WO2016117554A1 - 熱硬化性接着剤組成物、熱硬化性接着フィルム、および複合フィルム - Google Patents
熱硬化性接着剤組成物、熱硬化性接着フィルム、および複合フィルム Download PDFInfo
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- WO2016117554A1 WO2016117554A1 PCT/JP2016/051429 JP2016051429W WO2016117554A1 WO 2016117554 A1 WO2016117554 A1 WO 2016117554A1 JP 2016051429 W JP2016051429 W JP 2016051429W WO 2016117554 A1 WO2016117554 A1 WO 2016117554A1
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- WIPO (PCT)
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- film
- component
- adhesive composition
- thermosetting adhesive
- structural formula
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
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- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
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- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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- B32B2457/00—Electrical equipment
- B32B2457/14—Semiconductor wafers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F212/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring
- C08F212/34—Monomers containing two or more unsaturated aliphatic radicals
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
- C09J2203/326—Applications of adhesives in processes or use of adhesives in the form of films or foils for bonding electronic components such as wafers, chips or semiconductors
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2400/00—Presence of inorganic and organic materials
- C09J2400/10—Presence of inorganic materials
- C09J2400/16—Metal
- C09J2400/163—Metal in the substrate
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2400/00—Presence of inorganic and organic materials
- C09J2400/20—Presence of organic materials
- C09J2400/22—Presence of unspecified polymer
- C09J2400/226—Presence of unspecified polymer in the substrate
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2453/00—Presence of block copolymer
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2467/00—Presence of polyester
- C09J2467/006—Presence of polyester in the substrate
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2479/00—Presence of polyamine or polyimide
- C09J2479/08—Presence of polyamine or polyimide polyimide
Definitions
- the present invention relates to a thermosetting adhesive composition characterized by low dielectric properties, high adhesiveness, high heat resistance and high flexibility, an adhesive film using the adhesive composition, an adhesive film and a metal foil, and a plastic film
- the present invention relates to an adhesive film with a base material laminated with paper, and an adhesive film with a base material laminated with an adhesive film, a plastic film and a copper foil, and the thermosetting adhesive composition and thermosetting according to the present invention.
- the adhesive film and the thermosetting adhesive film with a substrate are useful as adhesive and insulating materials for printed wiring boards, flexible printed wiring boards, semiconductor lead frames and the like.
- FPC Flexible Printed Circuit
- FPC forms a circuit pattern on a copper foil laminated on a heat-resistant and insulating plastic film represented by polyimide, and the circuit pattern is filled with a thermosetting insulating resin. It has a structure covered with a heat-resistant film.
- An uncured circuit pattern filling resin and a heat-resistant film integrated in advance are referred to as a coverlay film, and various types have been proposed so far.
- coverlay film An uncured circuit pattern filling resin and a heat-resistant film integrated in advance are referred to as a coverlay film, and various types have been proposed so far.
- it is widely practiced to multilayer FPCs, and what is used for multilayering is a so-called bonding sheet obtained by processing a thermosetting adhesive into a thin sheet.
- FCCL Flexible Clad Laminate
- coverlay film and a bonding sheet in which copper foil is laminated on polyimide film, etc.
- the copper foil layer and Other copper foil layers ensure insulation by interposing a polyimide film, etc., but in recent years demand for higher functionality for FPC, especially for thinning, polyimide film etc. are excluded, cover lay film
- the construction method which ensures the insulation between copper foil layers using the thermosetting type adhesive agent used for the bonding sheet is proposed. What is used in this construction method is FRCC (Flexible Resin Coated ⁇ ⁇ Copper) in which an uncured thermosetting adhesive layer and copper foil are integrated.
- Coverlay film, bonding sheet and FRCC have high adhesive strength to insulating plastic film and copper foil, which are FPC base materials, as well as high heat resistance that can withstand soldering process, and withstand repeated bending. Flexibility to obtain is required.
- Materials used for printed wiring boards have a low dielectric constant ( ⁇ ). And a low dielectric loss tangent (tan ⁇ ).
- the printed wiring board base material soaked with resin in glass cloth, so-called prepreg has low dielectric constant and low dielectric loss tangent characteristics such as fluorine resin, cyanate ester resin, polyphenylene ether resin instead of the conventional epoxy resin. It has been proposed to use a resin. (For example, Patent Documents 1 to 3)
- LCP film Liquid Crystal Polymer film
- the prepreg is manufactured by impregnating a porous substrate such as glass cloth with a resin solution for impregnation diluted with a solvent, and then drying it, so that the resin solution for impregnation used in the prepreg has a solid content concentration. Is required, while the viscosity is low.
- multilayering is effective for miniaturization and high density in a printed wiring board, but in a multilayer printed wiring board, another prepreg is covered on a prepreg on which a copper foil pattern is formed, and then heated and heated.
- the printed wiring board is required to have a low coefficient of linear expansion and a high glass transition temperature in the impregnated resin in order to prevent the occurrence of cracks due to temperature changes.
- relatively low-molecular thermosetting resins that exhibit high rigidity and high glass transition temperature after curing are widely used as impregnating resin materials.
- an elastomer is a substance having a high coefficient of linear expansion and a low glass transition temperature, it is not preferable to use an elastomer as a main component of a resin for impregnating a prepreg (for example, Patent Documents 3 and 4).
- a resin composition not containing an elastomer, or a resin composition having an elastomer content of 50% by weight or less based on the whole resin composition exhibits a hard and brittle property, but the prepreg can be realized if strength can be secured in a composite state with a glass cloth or the like.
- the prepreg is not required to have high flexibility due to its durability and the characteristics of the printed wiring board.
- the resin composition for prepreg itself does not require high strength and high flexibility. Therefore, a resin composition that does not contain the above-mentioned elastomer or has a low elastomer content is preferably used as the prepreg material.
- the strength, flexibility, etc. when the FPC material is made into a film are particularly important.
- the FPC material is laminated by heating and pressurization, but it is also important that the melt viscosity is not significantly reduced and does not flow out.
- the FPC material is required to have high flexibility even after heat curing. That is, the properties required for the prepreg material and the FPC material differ greatly, and a resin composition containing a large amount of elastomer having high strength, high flexibility, and high melt viscosity is suitable as the FPC material.
- the resin compositions shown in the above documents have a mechanism that develops adhesive strength as the thermosetting resin cures, which can be said to be an extension of the prior art, that is, the adherend surface with polarity and the polarity. Therefore, it does not exhibit high adhesion to both the LCP film, which is a low-polarity material, and copper, which is a high-polarity material.
- it provides a thermosetting adhesive composition having a low dielectric constant and a low dielectric loss tangent, high heat resistance capable of withstanding rapid heating in the soldering process, and high flexibility capable of withstanding bending. It wasn't.
