WO2015152037A1 - フェノール樹脂、該フェノール樹脂を含むエポキシ樹脂組成物、該エポキシ樹脂組成物の硬化物、及び該硬化物を有する半導体装置 - Google Patents
フェノール樹脂、該フェノール樹脂を含むエポキシ樹脂組成物、該エポキシ樹脂組成物の硬化物、及び該硬化物を有する半導体装置 Download PDFInfo
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- epoxy resin
- phenol
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- general formula
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/16—Catalysts
- C08G18/22—Catalysts containing metal compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
- C08G18/12—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step using two or more compounds having active hydrogen in the first polymerisation step
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
- C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
- C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
- C08G8/12—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with monohydric phenols having only one hydrocarbon substituent ortho on para to the OH group, e.g. p-tert.-butyl phenol
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
- C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
- C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
- C08G8/20—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with polyhydric phenols
- C08G8/22—Resorcinol
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
- C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
- C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
- C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
- C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
- C08L61/12—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols with polyhydric phenols
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/29—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the material, e.g. carbon
- H01L23/293—Organic, e.g. plastic
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
Definitions
- the present invention relates to a phenol resin.
- the present invention also relates to an epoxy resin composition containing the phenol resin and a cured product of the epoxy resin composition. Furthermore, this invention relates to the semiconductor device which has this hardened
- Epoxy resin compositions are widely used in the fields of electrical / electronic parts, structural materials, adhesives, paints, etc. due to their workability and excellent electrical properties, heat resistance, adhesion, moisture resistance, etc.
- the thermal shrinkage ratio is improved by reducing the amount of the inorganic filler in the sealing resin (Patent Document 1), or the silicon compound is directly bonded to silicon.
- Patent Document 2 There has been proposed a method for improving the thermal contraction rate (Patent Document 2) of a sealing resin by using a silicone compound containing a silanol group without containing an alkoxy group.
- an object of the present invention is to provide a phenolic resin that can provide an epoxy resin composition having high heat shrinkage and high elastic modulus that can realize improvement in reliability by reducing warpage of a thinned single-side sealed package. It is to provide.
- the present invention is a phenol resin represented by the following general formula (1)
- the phenol resin includes the phenol resin and the following general formula (2).
- the present invention also provides an epoxy resin composition containing the phenol resin and the epoxy resin and a cured epoxy resin obtained by curing the epoxy resin composition.
- the semiconductor device of a thin single-sided sealed package having a sealing material formed from an epoxy resin composition using the phenolic resin of the present invention due to the high coefficient of thermal expansion during heating of the sealing material, The thermal contraction rate at the time of cooling is also high, whereby warpage generated in the substrate material on which the semiconductor device is mounted can be reduced.
- the phenol resin of the present invention is represented by the general formula (1).
- the saturated or unsaturated hydrocarbon group represented by R has a large rotational free volume around the phenylene axis, so that it exhibits high thermal expansion during heating, and consequently high thermal shrinkage during cooling.
- the carbon number of R is 2 or more and 15 or less as described above, preferably 3 or more and 15 or less, more preferably 3 or more and 10 or less, and most preferably 3 or 4.
- R when R is a saturated hydrocarbon group, examples of the group include an ethyl group, an n-butyl group, a tert-butyl group, a propyl group, and an octyl group. In particular, it is preferable to use a tert-butyl group which is a group having a large rotational free volume around the phenylene axis.
- examples of the group when R is an unsaturated hydrocarbon group, examples of the group include an allyl group, a 1-propenyl group, and an acetylene group.
- R may be the same or different. Preferably all R are the same group. In that case, the group is preferably an allyl group.
- q represents an integer of 1 or more and 3 or less as described above, and is preferably 1 or 2. In order to increase the thermal elastic modulus of the cured epoxy resin, a larger q value is preferable.
- p is preferably either 1 or 2. When p and q are both 1, R is preferably bonded to the o-position or p-position with respect to OH.
- n represents an integer of 0 or more as described above.
- the upper limit of n is preferably a value such that the melt viscosity at 150 ° C. of the phenol resin of the present invention is 30.0 P or less, more preferably 0.1 P or more and less than 20.0 P, and still more preferably 0.8.
- the value is preferably 1 P or more and 10.0 P or less, more preferably 0.1 P or more and 7.0 P or less, and most preferably 0.1 P or more and 5.0 P or less. Since the phenol resin of the present invention is an aggregate of polymers having various molecular weights, the value of n is represented by an average value in the aggregate.
- the phenol resin of the present invention preferably has a melt viscosity at 150 ° C. in the above-mentioned range from the viewpoint of successfully producing a semiconductor sealing material obtained by kneading with an inorganic filler or the like.
- the softening point is 100 ° C. or less, particularly 50 ° C. or more and 100 ° C. or less, particularly 60 ° C. or more and 90 ° C. or less, particularly 60 ° C. or more and 80 ° C. or less from a temperature lower than 25 ° C. (ie, liquid state at 25 ° C.).
- the hydroxyl group equivalent is 400 g / eq or less, particularly 300 g / eq or less, particularly 200 g / eq or less, and it is effectively prevented that the crosslinking density of the cured epoxy resin is excessively low, and the elasticity at the time of heating. It is preferable from the point which can suppress the fall of a rate effectively.
- the phenol resin of the present invention is a cured product obtained from the epoxy resin represented by the above general formula (2) and a curing accelerator, at 40 ° C. or higher and 180 ° C. or lower, 1.5% or higher, preferably 1 0.55% or more, more preferably 1.60% or more, still more preferably 1.65% or more, and most preferably 2.00% or more. In other words, it gives a high thermal contraction rate upon cooling. .
- a thermal expansion coefficient of the sealing material is high, that is, the thermal contraction rate during cooling is high. As a result, warpage generated in the substrate material on which the semiconductor device is mounted can be reduced.
