, a polyimide film, a polyamideimide film, a polypropylene film, or a polystyrene film is preferably used.
- the thickness of the carrier film is not particularly limited, but is generally appropriately selected within the range of 10 to 150 ⁇ m.
- the dry film of the present invention is preferably laminated with a peelable cover film on the surface of the curable resin composition layer for the purpose of preventing dust from adhering to the surface of the curable resin composition layer.
- a peelable cover film for example, a polyethylene film, a polytetrafluoroethylene film, a polypropylene film, a surface-treated paper or the like can be used, and when the cover film is peeled off, the curable resin composition layer and the carrier film Any adhesive strength may be used as long as the adhesive strength between the curable resin composition layer and the cover film is smaller than the adhesive strength.
- the method for producing the dry film of the present invention will be described by taking a dry film laminated in the order of carrier film, L1, L2 as an example.
- the photocurable resin composition for forming L1 is diluted with an organic solvent and adjusted to an appropriate viscosity.
- a film is obtained by applying a uniform thickness on a carrier film with a transfer roll coater, gravure coater, spray coater or the like, and drying usually at a temperature of 50 to 130 ° C. for 1 to 30 minutes.
- the thermosetting resin composition for forming L2 is similarly diluted, applied, and dried to obtain a film.
- each layer of L1 and L2 is not particularly limited, but is preferably the thickness after drying, and the thickness of the photocurable resin composition layer (L1) is 1 to 20 ⁇ m.
- the film thickness of the conductive resin composition layer (L2) is 1 to 100 ⁇ m.
- the dry film of the present invention can be used in the same manner as a known dry film. That is, the resin insulating layer can be formed by laminating the substrates so that L1 is positioned on the surface layer.
- the substrate examples include printed circuit boards and flexible printed circuit boards in which circuits are formed in advance, paper phenol, paper epoxy, glass cloth epoxy, glass polyimide, glass cloth / non-woven cloth epoxy, glass cloth / paper epoxy, synthetic fiber epoxy. , Copper-clad laminates of all grades (FR-4 etc.) and other polyimide films using materials such as copper-clad laminates for high-frequency circuits using fluorine, polyethylene, polyphenylene ether, polyphenylene oxide, cyanate esters, etc. , PET film, glass substrate, ceramic substrate, wafer plate and the like.
- the curable resin composition layer used for forming the cured film of the printed wiring board of the present invention is formed by the curable resin composition layer constituting the dry film of the present invention.
- the curable resin composition layer can also be formed by directly applying and drying the curable resin composition on the substrate by an appropriate method such as a blade coater, a lip coater, a comma coater, or a film coater.
- a thermosetting resin composition layer is formed by directly applying and drying a thermosetting resin composition on a substrate, and a dry film is laminated on the thermosetting resin composition layer so as to be photocurable.
- a resin composition layer may be formed.
- a thermosetting resin composition layer is formed by laminating a dry film on a substrate, and the photocurable resin composition is directly applied on the thermosetting resin composition layer and dried to be photocured.
- a functional resin composition layer may be formed.
- the L1 is a photocurable resin composition layer formed by applying and drying a photocurable resin composition.
- the layer is cured by light after the dry film of the present invention is bonded to the substrate. After curing, pattern formation can be performed by laser processing.
- the content of the inorganic filler described later is preferably 0 to 40 wt%, more preferably 0 to 30 wt%, based on the total solid content of the thermosetting resin composition forming L1. . By containing an inorganic filler in this range, good desmear resistance is expressed.
- the photocurable resin composition constituting L1 preferably contains (E) a carboxyl group-containing resin, (F) a photopolymerization initiator, and (G) a photosensitive monomer.
- carboxyl group-containing resin various conventionally known carboxyl group-containing resins having a carboxyl group in the molecule can be used.
- a carboxyl group-containing photosensitive resin having an ethylenically unsaturated double bond in the molecule is preferable from the viewpoint of photocurability and development resistance.
- the ethylenically unsaturated double bond is preferably derived from acrylic acid or methacrylic acid or a derivative thereof.
- Specific examples of the carboxyl group-containing resin include the following compounds (any of oligomers and polymers).
- a carboxyl group-containing resin obtained by copolymerization of an unsaturated carboxylic acid such as (meth) acrylic acid and an unsaturated group-containing compound such as styrene, ⁇ -methylstyrene, lower alkyl (meth) acrylate, and isobutylene.
- Diisocyanates such as aliphatic diisocyanates, branched aliphatic diisocyanates, alicyclic diisocyanates, and aromatic diisocyanates; carboxyl group-containing dialcohol compounds such as dimethylolpropionic acid and dimethylolbutanoic acid, polycarbonate polyols, and polyethers
- carboxyl group-containing urethane resin by a polyaddition reaction of a diol compound such as a polyol, a polyester-based polyol, a polyolefin-based polyol, an acrylic polyol, a bisphenol A-based alkylene oxide adduct diol, a compound having a phenolic hydroxyl group and an alcoholic hydroxyl group.
- Diisocyanate and bifunctional epoxy resin such as bisphenol A type epoxy resin, hydrogenated bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, bixylenol type epoxy resin, biphenol type epoxy resin ( A carboxyl group-containing photosensitive urethane resin obtained by a polyaddition reaction of (meth) acrylate or a partially acid anhydride-modified product thereof, a carboxyl group-containing dialcohol compound, and a diol compound.
- bisphenol A type epoxy resin hydrogenated bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, bixylenol type epoxy resin, biphenol type epoxy resin ( A carboxyl group-containing photosensitive urethane resin obtained by a polyaddition reaction of (meth) acrylate or a partially acid anhydride-modified product thereof, a carboxyl group-containing dialcohol compound, and a diol compound.
- one isocyanate group and one or more (meth) acryloyl groups are added in the molecule, such as an equimolar reaction product of isophorone diisocyanate and pentaerythritol triacrylate.
- a carboxyl group-containing photosensitive urethane resin obtained by adding a compound having a terminal (meth) acrylate.
- a polyfunctional epoxy resin obtained by epoxidizing a hydroxyl group of a bifunctional (solid) epoxy resin as described later with epichlorohydrin is reacted with (meth) acrylic acid, and a dibasic acid anhydride is added to the resulting hydroxyl group.
- a dicarboxylic acid such as adipic acid, phthalic acid or hexahydrophthalic acid is reacted with a bifunctional oxetane resin as described later, and the resulting primary hydroxyl group is phthalic anhydride, tetrahydrophthalic anhydride or hexahydrophthalic anhydride.
- a carboxyl group-containing polyester resin to which a dibasic acid anhydride such as
- Reaction product obtained by reacting a compound obtained by reacting a compound having a plurality of phenolic hydroxyl groups in one molecule with an alkylene oxide such as ethylene oxide or propylene oxide with an unsaturated group-containing monocarboxylic acid.
- a carboxyl group-containing photosensitive resin obtained by reacting a product with a polybasic acid anhydride.
- a carboxyl group-containing photosensitive resin obtained by adding a compound having one epoxy group and one or more (meth) acryloyl groups in one molecule to the resins (1) to (10).
- (meth) acrylate is a term that collectively refers to acrylate, methacrylate, and mixtures thereof, and the same applies to other similar expressions.
- the acid value of the carboxyl group-containing resin is suitably in the range of 40 to 200 mgKOH / g, more preferably in the range of 45 to 120 mgKOH / g.
- the acid value of the carboxyl group-containing resin is less than 40 mgKOH / g, alkali development becomes difficult.
- the acid value exceeds 200 mgKOH / g, dissolution of the exposed area by the developer proceeds and the line becomes thinner than necessary.
- the exposed portion and the unexposed portion are not distinguished from each other by dissolution and peeling with a developer, which makes it difficult to draw a normal resist pattern.
- the weight average molecular weight of the carboxyl group-containing resin varies depending on the resin skeleton, but is generally in the range of 2,000 to 150,000, more preferably 5,000 to 100,000.
- the weight average molecular weight is less than 2,000, tack-free performance may be inferior, the moisture resistance of the coated film after exposure may be poor, film thickness may be reduced during development, and resolution may be greatly inferior.
- the weight average molecular weight exceeds 150,000, developability may be remarkably deteriorated, and storage stability may be inferior.
- the blending amount of such a carboxyl group-containing resin is 20 to 60% by mass, preferably 30 to 50% by mass in the photopolymerizable resin composition.
- the amount of the carboxyl group-containing resin is less than the above range, the coating strength is lowered, which is not preferable.
- the amount is larger than the above range, the viscosity of the photopolymerizable resin composition is increased, and the applicability to a carrier film and the like are not preferable.
- carboxyl group-containing resins are not limited to those listed above, and one kind may be used alone, or a plurality of kinds may be mixed and used.
- resins having an aromatic ring are preferable because they have a high refractive index and excellent resolution, and those having a novolak structure not only have resolution but also PCT and It is preferable because of excellent crack resistance.
- carboxyl group-containing resins synthesized using a phenol compound as a starting material such as the carboxyl group-containing resins (9) and (10), are excellent in HAST resistance and PCT resistance, and can be suitably used.
- photopolymerization initiator one or more light selected from the group consisting of an oxime ester photopolymerization initiator having an oxime ester group, an ⁇ -aminoacetophenone photopolymerization initiator, and an acylphosphine oxide photopolymerization initiator.
- a polymerization initiator can be preferably used.
- the oxime ester-based initiator can be used in a small amount and the outgassing can be suppressed, which is advantageous in terms of PCT resistance and crack resistance.
- oxime ester photopolymerization initiator examples include CGI-325, Irgacure OXE01, Irgacure OXE02 manufactured by BASF Japan, N-1919, NCI-831 manufactured by Adeka, and the like as commercially available products.
- numerator can also be used suitably, Specifically, the oxime ester compound which has a carbazole structure represented with the following general formula is mentioned.
- X is a hydrogen atom, an alkyl group having 1 to 17 carbon atoms, an alkoxy group having 1 to 8 carbon atoms, a phenyl group, a phenyl group (an alkyl group having 1 to 17 carbon atoms, an alkoxy group having 1 to 8 carbon atoms).
- Y and Z are each a hydrogen atom, an alkyl group having 1 to 17 carbon atoms, or a carbon atom having 1 carbon atom), substituted with an alkyl group having a C 1-8 alkyl group or a dialkylamino group.
- X and Y are each a methyl group or an ethyl group
- Z is methyl or phenyl
- n is 0, and Ar is a bond, phenylene, naphthylene, thiophene or thienylene. It is preferable.
- the compound which can be represented by the following general formula can also be mentioned as a preferable carbazole oxime ester compound.
- R 1 represents an alkyl group having 1 to 4 carbon atoms, or a phenyl group optionally substituted with a nitro group, a halogen atom, or an alkyl group having 1 to 4 carbon atoms).
- R 2 represents an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, or a phenyl group optionally substituted with an alkyl group having 1 to 4 carbon atoms or an alkoxy group.
- R 3 may be linked with an oxygen atom or a sulfur atom, and may be substituted with an alkyl group having 1 to 20 carbon atoms or an alkoxy group having 1 to 4 carbon atoms which may be substituted with a phenyl group.
- R 4 represents a nitro group or an acyl group represented by X—C ( ⁇ O) —.
- X represents an aryl group, a thienyl group, a morpholino group, a thiophenyl group, or a structure represented by the following formula, which may be substituted with an alkyl group having 1 to 4 carbon atoms.
- the blending amount of such an oxime ester photopolymerization initiator is preferably 0.01 to 5 parts by mass with respect to 100 parts by mass of the carboxyl group-containing resin.
- it is less than 0.01 parts by mass, the photocurability on copper is insufficient, the coating film is peeled off, and the coating properties such as chemical resistance are deteriorated.
- it exceeds 5 parts by mass light absorption on the surface of the solder resist coating film becomes violent, and the deep curability tends to decrease. More preferably, it is 0.5 to 3 parts by mass.
- ⁇ -aminoacetophenone photopolymerization initiators include 2-methyl-1- [4- (methylthio) phenyl] -2-morpholinopropanone-1, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butan-1-one, 2- (dimethylamino) -2-[(4-methylphenyl) methyl] -1- [4- (4-morpholinyl) phenyl] -1-butanone, N , N-dimethylaminoacetophenone and the like.
- Examples of commercially available products include Irgacure 907, Irgacure 369, and Irgacure 379 manufactured by BASF Japan.
- acylphosphine oxide photopolymerization initiator examples include 2,4,6-trimethylbenzoyldiphenylphosphine oxide, bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide, and bis (2,6-dimethoxy). And benzoyl) -2,4,4-trimethyl-pentylphosphine oxide. Examples of commercially available products include Lucilin TPO and Irgacure 819 manufactured by BASF Japan.