- the present invention has a low dielectric constant and a low dielectric loss tangent, high adhesion strength to LCP film and copper foil, high heat resistance capable of withstanding rapid heating in the soldering process, and high flexibility capable of withstanding bending. It is an object of the present invention to provide a thermosetting adhesive composition, and a bonding sheet, coverlay film, FRCC, and FCCL with an adhesive using the adhesive composition.
- thermosetting adhesive comprising a combination of a vinyl compound having a polyphenylene ether skeleton represented by the structural formula (1), a bismaleimide resin having two or more maleimide groups in the molecule, and a polyolefin elastomer.
- thermosetting adhesive composition having a high adhesive strength to a foil, a high heat resistance that can withstand a soldering process, and a high flexibility that can withstand bending after thermosetting can be obtained.
- thermosetting adhesive is further applied to both sides of the bonding sheet applied to one surface of the release film, the coverlay film applied to one surface of the heat resistant film, and the heat resistant film.
- Component (A) Mainly comprises a vinyl compound having a polyphenylene ether skeleton represented by structural formula (1), Component (B) a maleimide resin having two or more maleimide groups in the molecule, and Component (C) a polyolefin skeleton.
- thermoplastic elastomer that is a copolymer of a polyolefin block and a polystyrene block
- the equivalent ratio of the vinyl group contained in the component (A) and the maleimide group contained in the component (B) is 1.0: 0.5 to 1.0: 4.0
- the ratio of the component (C) to the total weight of the component (A), the component (B), and the component (C) is 55 to 95% by weight
- the ratio of the styrene unit of the component (C) to the total weight of the component (C) is 10 to 40% by weight
- the 100% elongation tensile stress is 0.1 to 2.9 MPa
- the elongation at break is 100% or more.
- a thermosetting adhesive composition characterized by the above.
- each of the substituents R 1 , R 2 , R 3 and R 4 is a hydrogen atom, a halogen atom, an alkyl group, a phenyl group, or a haloalkyl group
- X is an organic group having 1 or more carbon atoms, and may contain an oxygen atom, a sulfur atom or a halogen atom
- a and d are each 0 or 1
- Y is represented by the following structural formula (2)
- b and c are each an integer from 0 to 20, both of which are not 0
- Z is represented by the following structural formula (3).
- R 5 , R 6 , R 7 and R 8 are each a hydrogen atom, a halogen atom, an alkyl group having 1 to 6 carbon atoms, or a phenyl group
- R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15 and R 16 are each a hydrogen atom, a halogen atom, an alkyl group having 1 to 6 carbon atoms, or a phenyl group
- A is a single bond or a linear, branched or cyclic hydrocarbon group having 1 to 20 carbon atoms
- thermosetting adhesive composition according to ⁇ 1> wherein the component (A) has a structure represented by the following structural formula (4).
- Y is one of the following structural formula (5) or structural formula (5 ′) arranged, or 2 It satisfies the structure where the seeds are randomly arranged.
- * 1 represents a bonding site with an oxygen atom in the structural formula (4)
- * 2 represents a carbon atom in the structural formula (4). The binding site is indicated.
- thermosetting adhesive composition according to ⁇ 1> or ⁇ 2>, wherein the component (B) is at least one compound group having the structures of the following structural formulas (6) to (9): object.
- R 17 to R 24 are each a hydrogen atom or an alkyl group having 1 to 6 carbon atoms
- B is a single bond or a divalent hydrocarbon group having 1 to 20 carbon atoms or an oxygen atom. is there.
- R 25 to R 32 are each a hydrogen atom or an alkyl group having 1 to 6 carbon atoms, and D is a divalent hydrocarbon group having 1 to 20 carbon atoms.
- R 33 to R 43 are each a hydrogen atom or an alkyl group having 1 to 6 carbon atoms, and p represents an integer of 1 to 20.
- E is a divalent aliphatic hydrocarbon group having 1 to 20 carbon atoms.
- the component (C) is a polystyrene-poly (ethylene / propylene) block copolymer, a polystyrene-poly (ethylene / butylene) block copolymer, a polystyrene-polyisoprene block copolymer, a polystyrene-poly (butadiene).
- / Butylene) block copolymer and hydrogenated polystyrene-poly (isoprene / butadiene) block copolymer are at least one selected from the group consisting of the heat described in any one of ⁇ 1> to ⁇ 3> above Curable adhesive composition.
- thermosetting adhesive composition according to any one of ⁇ 1> to ⁇ 4> further including a component (D) filler.
- ⁇ 6> When cured by heating at 180 ° C./1 hour, in the range of 25 to 150 ° C., the minimum value of the storage elastic modulus is 1 ⁇ 10 5 Pa or more and the maximum value is 1 ⁇ 10 8 Pa or less.
- ⁇ 7> A thermosetting adhesive film in which the thermosetting adhesive composition according to any one of ⁇ 1> to ⁇ 6> is laminated on a release film substrate or a release paper substrate.
- thermosetting adhesive film with a substrate wherein the thermosetting adhesive composition according to any one of the above ⁇ 1> to ⁇ 6> is laminated on one surface of a copper foil substrate.
- thermosetting adhesive film with a substrate wherein the thermosetting adhesive composition according to any one of the above ⁇ 1> to ⁇ 6> is laminated on at least one surface of a heat resistant film substrate.
- thermosetting adhesive composition according to any one of the above ⁇ 1> to ⁇ 6> is laminated on one surface of a heat resistant film substrate, and a copper foil layer is formed on the other surface A thermosetting adhesive film.
- ⁇ 12> A film obtained by curing the thermosetting resin film according to ⁇ 7>.
- ⁇ 13> A film obtained by curing the thermosetting resin film with a substrate according to any one of ⁇ 8> to ⁇ 11>.
- Composite film At least one substrate selected from the group consisting of copper foil, heat-resistant film, or a film in which both copper foil and heat-resistant film are laminated, and thermosetting according to ⁇ 7> above.
- thermosetting adhesive composition according to the present invention has a low dielectric constant and a low dielectric loss tangent, exhibits high adhesive strength to LCP film and copper foil, and has high heat resistance capable of withstanding rapid heating in the soldering process. In addition, it has high flexibility that can withstand bending, and is suitable as an adhesive material for FPC using an LCP film, specifically, an adhesive material for bonding sheets, coverlay films, FRCC, and FCCL with adhesive.
- thermosetting adhesive composition includes, as an essential component, a vinyl compound obtained by converting the terminal of component (A) bifunctional polyphenylene ether oligomer into a vinyl group, Component (B) contains a bismaleimide resin having two or more maleimide groups in the molecule, and component (C) a polyolefin-based elastomer.
- Component (A) of the present invention is a vinyl compound having a polyphenylene ether skeleton represented by Structural Formula (1).