- the phenol resin of the present invention is a cured product obtained from the epoxy resin represented by the general formula (2) and a curing accelerator. It is preferable to give a storage elastic modulus of 15 MPa or more at ° C. From the viewpoint of making the effect of reducing warpage even more pronounced, the phenolic resin of the present invention provides a storage elastic modulus of 15 MPa to 120 MPa, particularly 30 MPa to 110 MPa, particularly 80 MPa to 100 MPa. Even more preferred.
- the phenol resin of the present invention can be obtained by reacting a phenol compound represented by the following general formula (3) with formaldehyde under an acidic catalyst or a basic catalyst.
- phenol compound represented by the formula (3) examples include, but are not limited to, ethylphenol, propylphenol, n-butylphenol, tert-butylphenol, octylphenol, allylphenol, dipropylphenol, dibutylphenol and the like. These phenol compounds can be used individually by 1 type or in combination of 2 or more types. In particular, it is preferable to use allylphenol or tert-butylphenol from the viewpoint of increasing the thermal expansion coefficient during heating of the cured product obtained from the phenol resin of the present invention and increasing the thermal shrinkage ratio during cooling. Preference is given to using phenol.
- Formaldehyde which is a compound that forms a methylene crosslinking group between the compounds represented by formula (3), is not particularly limited in form.
- formaldehyde can be used in the form of its aqueous solution.
- it can be used in the form of a polymer such as paraformaldehyde or trioxane that decomposes in the presence of an acid to form formaldehyde.
- Preferable phenol resin in the present invention is a narrow dispersion type having a low low molecular weight component, can shorten the gelation time of the epoxy resin composition, and can increase the thermal expansion coefficient of the cured epoxy resin.
- limiting in particular in the lower limit of the ratio for which the compound of n 0 occupies the whole phenol resin, It is so preferable that it is small, Most preferably, it is 0.
- the total content with the compound is preferably 10.0 area% or less, and more preferably 7.0 area% or less.
- a narrow dispersion type phenol resin having a good balance between the molecular weight distribution and the molecular weight can be obtained, and the softening point and 150 ° C. melt viscosity of the phenol resin can be within a preferable range, and the gelation time of the epoxy resin composition
- the thermal expansion coefficient of the cured epoxy resin and the thermal elastic modulus can be increased.
- the weight average molecular weight of the preferred phenol resin in the present invention is not particularly limited, but is preferably 1000 or more and 8000 or less, more preferably 1400 or more and 4000 or less, and further preferably 1500 or more and 3000 or less.
- the value of weight average molecular weight / number average molecular weight, which is the degree of dispersion of the molecular weight distribution, is preferably 1.0 or more and 4.0 or less, more preferably 1.3 or more and 2.5 or less, and still more preferably 1.4 or more and 2. 0 or less.
- the gelation time of the epoxy resin composition can be shortened, and the thermal expansion coefficient of the cured epoxy resin can be increased and the elastic modulus during heat can be increased. it can.
- the phenol resin of the present invention can be obtained using the above-described phenol compound and formaldehyde as raw materials in the presence of an acidic catalyst or in the presence of a basic catalyst.
- the catalyst that can be used includes, for example, oxalic acid, sulfuric acid, paratoluenesulfonic acid and the like when it is an acidic catalyst.
- a basic catalyst for example, alkali metal catalysts such as sodium hydroxide and potassium hydroxide, ammonia, and amine-based catalysts such as triethylamine are exemplified.
- the above-mentioned narrow dispersion type phenol resin is not limited, but for example, a first resolation reaction of a phenol compound represented by the general formula (3) and formaldehyde in the presence of a basic catalyst. Suitable by a production method comprising a step and a second step of adding a phenol compound represented by the general formula (3) to the reaction mixture obtained in the first step and causing a novolak reaction in the presence of an acid catalyst. Can be prepared.
- the ratio of the phenol compound represented by the general formula (3) and formaldehyde that reacts in the first step is preferably 1 to 3 with respect to 1 mol of the phenol compound represented by the general formula (3). Mol, more preferably 1.5 to 2.5 mol.
- the amount of the basic catalyst used in the first step is not limited, but may be 0.1 to 1.5 moles per mole of the phenol compound represented by the general formula (3).
- the ratio is preferably 0.2 to 1.0 mol.
- the reaction temperature is not limited, but is preferably 10 to 80 ° C., more preferably 20 to 60 ° C. By setting the reaction temperature within this range, the reaction proceeds successfully, the high molecular weight component can also be suppressed, and the resolation reaction can be easily controlled.
- the reaction time is not limited, but is preferably 0.5 to 24 hours, and more preferably 3 to 12 hours.
- the reaction mixture obtained by the resolation reaction in the first step is neutralized with an acidic compound, then the phenol compound represented by the general formula (3) is added, and an acidic catalyst is further added.
- the acidic compound used for neutralization include hydrochloric acid, sulfuric acid, phosphoric acid, formic acid, acetic acid, oxalic acid, butyric acid, lactic acid, benzenesulfonic acid, and p-toluenesulfonic acid.
- One kind of acidic compound may be used alone, or two or more kinds may be used in combination.
- the phenol compound represented by the general formula (3) used in the second step is preferably 0.5 to 1. per mole of the phenol compound represented by the general formula (3) used in the first step. 5 moles, more preferably 0.7 to 1.1 moles.
- the amount of the acidic catalyst used in the second step is preferably 0.0001 to 0.07 mol with respect to 1 mol of the phenol represented by the general formula (3) used in the first step. More preferably, the proportion is 0.0005 to 0.05 mole.
- the reaction temperature is not limited, but is preferably about 50 to 150 ° C, more preferably about 80 to 120 ° C, and still more preferably about 70 to 100 ° C. By setting within this temperature range, the reaction can proceed successfully, the formation of high molecular weight components is suppressed, and the novolak reaction can be easily controlled.
- the reaction time is not limited, but is preferably 0.5 to 12 hours, and more preferably 1 to 6 hours. By setting the reaction time within this range, the reaction can proceed successfully, and the production of high molecular weight components is suppressed.
- the acidic catalyst used in the second step include the same acidic compounds used in the same step.