- the blending amount of these ⁇ -aminoacetophenone photopolymerization initiator and acylphosphine oxide photopolymerization initiator is 0.01 to 15 parts by mass with respect to 100 parts by mass of the (E) carboxyl group-containing resin. preferable. If it is less than 0.01 parts by mass, the photo-curability on copper is similarly insufficient, the coating film peels off, and the coating properties such as chemical resistance deteriorate. On the other hand, when the amount exceeds 15 parts by mass, the effect of reducing the outgas cannot be obtained, the light absorption on the surface of the coating film becomes intense, and the deep curability tends to decrease. More preferably, it is 0.5 to 10 parts by mass.
- Irgacure 389 manufactured by BASF Japan can be suitably used as a photopolymerization initiator.
- a preferred blending amount of Irgacure 389 is 0.1 to 20 parts by mass, and more preferably 1 to 15 parts by mass with respect to 100 parts by mass of the carboxyl group-containing resin.
- a photoinitiator assistant and a sensitizer can be used in addition to the photopolymerization initiator.
- Photoinitiators and sensitizers that can be suitably used in the photopolymerizable resin composition include benzoin compounds, acetophenone compounds, anthraquinone compounds, thioxanthone compounds, ketal compounds, benzophenone compounds, tertiary amine compounds, and xanthone compounds. And so on.
- benzoin compound examples include benzoin, benzoin methyl ether, benzoin ethyl ether, and benzoin isopropyl ether.
- acetophenone compound examples include acetophenone, 2,2-dimethoxy-2-phenylacetophenone, 2,2-diethoxy-2-phenylacetophenone, 1,1-dichloroacetophenone, and the like.
- anthraquinone compound examples include 2-methylanthraquinone, 2-ethylanthraquinone, 2-t-butylanthraquinone, 1-chloroanthraquinone and the like.
- thioxanthone compound examples include 2,4-dimethylthioxanthone, 2,4-diethylthioxanthone, 2-chlorothioxanthone, 2,4-diisopropylthioxanthone, and the like.
- ketal compound examples include acetophenone dimethyl ketal and benzyl dimethyl ketal.
- benzophenone compound examples include benzophenone, 4-benzoyldiphenyl sulfide, 4-benzoyl-4′-methyldiphenyl sulfide, 4-benzoyl-4′-ethyldiphenyl sulfide, and 4-benzoyl-4′-propyldiphenyl. And sulfides.
- the tertiary amine compound include an ethanolamine compound and a compound having a dialkylaminobenzene structure, such as 4,4′-dimethylaminobenzophenone (Nisso Cure MABP manufactured by Nippon Soda Co., Ltd.), Dialkylaminobenzophenone such as 4,4′-diethylaminobenzophenone (EAB manufactured by Hodogaya Chemical Co., Ltd.), 7- (diethylamino) -4-methyl-2H-1-benzopyran-2-one (7- (diethylamino) -4- Dialkylamino group-containing coumarin compounds such as methylcoumarin), ethyl 4-dimethylaminobenzoate (Kayacure EPA manufactured by Nippon Kayaku Co., Ltd.), ethyl 2-dimethylaminobenzoate (Quantacure DMB manufactured by International Bio-Synthetics) , -Dimethylaminobenz
- Kayacure DMBI 4-dimethylaminobenzoic acid
- 2-ethylhexyl acid (Esolol 507 manufactured by Van Dyk), 4,4'-diethylaminobenzophenone (EAB manufactured by Hodogaya Chemical Co., Ltd.), and the like.
- thioxanthone compounds and tertiary amine compounds are preferred.
- the inclusion of a thioxanthone compound is preferable from the viewpoint of deep curability.
- thioxanthone compounds such as 2,4-dimethylthioxanthone, 2,4-diethylthioxanthone, 2-chlorothioxanthone, and 2,4-diisopropylthioxanthone are preferably included.
- the compounding amount of such a thioxanthone compound is preferably 20 parts by mass or less with respect to 100 parts by mass of the (E) carboxyl group-containing resin.
- the blending amount of the thioxanthone compound exceeds 20 parts by mass, the thick film curability is lowered and the cost of the product is increased. More preferably, it is 10 parts by mass or less.
- a compound having a dialkylaminobenzene structure is preferable, and among them, a dialkylaminobenzophenone compound, a dialkylamino group-containing coumarin compound having a maximum absorption wavelength in the range of 350 to 450 nm, and ketocoumarins are particularly preferable. .
- dialkylaminobenzophenone compound 4,4′-diethylaminobenzophenone is preferable because of its low toxicity.
- Dialkylamino group-containing coumarin compounds have a maximum absorption wavelength of 350 to 410 nm in the ultraviolet region, so they are less colored and use colored pigments as well as colorless and transparent photocurable resin compositions to reflect the color of the colored pigments themselves. It is possible to provide a colored solder resist film.
- 7- (diethylamino) -4-methyl-2H-1-benzopyran-2-one is preferred because it exhibits an excellent sensitizing effect on laser light having a wavelength of 400 to 410 nm.
- the compounding amount of such a tertiary amine compound is preferably 0.1 to 20 parts by mass with respect to 100 parts by mass of the (E) carboxyl group-containing resin.
- the amount of the tertiary amine compound is less than 0.1 parts by mass, a sufficient sensitizing effect tends not to be obtained.
- the amount exceeds 20 parts by mass light absorption on the surface of the dry solder resist coating film by the tertiary amine compound becomes intense, and the deep curability tends to decrease. More preferably, it is 0.1 to 10 parts by mass.
- photopolymerization initiators can be used alone or as a mixture of two or more.
- the total amount of such photopolymerization initiator, photoinitiator assistant, and sensitizer is preferably 35 parts by mass or less with respect to 100 parts by mass of the (E) carboxyl group-containing resin. When it exceeds 35 parts by mass, the deep curability tends to decrease due to light absorption.
- the photosensitive monomer is a compound having one or more ethylenically unsaturated groups in the molecule.
- the photosensitive monomer assists photocuring of the carboxyl group-containing resin by irradiation with active energy rays.
- Examples of the compound used as the photosensitive monomer include conventionally known polyester (meth) acrylate, polyether (meth) acrylate, urethane (meth) acrylate, carbonate (meth) acrylate, epoxy (meth) acrylate, and the like. .
- hydroxyalkyl acrylates such as 2-hydroxyethyl acrylate and 2-hydroxypropyl acrylate; diacrylates of glycols such as ethylene glycol, methoxytetraethylene glycol, polyethylene glycol, and propylene glycol; N, N-dimethylacrylamide Acrylamides such as N-methylol acrylamide and N, N-dimethylaminopropyl acrylamide; aminoalkyl acrylates such as N, N-dimethylaminoethyl acrylate and N, N-dimethylaminopropyl acrylate; hexanediol, trimethylolpropane, Polyhydric alcohols such as pentaerythritol, dipentaerythritol, tris-hydroxyethyl isocyanurate or the like; Multivalent acrylates such as a peroxide adduct, a propylene oxide adduct, or an ⁇ -caprolactone ad
- an epoxy acrylate resin obtained by reacting acrylic acid with a polyfunctional epoxy resin such as a cresol novolac type epoxy resin, and further, a hydroxy acrylate such as pentaerythritol triacrylate and a diisocyanate such as isophorone diisocyanate on the hydroxyl group of the epoxy acrylate resin.
- An epoxy urethane acrylate compound obtained by reacting a half urethane compound may be used as a photosensitive monomer.
- Such an epoxy acrylate resin can improve photocurability without deteriorating the touch drying property.
- the compounding amount of the compound having an ethylenically unsaturated group in the molecule used as the photosensitive monomer is preferably 5 to 100 parts by mass, more preferably 100 parts by mass of the (E) carboxyl group-containing resin.
- the ratio is 5 to 70 parts by mass.
- thermosetting component The photocurable resin composition of the present invention may further contain a thermosetting component for the purpose of improving characteristics such as heat resistance and insulation reliability.
- thermosetting components include amino resins, isocyanate compounds, blocked isocyanate compounds, maleimide compounds, benzoxazine compounds, oxazoline compounds, carbodiimide compounds, cyclocarbonate compounds, polyfunctional oxetane compounds, episulfide resins, and epoxy resins.
- a curable resin can be used.
- amino resin examples include amino resins such as melamine derivatives and benzoguanamine derivatives.
- examples include methylol melamine compounds, methylol benzoguanamine compounds, methylol glycoluril compounds, and methylol urea compounds.
- the alkoxymethylated melamine compound, alkoxymethylated benzoguanamine compound, alkoxymethylated glycoluril compound and alkoxymethylated urea compound are the methylol groups of the respective methylolmelamine compound, methylolbenzoguanamine compound, methylolglycoluril compound and methylolurea compound. Obtained by conversion to an alkoxymethyl group.
- the type of the alkoxymethyl group is not particularly limited and can be, for example, a methoxymethyl group, an ethoxymethyl group, a propoxymethyl group, a butoxymethyl group, or the like.
- a melamine derivative having a formalin concentration which is friendly to the human body and the environment is preferably 0.2% or less.
- Examples of commercially available amino resins include Cymel 300, 301, 303, 370, 325, 327, 701, 266, 267, 238, 1141, 272, 202, and the like. 1156, 1158, 1123, 1170, 1174, UFR65, 300 (above, manufactured by Mitsui Cyanamid Co., Ltd.), Nicalak Mx-750, Mx-032, Mx-270, Mx-280, Mx-290, Mx-706, Mx-708, Mx-40, Mx-31, Ms-11, Ms-30, Mw-30HM, Mw-390, Mw-100LM, Mw-750LM (manufactured by Sanwa Chemical Co., Ltd.).
- the isocyanate compound a polyisocyanate compound having a plurality of isocyanate groups in the molecule can be used.
- the polyisocyanate compound for example, aromatic polyisocyanate, aliphatic polyisocyanate or alicyclic polyisocyanate is used.
- aromatic polyisocyanate include 4,4′-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, naphthalene-1,5-diisocyanate, o-xylylene diisocyanate, m- Examples include xylylene diisocyanate and 2,4-tolylene dimer.
- aliphatic polyisocyanate examples include tetramethylene diisocyanate, hexamethylene diisocyanate, methylene diisocyanate, trimethylhexamethylene diisocyanate, 4,4-methylenebis (cyclohexyl isocyanate), and isophorone diisocyanate.
- alicyclic polyisocyanate examples include bicycloheptane triisocyanate.
- adduct bodies, burette bodies, and isocyanurate bodies of the isocyanate compounds listed above may be mentioned.
- the blocked isocyanate group contained in the blocked isocyanate compound is a group in which the isocyanate group is protected by reaction with a blocking agent and temporarily deactivated. When heated to a predetermined temperature, the blocking agent is dissociated to produce isocyanate groups.
- the blocked isocyanate compound an addition reaction product of an isocyanate compound and an isocyanate blocking agent is used.
- the isocyanate compound that can react with the blocking agent include isocyanurate type, biuret type, and adduct type.
- an isocyanate compound used in order to synthesize combine a block isocyanate compound, aromatic polyisocyanate, aliphatic polyisocyanate, or alicyclic polyisocyanate is mentioned, for example.
- aromatic polyisocyanate, aliphatic polyisocyanate, and alicyclic polyisocyanate include the compounds exemplified above.
- isocyanate blocking agent examples include phenolic blocking agents such as phenol, cresol, xylenol, chlorophenol and ethylphenol; lactam blocking agents such as ⁇ -caprolactam, ⁇ -palerolactam, ⁇ -butyrolactam and ⁇ -propiolactam; Active methylene blocking agents such as ethyl acetoacetate and acetylacetone; methanol, ethanol, propanol, butanol, amyl alcohol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monobutyl ether, diethylene glycol monomethyl ether, propylene glycol monomethyl ether, benzyl Ether, methyl glycolate, butyl glycolate, diacetone alcohol, lactic acid Alcohol-based blocking agents such as chill and ethyl lactate; oxime-based blocking agents such as formaldehyde oxime, acetoaldoxime, acetoxi
- the blocked isocyanate compound may be commercially available, for example, Sumidur BL-3175, BL-4165, BL-1100, BL-1265, Death Module TPLS-2957, TPLS-2062, TPLS-2078, TPLS-2117.
- the compounding amount of the polyisocyanate compound or the blocked isocyanate compound is preferably 1 to 100 parts by mass, more preferably 2 to 70 parts by mass with respect to 100 parts by mass of the (E) carboxyl group-containing resin.
- the amount is less than 1 part by mass, sufficient toughness of the coating film may not be obtained, which is not preferable.
- the amount exceeds 100 parts by mass the storage stability may decrease, which is not preferable.
- a urethanization catalyst can be further added to the photocurable resin composition.
- the urethanization catalyst one or more urethanization catalysts selected from the group consisting of tin-based catalysts, metal chlorides, metal acetylacetonate salts, metal sulfates, amine compounds, and / or amine salts should be used. Is preferred.