- the component (A) mainly contributes to improvement of thermosetting, heat resistance and low dielectric properties of the adhesive composition.
- the substituents R 1 , R 2 , R 3 and R 4 are each a hydrogen atom, a halogen atom, an alkyl group, a phenyl group, or a haloalkyl group.
- the halogen atom include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom.
- the alkyl group is preferably an alkyl group having 1 to 6 carbon atoms.
- the haloalkyl group is preferably a haloalkyl group having 1 to 6 carbon atoms.
- each of the substituents R 1 , R 2 , R 3 and R 4 is preferably a hydrogen atom or an alkyl group having 1 to 6 carbon atoms.
- X is an organic group having 1 or more carbon atoms and may contain an oxygen atom, a sulfur atom or a halogen atom, and a and d are 0 or 1.
- the organic group having 1 or more carbon atoms is preferably an alkyl group having 1 to 6 carbon atoms.
- Y is represented by the structural formula (2), and R 5 , R 6 , R 7 and R 8 are each a hydrogen atom, a halogen atom, an alkyl group having 1 to 6 carbon atoms, or a phenyl group, preferably hydrogen An atom or an alkyl group having 1 to 6 carbon atoms.
- b and c are integers of 0 to 20, both of which are not 0.
- Z is represented by the structural formula (3), and R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15 and R 16 are each a hydrogen atom, a halogen atom, or an alkyl having 1 to 6 carbon atoms. Or a phenyl group, preferably a hydrogen atom or an alkyl group having 1 to 6 carbon atoms.
- a in the structural formula (3) is a single bond or a linear, branched or cyclic hydrocarbon group having 1 to 20 carbon atoms, preferably a single bond or a divalent fatty acid having 1 to 6 carbon atoms. Group saturated hydrocarbon group.
- “*” In the structural formulas (2) and (3) each represents a bonding site with an oxygen atom in the structural formula (1).
- the component (A) has a structure represented by the following structural formula (4).
- b and c are as described above.
- Y satisfies the structure in which one of the following structural formula (5) or structural formula (5 ′) is arranged, or two are randomly arranged.
- * 1 represents a bonding site with an oxygen atom in the structural formula (4)
- * 2 represents a carbon atom in the structural formula (4). The binding site is indicated.
- Y represents a structure in which one of the following structural formula (5) or structural formula (5 ′) is arranged or two are randomly arranged”.
- -YO- not only means that one of the following structural formulas (5) and (5 ') is arranged, or that two are randomly arranged
- -OY -Also includes a structure in which only one of the following structural formulas (5a) and (5a ′) is arranged, or two are randomly arranged.
- * 1 represents a bonding site with an oxygen atom in the structural formula (4)
- * 2 represents a carbon atom in the structural formula (4). The binding site is indicated.
- the number average molecular weight of the compound represented by the structural formula (1) is preferably in the range of 500 to 3000, more preferably 1000 to 2500.
- the number average molecular weight is measured with polystyrene standards by gel permeation chromatography.
- the number average molecular weight is 500 or more, it is preferable in the step of curing the resin composition, since the viscosity of the adhesive composition is hardly reduced extremely and does not easily flow out.
- the component (A) having a lower limit of the number average molecular weight of 500 does not have a too small vinyl group equivalent, and when determining the blending amount from the number of reactive groups, the necessary amount of the component (B) is reduced and low dielectric properties are obtained.
- the number average molecular weight is 3000 or less, the solubility in a solvent and the compatibility with other resins are increased, the stability of the varnish is good, and the appearance defect and the physical properties are hardly lowered when the film is formed. Therefore, it is preferable.
- Component (B) of the present invention is a maleimide compound having two or more maleimide groups in the molecule, preferably at least one selected from the group of compounds represented by structural formulas (6) to (9) is there.
- the component (B) mainly contributes to the thermosetting property of the adhesive composition.
- the aforementioned component (A) and component (B) can be cured individually when heated to 200 ° C. or higher, but the reaction temperature can be lowered by coexistence of component (A) and component (B). Specifically, good characteristics can be obtained by heat treatment at 150 ° C. to 180 ° C.
- the compounds represented by the structural formulas (6) to (9) may be used singly or in combination of two or more.
- R 17 to R 24 are each a hydrogen atom or an alkyl group having 1 to 6 carbon atoms.
- B is a single bond, a divalent hydrocarbon group having 1 to 20 carbon atoms, or an oxygen atom, and is preferably a divalent aliphatic saturated hydrocarbon group having 1 to 4 carbon atoms.
- R 25 to R 32 are each a hydrogen atom or an alkyl group having 1 to 6 carbon atoms.
- D is a divalent hydrocarbon group having 1 to 20 carbon atoms, preferably a hydrocarbon group represented by the following formula (15).
- R 44 and R 45 each represent a hydrogen atom or an alkyl group having 1 to 4 carbon atoms
- F represents a divalent aliphatic saturated hydrocarbon group having 1 to 4 carbon atoms
- * The bonding site with an oxygen atom is shown.
- R 33 to R 43 are each a hydrogen atom or an alkyl group having 1 to 6 carbon atoms, and p represents an integer of 1 to 20.
- E is a divalent aliphatic hydrocarbon group having 1 to 20 carbon atoms, preferably a divalent aliphatic saturated hydrocarbon group having 1 to 10 carbon atoms.
- the blending amount of component (A) and component (B) is determined in consideration of the equivalent ratio of vinyl group and maleimide group. That is, the equivalent ratio of the vinyl group contained in component (A) to the maleimide group contained in component (B) (vinyl group: maleimide group) is 1.0: 0.5 to 1.0: 4.0, preferably Is set to 1.0: 0.75 to 1.0: 3.5, more preferably 1.0: 1.0 to 1.0: 3.0.
- the ratio of maleimide groups is less than 1.0: 0.5, the component (A) having a low molecular weight remains unreacted in the cured adhesive composition, and the adhesive composition has a high temperature machine. This is not preferable because the mechanical characteristics deteriorate.
- the ratio of the maleimide group is larger than 1.0: 5.0, the amount of the component (B) in the adhesive composition increases, and the component (B) has a higher dielectric constant than the component (A). Ratio, a high dielectric loss tangent, and a high moisture absorption rate. As a result, the electrical characteristics of the adhesive composition and the heat resistance in the soldering process during moisture absorption are not preferable.
- the component (C) mainly contributes to the improvement of the low dielectric properties, heat resistance and adhesiveness of the adhesive composition, and improvement of flexibility when the adhesive composition is formed into a film.
- Component (C) used in the present invention has a polyolefin skeleton composed of one or more selected from ethylene, propylene, butene, isobutene, butadiene, and isoprene as a main component, and is a copolymer of a polyolefin block and a polystyrene block.