- the epoxy resin used in the epoxy resin composition of the present invention is not particularly limited.
- the epoxy resin used in the epoxy resin composition of the present invention is not particularly limited.
- Glycidyl ether type epoxy resin such as triphenolmethane type epoxy resin, biphenyl type epoxy resin, glycidyl ester type epoxy resin, glycidyl amine type epoxy resin, halogenated epoxy resin, etc. epoxy resin having two or more epoxy groups in the molecule, etc. Is mentioned.
- These epoxy resins may be used individually by 1 type, and may use 2 or more types together.
- a particularly preferable epoxy resin is the biphenyl type epoxy resin represented by the general formula (2) described above.
- the addition ratio of the epoxy resin used in the epoxy resin composition of the present invention is the ratio of the hydroxyl equivalent (g / eq) of the phenol resin represented by the formula (1) to the epoxy equivalent in the epoxy resin. Is preferably in the range of 0.5 to 2.0, more preferably in the range of 0.8 to 1.2.
- the curing reaction can sufficiently proceed, and it is possible to effectively prevent the unreacted curing agent and epoxy resin from remaining. Thereby, a cured product having a high coefficient of thermal expansion when heated, and thus having a high coefficient of thermal shrinkage when cooled can be obtained.
- the phenol resin represented by the formula (1) has a role of a curing agent for the epoxy resin in the epoxy resin composition of the present invention, and the epoxy resin composition of the present invention is a phenol represented by the formula (1).
- a curing agent other than the resin may be included.
- curing agents can be used.
- an amine curing agent, an amide curing agent, an acid anhydride curing agent, or the like can be used.
- the proportion of the phenol resin represented by the formula (1) in all the curing agents is sufficient for high expansion during heating of the cured product obtained from the epoxy resin composition. From the viewpoint of increasing the temperature and, in turn, sufficiently increasing the high heat shrinkability during cooling, a higher ratio is preferable.
- the proportion of the phenol resin represented by the formula (1) in all the curing agents is preferably 30% by mass or more, more preferably 50% by mass or more, and further preferably 70% by mass or more. More preferably, it is 90 mass%, Most preferably, it is 100 mass%.
- a curing accelerator for curing an epoxy resin with a phenol resin can be used.
- Preferred examples of the curing accelerator include known organic phosphine compounds and their boron salts, tertiary amines, quaternary ammonium salts, imidazoles and their tetraphenylboron salts. Among these, it is preferable to use triphenylphosphine from the viewpoints of curability and moisture resistance.
- fever latent hardening accelerator which expresses activity by heat processing.
- Examples of such a curing accelerator include tetraphenylphosphonium derivatives such as tetraphenylphosphonium and tetraphenylborate.
- the ratio of the curing accelerator added to the epoxy resin composition can be the same as the ratio in the known epoxy resin composition.
- a filler such as an inorganic filler can be suitably blended.
- the inorganic filler for example, amorphous silica, crystalline silica, alumina, calcium silicate, calcium carbonate, talc, mica, barium sulfate and the like can be used. In particular, it is preferable to use amorphous silica and crystalline silica.
- a filling rate when a filling rate is considered, it is desirable that it is 0.01 micrometer or more and 150 micrometers or less.
- the ratio of the inorganic filler to an epoxy resin composition is 70 to 95 mass%, and it is 70 to 90 mass%. Is more preferable. Setting the blending ratio of the inorganic filler within this range is preferable because the water absorption rate of the cured product of the epoxy resin composition is difficult to increase. Moreover, the thermal expansion property at the time of heating of this hardened
- the epoxy resin composition of the present invention if necessary, a release agent, a colorant, a coupling agent, a flame retardant and the like can be added or reacted in advance.
- the mixing ratio of these additives may be the same as the ratio in the known epoxy resin composition.
- the epoxy resin composition of the present invention contains a nitrogen-based flame retardant such as melamine and an isocyanuric acid compound, and a phosphorus-based flame retardant such as red phosphorus, a phosphoric acid compound and an organic phosphorus compound, if necessary. It can be added appropriately as a combustion aid.
- the epoxy resin composition of the present invention for example, a phenol resin, an epoxy resin, and a curing accelerator, an inorganic filler, and other additives that are added as necessary are uniformly mixed using a mixer or the like.
- the kneaded material is kneaded in a molten state using a kneader such as a heating roll, a kneader, or an extruder, the kneaded product is cooled, and pulverized as necessary.
- the epoxy resin composition thus obtained is not particularly limited, but can be suitably used as a sealing material for sealing a semiconductor element.
- an epoxy resin composition is molded by a molding method such as a transfer mold, a compression mold, or an injection mold, and the temperature is about 120 ° C. to 300 ° C.
- a semiconductor device can be suitably obtained by curing the epoxy resin composition by heat treatment or the like.
- the cured product of the epoxy resin composition has a high expansibility, so that the cured product is greatly shrunk when cooled, thereby causing warping. There is an advantageous effect that generation can be effectively reduced.
- the straight line part before and after the peak was taken as the baseline (zero value), and the peak was divided by the vertical cut at the lowest point between the peaks of each component.
- the sampling pitch was 500 milliseconds.
- molecular weight (Mw, Mn) and dispersity (Mw / Mn) were calculated by standard polystyrene conversion.
- HLC-8220 manufactured by Tosoh Corporation, gel permeation chromatograph analyzer
- Column pressure 13.5 MPa
- Flow rate 1 mL / min
- Measurement temperature 40 ° C
- Detector RI detector RANGE: 256 (Recorder output: 256 ⁇ 10 ⁇ 6 RIU / 10 mV)
- Temperature control temperature of RI optical block
- Injection volume 100 ⁇ mL
- Sample concentration 5 mg / mL (THF)
- Mw, Mn The molecular weight (Mw, Mn) and dispersity (Mw / Mn) of the phenol resin were measured by gel permeation chromatography
- HLC-8220 manufactured by Tosoh Corporation, gel permeation chromatograph analyzer
- Column pressure 13.5 MPa
- Flow rate 1 mL / min
- Measurement temperature 40 ° C
- Detector Spectrophotometer (UV-8020)
- RANGE 2.56 WAVE LENGTH: 254nm
- Injection volume 100 ⁇ mL
- Sample concentration 5 mg / mL (THF) ⁇ Gelification time>
- Equipment used Cyber Co., Ltd.