- tin catalyst examples include organic tin compounds such as stannous octoate and dibutyltin dilaurate, and inorganic tin compounds.
- metal chloride examples include metal chlorides selected from the group consisting of Cr, Mn, Co, Ni, Fe, Cu, and Al.
- metal chlorides selected from the group consisting of Cr, Mn, Co, Ni, Fe, Cu, and Al.
- cobalt chloride, nickel chloride, ferric chloride, and the like. Can be mentioned.
- the metal acetylacetonate salt is a metal acetylacetonate salt selected from the group consisting of Cr, Mn, Co, Ni, Fe, Cu and Al.
- metal acetylacetonate salt selected from the group consisting of Cr, Mn, Co, Ni, Fe, Cu and Al.
- cobalt acetylacetonate, nickel acetylacetonate, iron acetyl Examples include acetonate.
- the metal sulfate is a metal sulfate selected from the group consisting of Cr, Mn, Co, Ni, Fe, Cu, and Al, and examples thereof include copper sulfate.
- maleimide compound examples include polyfunctional aliphatic / alicyclic maleimide and polyfunctional aromatic maleimide.
- examples of the polyfunctional aliphatic / alicyclic maleimide include N, N′-methylene bismaleimide, N, N′-ethylene bismaleimide, tris (hydroxyethyl) isocyanurate, and aliphatic / alicyclic maleimide carboxylic acid.
- Isocyanurate skeletal polymide compounds such as isocyanurate skeleton maleimide urethane compounds obtained by urethanization of tris (carbamate hexyl) isocyanurate and aliphatic / alicyclic maleimide alcohols.
- Maleimides isophorone bisurethane bis (N-ethylmaleimide), triethylene glycol bis (maleimide ethyl carbonate), aliphatic / alicyclic maleimide carboxylic acid and various aliphatic / alicyclic polyols, or dehydrated ester Aliphatic / alicyclic polymaleimide compounds obtained by transesterification of aliphatic / alicyclic maleimide carboxylic acid esters with various aliphatic / alicyclic polyols; aliphatic / alicyclic maleimide carboxylic acids and various types Aliphatic / alicyclic polymaleimide ester compounds obtained by ether ring-opening reaction of aliphatic / alicyclic polyepoxides, urethanes of aliphatic / alicyclic maleimide alcohols and various aliphatic / alicyclic polyisocyanates Aliphatic / alicyclic polymaleimide urethan
- aromatic polymaleimide ester compounds obtained by dehydrating esterification of maleimide carboxylic acid and various aromatic polyols, or transesterification reaction of maleimide carboxylic acid ester and various aromatic polyols
- maleimide Of aromatic polymaleimide ester compounds obtained by ether ring-opening reaction of carboxylic acid and various aromatic polyepoxides aromatic polymaleimide urethane compounds obtained by urethanization reaction of maleimide alcohol and various aromatic polyisocyanates
- aromatic polyfunctional maleimides aromatic polymaleimide ester compounds obtained by dehydrating esterification of maleimide carboxylic acid and various aromatic polyols, or transesterification reaction of maleimide carboxylic acid ester and various aromatic polyols
- maleimide Of aromatic polymaleimide ester compounds obtained by ether ring-opening reaction of carboxylic acid and various aromatic polyepoxides
- aromatic polymaleimide urethane compounds obtained by urethanization reaction of maleimide alcohol and various aromatic polyiso
- polyfunctional aromatic maleimide examples include, for example, N, N ′-(4,4′-diphenylmethane) bismaleimide, N, N′-2,4-tolylene bismaleimide, N, N′-2, 6-tolylene bismaleimide, 1-methyl-2,4-bismaleimide benzene, N, N′-m-phenylene bismaleimide, N, N′-p-phenylene bismaleimide, N, N′-m-toluylene Bismaleimide, N, N′-4,4′-biphenylenebismaleimide, N, N′-4,4 ′-[3,3′-dimethyl-biphenylene] bismaleimide, N, N′-4,4′- [3,3′-dimethyldiphenylmethane] bismaleimide, N, N′-4,4 ′-[3,3′-diethyldiphenylmethane] bismaleimide, N, N′-4,4′-diphenylme
- Examples of commercially available maleimide compounds include BMI-1000, BMI-1000H, BMI-1000S, BMI-1100, BMI-1100H, BMI-2000, BMI-2300, BMI-3000, BMI-3000H, BMI-4000, Examples thereof include BMI-5100, BMI-7000, BMI-7000H, BMI-TMH (manufactured by Daiwa Kasei Kogyo Co., Ltd.), MIA-200 (manufactured by DIC), and the like.
- bismaleimide derivatives may be synthesized by conventional methods, or commercially available products may be used.
- those that do not contain a halogen atom in the molecule are preferable from the viewpoint of not placing a burden on the environment.
- These can be used individually by 1 type or in combination of 2 or more types.
- benzoxazine compound examples include bisphenol A type benzoxazine, bisphenol F type benzoxazine, and bisphenol S type benzoxazine.
- examples of these commercially available products include “Fa” (manufactured by Shikoku Kasei Co., Ltd.).
- the oxazoline compound is not particularly limited as long as it contains an oxazoline group.
- examples of these commercially available products include K-2010E, K-2020E, K-2030E, WS-500, WS-700 and RPS-1005 manufactured by EPOCROS (manufactured by Nippon Shokubai Co., Ltd.).
- carbodiimide compound examples include dicyclohexylcarbodiimide and diisopropylcarbodiimide.
- the cyclocarbonate compound is not particularly limited as long as it is a cyclic compound and has a carbonate bond.
- Examples include alkylene carbonate compounds having a polyfunctional structure.
- polyfunctional oxetane compound examples include bis [(3-methyl-3-oxetanylmethoxy) methyl] ether, bis [(3-ethyl-3-oxetanylmethoxy) methyl] ether, 1,4-bis [(3-methyl -3-Oxetanylmethoxy) methyl] benzene, 1,4-bis [(3-ethyl-3-oxetanylmethoxy) methyl] benzene, (3-methyl-3-oxetanyl) methyl acrylate, (3-ethyl-3-oxetanyl)
- polyfunctional oxetanes such as methyl acrylate, (3-methyl-3-oxetanyl) methyl methacrylate, (3-ethyl-3-oxetanyl) methyl methacrylate and oligomers or copolymers thereof, oxetane alcohol and novolak resin, Poly (p-hydroxystyrene
- episulfide resin examples include YL7000 (bisphenol A type episulfide resin) manufactured by Mitsubishi Chemical Corporation and YSLV-120TE manufactured by Tohto Kasei Co., Ltd. Moreover, episulfide resin etc. which replaced the oxygen atom of the epoxy group of the novolak-type epoxy resin with the sulfur atom using the same synthesis method can be used.
- the epoxy resin a known and commonly used polyfunctional epoxy resin having at least two epoxy groups in one molecule can be used.
- the epoxy resin may be liquid or may be solid or semi-solid.
- Examples of the epoxy resin include jER828, jER834, jER1001, and jER1004 manufactured by Mitsubishi Chemical Corporation, Epicron 840, Epicron 850, Epicron 1050, and Epicron 2055 manufactured by DIC Corporation, Epoto YD-011, YD-013 manufactured by Tohto Kasei Co., Ltd. YD-127, YD-128, D.C. E. R. 317, D.E. E. R. 331, D.D. E. R. 661, D.E. E. R. 664, BASF Japan Araldide 6071, Araldide 6084, Araldide GY250, Araldide GY260, Sumitomo Chemical Co., Ltd.
- Novolak type epoxy resins such as 704A, Epicron N-680, N-690, N-695 (all trade names) manufactured by DIC; Epicron 830 manufactured by DIC, jER807 manufactured by Mitsubishi Chemical Co., Ltd., Epoto manufactured by Tohto Kasei Co., Ltd.
- Bisphenol F type epoxy resins such as YDF-170, YDF-175, YDF-2004, Araldide XPY306 manufactured by BASF Japan (all trade names); Epotot ST-2004, ST-2007, ST-3000 manufactured by Toto Kasei Hydrogenated bisphenol A type epoxy resin such as (trade name); jE manufactured by Mitsubishi Chemical Corporation R604, Etototo YH-434 manufactured by Tohto Kasei Co., Ltd., Araldide MY720 manufactured by BASF Japan, Sumi-epoxy ELM-120 manufactured by Sumitomo Chemical Co., Ltd.
- Type or biphenol type epoxy resin or a mixture thereof Nippon Kayaku EBPS-200, ADEKA EPX-30, DIC EXA-1514 (trade name), etc .; bisphenol S type epoxy resin; Bisphenol A novolac type epoxy resin such as jER157S (trade name); tetraphenylolethane type epoxy resin such as jERYL-931 manufactured by Mitsubishi Chemical Corporation, Araldide 163 manufactured by BASF Japan Co., Ltd.
- bisphenol A type epoxy resin bisphenol A type epoxy resin, naphthalene type epoxy resin, phenol novolac type epoxy resin, biphenol type epoxy resin or a mixture thereof is preferable.
- These epoxy resins may be used individually by 1 type, and may be used in combination of 2 or more type.
- thermosetting catalyst When it contains the said thermosetting component, it is preferable to contain a thermosetting catalyst further.
- the thermosetting catalyst include imidazole, 2-methylimidazole, 2-ethylimidazole, 2-ethyl-4-methylimidazole, 2-phenylimidazole, 4-phenylimidazole, 1-cyanoethyl-2-phenylimidazole, 1- Imidazole derivatives such as (2-cyanoethyl) -2-ethyl-4-methylimidazole; dicyandiamide, benzyldimethylamine, 4- (dimethylamino) -N, N-dimethylbenzylamine, 4-methoxy-N, N-dimethylbenzyl Examples include amines, amine compounds such as 4-methyl-N, N-dimethylbenzylamine, hydrazine compounds such as adipic acid dihydrazide and sebacic acid dihydrazide; phosphorus compounds such as
- Examples of commercially available products include 2MZ-A, 2MZ-OK, 2PHZ, 2P4BHZ, 2P4MHZ (both trade names of imidazole compounds) manufactured by Shikoku Kasei Kogyo Co., Ltd., and U-CAT manufactured by San Apro. (Registered trademark) 3503N, U-CAT3502T (all are trade names of blocked isocyanate compounds of dimethylamine), DBU, DBN, U-CATSA102, U-CAT5002 (all are bicyclic amidine compounds and salts thereof), etc. .
- thermosetting catalyst for epoxy resins or oxetane compounds or a catalyst that promotes the reaction of epoxy groups and / or oxetanyl groups with carboxyl groups, either alone or in combination of two or more. Can be used.
- the blending amount of the thermosetting catalyst is preferably 0.1 to 20 parts by mass, more preferably 0.5 to 15.0 parts by mass with respect to 100 parts by mass of the thermosetting component.
- inorganic filler As the inorganic filler, known and commonly used inorganic fillers can be used. In particular, silica, alumina (aluminum oxide), boron nitride, barium sulfate, talc, and Neuburg silica are preferably used. Further, for the purpose of imparting flame retardancy, aluminum hydroxide, magnesium hydroxide, boehmite and the like can also be used.
- NANOCRYL (trade names) XP 0396, XP 0596, XP 0733, XP 0746, XP 0765 manufactured by Hanse-Chemie, in which nano-silica is dispersed in the compound having one or more ethylenically unsaturated groups or the polyfunctional epoxy resin.
- XP 0768, XP 0953, XP 0954, XP 1045 (all product grade names)
- Hanose-Chemie NANOPOX (trade name) XP 0516, XP 0525, XP 0314 (all product grade names) can also be used. .
- the silica and alumina are preferably spherical.
- the average particle diameter (D50) of the spherical silica is preferably 0.1 to 10 ⁇ m.
- the average particle diameter of the spherical alumina is preferably 0.1 to 20 ⁇ m.
- the average particle diameter is measured by a laser diffraction method.
- the sphericity of spherical silica and spherical alumina is preferably 0.8 or more.
- the surface may be treated with a silane coupling agent. The sphericity is measured as follows.
- spherical silica includes Admatech SO series, Toa Gosei HPS series (HPS-0500, HPS-1000, HPS3500, etc.), and the like.
- Examples of commercially available spherical alumina include Admatex AO series, Admatex TC-975c, Showa Denko Aruna beads / CB series, and the like.
- components described below can be arbitrarily added to the photocurable resin composition for forming L1.
- L2 is a thermosetting resin composition layer formed by applying and drying a thermosetting resin composition.
- the layer can be cured by heat treatment after the dry film of the present invention is bonded to a substrate, and patterned by laser.
- thermosetting resin composition constituting the L2 preferably contains (A) an epoxy resin, (B) an epoxy curing agent, and (C) an inorganic filler.