- a thermoplastic elastomer hereinafter referred to as a thermoplastic elastomer
- a thermoplastic elastomer can be used.
- polystyrene-poly (ethylene / propylene) block copolymer polystyrene-poly (ethylene / butylene) block copolymer, polystyrene-polyisoprene block copolymer, polystyrene-poly (butadiene / butylene) block copolymer
- polymers hydrogenated polystyrene-poly (isoprene / butadiene) block copolymers
- polystyrene-poly (ethylene / propylene) block copolymers and polystyrene-polyisoprene block copolymers More preferred are polymers, hydrogenated polystyrene-poly (isoprene / butadiene) block copolymers, and particularly preferred are polystyrene-poly (ethylene / propylene) block copolymers and polystyrene-polyisoprene block copolymers.
- the weight ratio of styrene units in the thermoplastic elastomer used in the present invention (hereinafter referred to as styrene content) is 10 to 40% by weight, preferably 10 to 30% by weight, based on the total weight of the thermoplastic elastomer. More preferably, it is 10 to 25% by weight.
- styrene content is less than 10% by weight, the compatibility with other resins decreases, which is not preferable.
- the styrene content is more than 40% by weight, cracks are likely to occur when the adhesive composition is formed into a film. Since the storage elastic modulus E ′ of the adhesive composition after heat curing is increased, the flexibility is impaired and the folding resistance is lowered, which is not preferable.
- thermoplastic elastomer used in the present invention exhibits predetermined values for 100% elongation tensile stress and elongation at break measured in accordance with JIS K-6251. This will be specifically described below.
- the 100% elongation tensile stress is in the range of 0.1 to 2.9 MPa, preferably 0.2 to 2.7 MPa, and more preferably 0.3 to 2.5 MPa. If it is less than 0.1 MPa, the adhesive composition after curing becomes too soft, and it is not preferable because the necessary strength as an adhesive cannot be obtained. If it exceeds 2.9 MPa, the adhesive composition after heat curing becomes rigid. Therefore, the stress relaxation performance is reduced, that is, it is not preferable because a large stress is easily generated with respect to a small amount of displacement.
- the elongation at break is 100% or more, preferably 200% or more, more preferably 300% or more, and particularly preferably 400% or more. If it is less than 100%, the adhesive composition lacks flexibility, so a crack occurs in a thermosetting adhesive film (hereinafter abbreviated as “adhesive film” where appropriate) in which the adhesive composition is laminated with another substrate. This is not preferable because it is easy and the folding resistance is lowered.
- the number average molecular weight of the thermoplastic elastomer used in the present invention is not particularly limited, but is 10,000 to 300,000 from the viewpoint of reducing the storage elastic modulus E ′ of the adhesive composition and imparting high flexibility. It is preferably 10,000 to 250,000, more preferably 10,000 to 200,000.
- the number average molecular weight of the thermoplastic elastomer is 10,000 or more, the flexibility of the adhesive composition can be made appropriate, and the strength required as an adhesive can be obtained.
- the storage elastic modulus E ′ of the adhesive composition does not increase by being 300,000 or less, the flexibility is not impaired, and the folding resistance of the adhesive composition is not easily lowered. Solubility and compatibility with other components are maintained, and phase separation is difficult.
- one type of the above elastomer may be used alone, or two or more types may be mixed and used.
- the ratio of the component (C) to the components (A) + (B) + (C) is 55 to 95% by weight. More preferred is 60 to 95% by weight, still more preferred is 70 to 95% by weight, and particularly preferred is 75 to 95% by weight.
- the component (C) is 55% by weight or more, each component is difficult to separate in the adhesive composition solution, and the film is difficult to break when formed into a film.
- the composition is suitable for use as an adhesive for FPC.
- it is 95% by weight or less appropriate curability can be obtained, and the mechanical properties of the adhesive composition after curing are hardly deficient, so that it is more suitable for practical use.
- the adhesive composition of the present invention preferably has a minimum value of 1 ⁇ 10 5 Pa or more and a maximum value of 1 ⁇ 10 8 when the storage elastic modulus after heat treatment at 180 ° C./1 hour is in the range of 25 to 150 ° C. More preferably, the minimum value is 2 ⁇ 10 5 Pa or more and the maximum value is 1 ⁇ 10 8 Pa or less, and still more preferably, the minimum value is 3 ⁇ 10 5 Pa or more. Is 1 ⁇ 10 8 Pa or less.
- the storage elastic modulus is measured by a dynamic viscoelasticity measuring apparatus while setting the measurement frequency to 11 Hz and increasing the temperature from a measurement temperature of 25 ° C. to 150 ° C. at 10 ° C./min.
- the storage elastic modulus is 1 ⁇ 10 5 Pa or more, it is suitable softness, easy to handle, and can further secure the mechanical strength necessary as an adhesive material for FPC. In addition, significant softening in the soldering process can be prevented.
- it is 1 ⁇ 10 8 Pa or less, the flexibility of the adhesive composition after curing is further ensured, and more preferable folding resistance is ensured.
- the adhesiveness with respect to an LCP film can be improved more.
- the adhesive composition of the present invention includes improvement of mechanical strength, adjustment of melting behavior, suppression of surface tack, improvement of plating property, improvement of adhesiveness of conductive paste, improvement of flame retardancy, adjustment of dielectric properties, etc. Therefore, a filler may be added.
- the filler include fillers that are resin particles, inorganic particles, or inorganic fibers, and known fillers can be used.
- the filler include resin particles such as acrylic resin, polystyrene resin, styrene-acrylic copolymer, polyethylene resin, epoxy resin, silicone resin, polyvinylidene fluoride, polytetrafluoroethylene, divinylbenzene resin, Phenol resin, urethane resin, cellulose acetate, nylon, cellulose, benzoguanamine resin, melamine resin, etc .; inorganic particles such as silica, titanium oxide, aluminum oxide, zinc oxide, magnesium oxide, silicon carbide, silicon nitride, boron nitride, barium sulfate, Metal salts such as magnesium sulfate, aluminum hydroxide, magnesium hydroxide, boron nitride, kaolin, clay, talc, zinc white, lead white, dikelite, quartz, diatomaceous earth, perlite, bentonite, mica, synthetic mica, etc .; and Fiber As Jo fillers, glass fibers, aramid fibers, poly
- the adhesive composition of the present invention In order not to impair the low dielectric constant and low dielectric loss tangent characteristics which are the features of the adhesive composition of the present invention, it is effective to use shirasu balloons or nano-sized hollow silica which are inorganic particles.
- the above fillers may be used alone or in combination of two or more.
- the blending amount when the total volume of the adhesive composition is 100 parts by volume, the preferred blending amount of the filler is 0.1 to 200 parts by volume, more preferably 0.5 to 150 parts by volume, and still more preferably. 1 to 100 parts by volume.