- Example 1 In a glass flask having a capacity of 300 parts equipped with a thermometer, charging / distilling outlet, condenser and stirrer, 134 parts (1.0 mol) of o-allylphenol, 32 parts of paraformaldehyde (0.98 mol), 0.4 parts of pure water and 1.1 parts of oxalic acid were added. The mixture was reacted at 100 ° C. for 12 hours under reflux, further reacted at 160 ° C. for 2 hours, and then cooled to 95 ° C. After cooling, 130 parts of pure water of 90 ° C. or higher was added and washed with water.
- the obtained phenol novolac resin A had a softening point of 73 ° C., a melt viscosity at 150 ° C. of 4.3 P, a hydroxyl group equivalent of 170 g / eq, and a gel time of 72 seconds.
- Example 2 In a glass flask having a capacity of 300 parts equipped with a thermometer, charging / distilling outlet, condenser and stirrer, 134 parts (1.0 mol) of o-allylphenol, 36 parts of 92% paraformaldehyde (1.1 mol), 0.4 parts of pure water and 1.1 parts of oxalic acid were added. The mixture was reacted at 100 ° C. for 12 hours under reflux, further reacted at 160 ° C. for 2 hours, and then cooled to 95 ° C. After cooling, 130 parts of pure water of 90 ° C. or higher was added and washed with water.
- the obtained phenol novolac resin B had a softening point of 98 ° C., a melt viscosity at 150 ° C. of 20 P, and a hydroxyl group equivalent of 172 g / eq.
- Example 3 In a glass flask with a capacity of 2000 parts equipped with a thermometer, charging / distilling outlet, condenser and stirrer, 1200 parts (9.0 moles) of o-allylphenol, 127 parts (1.8 moles) of 42% formalin, and 12 parts of oxalic acid was added. The mixture was reacted at 100 ° C. for 7 hours under reflux. After completion of the reaction, 600 parts of pure water of 90 ° C. or higher was added and washed with water.
- the obtained phenol novolac resin C was liquid at room temperature, and the hydroxyl group equivalent was 141 g / eq.
- Example 5 Into a glass flask having a capacity of 1000 parts equipped with a thermometer, a charging / distilling outlet, a condenser and a stirrer, p-tert-butylphenol 200 parts (1.3 mol), 42% formalin 57 parts (0.8 mol), 0.3 parts of oxalic acid was added. The mixture was reacted at 100 ° C. for 20 hours under reflux, and then cooled to 95 ° C. After cooling, 130 parts of pure water of 90 ° C. or higher was added and washed with water.
- the obtained phenol novolac resin E had a softening point of 99 ° C., an ICI viscosity at 150 ° C. of 4.3 P, and a hydroxyl group equivalent of 167 g / eq.
- Example 6 In a glass flask having a capacity of 300 parts (300 mL) equipped with a thermometer, charging / distilling outlet, condenser and stirrer, 67.0 parts (0.50 mol) of o-allylphenol, 71.4 parts of 42% formalin (1.00 mol) and 19.2 parts (0.12 mol) of 25% sodium hydroxide as a basic catalyst were added and reacted at 60 ° C. for 7 hours to carry out a resolation reaction in the first step. To this reaction mixture, 134 parts of pure water for stopping the reaction was added, the temperature was lowered to 40 ° C., and 17.5 parts (0.12 mol) of 25% hydrogen chloride was added to neutralize to obtain a reaction mixture. It was.
- the obtained phenol novolac resin I had a softening point of 59 ° C., an ICI viscosity of 1.2 P at 150 ° C., a hydroxyl group equivalent of 154 g / eq, and a gelation time of 59 seconds.
- Example 7 In a 300-part glass flask equipped with a thermometer, charging / distilling outlet, condenser and stirrer, 67.0 parts (0.50 mol) of o-allylphenol, 71.4 parts of 42% formalin (1. 00 mol) and 19.2 parts (0.12 mol) of 25% sodium hydroxide as a basic catalyst were added and reacted at 60 ° C. for 7 hours to carry out a resorching reaction in the first step. To this reaction mixture, 134 parts of pure water for stopping the reaction was added, the temperature was lowered to 40 ° C., and 17.5 parts (0.12 mol) of 25% hydrogen chloride was added to neutralize to obtain a reaction mixture. It was.
- the obtained phenol novolac resin J had a softening point of 74 ° C., an ICI viscosity of 4.3 P at 150 ° C., a hydroxyl group equivalent of 159 g / eq, and a gel time of 55 seconds.
- Example 8 In a 300-part glass flask equipped with a thermometer, charging / distilling outlet, condenser and stirrer, 67.0 parts (0.50 mol) of o-allylphenol, 71.4 parts of 42% formalin (1. 00 mol) and 19.2 parts (0.12 mol) of 25% sodium hydroxide as a basic catalyst were added and reacted at 60 ° C. for 7 hours to carry out a resorching reaction in the first step. To this reaction mixture, 134 parts of pure water for stopping the reaction was added, the temperature was lowered to 40 ° C., and 17.5 parts (0.12 mol) of 25% hydrogen chloride was added to neutralize to obtain a reaction mixture. It was.
- the obtained phenol novolak resin K had a softening point of 91 ° C., an ICI viscosity of 29 P at 150 ° C., a hydroxyl group equivalent of 159 g / eq, and a gelation time of 51 seconds.
- the resulting phenol novolac resin G had a softening point of 130 ° C., but the ICI viscosity at 150 ° C. could not be measured.
- the hydroxyl equivalent was 116 g / eq.