- the thermosetting resin composition preferably further contains (D) a thermoplastic resin composition.
- Epoxy resin As an epoxy resin, the thing similar to the said epoxy resin can be mentioned. Among them, bisphenol A type epoxy resin, naphthol type epoxy resin, cresol novolac type epoxy resin, phenol novolac type epoxy resin, or a mixture thereof is preferable. These epoxy resins may be used individually by 1 type, and may be used in combination of 2 or more type. (A) The amount of the epoxy resin in the composition is preferably 15 to 80% by mass, more preferably 15 to 60% by mass, based on the total solid content of the thermosetting resin composition for L2. is there.
- the curing agent for epoxy resin is a compound having a group that reacts with an epoxy group, and any known curing agent for epoxy resin can be used.
- curing agents for epoxy resins include polyfunctional phenolic compounds, polycarboxylic acids and their anhydrides, cyanate ester resins, active ester resins, aliphatic or aromatic primary or secondary amines, polyamide resins, polymercapto compounds, and the like. Can be mentioned. Among these, polyfunctional phenol compounds, polycarboxylic acids and acid anhydrides thereof, cyanate ester resins, and active ester resins are preferable, and polyfunctional phenol compounds are more preferable.
- the polyfunctional phenol compound may be any polyfunctional phenol compound having two or more phenolic hydroxyl groups in one molecule, and known and conventional ones can be used. Specific examples include phenol novolac resins, cresol novolac resins, bisphenol A, allylated bisphenol A, bisphenol F, bisphenol A novolac resins, vinylphenol copolymer resins, and the like. Moreover, the triazine ring containing novolak resin which is a polycondensate of these phenols, aldehydes, and the compound which has a triazine ring may be sufficient.
- phenol compounds a phenol resin is preferable, and a phenol novolac resin is more preferable because of high reactivity and high effect of increasing heat resistance.
- examples of commercially available polyfunctional phenolic compounds used as curing agents for epoxy resins include cresol novolak resins such as GPX-41 manufactured by Gifu Seratec Co., Ltd., and trisphenol methane type phenol resins such as MEH-7500H manufactured by Meiwa Kasei Co., Ltd.
- biphenylaralkyl type phenol resins such as MEH-7851-4H manufactured by Meiwa Kasei Co., Ltd., and phenol novolac resins such as HF-1M H60 manufactured by Meiwa Kasei Co., Ltd., and the like.
- the polycarboxylic acid and acid anhydride thereof are compounds having two or more carboxyl groups in one molecule and acid anhydrides thereof, such as (meth) acrylic acid copolymer and maleic anhydride copolymer.
- resins having a carboxylic acid end such as a carboxylic acid-terminated imide resin can be mentioned.
- Commercially available products include John Kuryl (product group name) manufactured by BASF Japan, SMA Resin (product group name) manufactured by Sartomer, polyazeline acid anhydride manufactured by Shin Nippon Chemical Co., Ltd., V-8000 manufactured by DIC, Examples thereof include carboxylic acid-terminated polyimide resins such as V-8002.
- the cyanate ester resin is a compound having two or more cyanate ester groups (—OCN) in one molecule. Any known cyanate ester resin can be used. Examples of the cyanate ester resin include phenol novolac type cyanate ester resin, alkylphenol novolak type cyanate ester resin, dicyclopentadiene type cyanate ester resin, bisphenol A type cyanate ester resin, bisphenol F type cyanate ester resin, and bisphenol S type cyanate ester resin. Is mentioned. Further, it may be a prepolymer partially triazine.
- cyanate ester resins examples include phenol novolac polyfunctional cyanate ester resin PT30 manufactured by Lonza Japan, prepolymer BA230 partially triazineated with bisphenol A type dicyanate manufactured by Lonza Japan, manufactured by Lonza Japan Examples thereof include dicyclopentadiene structure-containing cyanate ester resins DT-4000 and DT-7000.
- the active ester resin is a resin having two or more active ester groups in one molecule.
- the active ester resin can generally be obtained by a condensation reaction between a carboxylic acid compound and a hydroxy compound.
- an active ester compound obtained by using a phenol compound or a naphthol compound as the hydroxy compound is preferable.
- phenol compound or naphthol compound examples include hydroquinone, resorcin, bisphenol A, bisphenol F, bisphenol S, phenolphthaline, methylated bisphenol A, methylated bisphenol F, methylated bisphenol S, phenol, o-cresol, m-cresol, p-cresol, catechol, ⁇ -naphthol, ⁇ -naphthol, 1,5-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, dihydroxybenzophenone, trihydroxybenzophenone, tetrahydroxybenzophenone, phloroglucin, benzenetriol , Dicyclopentadienyl diphenol, phenol novolac and the like.
- active ester compounds examples include EXB-9451 and EXB-9460 manufactured by DIC, DC808 manufactured by Mitsubishi Chemical Corporation, and YLH1030).
- the compounding amount of the curing agent for epoxy resin is preferably 3: 1 to 0.75: 1 in terms of the molar ratio of the number of moles of epoxy groups and the number of moles of groups reacting with the epoxy groups in the curing agent, 2.5: 1 to 1: 1 is more preferable, and 2.3: 1 to 1.1: 1 is particularly preferable. If the compounding ratio is out of the range of 3: 1 to 0.75: 1, there is a concern that the laminating property is lowered and the insulation reliability is lowered.
- thermosetting resin composition for forming L2 is preferably 30 to 80% by mass based on the total solid content of the thermosetting composition forming L2.
- thermoplastic resin The said thermoplastic resin (binder polymer) is mix
- a conventionally well-known thing can be used as a thermoplastic resin.
- a thermoplastic resin a cellulose resin, a polyester resin, and a phenoxy resin are preferable.
- cellulose resins include Eastman's cellulose acetate butyrate (CAB) and cellulose acetate propionate (CAP) series.
- Polyester resins include Byron series manufactured by Toyobo, and phenoxy resins include bisphenol A type, Bisphenol F type and phenoxy resins of their hydrogenated compounds are preferred.
- the weight average molecular weight (Mw) of the thermoplastic resin is preferably 5000 or more, more preferably 5000 to 100,000.
- the blending amount of the thermoplastic resin (D) is preferably 50% by mass or less, more preferably 1 to 50% by mass based on the total solid content of the thermosetting resin composition for the thermosetting resin composition layer. Particularly preferred is 5 to 35% by mass. In this range, by including a thermoplastic resin, good laminating properties and residue removal properties of the opening are expressed.
- a block copolymer can be suitably blended in the thermosetting resin composition for L2.
- the block copolymer is a copolymer having a molecular structure in which two or more kinds of polymers having different properties are connected by a covalent bond to form a long chain.
- Those which are solid in the range of 20 ° C. to 30 ° C. are preferred. Any solid may be used within this range, and it may be solid even at a temperature outside this range. Due to being solid in the above temperature range, it is excellent in tackiness when formed into a dry film or applied to a substrate and temporarily dried.
- the block copolymer used in the present invention is preferably an XYX or XYX ′ type block copolymer.
- the center Y is a soft block and has a low glass transition point Tg, preferably less than 0 ° C.
- both outer X or X ′ Is a hard block and has a high Tg, and is preferably composed of polymer units of 0 ° C. or higher.
- the glass transition point Tg is measured by differential scanning calorimetry (DSC).
- DSC differential scanning calorimetry
- X or X ′ is a polymer unit having a Tg of 50 ° C.
- Y is a polymer unit having a Tg of ⁇ 20 ° C. or less. More preferred is a block copolymer of Of the XYX or XYX ′ type block copolymers, X or X ′ is preferably one having high compatibility with the above (A) epoxy resin, and Y is preferably the above (A) epoxy. Those having low compatibility with the resin are preferred. Thus, it is considered that a specific structure in the matrix can be easily shown by using a block copolymer in which the blocks at both ends are compatible with the matrix and the central block is incompatible with the matrix.
- X or X ' preferably contains polymethyl (meth) acrylate (PMMA), polystyrene (PS) or the like, and Y preferably contains poly n-butyl acrylate (PBA), polybutadiene (PB) or the like.
- PMMA polymethyl (meth) acrylate
- PS polystyrene
- Y preferably contains poly n-butyl acrylate (PBA), polybutadiene (PB) or the like.
- hydrophilicity excellent in compatibility with the above-described carboxyl group-containing resins represented by styrene units, hydroxyl group-containing units, carboxyl group-containing units, epoxy-containing units, N-substituted acrylamide units, etc. as part of the X or X ′ component Compatibility unit can be introduced to further improve the compatibility.
- Examples of commercially available block copolymers include acrylic triblock copolymers manufactured using living polymerization manufactured by Arkema. SBM type represented by polystyrene-polybutadiene-polymethyl methacrylate, MAM type represented by polymethyl methacrylate-polybutyl acrylate-polymethyl methacrylate, and MAM N type treated with carboxylic acid modification or hydrophilic group modification. And MAM A type. Examples of SBM types include E41, E40, E21, E20, MAM types include M51, M52, M53, M22, etc., MAM N types include 52N, 22N, and MAM A types include SM4032XM10. It is done. Moreover, the clarity produced by Kuraray Co., Ltd. is also a block copolymer derived from methyl methacrylate and butyl acrylate.
- the block copolymer used in the present invention is preferably a ternary or more block copolymer, and a block copolymer having a precisely controlled molecular structure synthesized by a living polymerization method is effective for obtaining the effects of the present invention. More preferred. This is considered to be because the block copolymer synthesized by the living polymerization method has a narrow molecular weight distribution, and the characteristics of each unit have been clarified.
- the molecular weight distribution (Mw / Mn) of the block copolymer used is preferably 3 or less, more preferably 2.5 or less, and still more preferably 2.0 or less.
- the block copolymers containing the (meth) acrylate polymer block as described above are, for example, the methods described in JP-A-2007-516326 and JP-A-2005-515281, particularly the following formulas (1) to (4).
- the Y unit is polymerized using the alkoxyamine compound represented by any of the above as an initiator, it can be suitably obtained by polymerizing the X unit.
- n 2 and Z represents a divalent organic group, preferably 1,2-ethanedioxy, 1,3-propanedioxy, 1,4-butanedioxy, 1,6-hexanedioxy Selected from among oxy, 1,3,5-tris (2-ethoxy) cyanuric acid, polyaminoamines such as polyethyleneamine, 1,3,5-tris (2-ethylamino) cyanuric acid, polythioxy, phosphonate or polyphosphonate Ar represents a divalent aryl group.
- the weight average molecular weight of the block copolymer is preferably in the range of 20,000 to 400,000, more preferably 50,000 to 300,000. If the weight average molecular weight is less than 20,000, the desired toughness and flexibility effects cannot be obtained, and tack when a thermosetting resin composition is formed into a dry film or applied to a substrate and temporarily dried is used. Also inferior in nature. On the other hand, when the weight average molecular weight exceeds 400,000, the viscosity of the thermosetting resin composition becomes high, and the printability and processability may be remarkably deteriorated. When the weight average molecular weight is 50,000 or more, an excellent effect can be obtained in terms of relaxation against external impact.
- the blending amount of the block copolymer is preferably 50% by mass or less, more preferably 1 to 50% by mass, particularly based on the total solid content of the thermosetting resin composition for the thermosetting resin composition layer. Preferably, it is 5 to 35% by mass. In this range, by containing the block copolymer, good laminating properties and residue residue removing properties are exhibited.
- the thermosetting resin composition may contain a thermosetting component other than an epoxy resin and a thermosetting catalyst.
- a thermosetting component other than an epoxy resin
- thermosetting catalyst examples of the thermosetting component and the thermosetting catalyst are the same as those described above.
- the blending amount of the thermosetting catalyst is preferably 0.1 to 20 parts by mass, more preferably 0.5 to 15.0 parts by mass with respect to 100 parts by mass of the (A) epoxy resin.
- an organic solvent in the above-mentioned photocurable resin composition and thermosetting resin composition, an organic solvent can be used for preparing the resin composition and adjusting the viscosity for application to a substrate or a carrier film. .
- organic solvents examples include ketones, aromatic hydrocarbons, glycol ethers, glycol ether acetates, esters, alcohols, aliphatic hydrocarbons, petroleum solvents, and the like. More specifically, ketones such as methyl ethyl ketone and cyclohexanone; aromatic hydrocarbons such as toluene, xylene and tetramethylbenzene; cellosolve, methyl cellosolve, butyl cellosolve, carbitol, methyl carbitol, butyl carbitol, propylene glycol monomethyl Glycol ethers such as ether, dipropylene glycol monomethyl ether, dipropylene glycol diethyl ether, triethylene glycol monoethyl ether; ethyl acetate, butyl acetate, dipropylene glycol methyl ether acetate, propylene glycol methyl ether acetate, propylene glycol ethyl ether a
- thermosetting resin composition components such as an elastomer, an adhesion promoter, a colorant, an antioxidant, and an ultraviolet absorber can be further blended as necessary.