- thermosetting resin thermosetting agent
- plastic resins, dyes, pigments, thickeners, lubricants, antifoaming agents, ultraviolet absorbers and the like can be added.
- the adhesive composition of the present invention preferably does not contain an epoxy resin.
- the adhesive composition solution of the present invention can be obtained by dissolving or dispersing each component such as components (A), (B), and (C), which are raw materials of the adhesive composition of the present invention, in a solvent. it can.
- Each component of the adhesive composition may be individually dissolved in a solvent, and then a predetermined amount of each solution may be blended, or a predetermined amount of each component that is a raw material of the adhesive composition may be mixed in advance.
- a solvent may be added and dissolved.
- the dissolution method examples include a method in which an adhesive composition and a solvent are blended in a container equipped with a stirring device and stirred. Heating is also effective when it is desired to shorten the dissolution time.
- the solid content of the adhesive composition solution is desirably set to 10 to 50% by weight, preferably 15 to 40% by weight. When the solid content is 10% by weight or more, the viscosity of the adhesive composition solution is prevented from becoming too low. For example, a film having a desired thickness and shape is formed without flowing out when applied to a base film. It tends to be easy to be done.
- the viscosity of the adhesive composition solution is prevented from becoming too high, the application work is facilitated, the separation and crystallization of each component are prevented, and the adhesive composition The storage stability of the solution tends to improve.
- the solvent used in the present invention is not particularly limited as long as the adhesive composition is soluble, and even if it is a solvent that does not dissolve the adhesive composition, it is a solvent that can obtain a uniform dispersion state. It can be used. Specifically, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, cyclopentanone, toluene, xylene, ethyl acetate, butyl acetate, tetrahydrofuran, N, N-dimethylformamide, N, N-dimethylacetamide, N-methyl-2 -Pyrrolidone, dimethyl sulfoxide, ethylene glycol monomethyl ether acetate, propylene glycol dimethyl ether, benzenedioxane, cyclopentyl methyl ether, methylene chloride, chloroform, 1,2-dichloroethane, ⁇ -butyrolactone, cell
- ⁇ Coating method of adhesive composition solution> a method for obtaining an adhesive film with a substrate by laminating the adhesive composition of the present invention on a substrate such as a plastic film, metal foil, paper, woven fabric, and nonwoven fabric will be described.
- a substrate such as a plastic film, metal foil, paper, woven fabric, and nonwoven fabric.
- the adhesive film with a substrate of the present invention may be obtained by applying an adhesive composition solution to a substrate and drying, or by preparing an adhesive film on a release film or a release paper in advance, and using this as a substrate It may be obtained by pasting together.
- a normal coating method and a printing method can be mentioned. Specifically, air doctor coating, bar coating, blade coating, knife coating, reverse coating, transfer roll coating, gravure roll coating, kiss coating, cast coating, spray coating, slot orifice coating, calendar coating, dam coating, dip coating Coating such as die coating, intaglio printing such as gravure printing, printing such as stencil printing such as screen printing, and the like can be used.
- drying conditions for drying the solvent there are no particular restrictions on the drying conditions for drying the solvent, but it is desirable to adjust the temperature within the range of 60 to 150 ° C. depending on the solvent used. If the temperature is lower than 60 ° C., the solvent tends to remain in the adhesive film, and the temperature of the applied adhesive composition solution decreases as the solvent evaporates, causing condensation, and the resin component is phase separated or precipitated. Since there are cases, it is not preferable. When the temperature is higher than 150 ° C., curing of the adhesive composition proceeds or the coating film becomes rough due to a sudden temperature rise, which is not preferable.
- the drying time is not particularly limited, but a treatment of 1 to 10 minutes is preferable in consideration of practicality.
- the thickness of the adhesive film can be adjusted by the concentration of the adhesive composition solution and the coating thickness.
- a release film or release paper can be laminated as a separator (protective layer) on the adhesive film after drying.
- Any release film or release paper can be used as long as it does not impair the properties of the adhesive film and can be easily peeled off.
- Specific examples include a polyethylene film, a polypropylene film, a polymethylpentene film, a polyethylene terephthalate film that has been subjected to a release treatment with silicone or the like, a polyethylene-coated paper, a polypropylene-coated paper, and a silicone release paper.
- the thickness of the separator is preferably 10 to 100 ⁇ m for a release film using a plastic film as a base material, and 50 to 200 ⁇ m for a release paper using a paper as a base material.
- the adhesive film surface is affixed to the adherend after peeling only the separator.
- a sheet or a roll is mentioned as a form of said adhesive film with a base material.
- the adhesive composition solution is continuously applied to a substrate wound in a roll state using a known coating machine or the like, and the substrate on which the adhesive composition solution is applied is placed in a drying furnace. Pass through and dry at 60 to 150 ° C. for 1 to 10 minutes, and when it comes out of the drying furnace, a protective layer is attached using a roll laminator to form an adhesive film with a substrate and wound into a roll Preferably stored.
- a cured product is obtained.
- the heating time is 20 minutes to 5 hours, preferably 30 minutes to 2 hours.
- the heating method is arbitrary, and for example, a hot air circulation type oven, a press machine, an autoclave or the like can be used.
- the cured product of the adhesive composition of the present invention is characterized in that it is highly flexible even at low temperatures and has a small decrease in elastic modulus even at high temperatures.
- the storage elastic modulus after heat treatment at 180 ° C./1 hour has a minimum value of 1 ⁇ 10 5 Pa or more and a maximum value of 1 ⁇ 10 8 Pa or less in the range of 25 to 150 ° C.
- thermosetting adhesive composition of the present invention described above can be laminated with a substrate and used for various members of an FPC in the form of an adhesive film.
- each application example will be described.
- the bonding sheet can be said to be a thermosetting adhesive film in which the thermosetting adhesive composition of the present invention is laminated on a release film substrate.
- a release film using a plastic film as a base material as a base material, or a release paper using paper as a base material can be used as a bonding sheet
- the substrate used for the bonding sheet is not particularly limited, but a release film having a thickness of 10 to 100 ⁇ m or a release paper having a thickness of 50 to 200 ⁇ m is preferable.
- the release film include polyethylene film, polypropylene film, polymethylpentene film, polyvinyl chloride film, release-treated polyethylene terephthalate film, release-treated polyethylene naphthalate film, and the like.
- Specific examples of the release paper include polyethylene-coated paper, polypropylene-coated paper, and silicone release paper.
- the thickness of the adhesive film can be arbitrarily set, but is preferably 5 to 50 ⁇ m in a dry state, and more preferably 5 to 25 ⁇ m.
- FRCC Adhesive film with copper foil
- those using copper foil as the substrate can be used as FRCC.