- the obtained phenol novolac resin H had a softening point of 81 ° C., an ICI viscosity at 150 ° C. of 1.7 P, and a hydroxyl group equivalent of 188 g / eq.
- the epoxy resin composition was prepared using the phenol resin obtained by the Example and the comparative example, and hardened
- the mixture was heated and melted and mixed, and then the amount of triphenylphosphine shown in Table 1 was added and mixed uniformly to obtain an epoxy resin composition.
- the obtained epoxy resin composition was post-cured at 150 ° C. for 5 hours and at 180 ° C. for 8 hours to obtain a cured epoxy resin.
- cured material about the obtained epoxy resin hardened
- the analysis method and the evaluation method used in the example of the cured product of the epoxy resin composition will be described.
- (1) Storage elastic modulus The epoxy cured product was cut into 40 mm ⁇ 2 mm ⁇ 4 mm and used as a measurement sample. The measurement was performed using a dynamic viscoelasticity measuring device RSA-G2 manufactured by TA Instruments Inc., and the storage elastic modulus was measured while increasing the temperature from 30 ° C. at a rate of 3 ° C./min. The storage elastic modulus was determined. The peak temperature of Tan ⁇ was defined as Tg.
- An epoxy cured product was cut into 10 mm ⁇ 6 mm ⁇ 4 mm and used as a measurement sample.
- thermomechanical analyzer TMA-60 manufactured by Shimadzu Corporation, the glass transition temperature and linear expansion coefficient ( ⁇ 1, ⁇ 2) of the sample were measured while increasing the temperature from 30 ° C. at a rate of 3 ° C./min.
- the linear expansion coefficient from 40 ° C to 70 ° C was ⁇ 1
- the linear expansion coefficient from 185 ° C to 220 ° C was ⁇ 2.
- the thermal expansion coefficient of the sample in 40 to 180 degreeC was calculated
- the cured epoxy resin obtained using the phenol novolak resin obtained in each example is the epoxy resin obtained using the phenol novolak resin obtained in each comparative example. It can be seen that the coefficient of thermal expansion is higher when heated compared to the cured product, in other words, the coefficient of thermal shrinkage is high when cooled, and the storage modulus is high.
- the coefficient of thermal expansion of the cured product can be increased and the gelation time can be shortened.
- the elastic modulus (thermal elastic modulus) can be increased.
- the substituent R is an allyl group.
- the coefficient of thermal expansion of the cured product can be increased, and the elastic modulus during heating can also be increased.
- Example 1 (150 ° C.
- the 150 ° C. melt viscosity value is more preferably 0.1 P or more and less than 20.0 P, further preferably 0.1 P or more and 10.0 P or less, and further preferably 0.1 P or more and 7 or less.
- Example 7 150 ° C. melt viscosity: 4.3 P, softening point: 74 ° C., storage modulus 96 MPa
- Example 8 150 ° C. melt viscosity: 29.0 P, softening point: 91 ° C., It is also clear by comparison with the storage elastic modulus 26 MPa).
- the number of groups is more than 1 (when it is 2 or more)
- even when the phenol novolak resin has a low melt viscosity at 150 ° C., for example, less than 0.1 P, it is cured with a high thermal modulus. You can get a body.