- those known in the field of electronic materials can be used.
- the photocurable resin composition and the thermosetting resin composition include known thickeners such as fine silica, hydrotalcite, organic bentonite, and montmorillonite, silicone, fluorine, and polymer.
- the known antifoaming agent and / or leveling agent, imidazole-based, thiazole-based, triazole-based silane coupling agents, antirust agents, and the like can be blended.
- the printed wiring board of the present invention is a printed wiring board provided with a cured film obtained by using the dry film of the present invention on a substrate on which a circuit pattern is formed, and a photocurable resin composition layer on the surface layer side (L1) is cured, and the thermosetting resin composition layer (L2) is cured between the substrate and the cured film derived from the photocurable resin composition layer (L1). It is characterized by having at least a cured film.
- the printed wiring board of the present invention uses a light exposure resin used for active energy ray irradiation such as a high-pressure mercury lamp lamp, an ultra-high pressure mercury lamp lamp, a metal halide lamp, or a mercury short arc lamp to illuminate the photocurable resin composition layer on the surface layer.
- a light exposure resin used for active energy ray irradiation such as a high-pressure mercury lamp lamp, an ultra-high pressure mercury lamp lamp, a metal halide lamp, or a mercury short arc lamp to illuminate the photocurable resin composition layer on the surface layer.
- the photocurable resin composition is post-cured by heating to a temperature of about 140 to 180 ° C. and thermally cured, and the thermosetting resin composition is thermally cured to form a cured film. obtain.
- pattern formation processing is performed with a laser to form a fine pattern.
- the smear is removed by a desmear process.
- Laser processing and desmear treatment can be performed by known methods. The desmear treatment can
- the method for producing a printed wiring board of the present invention includes a step of forming a resin insulating layer having a thermosetting resin composition layer (L2) and a photocurable resin composition layer (L1) in this order from the substrate surface side, It includes a step of patterning by photolithography and a step of patterning by laser processing.
- a step of forming dams by photolithography even a wide range of dams can be formed with high definition in a single development process.
- the conductor pattern can be protected even after the development step by the thermosetting resin composition layer (L2) located under the photocurable resin composition layer (L1).
- thermosetting resin composition layer (L2) intended to cover the conductor.
- the photocurable resin composition layer (L1) is patterned by the patterning step by the photolithography method, and the thermosetting resin is patterned by the laser processing. It is preferable to pattern the composition layer (L2).
- the dam is preferably formed in at least one of a groove shape and a projecting shape. Further, according to the present invention, not only a dam but also a marking can be formed.
- the manufacturing method of the printed wiring board of this invention is demonstrated in detail.
- a resin insulation having a thermosetting resin composition layer (L2) and a photocurable resin composition layer (L1) in order from the substrate surface side on the surface of the substrate.
- the surface of the substrate is a surface on which a component mounting portion is provided.
- the photocurable resin composition layer (L1) and the thermosetting resin composition layer (L2) can be formed using a photocurable resin composition and a thermosetting resin composition, respectively, which will be described later.
- the said photocurable resin composition is a film thickness after drying.
- the layer (L1) has a thickness of 1 to 20 ⁇ m
- the thermosetting resin composition layer (L2) has a thickness of 1 to 100 ⁇ m.
- the resin insulation layer preferably forms a solder resist.
- the conductor pattern formed on the printed wiring board is not particularly limited, and a conventionally known pattern such as a copper foil can be used.
- the substrate examples include printed circuit boards and flexible printed circuit boards in which circuits are formed in advance, paper phenol, paper epoxy, glass cloth epoxy, glass polyimide, glass cloth / non-woven cloth epoxy, glass cloth / paper epoxy, synthetic fiber epoxy. , Copper-clad laminates of all grades (FR-4 etc.) and other polyimide films using materials such as copper-clad laminates for high-frequency circuits using fluorine, polyethylene, polyphenylene ether, polyphenylene oxide, cyanate esters, etc. , PET film, glass substrate, ceramic substrate, wafer plate and the like.
- thermosetting resin composition layer (L2) and the photocurable resin composition layer (L1) may form two or more resin composition layers. That is, another resin composition between the substrate and the thermosetting resin composition layer (L2) or between the thermosetting resin composition layer (L2) and the photocurable resin composition layer (L1). You may have a layer of.
- the method for forming the thermosetting resin composition layer (L2) and the photocurable resin composition layer (L1) on the surface of the substrate is not particularly limited, and can be formed by a conventionally known method.
- a method of laminating a dry film formed by laminating a photocurable resin composition layer (L1) and a thermosetting resin composition layer (L2) on a film, and the substrate examples include a method in which a thermosetting resin composition and a photocurable resin composition are directly applied to the substrate and dried.
- the former method using a dry film is more preferable because the thermosetting resin composition layer (L2) and the photocurable resin composition layer (L1) can be collectively formed on the surface of the substrate.
- the dry film comprises a carrier film, a photocurable resin composition layer (L1) formed by applying and drying a photocurable resin composition, and a thermosetting resin composition. It is sufficient to have at least a thermosetting resin composition layer (L2) formed by coating and drying, and the carrier film, the thermosetting resin composition layer (L2), and the photocurable resin composition layer (L1).
- the curable resin composition layer may be laminated in the order of the carrier film, the photocurable resin composition layer (L1), and the thermosetting resin composition layer (L2).
- the photocurable resin composition layer (L1) may be laminated to the substrate so that the surface layer and the thermosetting resin composition layer (L2) are located on the substrate side.
- thermosetting resin composition layer (L2) is formed by directly applying and drying the thermosetting resin composition on the substrate, and a dry film is formed on the thermosetting resin composition layer (L2).
- the photocurable resin composition layer (L1) may be formed by laminating.
- thermosetting resin composition layer (L2) is formed by laminating the dry film on the substrate, and the photocurable resin composition is directly applied on the thermosetting resin composition layer (L2).
- the photocurable resin composition layer (L1) may be formed by drying.
- Step of patterning by photolithography As a step of patterning by the photolithography method in the present invention, patterning by a conventionally known photolithography method by an exposure step and a development step can be applied. By forming a recess in the photocurable resin composition layer (L1) by photolithography, a dam that prevents the underfill from spreading is easily formed on the thermosetting resin composition layer (L2). can do.
- the exposure process is not particularly limited.
- the exposure process may be selectively exposed with active energy rays through a photomask in which a dam pattern is formed by a contact type (or non-contact type), or directly by a drawing apparatus.
- the pattern of the dam may be directly exposed with active energy rays.
- the exposure time can be shortened. Therefore, it is preferable to perform exposure through a photomask rather than direct exposure with a drawing apparatus.
- a metal halide lamp for example, a high-pressure mercury lamp, an ultra-high pressure mercury lamp, a mercury short arc lamp, an LED, or the like can be used.
- a laser such as a gas laser or a solid laser, an ultraviolet lamp such as a high pressure mercury lamp or an ultrahigh pressure mercury lamp, an LED, or the like can be used.
- a direct drawing apparatus for example, those manufactured by Nippon Orbotech Co., Ltd., Oak Manufacturing Co., Ltd., Dainippon Screen Manufacturing Co., etc. can be used.
- the active energy ray it is preferable to use laser light having a maximum wavelength in the range of 350 to 410 nm. By setting the maximum wavelength within this range, radicals can be efficiently generated from the photopolymerization initiator.
- the amount of exposure varies depending on the film thickness and the like, but can generally be in the range of 5 to 500 mJ / cm 2 , preferably 10 to 300 mJ / cm 2 .
- the development process is not particularly limited, and a dipping method, a shower method, a spray method, a brush method, or the like can be used.
- an alkaline aqueous solution such as potassium hydroxide, sodium hydroxide, sodium carbonate, potassium carbonate, sodium phosphate, sodium silicate, ammonia, amines and the like can be used.
- the dam pattern is not particularly limited, but it is preferable to form the dam so as to surround the component mounting portion. Further, for example, as shown in FIGS. 3 and 4, a recess may be formed to form a grooved dam and / or a protruding dam. The width and depth (height) of the dam may be determined according to the amount and type of underfill used. Further, portions other than the dam may be patterned by a photolithography method.
- the photocurable resin composition layer (L1) contains a thermosetting component
- the photocurable resin composition layer (L1) can be thermoset by heat treatment, for example, heating to a temperature of about 140 to 180 ° C. Even if it does not contain a thermosetting component, the ethylenically unsaturated bond of the photocurable component remaining in an unreacted state at the time of exposure undergoes thermal radical polymerization to improve the coating film properties by heat treatment. be able to.
- thermosetting resin composition layer (L2) is preferably performed after exposing the thermosetting resin composition layer (L2) by the step of patterning by the photolithography method and before the step of patterning by the laser processing, In this case, the post-cure of the photocurable resin composition and the thermosetting step of the thermosetting composition layer can be performed simultaneously.
- thermosetting resin composition layer (L2) As the step of performing patterning by laser processing in the present invention, conventionally known patterning by laser processing for irradiating the resin composition with laser can be applied. By patterning by laser processing, a desired pattern can be formed in the thermosetting resin composition layer (L2), and details such as formation of vias provided in the component mounting portion can also be patterned.
- the patterning of the thermosetting resin composition layer (L2) by laser processing may be performed together with the photocurable resin composition layer (L1), or a portion exposed by the patterning process by the photolithography method. You may go to The laser processing is preferably performed after thermosetting the thermosetting resin composition.
- a carbon dioxide laser, a UV-YAG laser, an excimer laser, or the like can be used.
- the resin residue (smear) after the laser irradiation is preferably removed by an oxidizing agent such as permanganate or dichromate, that is, desmear treatment. If the desmear treatment is insufficient, there is a risk that sufficient conductivity cannot be secured due to smear.
- FIG. 2 has a thermosetting resin composition layer (L2) 3 and a photocurable resin composition layer (L1) 4 in order from the substrate surface side on the surface of the substrate 1 on which the conductor pattern 2 is formed.
- the resin insulation layer 5 is shown.
- FIG. 3 shows a specific example when a grooved dam is formed by the method for manufacturing a printed wiring board of the present invention.
- a groove-shaped dam 6 is formed in the photocurable resin composition layer (L1) 4 so as to surround the component mounting portion 2a by patterning by photolithography (FIG. 3A).
- the dam can be formed without affecting the pattern of the thermosetting resin composition layer (L2) intended for covering the conductor.
- it heat-processes and performs the heat processing of the photocurable resin composition layer (L1), and the thermosetting of the thermosetting resin composition layer (L2) simultaneously.
- the photocurable resin composition layer (L1) 4 and the thermosetting resin composition 3 are patterned by laser processing to provide an opening 8 (FIG. 3B). .
- the coating derived from the photocurable resin composition layer (L1) and the coating derived from the thermosetting resin composition layer (L2) can be scraped together.
- the printed wiring board 9a provided with the groove-shaped dam can be manufactured (FIG. 3B, FIG. 5).
- FIG. 4 shows a specific example when a protruding dam is formed by the method for manufacturing a printed wiring board of the present invention.
- a projecting dam 7 is formed on the photocurable resin composition layer (L1) 4 so as to surround the component mounting portion 2a by patterning by photolithography (FIG. 4A).
- the thermosetting resin composition layer (L2) remains as described above, the conductor pattern is not exposed, and the pattern of the thermosetting resin composition layer (L2) intended to cover the conductor is formed.
- a dam can be formed without affecting it.
- it heat-processes and performs the heat processing of the photocurable resin composition layer (L1), and the thermosetting of the thermosetting resin composition layer (L2) simultaneously.
- the thermosetting resin composition 3 is patterned by laser processing and the opening 8 is provided, whereby the printed wiring board 9b provided with the projecting dam is manufactured ( FIG. 4 (B)).
- a conventionally known method can be used as a method of flip-chip connecting the chip and the printed wiring board.
- a solder ball 10 is provided in the opening 8 and aligned with the bump 12 provided on the chip 11 and then reflowed to perform flip chip connection (FIG. 5). 3 (C), FIG. 4 (C)).
- the underfill 14 filled to fill the gap with the chip overflows it can be blocked by the groove-shaped or protruding dam provided as described above (FIGS. 3D and 4D). ).
- the photocurable resin composition constituting the photocurable resin composition layer (L1) preferably contains a carboxyl group-containing resin, a photopolymerization initiator, and a photosensitive monomer.
- the carboxyl group-containing resin, photopolymerization initiator, and photosensitive monomer are the same as (E), (F), and (G), respectively.
- arbitrary components such as a thermosetting component, a thermosetting catalyst, and an inorganic filler, are the same as the above.