- FRCC can be said to be a thermosetting adhesive tape in which the thermosetting adhesive composition of the present invention is laminated on one surface of a copper foil.
- the copper foil marketed for electronic material component uses is suitable.
- the thickness of the copper foil is preferably 5 to 50 ⁇ m, more preferably 9 to 25 ⁇ m.
- the thickness of the adhesive film can be arbitrarily set, but is preferably 1 to 50 ⁇ m, more preferably 1 to 25 ⁇ m in a dry state.
- the heat-resistant film used for the coverlay film is not particularly limited as long as it has high electrical insulation and is usually used for a coverlay film.
- Specific examples include polyimide film, polyethylene terephthalate film, polyethylene naphthalate film, polybutylene terephthalate film, polyparabanic acid film, polyetheretherketone film, polyphenylene sulfide film, liquid crystal polymer film, syndiotactic polystyrene film, polycarbonate film and the like.
- a liquid crystal polymer (LCP) film is more preferable.
- the thickness of the heat resistant film may be selected depending on the purpose of use, but is usually 1 to 50 ⁇ m, preferably 3 to 38 ⁇ m, particularly preferably 5 to 25 ⁇ m.
- the surface of the heat-resistant film may be treated with a chemical solution, or may be subjected to surface modification treatment such as plasma treatment, corona discharge treatment, sandblast treatment, etc. for the purpose of increasing the adhesion with the adhesive composition. Good.
- the thickness of the adhesive film can be arbitrarily set, but is preferably 5 to 50 ⁇ m in a dry state, more preferably 5 to 38 ⁇ m, and particularly preferably 5 to 25 ⁇ m.
- thermosetting adhesive film with a substrate of the present invention is one in which the thermosetting adhesive composition of the present invention is laminated on one surface of a heat resistant film substrate and has a copper foil layer on the other surface. is there.
- This FCCL with an adhesive having a structure in which the adhesive film of the present invention, a heat resistant film, and a copper foil are sequentially laminated has a structure in which a bonding sheet is laminated in advance on the heat resistant film surface of the FCCL. ing.
- FCCL copper foil and heat-resistant film used in the FCCL with an adhesive of the present invention
- coverlay film and FRCC coverlay film and FRCC
- FCCL coverlay film
- the thickness of the copper foil is 5 to 50 ⁇ m, preferably 9 to 25 ⁇ m, and the thickness of the heat resistant film is 1 to 50 ⁇ m, preferably 3 to 38 ⁇ m, more preferably 5 to 25 ⁇ m.
- the thickness of the adhesive film can be arbitrarily set, but is preferably 1 to 50 ⁇ m in a dry state, and more preferably 1 to 25 ⁇ m.
- an LCP film is used as the heat resistant film.
- an FPC material having a lower dielectric constant and a lower dielectric loss tangent can be obtained.
- the adhesive composition of the present invention has characteristics particularly suitable as a high-frequency FPC material, that is, a bonding sheet, a coverlay, an FRCC, and an FCCL with an adhesive.
- the adhesive composition of the present invention exhibits excellent electrical properties, adhesive strength, heat resistance, and flexibility by heating at 150 to 180 ° C. for 30 minutes to 1 hour.
- the dielectric constant ( ⁇ ) at a frequency of 10 GHz is 3.0 or less
- the dielectric loss tangent (tan ⁇ ) is 0.005 or less
- the peel strength with respect to the LPC film and the copper foil is 4 N / cm or more
- the laminated structure of the LCP film and the copper foil There is no abnormality in the solder float test at 300 ° C./60 seconds, and the folding resistance is 5 times or more in the laminated structure with the copper foil.
- Example 19 [Example 19 (with filler)]
- a filler (D) and a solvent shown in Tables 1 to 4 were charged, and the filler was dispersed using an ultrasonic cleaning device.
- each component other than the filler and the solvent was added to the flask.
- a thermometer and a stirring device were set in the flask, and each component was dissolved by stirring for 2 hours.
- the solution was filtered using a nylon mesh (wire diameter: 30 ⁇ m, 255 mesh) to obtain an adhesive composition solution.
- the liquid temperature was controlled so as not to exceed 30 ° C.
- Aerosil RX200 Hydrophobic silica (Nippon Aerosil Co., Ltd.)
- THF tetrahydrofuran
- the above laminate is heat-pressed at 160 ° C x 0.5MPa for 2 minutes, then heated and cured in a ventilated oven at 180 ° C for 1 hour, then cut to 10mm x 100mm and a sample for peel strength measurement on LCP film Was made.
- a 20 mm x 100 mm sample is lightly folded in the longitudinal direction, then placed on a SUS304 plate with a thickness of 5 mm and 300 mm x 300 mm, and specified in JIS C-2107 Annex A
- a manual roller hereinafter referred to as a roller
- the sample was placed on a sample SUS plate, while lifting one of the two stacked sheets, the roller was reciprocated in the longitudinal direction from the end of the other sheet to apply a load to extend the sample.
- Examples 1-6 Elastomers 1, 3, 5, 7, 8 and 9 having a styrene content of 10 to 40% by weight, a 100% elongation tensile stress in the range of 0.1 to 2.9 MPa, and an elongation at break of 100% or more are used.
- Each material has a dielectric constant ( ⁇ ) of 3.0 or less, a dielectric loss tangent (tan ⁇ ) of 0.005 or less, a peel strength of 4 N / cm or more for LPC film and copper foil, and no abnormality in the solder float test at 300 ° C / 60 seconds.
- the folding endurance was 5 times or more and had good characteristics.
- Comparative Example 1 When the elastomer 2 having an elongation at cutting of less than 100% was used, cracks occurred when the adhesive composition was applied to a substrate and dried to form a film, and an evaluation sample could not be produced.
- Comparative Example 2 When the elastomer 4 having a styrene content exceeding 40% by weight was used, the adhesive composition film became hard and easily cracked when bent, so that an evaluation sample could not be prepared.
- Examples 7 to 10 When the content of component (C) (elastomer) in the total weight of component (A), component (B), and component (C) is 55 to 95% by weight, all evaluations It showed a good value.
- Comparative Example 3 When the content of component (C) (elastomer) in the total weight of component (A), component (B), and component (C) is 45% by weight, each component in the adhesive composition solution As a result, the film after coating and drying was uneven in thickness and cracks, and a sample for evaluation could not be produced.
- Comparative Example 4 When the content of component (C) (elastomer) in the total weight of component (A), component (B), and component (C) is 97.5% by weight, 40 ° C./90% RH / 96 hours In the solder heat resistance test after the treatment, both the LCP film sample and the copper foil sample were swollen.
- Examples 11 to 14 When the equivalent ratio of the vinyl group contained in component (A) and the maleimide group contained in component (B) is in the range of 1.0: 0.5 to 1.0: 4.0, all evaluations are good Showed a good value.