- the phenol resin of the present invention it is possible to obtain a cured product of an epoxy resin composition having a high thermal expansion coefficient during heating, that is, a high shrinkage ratio during cooling, and an elastic modulus during high heat. it can. Therefore, according to this invention, the phenol resin which can be used suitably for the epoxy resin composition of a thin single-sided sealing package can be provided.
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Abstract
Description
第1工程で反応する、一般式(3)で表されるフェノール化合物と、ホルムアルデヒドとの割合は、一般式(3)で表されるフェノール化合物1モルに対して、ホルムアルデヒドが好ましくは1~3モル、より好ましくは1.5~2.5モルである。フェノール化合物と、ホルムアルデヒドとの割合をこの範囲内に設定することで、低分子量成分の生成を抑制し得るとともに、高分子量成分の成分も抑制することができ、狭分散型のフェノール樹脂が得られる。
第2工程では、好ましくは、第1工程のレゾール化反応で得られた反応混合物を酸性化合物で中和した後、一般式(3)で表されるフェノール化合物を加え、更に酸性触媒を加える。中和に用いる酸性化合物としては、例えば塩酸、硫酸、リン酸、蟻酸、酢酸、シュウ酸、酪酸、乳酸、ベンゼンスルホン酸、p-トルエンスルホン酸等を好適に挙げることができる。酸性化合物は、一種類を単独で用いてもよく、二種類以上の複数種を併用して構わない。
以下のフェノール樹脂の調製の例で用いた分析方法及び評価方法について説明する。
<軟化点>JIS K6910に基づく環球法軟化点測定によって求めた。
<150℃溶融粘度>ICI溶融粘度計を用い、150℃でのフェノール樹脂及びエポキシ樹脂の溶融粘度を測定した。
ICI粘度の測定方法は以下のとおりである。
ICIコーンプレート粘度計 MODEL CV-1S TOA工業(株)
ICI粘度計のプレート温度を150℃に設定し、試料を所定量秤量する。
プレート部に秤量した樹脂を置き、上部からコーンで押さえつけ、90秒放置する。コーンを回転させて、そのトルク値をICI粘度として読み取る。
<水酸基当量>JIS K0070に準じた水酸基当量測定によって求めた。
<分子量分布の測定>以下のようにしてゲル浸透クロマトグラフ測定によりフェノール樹脂の分子量分布を測定した。フェノール樹脂におけるi成分(iは一般式(1)におけるn=iの成分を表す)の割合は解析ソフトMulti Station GPC-8020を用い、測定されたチャートにおけるピーク面積に基づき算出した。その際、ピーク前後の直線部分をベースライン(ゼロ値)とし、各成分のピーク間は最も低くなるところでの縦切りでピークを分けた。サンプリングピッチは500ミリ秒とした。また分子量(Mw、Mn)及び分散度(Mw/Mn)は標準ポリスチレン換算によって算出した。
装置:HLC-8220(東ソー株式会社製、ゲル浸透クロマトグラフ分析装置)
カラム:TSK-GEL Hタイプ
G2000H×L 4本
G3000H×L 1本
G4000H×L 1本
測定条件:カラム圧力 13.5MPa
溶解液:テトラヒドロフラン(THF)
フローレート:1mL/分
測定温度:40℃
検出器:RI検出部
RANGE:256(レコーダ出力:256×10-6RIU/10mV)
温度制御(RI光学ブロックの温調温度):40℃
インジェクション量:100μmL
試料濃度:5mg/mL(THF)
<分子量(Mw、Mn)及び分散度(Mw/Mn)の測定>以下のようにしてゲル浸透クロマトグラフ測定によりフェノール樹脂の分子量(Mw、Mn)及び分散度(Mw/Mn)を測定した。フェノール樹脂におけるi成分(iは一般式(1)におけるn=iの成分を表す)の割合は解析ソフトMulti Station GPC-8020を用い、測定されたチャートにおけるピーク面積に基づき算出した。その際、ピーク前後の直線部分をベースライン(ゼロ値)とし、各成分のピーク間は最も低くなるところでの縦切りでピークを分けた。サンプリングピッチは500ミリ秒とした。また分子量(Mw、Mn)及び分散度(Mw/Mn)は標準ポリスチレン換算によって算出した。
装置:HLC-8220(東ソー株式会社製、ゲル浸透クロマトグラフ分析装置)
カラム:TSK-GEL Hタイプ
G2000H×L 4本
G3000H×L 1本
G4000H×L 1本
測定条件:カラム圧力 13.5MPa
溶解液:テトラヒドロフラン(THF)
フローレート:1mL/分
測定温度:40℃
検出器:スペクトロフォトメーター(UV-8020)
RANGE:2.56
WAVE LENGTH:254nm
インジェクション量:100μmL
試料濃度:5mg/mL(THF)
<ゲル化時間>
使用機器:株式会社サイバー製 自動硬化時間測定装置
測定条件:150℃ 600rpm
測定方法:o-クレゾール型エポキシ樹脂 EOCN-1020-55(日本化薬株式会社製 エポキシ当量:195g/eq)のエポキシ当量とフェノール樹脂の水酸基当量を当量比(エポキシ当量と水酸基当量との比が1)にて混合し、硬化促進剤としてトリフェニルホスフィンをエポキシ樹脂に対し1.9%配合したエポキシ樹脂組成物を、50%メチルエチルケトン(MEK)溶液に調製する。エポキシ樹脂組成物のMEK溶液を約0.6mL量りとり装置の熱板上に乗せ測定する。測定されたトルクが、装置の測定上限トルク値の20%になった時間をゲルタイムとした。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量300部のガラス製フラスコに、o-アリルフェノール134部(1.0モル)、92%パラホルムアルデヒド32部(0.98モル)、純水0.4部及びシュウ酸1.1部を入れた。還流下に、100℃で12時間反応させ、更に160℃で2時間反応させた後、95℃まで冷却した。冷却後、90℃以上の純水130部を投入して水洗した。その後、内温を160℃まで昇温し、減圧-スチーミング処理を行い、未反応成分を除去することで、フェノールノボラック樹脂A(一般式(1)におけるRがアリル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Aの軟化点は73℃、150℃での溶融粘度は4.3P、水酸基当量は170g/eq、ゲル化時間は72秒であった。ゲル浸透クロマトグラフ測定による、n=0の化合物はフェノール樹脂全体の5.9面積%であり、n=1の化合物はフェノール樹脂全体の6.2面積%であった。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量300部のガラス製フラスコに、o-アリルフェノール134部(1.0モル)、92%パラホルムアルデヒド36部(1.1モル)、純水0.4部及びシュウ酸1.1部を入れた。還流下に、100℃で12時間反応させ、更に160℃にて2時間反応させた後、95℃まで冷却した。