- thermosetting resin composition constituting the thermosetting resin composition layer (L2) preferably contains an epoxy resin, an epoxy curing agent, and an inorganic filler. Moreover, it is preferable that this thermosetting resin composition further contains a thermoplastic resin composition.
- the epoxy resin, the epoxy curing agent, the inorganic filler, and the thermoplastic resin composition are the same as the components (A), (B), (C), and (D), respectively.
- arbitrary components, such as a block copolymer and an organic solvent, are the same as the above.
- the printed wiring board for flip chip mounting substrate of the present invention is manufactured by the method of the present invention. Specific examples include, but are not limited to, a printed wiring board for a flip chip mounting board manufactured by the method described above with FIGS. 3A and 3B and FIGS. 4A and 4B. Is not to be done.
- the flip chip mounting substrate of the present invention is a flip chip mounted on the printed wiring board for a flip chip mounting substrate of the present invention.
- a specific example is a printed wiring board for a flip chip mounting board on which a flip chip is mounted as described above with reference to FIGS. 3C and 4C, but is not limited to this.
- the gap with the chip may be filled with an underfill (for example, FIG. 3D and FIG. 4D).
- the L1 varnish prepared above was applied onto a carrier film (PET film, thickness: 38 ⁇ m) with an applicator. In addition, after drying at 90 degreeC for 10 minutes, it prepared so that thickness might be set to about 5 micrometers. After drying at 90 ° C. for 10 minutes, the varnish for L2 prepared above was applied onto L1 with an applicator. The L2 varnish was prepared so as to have a thickness of about 20 ⁇ m after drying at 90 ° C. for 10 minutes.
- each test board of each example and comparative example was evaluated.
- the results are shown in Tables 3 and 4 below.
- Laser workability was evaluated using a CO 2 laser (manufactured by Hitachi Via Mechanics).
- the processing diameter is aimed at a top diameter of 65 ⁇ m / bottom diameter of 50 ⁇ m.
- the processing conditions were aperture (mask diameter): 3.1 mm, pulse width 20 ⁇ sec, output 2 W, frequency 5 kHz, number of shots: burst 3 shots.
- Each test substrate was evaluated according to the following criteria.
- the difference from the target processing diameter includes both cases where the difference is larger than the target processing diameter and small.
- ⁇ The difference from the target processing diameter is less than 2 ⁇ m
- ⁇ The difference from the target processing diameter is 2 ⁇ m to 5 ⁇ m
- the difference from the target machining diameter is more than 5 ⁇ m
- the resistance to desmear treatment was remarkably improved by providing the surface layer with a layer made of a cured product of the photocurable resin composition.
- the test substrate of each Example was favorable also about laser workability.
- the test substrate of the comparative example provided with a resist layer made of only the cured product of the thermosetting resin composition without the cured product of the photocurable resin composition on the surface layer has laser processability and desmear resistance. Both were inferior.
- test substrate of each example was evaluated according to the following method. The results are shown in Tables 5 and 6 below.
- Formation of grooved or protruding dams by photolithography The test substrate is exposed using an exposure apparatus on which a high-pressure mercury lamp is mounted so as to form a grooved or protruding dam having a line width of 100 ⁇ m and a length of 11 mm ⁇ width of 11 mm. Development was carried out using a 1.0 wt% Na 2 CO 3 aqueous solution at a temperature of 30 ° C. for a development time of 90 seconds. It was set as the exposure amount with which the residual sensitivity of 7 steps
- Laser workability was evaluated using a CO 2 laser (manufactured by Hitachi Via Mechanics).
- the processing diameter is aimed at a top diameter of 65 ⁇ m / bottom diameter of 50 ⁇ m.
- the processing conditions were aperture (mask diameter): 3.1 mm, pulse width 20 ⁇ sec, output 2 W, frequency 5 kHz, number of shots: burst 3 shots.
- the thermosetting resin composition layer was laser-processed with the photocurable resin composition layer, and it evaluated according to the following reference
- the difference from the target processing diameter includes both cases where the difference is larger than the target processing diameter and small.
- patterning is performed by a photolithography method on the resin insulating layer having the thermosetting resin composition layer and the photocurable resin composition layer in order from the substrate surface side.
- the dam was able to be formed. Formation of a dam by this method enables formation of a high-definition dam as compared with a method such as screen printing, and also enables rapid formation of a dam as compared with laser processing.
- the test substrate of each example was also good in laser processability.
- Substrate 1.
- Component mounting unit 3.
- Thermosetting resin composition layer 4.
- Photocurable resin composition layer Resin insulation layer 6.
- Printed wiring board 9b. Printed wiring board 10.
- Solder ball Chip 12.
- Flip chip mounting substrate 14 Underfill 15a.
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- Manufacturing & Machinery (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- Computer Hardware Design (AREA)
- Power Engineering (AREA)
- Materials For Photolithography (AREA)
- Non-Metallic Protective Coatings For Printed Circuits (AREA)
Abstract
Description
さらに、熱硬化性樹脂組成物層と、光硬化性樹脂組成物層とを、基板表面側から順に有する樹脂絶縁層に対し、フォトリソグラフィー法によるパターニングと、レーザー加工によるパターニングとを併用することによって、上記課題を解決しうることを見出し、本発明を完成するに至った。
また、本発明により、アンダーフィルの広がりを防止するダムを簡便に形成することのできるプリント配線板の製造方法、該方法で製造したプリント配線板、該プリント配線板にチップをフリップチップ実装したフリップチップ実装基板を提供することが可能となる。
本発明のドライフィルムは、キャリアフィルムと、光硬化性樹脂組成物を塗布、乾燥してなる光硬化性樹脂組成物層(L1)と、熱硬化性樹脂組成物を塗布、乾燥してなる熱硬化性樹脂組成物層(L2)とを少なくとも備えることを特徴とするものである。キャリアフィルム、L2、L1の順で、硬化性樹脂組成物層が積層されていてもよく、キャリアフィルム、L1、L2の順で硬化性樹脂組成物層が積層されていてもよい。いずれの態様においても、L1が表層、L2が基板側に位置するように、基板に対してラミネートすることにより用いる。表層側に光硬化性樹脂組成物層(L1)由来の硬化被膜が位置することによりデスミア耐性に優れるソルダーレジストを得ることができる。また、L1と基板との間に熱硬化性樹脂組成物層(L2)由来の硬化被膜を備える事により、電気特性に優れたソルダーレジストとすることができる。
剥離可能なカバーフィルムとしては、例えば、ポリエチレンフィルム、ポリテトラフルオロエチレンフィルム、ポリプロピレンフィルム、表面処理した紙等を用いることができ、カバーフィルムを剥離するときに硬化性樹脂組成物層とキャリアフィルムとの接着力よりも硬化性樹脂組成物層とカバーフィルムとの接着力がより小さいものであればよい。
なお、ブレードコーター、リップコーター、コンマコーター、フィルムコーター等の適宜の方法により、基板に硬化性樹脂組成物を直接塗布・乾燥して硬化性樹脂組成物層を形成することもできる。
また、基板に熱硬化性樹脂組成物を直接塗布、乾燥することにより熱硬化性樹脂組成物層を形成し、その熱硬化性樹脂組成物層上に、ドライフィルムをラミネートすることにより光硬化性樹脂組成物層を形成してもよい。