- Comparative Example 5 When the equivalent ratio of the vinyl group contained in the component (A) and the maleimide group contained in the component (B) is 1.0: 0.25, and the maleimide group is decreased, 40 ° C./90% RH / 96 hours In the solder heat resistance test after the treatment, both the LCP film sample and the copper foil sample were swollen. Comparative Example 6: When the equivalent ratio of the vinyl group contained in the component (A) and the maleimide group contained in the component (B) is 1.0: 5.0 and the maleimide group is increased, the peel strength against the LCP film is 4 N / cm. Was less than.
- Examples 15 to 18 When the molecular weight of component (A) was reduced, even when different compounds were used as component (B), good values were obtained in all evaluations.
- Example 19 Even when a filler was added to Example 2, good values were shown in all evaluations.
- thermosetting adhesive composition according to the present invention has a low dielectric constant and a low dielectric loss tangent, exhibits high adhesive strength to LCP film and copper foil, and has high heat resistance capable of withstanding rapid heating in the soldering process. In addition, it has high flexibility that can withstand bending, and is suitable as an adhesive material for FPC using an LCP film, specifically, an adhesive material for bonding sheets, coverlay films, FRCC, and FCCL with adhesive.
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Abstract
Description
本願は、2015年1月19日に日本に出願された特願2015-8180号及び2015年10月27日に日本に出願された特願2015-210645号に基づき優先権を主張し、その内容をここに援用する。
(例えば特許文献1~3)
また、プリント配線板における小型化および高密度化に対しては多層化が有効であるが、多層プリント配線板においては、銅箔パターンが形成されたプリプレグ上に他のプリプレグを被せ、次いで加熱および加圧してプリプレグからしみ出した含浸樹脂で銅箔パターンを埋設するため、含浸樹脂の溶融粘度を低く設計する必要がある。
上記の要求に対して、高分子量化合物であるエラストマーを添加することは、含浸用樹脂溶液の粘度および含浸用樹脂の溶融粘度を著しく増大させることに繋がるため、プリプレグ用材料に関しては多量のエラストマーを添加することは好まれない。
エラストマーを含有しない樹脂組成物、もしくは樹脂組成物全体に対するエラストマー含有量が50重量%以下である樹脂組成物は硬く脆い性状を示すが、プリプレグはガラスクロス等との複合状態で強度が確保できれば実使用に耐え、またプリント配線板の特性上、プリプレグには高い柔軟性は要求されない。必然的にプリプレグ用の樹脂組成物そのものには高い強度および高い柔軟性は求められないため、プリプレグ用材料としては上記のエラストマーを含まない、もしくはエラストマー含有量の小さな樹脂組成物が好適に使用される。
また、FPCの最大の特長である柔軟性を損なわないために、FPC材料には加熱硬化後にも高い柔軟性を有していることが求められる。
すなわち、プリプレグ用材料とFPC用材料とでは、それぞれに求められる特性が大きく異なり、高強度、高柔軟性、高溶融粘度を有するエラストマーを多く含有する樹脂組成物がFPC用材料として好適である。
また、LCPフィルムに高い接着性を示す樹脂組成物が、特許文献8あるいは特許文献9に示されている。
<1> 成分(A)構造式(1)で示されるポリフェニレンエーテル骨格を有するビニル化合物、成分(B)分子内に2個以上のマレイミド基を有するマレイミド樹脂、および成分(C)ポリオレフィン骨格を主成分とし、ポリオレフィンブロックとポリスチレンブロックの共重合体である熱可塑性エラストマー、を含有し、
上記成分(A)に含まれるビニル基と上記成分(B)に含まれるマレイミド基との当量比が、1.0:0.5~1.0:4.0であり、
上記成分(A)、上記成分(B)、及び上記成分(C)の総重量に占める上記成分(C)の割合が55~95重量%であり、
上記成分(C)の総重量に対する上記成分(C)のスチレン単位の比率が10~40重量%、100%伸び引張応力が0.1~2.9MPa、切断時伸びが100%以上であることを特徴とする熱硬化性接着剤組成物。
Xは炭素数1以上の有機基であり、酸素原子、硫黄原子またはハロゲン原子を含んでもよく、
aおよびdは、それぞれ、0または1であり、
Yは下記構造式(2)で表され、
bおよびcは、それぞれ、その両方が0ではない0~20の整数であり、
Zは下記構造式(3)で表される。
R9、R10、R11、R12、R13、R14、R15およびR16はそれぞれ、水素原子、ハロゲン原子、炭素数1~6のアルキル基、またはフェニル基であり、
Aは、単結合または炭素数1~20の直鎖状、分岐状もしくは環状の炭化水素基であり、
*は酸素原子との結合部位を示す。
<5> さらに成分(D)充填材を含む、上記<1>~<4>のいずれかに記載の熱硬化性接着剤組成物。
<6> 180℃/1時間の加熱により硬化させた場合、25~150℃の範囲において、貯蔵弾性率の最小値が1×105Pa以上、最大値が1×108Pa以下である、上記<1>~<5>のいずれかに記載の熱硬化性接着剤組成物。
<7> 離型フィルム基材、または離型紙基材上に上記<1>~<6>のいずれかに記載の熱硬化性接着剤組成物が積層された熱硬化性接着フィルム。
<8> 銅箔基材の一方の面に上記<1>~<6>のいずれかに記載の熱硬化性接着剤組成物が積層された基材付き熱硬化性接着フィルム。
<9> 耐熱性フィルム基材の少なくとも一方の面に上記<1>~<6>のいずれかに記載の熱硬化性接着剤組成物が積層された基材付き熱硬化性接着フィルム。