冷却後、90℃以上の純水130部を投入して水洗した。その後、内温を160℃まで昇温し、減圧-スチーミング処理を行い、未反応成分を除去することで、フェノールノボラック樹脂B(一般式(1)におけるRがアリル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Bの軟化点は98℃、150℃での溶融粘度は20P、水酸基当量は172g/eqであった。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量2000部のガラス製フラスコに、o-アリルフェノール1200部(9.0モル)、42%ホルマリン127部(1.8モル)、及びシュウ酸12部を入れた。還流下に、100℃で7時間反応させた。反応終了後、90℃以上の純水600部を投入して水洗した。その後、内温を160℃まで昇温し、減圧-スチーミング処理を行い、未反応成分を除去することでフェノールノボラック樹脂C(一般式(1)におけるRがアリル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Cは常温で液状であり、水酸基当量は141g/eqであった。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量300部のガラス製フラスコに、ジアリルレゾルシン95部(0.5モル)、42%ホルマリン14部(0.2モル)を入れた。還流下に、100℃で12時間反応させた後、95℃まで冷却した。冷却後、90℃以上の純水110部を投入して水洗した。その後、内温を160℃まで昇温し、減圧を行い、フェノールノボラック樹脂D(一般式(1)におけるRがアリル基、p=2、q=2のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Dは常温で液状であり、水酸基当量は108g/eqであった。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量1000部のガラス製フラスコに、p-tert-ブチルフェノール200部(1.3モル)、42%ホルマリン57部(0.8モル)、シュウ酸0.3部を入れた。還流下に、100℃で20時間反応させた後、95℃まで冷却した。冷却後、90℃以上の純水130部を投入して水洗した。その後、内温を180℃まで昇温し、減圧-スチーミング処理を行い、未反応成分を除去することで、フェノールノボラック樹脂E(一般式(1)におけるRがtert-ブチル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Eの軟化点は99℃、150℃でのICI粘度は4.3P、水酸基当量は167g/eqであった。
温度計、仕込み・留出口、冷却器及び撹拌器を備えた容量300部(300mL)のガラス製フラスコに、o-アリルフェノール67.0部(0.50モル)、42%ホルマリン71.4部(1.00モル)、及び塩基性触媒として25%水酸化ナトリウム19.2部(0.12モル)を投入し、60℃で7時間反応させて第1工程のレゾール化反応を行った。この反応混合物に、反応停止用の純水134部を投入し、40℃に温度を下げて、25%塩化水素を17.5部(0.12モル)加えて中和して反応混合物を得た。次いで反応混合物にo-アリルフェノール73.7部(0.55モル)、及び酸触媒としてシュウ酸1.3部を投入し、100℃で2時間、次いで120℃で2時間反応させて第2工程のノボラック化反応を行った。得られた反応混合液を、95℃に温度を下げて、同温度の純水134部にて水洗した。水洗後、160℃に昇温し、減圧スチーミング処理を行い、未反応性分を除去することで、フェノールノボラック樹脂I(一般式(1)におけるRがアリル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Iの軟化点は59℃、150℃でのICI粘度は1.2P、水酸基当量は154g/eq、ゲル化時間は59秒であった。ゲル浸透クロマトグラフ測定による、n=0の化合物はフェノール樹脂全体の3.5面積%であり、n=1の化合物はフェノール樹脂全体の6.0面積%であった。
温度計、仕込み・留出口、冷却器及び撹拌器を備えた容量300部のガラス製フラスコに、o-アリルフェノール67.0部(0.50モル)、42%ホルマリン71.4部(1.00モル)、及び塩基性触媒として25%水酸化ナトリウム19.2部(0.12モル)を投入し、60℃で7時間反応させて第1工程のレゾール化反応を行った。この反応混合物に、反応停止用の純水134部を投入し、40℃に温度を下げて、25%塩化水素を17.5部(0.12モル)加えて中和して反応混合物を得た。次いで反応混合物にo-アリルフェノール60.3部(0.45モル)、及び酸触媒としてシュウ酸1.3部を投入し、100℃で2時間、次いで120℃で2時間反応させて第2工程のノボラック化反応を行った。その後は実施例6と同様にして、フェノールノボラック樹脂J(一般式(1)におけるRがアリル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Jの軟化点は74℃、150℃でのICI粘度は4.3P、水酸基当量は159g/eq、ゲル化時間は55秒であった。ゲル浸透クロマトグラフ測定による、n=0の化合物はフェノール樹脂全体の1.9面積%であり、n=1の化合物はフェノール樹脂全体の4.1面積%であった。
温度計、仕込み・留出口、冷却器及び撹拌器を備えた容量300部のガラス製フラスコに、o-アリルフェノール67.0部(0.50モル)、42%ホルマリン71.4部(1.00モル)、及び塩基性触媒として25%水酸化ナトリウム19.2部(0.12モル)を投入し、60℃で7時間反応させて第1工程のレゾール化反応を行った。この反応混合物に、反応停止用の純水134部を投入し、40℃に温度を下げて、25%塩化水素を17.5部(0.12モル)加えて中和して反応混合物を得た。次いで反応混合物にo-アリルフェノール46.9部(0.35モル)、及び酸触媒としてシュウ酸1.3部を投入し、100℃で2時間、次いで120℃で2時間反応させて第2工程のノボラック化反応を行った。その後は実施例6と同様にして、フェノールノボラック樹脂K(一般式(1)におけるRがアリル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Kの軟化点は91℃、150℃でのICI粘度は29P、水酸基当量は159g/eq、ゲル化時間は51秒であった。ゲル浸透クロマトグラフ測定による、n=0の化合物はフェノール樹脂全体の1.4面積%であり、n=1の化合物はフェノール樹脂全体の2.8面積%であった。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量1000部のガラス製フラスコに、フェノール513部(5.5モル)、42%ホルマリン229部(3.3モル)、及びシュウ酸0.6部を入れた。還流下に、100℃で6時間反応させた。反応終了後、内温を160℃まで昇温し、減圧-スチーミング処理を行い、未反応成分を除去することで、フェノールノボラック樹脂F(一般式(1)におけるp=1、q=0のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Fの軟化点は83℃、150℃でのICI粘度は2.0P、水酸基当量は107g/eqであった。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量300部のガラス製フラスコに、o-クレゾール108部(1.0モル)、92%パラホルムアルデヒド32部(0.98モル)、純水0.4部及びシュウ酸1.1部を入れた。還流下に、100℃で6時間反応させ、更に160℃で2時間反応させた。反応終了後、減圧-スチーミング処理を行い、未反応成分を除去することで、フェノールノボラック樹脂G(一般式(1)におけるRがメチル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Gの軟化点は130℃であったが、150℃でのICI粘度は測定できなかった。水酸基当量は116g/eqであった。