逆に、ドライフィルムを基板にラミネートすることにより熱硬化性樹脂組成物層を形成し、その熱硬化性樹脂組成物層上に、光硬化性樹脂組成物を直接塗布、乾燥することにより光硬化性樹脂組成物層を形成してもよい。
カルボキシル基含有樹脂としては、分子中にカルボキシル基を有している従来公知の各種カルボキシル基含有樹脂を使用できる。特に、分子中にエチレン性不飽和二重結合を有するカルボキシル基含有感光性樹脂が、光硬化性や耐現像性の面から好ましい。エチレン性不飽和二重結合は、アクリル酸もしくはメタアクリル酸又はそれらの誘導体由来であることが好ましい。
カルボキシル基含有樹脂の具体例としては、以下のような化合物(オリゴマー及びポリマーのいずれでもよい)を挙げることができる。
なお、本明細書において、(メタ)アクリレートとは、アクリレート、メタクリレート及びそれらの混合物を総称する用語で、他の類似の表現についても同様である。
また、前記カルボキシル基含有樹脂の酸価は、40~200mgKOH/gの範囲が適当であり、より好ましくは45~120mgKOH/gの範囲である。カルボキシル基含有樹脂の酸価が40mgKOH/g未満であるとアルカリ現像が困難となり、一方、200mgKOH/gを超えると現像液による露光部の溶解が進むために、必要以上にラインが痩せたり、場合によっては、露光部と未露光部の区別なく現像液で溶解剥離してしまい、正常なレジストパターンの描画が困難となるので好ましくない。
光重合開始剤としては、オキシムエステル基を有するオキシムエステル系光重合開始剤、α-アミノアセトフェノン系光重合開始剤、アシルホスフィンオキサイド系光重合開始剤からなる群から選択される1種以上の光重合開始剤を好適に使用することができる。
(式中、Xは、水素原子、炭素数1~17のアルキル基、炭素数1~8のアルコキシ基、フェニル基、フェニル基(炭素数1~17のアルキル基、炭素数1~8のアルコキシ基、アミノ基、炭素数1~8のアルキル基を持つアルキルアミノ基又はジアルキルアミノ基により置換されている)、ナフチル基(炭素数1~17のアルキル基、炭素数1~8のアルコキシ基、アミノ基、炭素数1~8のアルキル基を持つアルキルアミノ基又はジアルキルアミノ基により置換されている)を表し、Y、Zはそれぞれ、水素原子、炭素数1~17のアルキル基、炭素数1~8のアルコキシ基、ハロゲン基、フェニル基、フェニル基(炭素数1~17のアルキル基、炭素数1~8のアルコキシ基、アミノ基、炭素数1~8のアルキル基を持つアルキルアミノ基又はジアルキルアミノ基により置換されている)、ナフチル基(炭素数1~17のアルキル基、炭素数1~8のアルコキシ基、アミノ基、炭素数1~8のアルキル基を持つアルキルアミノ基又はジアルキルアミノ基により置換されている)、アンスリル基、ピリジル基、ベンゾフリル基、ベンゾチエニル基を表し、Arは、結合か、炭素数1~10のアルキレン、ビニレン、フェニレン、ビフェニレン、ピリジレン、ナフチレン、チオフェン、アントリレン、チエニレン、フリレン、2,5-ピロール-ジイル、4,4’-スチルベン-ジイル、4,2’-スチレン-ジイルで表し、nは0か1の整数である。)
(式中、R1は、炭素原子数1~4のアルキル基、または、ニトロ基、ハロゲン原子もしくは炭素原子数1~4のアルキル基で置換されていてもよいフェニル基を表す。
R2は、炭素原子数1~4のアルキル基、炭素原子数1~4のアルコキシ基、または、炭素原子数1~4のアルキル基もしくはアルコキシ基で置換されていてもよいフェニル基を表す。
R3は、酸素原子または硫黄原子で連結されていてもよく、フェニル基で置換されていてもよい炭素原子数1~20のアルキル基、炭素原子数1~4のアルコキシ基で置換されていてもよいベンジル基を表す。
R4は、ニトロ基、または、X-C(=O)-で表されるアシル基を表す。
Xは、炭素原子数1~4のアルキル基で置換されていてもよいアリール基、チエニル基、モルホリノ基、チオフェニル基、または、下記式で示される構造を表す。)
このような光重合開始剤、光開始助剤、及び増感剤の総量は、前記(E)カルボキシル基含有樹脂100質量部に対して35質量部以下であることが好ましい。35質量部を超えると、これらの光吸収により深部硬化性が低下する傾向にある。
感光性モノマーは、分子中に1個以上のエチレン性不飽和基を有する化合物である。感光性モノマーは、活性エネルギー線照射によるカルボキシル基含有樹脂の光硬化を助けるものである。
本発明の光硬化性樹脂組成物は、耐熱性、絶縁信頼性等の特性を向上させる目的で更に熱硬化性成分を含んでいてもよい。熱硬化性成分としては、アミノ樹脂、イソシアネート化合物、ブロックイソシアネート化合物、マレイミド化合物、ベンゾオキサジン化合物、オキサゾリン化合物、カルボジイミド化合物、シクロカーボネート化合物、多官能オキセタン化合物、エピスルフィド樹脂、エポキシ樹脂などの公知慣用の熱硬化性樹脂が使用できる。
これらのエポキシ樹脂は、1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。
前記の熱硬化性成分を含有する場合は、さらに熱硬化触媒を含有することが好ましい。熱硬化触媒としては、例えば、イミダゾール、2-メチルイミダゾール、2-エチルイミダゾール、2-エチル-4-メチルイミダゾール、2-フェニルイミダゾール、4-フェニルイミダゾール、1-シアノエチル-2-フェニルイミダゾール、1-(2-シアノエチル)-2-エチル-4-メチルイミダゾール等のイミダゾール誘導体;ジシアンジアミド、ベンジルジメチルアミン、4-(ジメチルアミノ)-N,N-ジメチルベンジルアミン、4-メトキシ-N,N-ジメチルベンジルアミン、4-メチル-N,N-ジメチルベンジルアミン等のアミン化合物、アジピン酸ジヒドラジド、セバシン酸ジヒドラジド等のヒドラジン化合物;トリフェニルホスフィン等のリン化合物などが挙げられる。また、市販されているものとしては、例えば四国化成工業(株)製の2MZ-A、2MZ-OK、2PHZ、2P4BHZ、2P4MHZ(いずれもイミダゾール系化合物の商品名)、サンアプロ社製のU-CAT(登録商標)3503N、U-CAT3502T(いずれもジメチルアミンのブロックイソシアネート化合物の商品名)、DBU、DBN、U-CATSA102、U-CAT5002(いずれも二環式アミジン化合物及びその塩)などが挙げられる。特に、これらに限られるものではなく、エポキシ樹脂やオキセタン化合物の熱硬化触媒、もしくはエポキシ基及び/又はオキセタニル基とカルボキシル基の反応を促進するものであればよく、単独で又は2種以上を混合して使用してもかまわない。また、グアナミン、アセトグアナミン、ベンゾグアナミン、メラミン、2,4-ジアミノ-6-メタクリロイルオキシエチル-S-トリアジン、2-ビニル-2,4-ジアミノ-S-トリアジン、2-ビニル-4,6-ジアミノ-S-トリアジン・イソシアヌル酸付加物、2,4-ジアミノ-6-メタクリロイルオキシエチル-S-トリアジン・イソシアヌル酸付加物等のS-トリアジン誘導体を用いることもでき、好ましくはこれら密着性付与剤としても機能する化合物を前記熱硬化触媒と併用する。
前記無機フィラーとしては、公知慣用の無機フィラーが使用できるが、特にシリカ、アルミナ(酸化アルミニウム)、窒化ホウ素、硫酸バリウム、タルク、及びノイブルグ珪土が好ましく用いられる。また、難燃性を付与する目的で、水酸化アルミニウム、水酸化マグネシウム、ベーマイトなども使用することができる。さらに、1個以上のエチレン性不飽和基を有する化合物や前記多官能エポキシ樹脂にナノシリカを分散したHanse-Chemie社製のNANOCRYL(商品名) XP 0396、XP 0596、XP 0733、XP 0746、XP 0765、XP 0768、XP 0953、XP 0954、XP 1045(何れも製品グレード名)や、Hanse-Chemie社製のNANOPOX(商品名) XP 0516、XP 0525、XP 0314(何れも製品グレード名)も使用できる。
(A)エポキシ樹脂としては、前記のエポキシ樹脂と同様のものを挙げることができる。中でも、ビスフェノールA型エポキシ樹脂、ナフトール型エポキシ樹脂、クレゾールノボラック型エポキシ樹脂、フェノールノボラック型エポキシ樹脂、又はそれらの混合物が好ましい。
これらのエポキシ樹脂は、1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。
(A)エポキシ樹脂の組成物中の配合量は、L2用の熱硬化性樹脂組成物の全固形分を基準として、好ましくは15~80質量%であり、より好ましくは15~60質量%である。
(B)エポキシ樹脂用硬化剤は、エポキシ基と反応する基を有する化合物であり、エポキシ樹脂用硬化剤として公知のものをいずれも使用することができる。エポキシ樹脂用硬化剤としては、多官能フェノール化合物、ポリカルボン酸及びその酸無水物、シアネートエステル樹脂、活性エステル樹脂、脂肪族又は芳香族の一級又は二級アミン、ポリアミド樹脂、ポリメルカプト化合物などが挙げられる。これらの中で、多官能フェノール化合物、及びポリカルボン酸及びその酸無水物、シアネートエステル樹脂、活性エステル樹脂が好ましく、多官能フェノール化合物がより好ましい。
上記(C)無機フィラーとしては、上記した無機フィラーと同様のものを挙げることができる。L2を形成する為の熱硬化性樹脂組成物中の配合量は、L2を形成する熱硬化性組成物の全固形分を基準として30~80質量%が好ましい。
上記熱可塑性樹脂(バインダーポリマー)は得られる硬化物の可撓性、指触乾燥性の向上を目的に配合される。熱可塑性樹脂としては、慣用公知のものを使用することができる。熱可塑性樹脂としてはセルロース系樹脂、ポリエステル系樹脂、フェノキシ樹脂が好ましい。セルロース系樹脂としてはイーストマン社製セルロースアセテートブチレート(CAB)、セルロースアセテートプロピオネート(CAP)シリーズ等が挙げられ、ポリエステル系樹脂としては東洋紡社製バイロンシリーズ、フェノキシ樹脂としてはビスフェノールA型、ビスフェノールF型、およびそれらの水添化合物のフェノキシ樹脂が好ましい。(D)熱可塑性樹脂の重量平均分子量(Mw)は好ましくは5000以上であり、より好ましくは、5000~100000である。
この範囲において、熱可塑性樹脂を含有することにより、良好なラミネート性、開口部の残渣除去性を発現する。
上記L2用の熱硬化性樹脂組成物には、ブロック共重合体を好適に配合することができる。ブロック共重合体とは、性質の異なる二種類以上のポリマーが、共有結合で繋がり長い連鎖になった分子構造の共重合体のことである。20℃~30℃の範囲において固体であるものが好ましい。この範囲内において固体であればよく、この範囲外の温度においても固体であってもよい。上記温度範囲において固体であることによりドライフィルム化したときや基板に塗布し仮乾燥したときのタック性に優れる。
また、X-Y-XあるいはX-Y-X’型ブロック共重合体のうち、X又はX’がTgが50℃以上のポリマー単位からなり、YがTgが-20℃以下であるポリマー単位からなるブロック共重合体がさらに好ましい。
また、X-Y-XあるいはX-Y-X’型ブロック共重合体のうち、X又はX’が上記(A)エポキシ樹脂との相溶性が高いものが好ましく、Yが上記(A)エポキシ樹脂との相溶性が低いものが好ましい。このように、両端のブロックがマトリックスに相溶であり、中央のブロックがマトリックスに不相溶であるブロック共重合体とすることで、マトリックス中において特異的な構造を示しやすくなると考えられる。
また、株式会社クラレ製のクラリティもメタクリル酸メチルとアクリル酸ブチルより誘導されるブロック共重合である。
(式中、nは2を表し、Zは、2価の有機基を表し、好ましくは、1,2-エタンジオキシ、1,3-プロパンジオキシ、1,4-ブタンジオキシ、1,6-ヘキサンジオキシ、1,3,5-トリス(2-エトキシ)シアヌル酸、ポリアミノアミン、例えばポリエチレンアミン、1,3,5-トリス(2-エチルアミノ)シアヌル酸、ポリチオキシ、ホスホネートまたはポリホスホネートの中から選択されるものである。Arは2価のアリール基を表す。)
この範囲において、ブロック共重合体を含有することにより、良好なラミネート性、開口部の残渣除去性を発現する。
上記の光硬化性樹脂組成物、熱硬化性樹脂組成物には、樹脂組成物の調製のためや、基板やキャリアフィルムに塗布するための粘度調整のために、有機溶剤を使用することができる。
上記の光硬化性樹脂組成物、熱硬化性樹脂組成物には、必要に応じてさらに、エラストマー、密着促進剤、着色剤、酸化防止剤、紫外線吸収剤などの成分を配合することができる。これらは、電子材料の分野において公知の物を使用することができる。また、上記の光硬化性樹脂組成物、熱硬化性樹脂組成物には、微粉シリカ、ハイドロタルサイト、有機ベントナイト、モンモリロナイトなどの公知慣用の増粘剤、シリコーン系、フッ素系、高分子系などの消泡剤及び/又はレベリング剤、イミダゾール系、チアゾール系、トリアゾール系等のシランカップリング剤、防錆剤などのような公知慣用の添加剤類を配合することができる。
本発明のプリント配線板の製造方法は、熱硬化性樹脂組成物層(L2)と、光硬化性樹脂組成物層(L1)とを、基板表面側から順に有する樹脂絶縁層を形成する工程、フォトリソグラフィー法でパターニングを行う工程、および、レーザー加工でパターニングを行う工程を含むものである。フォトリソグラフィー法でダムを形成することによって、広範囲なダムであっても、一度の現像工程で高精細に形成することができる。また、光硬化性樹脂組成物層(L1)の下に位置する熱硬化性樹脂組成物層(L2)によって、現像工程後も導体パターンを保護できる。また、ビアの形成等のフリップチップ接続される導体部等の部品実装部の露出にはレーザー加工を適用することができ、より高精細なパターニングが可能となる。さらに、導体の被覆を目的とする熱硬化性樹脂組成物層(L2)のパターンに影響を与えずにダムを形成することができる。本発明のプリント配線板の製造方法において、前記フォトリソグラフィー法でパターニングを行う工程によって前記光硬化性樹脂組成物層(L1)をパターニングし、前記レーザー加工でパターニングを行う工程によって前記熱硬化性樹脂組成物層(L2)をパターニングすることが好ましい。ダムは、溝状及び突状の少なくともいずれか一方の形状で形成されていることが好ましい。また、本発明により、ダムのみならず、マーキングも形成することができる。
以下、本発明のプリント配線板の製造方法について詳細に説明する。
本発明のプリント配線板の製造方法における、前記基板の表面に、熱硬化性樹脂組成物層(L2)と、光硬化性樹脂組成物層(L1)とを、基板表面側から順に有する樹脂絶縁層を形成する工程において、前記基板の表面とは、部品実装部が設けられた表面である。前記光硬化性樹脂組成物層(L1)と前記熱硬化性樹脂組成物層(L2)はそれぞれ、後述する光硬化性樹脂組成物と熱硬化性樹脂組成物を用いて形成することができる。光硬化性樹脂組成物層(L1)と熱硬化性樹脂組成物層(L2)の各層の膜厚について特に制限はないが、好ましくは、乾燥後の膜厚で、前記光硬化性樹脂組成物層(L1)の膜厚が1~20μmであり、前記熱硬化性樹脂組成物層(L2)の膜厚が1~100μmである。また、前記樹脂絶縁層はソルダーレジストを形成することが好ましい。プリント配線板上に形成された導体パターンとしては特に限定されるものではなく、従来公知の銅箔等のパターンを使用することができる。
また、前記基板に熱硬化性樹脂組成物を直接塗布、乾燥することにより熱硬化性樹脂組成物層(L2)を形成し、その熱硬化性樹脂組成物層(L2)上に、ドライフィルムをラミネートすることにより光硬化性樹脂組成物層(L1)を形成してもよい。
逆に、ドライフィルムを前記基板にラミネートすることにより熱硬化性樹脂組成物層(L2)を形成し、その熱硬化性樹脂組成物層(L2)上に、光硬化性樹脂組成物を直接塗布、乾燥することにより光硬化性樹脂組成物層(L1)を形成してもよい。
本発明における前記フォトリソグラフィー法でパターニングを行う工程として、露光工程と現像工程による従来公知のフォトリソグラフィー法によるパターニングを適用することができる。フォトリソグラフィー法で前記光硬化性樹脂組成物層(L1)に凹部を形成することにより、前記熱硬化性樹脂組成物層(L2)の上に、アンダーフィルの広がりを防止するダムを簡便に形成することができる。
露光工程は特に限定されるものではなく、例えば、接触式(又は非接触方式)により、ダムのパターンを形成したフォトマスクを通して選択的に活性エネルギー線により露光してもよく、もしくは直接描画装置により直接にダムのパターンを活性エネルギー線により露光してもよい。ただし、広範囲のダムを形成する場合には、露光時間を短縮できるため、直接描画装置で露光するよりも、フォトマスクを通して露光することが好ましい。
本発明における前記レーザー加工でパターニングを行う工程として、樹脂組成物にレーザーを照射する従来公知のレーザー加工によるパターニングを適用することができる。レーザー加工でパターニングすることによって、前記熱硬化性樹脂組成物層(L2)に所望のパターンを形成することができ、また、部品実装部に設けるビアの形成等の細部もパターニングすることができる。レーザー加工による前記熱硬化性樹脂組成物層(L2)のパターニングは、前記光硬化性樹脂組成物層(L1)ごと行ってもよく、また、前記フォトリソグラフィー法でパターニングを行う工程によって露出した部分に対して行ってもよい。レーザー加工は、熱硬化性樹脂組成物を熱硬化してから行うことが好ましい。照射するレーザーとしては、炭酸ガスレーザー、UV-YAGレーザー、エキシマレーザー等を使用することができる。
下記表1に示す成分を、表中に示す割合(質量部)にて配合し、攪拌機にて予備混合した後、3本ロールミルで混練し、L1用の光硬化性樹脂組成物ワニスを調製した。同様に、下記表2に示す成分を、表中に示す割合(質量部)にて配合し、攪拌機にて予備混合した後、3本ロールミルで混練し、L2用の熱硬化性樹脂組成物ワニスを調製した。
※2:サイクロマーP(ACA)Z250、固形分45%(ダイセル・サイテック社製)
※3:RMA-11902、固形分65%(日本乳化剤社製)
※4:DA-600(三洋化成工業社製)
※5:イルガキュアOXE02(BASFジャパン社製)
※6:イルガキュア389(BASFジャパン社製)
※7:ルシリン TPO(BASFジャパン社製)
※8:YX-4000(三菱化学社製)、粉体
※9:1B2PZ(四国化成社製)
※10:SO-C2(アドマテックス社製)、D50=0.5μm
※2:ナフトール型エポキシ樹脂、HP-4032(DIC社製)
※3:クレゾールノボラック型エポキシ樹脂、N-665 H60(DIC社製)
シクロヘキサノンで溶解、固形分60%
※4:フェノールノボラック型、HF-1M H60(明和化成社製)
シクロヘキサノンで溶解、固形分60%
※5:V-8000(DIC社製)、固形分45%
※6:EXB9560-65T(DIC社製)、固形分65%
※7:PT30(ロンザ社製)、半固形
※8:FX293H30、Mw=30000~50000(新日鐵化学社製)
シクロヘキサノンで溶解、固形分30%
※9:MMA部親水処理、MAM M52N H30(アルケマ社製)
シクロヘキサノンで溶解、固形分30%
※10:MAM M52 H30、Mw=95000(アルケマ社製)
シクロヘキサノンで溶解、固形分30%
※11:CAP-482-20、Mw=75000(EASTMAN社製)
※12:エスレックKS10 H30、Mw=17000(積水化学社製)
シクロヘキサノンで溶解、固形分30%
※13:SO-C2(アドマテックス社製)、D50=0.5μm
※14:AO-802(アドマテックス社製)、D50=0.7μm
※15:SN-9FWS、D50=0.7μm(電気化学工業社製)
※16:Co(II)acacの1%DMF溶液
※17:1B2PZ(四国化成社製)
※18:熱可塑性樹脂又はブロック共重合体の固形分換算の配合量
※19:熱可塑性樹脂又はブロック共重合体の固形分換算の配合率
上記で調製したL1用ワニスをキャリアフィルム(PETフィルム、厚さ:38μm)上にアプリケ-ターにより塗布した。なお、90℃で10分乾燥した後、厚みが約5μmになるように調製した。90℃、10分の乾燥後、上記で調製したL2用ワニスをL1の上にアプリケーターにより塗布した。L2用ワニスは、90℃で10分乾燥した後、厚みが約20μmになるように調製した。
各実施例、比較例について、下記表3、表4の記載に従って、L1用ワニス、L2用ワニスを用いた。銅厚みが15μmの、予め回路パターンが形成されている片面プリント配線板に対して、メック株式会社のCZ-8100を用いて前処理を行った。その後、上記で作製したドライフィルムを真空ラミネーターにより貼り合わせることで、基板から順に、L2、L1が積層されている基板を作製した。貼り合わせは、ラミネート後のフィルム厚みが、銅上で約15μmになる条件にて行った。
次に、高圧水銀灯を登載した露光装置を用いて、最適露光量でL1の光硬化性樹脂組成物を光硬化させた。その後、キャリアフィルムを剥離し、熱風循環式乾燥炉において170℃にて60分熱硬化させ、試験基板を作製した。
下記方法に従い、各実施例、比較例それぞれの試験基板について評価を行った。結果を下記表3、表4に示す。
(レーザー加工性)
CO2レーザー(日立ビアメカニクス社製)を用いてレーザー加工性を評価した。加工径狙いはトップ径65μm/ボトム径50μm。加工条件は、アパチャー(マスク径):3.1mm、パルス幅20μsec、出力2W、周波数5kHz、ショット数:バースト3ショットとした。各試験基板について、下記基準に従って評価した。なお、狙い加工径との差とは、狙い加工径よりも大きい場合、小さい場合の双方を含む。
○:狙い加工径との差が2μm未満
△:狙い加工径との差が2μm~5μm
×:狙い加工径との差が5μm超
下記デスミア処理条件および評価基準に従って、過マンガン酸デスミア水溶液(湿式法)によるデスミア耐性を評価した。
デスミア処理に用いた薬剤(ローム&ハース社)と条件は以下の通り。
膨潤 MLB-211 温度80℃/時間10min
過マンガン酸 MLB-213 温度80℃/時間15min
還元 MLB-216 温度50℃/時間5min
デスミア後、表面状態を評価する為、レーザー顕微鏡(VK-8500、キーエンス社製)を用いて表面粗度Raを測定した。評価基準は以下の通り。
○: 表面粗度Raが0.1μm未満
△: 表面粗度Raが0.1~0.3μm
×: 表面粗度Raが0.3μm超
デスミア処理後のビアホール周辺部のSEM観察を行って下記基準にしたがって評価した。
○:デスミア処理後でも、ビアホール周辺部にダメージが見られない。
△:デスミア処理後に、ビアホール周辺部にわずかにダメージが見られた。
×:デスミア処理後に、ビアホール周辺部にダメージが見られた。
各実施例について、下記表5、表6の記載に従って、光硬化性樹脂組成物層用ワニス、熱硬化性樹脂組成物層用ワニスを用いた。銅厚みが15μmの、予め回路パターンが形成されている片面プリント配線板に対して、メック株式会社のCZ-8100を用いて前処理を行った。その後、上記で作製したドライフィルムを真空ラミネーターにより貼り合わせることで、基板から順に、熱硬化性樹脂組成物層、光硬化性樹脂組成物層が積層されている基板を、試験基板として作製した。貼り合わせは、ラミネート後のフィルム厚みが、銅上で約15μmになる条件にて行った。
下記方法に従い、各実施例の試験基板について評価を行った。結果を下記表5、表6に示す。
(フォトリソグラフィー法による溝状または突状のダムの形成)
上記試験基板に対し、ライン幅100μm、縦11mm×横11mmの溝状または突状のダムを形成するように、高圧水銀灯を登載した露光装置を用いて露光した後、キャリアフィルムを剥離し、液温30℃の1.0wt%Na2CO3水溶液を用いて現像時間を90秒で現像を行った。ステップタブレット(コダック社製No.2 21段)にて7段の残存感度が得られる露光量とした。その後、熱風循環式乾燥炉において170℃にて60分熱硬化させた。乾燥後の基板を用いて、溝状または突状のダムの形成の可否を観察して評価し、形成できたものを○と評価した。
CO2レーザー(日立ビアメカニクス社製)を用いてレーザー加工性を評価した。加工径狙いはトップ径65μm/ボトム径50μm。加工条件は、アパチャー(マスク径):3.1mm、パルス幅20μsec、出力2W、周波数5kHz、ショット数:バースト3ショットとした。各試験基板について、光硬化性樹脂組成物層ごと熱硬化性樹脂組成物層をレーザー加工し、下記基準に従って評価した。なお、狙い加工径との差とは、狙い加工径よりも大きい場合、小さい場合の双方を含む。
○:狙い加工径との差が2μm未満
△:狙い加工径との差が2μm~5μm
各実施例の試験基板はレーザー加工性についても良好であった。
2.導体パターン
2a.部品実装部
3.熱硬化性樹脂組成物層
4.光硬化性樹脂組成物層
5.樹脂絶縁層
6.溝状のダム
7.突状のダム
8.開口部
9a.プリント配線板
9b.プリント配線板
10.はんだボール
11.チップ
12.バンプ
13a.フリップチップ実装基板
13b.フリップチップ実装基板
14.アンダーフィル
15a.アンダーフィルを充填したフリップチップ実装基板
15b.アンダーフィルを充填したフリップチップ実装基板
Claims (17)
- キャリアフィルムと、光硬化性樹脂組成物層(L1)とを備え、該光硬化性樹脂組成物層(L1)とキャリアフィルムとの間に、熱硬化性樹脂組成物層(L2)を少なくとも備えることを特徴とするドライフィルム。
- キャリアフィルムと、熱硬化性樹脂組成物層(L2)とを備え、該熱硬化性樹脂組成物層(L2)とキャリアフィルムとの間に、光硬化性樹脂組成物層(L1)を少なくとも備えることを特徴とするドライフィルム。
- 前記光硬化性樹脂組成物層(L1)の膜厚が1~20μmであり、前記熱硬化性樹脂組成物層(L2)の膜厚が1~100μmであることを特徴とする請求項1または2記載のドライフィルム。
- 前記光硬化性樹脂組成物層(L1)中の無機フィラーの含有割合が、L1を形成する光硬化性樹脂組成物の全固形分を基準として0~40wt%であることを特徴とする請求項1~3のいずれか一項記載のドライフィルム。
- 前記熱硬化性樹脂組成物層(L2)が、
(A)エポキシ樹脂、
(B)エポキシ硬化剤、および、
(C)無機フィラー、
を含有することを特徴とする請求項1~4のいずれか一項記載のドライフィルム。 - 前記熱硬化性樹脂組成物層(L2)が、さらに(D)熱可塑性樹脂を含むものであることを特徴とする請求項5記載のドライフィルム。
- 前記(D)熱可塑性樹脂の重量平均分子量(Mw)が5000以上であることを特徴とする請求項6記載のドライフィルム。
- 前記光硬化性樹脂組成物層(L1)が、
(E)カルボキシル基含有樹脂、
(F)光重合開始剤、および、
(G)感光性モノマー、
を含有することを特徴とする請求項1~7のいずれか一項記載のドライフィルム。 - 回路パターンが形成された基板上に、請求項1~8のいずれか一項記載のドライフィルムを用いて得られる硬化被膜を備えるプリント配線板であって、
表層側に光硬化性樹脂組成物層(L1)を硬化してなる硬化被膜を有し、基板と前記光硬化性樹脂組成物層(L1)由来の硬化被膜との間に、前記熱硬化性樹脂組成物層(L2)を硬化してなる硬化被膜を少なくとも有することを特徴とするプリント配線板。 - 基板の表面に、熱硬化性樹脂組成物層(L2)と、光硬化性樹脂組成物層(L1)とを、基板表面側から順に有する樹脂絶縁層を形成する工程、
フォトリソグラフィー法でパターニングを行う工程、および、
レーザー加工でパターニングを行う工程、
を含むことを特徴とするプリント配線板の製造方法。 - 前記フォトリソグラフィー法でパターニングを行う工程で形成された凹部がダムであることを特徴とする請求項10記載のプリント配線板の製造方法。
- 前記ダムが溝状及び突状の少なくとも何れか一方の形状で形成されていることを特徴とする請求項11記載のプリント配線板の製造方法。
- 前記樹脂絶縁層が、フィルム上に前記光硬化性樹脂組成物層(L1)と前記熱硬化性樹脂組成物層(L2)とが積層されてなるドライフィルムを、前記基板にラミネートすることにより形成されたものであることを特徴とする請求項10~12のいずれか一項記載のプリント配線板の製造方法。
- 前記樹脂絶縁層が、前記基板上に、熱硬化性樹脂組成物と光硬化性樹脂組成物とを順に直接塗布、乾燥することにより形成されたものであることを特徴とする請求項10~12のいずれか一項記載のプリント配線板の製造方法。
- 前記フォトリソグラフィー法でパターニングを行う工程によって前記光硬化性樹脂組成物層(L1)をパターニングし、前記レーザー加工でパターニングを行う工程によって前記熱硬化性樹脂組成物層(L2)をパターニングすることを特徴とする請求項10~14のいずれか一項記載のプリント配線板の製造方法。
- 請求項10~15のいずれか一項記載のプリント配線板の方法により製造されたことを特徴とするプリント配線板。
- 請求項16に記載のプリント配線板に、チップをフリップチップ実装したことを特徴とするフリップチップ実装基板。
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US14/367,611 US9596754B2 (en) | 2011-12-22 | 2012-12-18 | Dry film, printed wiring board using same, method for producing printed wiring board, and flip chip mounting substrate |
CN201280063442.XA CN104010815B (zh) | 2011-12-22 | 2012-12-18 | 干膜及使用其的印刷电路板、印刷电路板的制造方法、以及倒装芯片安装基板 |
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JP2011282020A JP5930704B2 (ja) | 2011-12-22 | 2011-12-22 | プリント配線板の製造方法、プリント配線板およびフリップチップ実装基板 |
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