温度計、仕込み・留出口、冷却器及び攪拌機を備えた容量300部のガラス製フラスコに、o-フェニルフェノール170部(1.0モル)、42%ホルマリン42部(0.58モル)、及びパラトルエンスルホン酸3.8部を入れた。還流下に、100℃で7時間反応させた後、95℃まで冷却した。冷却後、25%水酸化ナトリウム水溶液で中和した。更に、90℃以上の純水340部を投入して水洗した。その後、内温を160℃まで昇温し、減圧-スチーミング処理を行い、未反応成分を除去することで、フェノールノボラック樹脂H(一般式(1)におけるRがフェニル基、p=1、q=1のフェノールノボラック樹脂)を得た。得られたフェノールノボラック樹脂Hの軟化点は81℃、150℃でのICI粘度は1.7P、水酸基当量は188g/eqであった。
実施例及び比較例で得られたフェノール樹脂と、前記の一般式(2)で表されるビフェニル型エポキシ樹脂(三菱化学株式会社製 YX-4000 エポキシ当量:186g/eq)と、硬化促進剤としてのトリフェニルホスフィン(北興化学株式会社製 TPP)とを使用してエポキシ樹脂組成物を調製した。調製においては、フェノール樹脂とエポキシ樹脂とを、水酸基当量とエポキシ当量との比である〔水酸基当量(g/eq)/エポキシ当量(g/eq)〕の値が1となるように両者を配合して加熱溶融混合した後、表1に示す量のトリフェニルホスフィンを加え均一に混合し、エポキシ樹脂組成物を得た。得られたエポキシ樹脂組成物を150℃で5時間、180℃で8時間のポストキュアを行い、エポキシ樹脂硬化物を得た。得られたエポキシ樹脂硬化物について、熱膨張率、ガラス転移点、線膨張係数及び貯蔵弾性率を測定した。
(1)貯蔵弾性率
エポキシ硬化物を40mm×2mm×4mmに切り出し測定試料とした。測定は、ティー・エイ・インスツルメント社製動的粘弾性測定装置RSA-G2を用い、30℃から3℃/分の昇温速度で昇温しながら貯蔵弾性率を測定し、250℃での貯蔵弾性率を求めた。またTanδのピーク温度をTgとした。
(2)ガラス転移温度(Tg)、線膨張係数(α1、α2)及び熱膨張率
エポキシ硬化物を10mm×6mm×4mmに切り出し測定試料とした。島津製作所株式会社製熱機械分析装置 TMA-60を用い、30℃から3℃/分の昇温速度で昇温しながら試料のガラス転移温度及び線膨張係数(α1、α2)を測定した。40℃から70℃の線膨張係数をα1、185℃から220℃の線膨張係数をα2とした。また、40℃から180℃における試料の熱膨張率を求めた。
特に、実施例1と実施例6ないし8との対比から明らかなとおり、一般式(1)においてn=0の化合物の割合を、フェノールノボラック樹脂の全体に対して5%以下の少量にすることによって、硬化物の熱膨張率を高くすることができ、且つゲル化時間を短縮化できる。
また、実施例1と実施例6ないし8との対比から明らかなとおり、一般式(1)においてn=0の化合物とn=1の化合物との合計の割合を、フェノールノボラック樹脂の全体に対して10%以下にすることによって、硬化物の熱膨張率を高くすることができ、且つゲル化時間を短縮化できる。
更に、実施例6ないし8との対比から明らかなとおり、一般式(1)においてn=0の化合物とn=1の化合物との合計の割合をフェノールノボラック樹脂の全体に対して10%以下とし、且つn=2である化合物の割合を5.0%以上13.5%以下とすることによって、硬化物の熱膨張率を高くすることができ、且つゲル化時間を短縮化でき、且つ貯蔵弾性率(熱時弾性率)を高くすることができる。
また実施例1、2、4及び7(置換基Rはアリル基)と、比較例1、2及び3(置換基Rはアリル基以外)との対比から明らかなとおり、置換基Rがアリル基とすることによって、硬化物の熱膨張率を高くすることができ、且つ熱時弾性率も高くすることができる。同様のことは、実施例1(置換基Rはアリル基)と実施例5(置換基Rはtert-ブチル基)との対比からも明らかである。
また、実施例1(150℃溶融粘度:4.3P、軟化点:73℃、貯蔵弾性率86MPa)と実施例2(150℃溶融粘度:20.0P、軟化点:98℃、貯蔵弾性率:33MPa)との対比から明らかなとおり、150℃溶融粘度の値が、より好ましくは0.1P以上20.0P未満、更に好ましくは0.1P以上10.0P以下、更に好ましくは0.1P以上7.0P以下、最も好ましくは、0.1P以上5.0P以下であるフェノールノボラック樹脂を用いて硬化体を製造すると、該硬化物の熱時弾性率を高くすることができる。同様のことは、実施例7(150℃溶融粘度:4.3P、軟化点:74℃、貯蔵弾性率96MPa)と、実施例8(150℃溶融粘度:29.0P、軟化点:91℃、貯蔵弾性率26MPa)との対比によっても明らかである。
更に、実施例4(置換基R:アリル基、p=2、q=2、軟化点:液状、150℃溶融粘度:<0.1、貯蔵弾性率100MPa)と、実施例3(置換基R:アリル基、p=1、q=1、軟化点:液状、150℃溶融粘度:<0.1、貯蔵弾性率19MPa)との対比から明らかなとおり、q(一つのフェノール核に結合するアリル基の数)が1を超える場合(2以上である場合)には、フェノールノボラック樹脂の150℃における溶融粘度が低い場合、例えば0.1P未満の場合であっても、高熱時弾性率の硬化体を得ることができる。
Claims (13)
- 前記硬化物に、250℃において、15MPa以上の貯蔵弾性率を与えるものである請求項1に記載のフェノール樹脂。
- 前記一般式(1)におけるRがアリル基であり、pが1又は2であり、qが1又は2である請求項1又は2に記載のフェノール樹脂。
- 軟化点が60℃以上90℃以下である請求項1ないし3のいずれか一項に記載のフェノール樹脂。
- ゲル浸透クロマトグラフ測定による分子量分布において、一般式(1)中、n=0である化合物の含有量が5.5面積%以下である請求項1ないし4のいずれか一項に記載のフェノール樹脂。
- ゲル浸透クロマトグラフ測定による分散度[重量平均分子量/数平均分子量]が1.0以上4.0以下である請求項1ないし5のいずれか一項に記載のフェノール樹脂。
- 請求項1ないし6のいずれか一項に記載のフェノール樹脂とエポキシ樹脂とを含むエポキシ樹脂組成物。
- 更に硬化促進剤を含む請求項7に記載のエポキシ樹脂組成物。
- 更に無機充填剤を含む請求項7又は8に記載のエポキシ樹脂組成物。
- 請求項7ないし9のいずれか一項に記載のエポキシ樹脂組成物を硬化させてなるエポキシ樹脂硬化物。
- 40℃以上180℃以下における熱膨張率が1.5%以上である請求項10に記載のエポキシ樹脂硬化物。
- 請求項10又は11に記載のエポキシ樹脂硬化物を有する半導体装置。
- 薄型片面封止パッケージからなる請求項12に記載の半導体装置。
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