<10> 耐熱性フィルム基材の一方の面に上記<1>~<6>のいずれかに記載の熱硬化性接着剤組成物が積層され、もう一方の面に銅箔層を有する基材付き熱硬化性接着フィルム。
<11> 上記耐熱性フィルム基材が液晶ポリマーフィルムであることを特徴とする、上記<9>または<10>に記載の基材付き熱硬化性接着フィルム。
<12> 上記<7>に記載の熱硬化性樹脂フィルムを硬化させたフィルム。
<13> 上記<8>~<11>のいずれかに記載の基材付き熱硬化性樹脂フィルムを硬化させたフィルム。
<14> 銅箔、耐熱性フィルム、または、銅箔および耐熱性フィルムの両方が積層されたフィルムからなる群から選択される少なくとも1種の基材と、上記<7>に記載の熱硬化性接着フィルムおよび上記<8>~<10>のいずれかに記載の基材付き熱硬化性接着フィルムからなる群から選択される少なくとも1種の熱硬化性接着フィルムとが、それぞれ少なくとも1枚積層された複合フィルム。
本発明における熱硬化性接着剤組成物(以下、接着剤組成物と適宜、略す)は、必須成分として、成分(A)2官能性ポリフェニレンエーテルオリゴマーの末端をビニル基に変換したビニル化合物と、成分(B)分子内に2個以上のマレイミド基を有するビスマレイミド樹脂と、成分(C)ポリオレフィン系エラストマーと、を含有する。
本発明の成分(A)は、構造式(1)で表される、ポリフェニレンエーテル骨格を有するビニル化合物である。本発明において、成分(A)は、主に、接着剤組成物の熱硬化性、耐熱性および低誘電特性向上に寄与する。
ハロゲン原子としては、フッ素原子、塩素原子、臭素原子、ヨウ素原子などが挙げられる。
アルキル基としては、炭素原子数1~6のアルキル基であることが好ましい。
ハロアルキル基としては、炭素原子数1~6のハロアルキル基であることが好ましい。
これらの中でも、置換基R1、R2、R3およびR4はそれぞれ、水素原子、または、炭素原子数1~6のアルキル基であることが好ましい。
炭素数1以上の有機基として、炭素数1~6のアルキル基であることが好ましい。
bおよびcは、その両方が0ではない0~20の整数である。
構造式(3)中のAは、単結合または炭素数1~20の直鎖状、分岐状もしくは環状の炭化水素基であり、好ましくは、単結合または炭素数1~6の2価の脂肪族飽和炭化水素基である。
上記構造式(2)及び(3)における「*」は、各々、上記構造式(1)における酸素原子との結合部位を示す。
上記構造式(4)中、Yは下記構造式(5)または構造式(5’)のうち1種が配列した、または、2種がランダムで配列した構造を満たすものである。下記構造式(5)および構造式(5’)において、*1は上記構造式(4)にける酸素原子との結合部位を示し、*2は上記構造式(4)にける炭素原子との結合部位を示す。
構造式(1)で示される化合物の数平均分子量は、500~3000の範囲にあることが好ましく、1000~2500であることがさらに好ましい。数平均分子量は、ゲル透過クロマトグラフィー法により、ポリスチレン標準により測定される。
数平均分子量が500以上である場合、樹脂組成物を硬化させる工程において、接着剤組成物の粘度が極端に低くなり難く、流れ出しが起こり難くなるため好ましい。また、数平均分子量の下限が500である成分(A)はビニル基当量が小さくなり過ぎず、反応基数から配合量を決定する際、成分(B)の必要量が少なくなり、低誘電特性が得られ易くなるため好ましい。
一方、数平均分子量が3000以下である場合、溶剤への溶解性および他の樹脂との相溶性が高まり、ワニスの安定性が良好で、フィルム状態にした際の外観不良および物性低下が起こり難いため好ましい。
本発明の成分(B)は、分子内に2個以上のマレイミド基を有するマレイミド化合物であり、好ましくは構造式(6)~(9)で表される化合物群から選択される少なくとも1種である。本発明において、成分(B)は、主に、接着剤組成物の熱硬化性に寄与する。前述の成分(A)、および成分(B)は、200℃以上に加熱すれば、それぞれ単独でも硬化するが、成分(A)と成分(B)を共存させることで反応温度を下げることができ、具体的には150℃~180℃の加熱処理によって良好な特性が得られる。
本発明の接着剤組成物において、構造式(6)~(9)で示される化合物は1種を単独で用いても良いし、2種以上を混合して使用しても良い。
成分(A)と成分(B)の配合量は、ビニル基とマレイミド基との当量比を考慮して決定する。すなわち、成分(A)に含まれるビニル基と成分(B)に含まれるマレイミド基の当量比(ビニル基:マレイミド基)を、1.0:0.5~1.0:4.0、好ましくは、1.0:0.75~1.0:3.5、さらに好ましくは、1.0:1.0~1.0:3.0に設定する。
本発明において、成分(C)は主に、接着剤組成物の低誘電特性、耐熱性および接着性向上ならびに接着剤組成物をフィルム化した際の柔軟性向上に寄与する。
具体的には、ポリスチレン-ポリ(エチレン/プロピレン)ブロック共重合体、ポリスチレン-ポリ(エチレン/ブチレン)ブロック共重合体、ポリスチレン-ポリイソプレンブロック共重合体、ポリスチレン-ポリ(ブタジエン/ブチレン)ブロック共重合体、水添ポリスチレン-ポリ(イソプレン/ブタジエン)ブロック共重合体がより好ましく、ポリスチレン-ポリ(エチレン/プロピレン)ブロック共重合体およびポリスチレン-ポリイソプレンブロック共重合体が特に好ましい。
本発明の接着剤組成物は、成分(A)+(B)+(C)に占める成分(C)の割合が55~95重量%である。より好ましくは60~95重量%、さらに好ましくは70~95重量%、特に好ましくは75~95重量%である。
成分(C)が55重量%以上であることで、接着剤組成物溶液中で各成分が分離し難く、また、フィルム化した際に膜が割れ難い。さらに、LCPフィルムおよび銅箔に対するピール強度が大きいため、上記組成物はFPC用接着剤の用途に好適である。一方、95重量%以下である場合、適切な硬化性が得られ、硬化後の接着剤組成物の機械的特性が不足し難いため、より実用に適するものとなる。
本発明の接着剤組成物は、180℃/1時間の熱処理後の貯蔵弾性率が、25~150℃の範囲において、好ましくは最小値が1×105Pa以上、最大値が1×108Pa以下であって、より好ましくは、最小値が2×105Pa以上、最大値が1×108Pa以下であって、よりさらに好ましくは、最小値が3×105Pa以上、最大値が1×108Pa以下、である。ここで、貯蔵弾性率は、動的粘弾性測定装置により、測定周波数を11Hzとし、測定温度25℃から150℃まで、10℃/分で昇温しながら測定される。
貯蔵弾性率が1×105Pa以上であると適切な柔らかさであり、扱い易いうえ、FPC用接着材料として必要な機械的強度をより確保できる。また半田付け工程における著しい軟化をより防ぐことができる。一方、1×108Pa以下であると、硬化後の接着剤組成物の柔軟性がより確保され、より好適な耐折性が確保される。また、LCPフィルムに対する接着性をより向上することができる。
本発明の接着剤組成物には、機械的強度の改善、溶融挙動の調整、表面タックの抑制、めっき性の向上、導電ペーストの接着性向上、難燃性向上、誘電特性の調整、等のため、充填材を添加しても良い。充填材としては、樹脂粒子、無機粒子、または無機繊維である充填材が挙げられ、公知の充填材を使用できる。
上記の具体的な充填材としては、樹脂粒子として、アクリル樹脂、ポリスチレン樹脂、スチレン-アクリル共重合体、ポリエチレン樹脂、エポキシ樹脂、シリコーン樹脂、ポリフッ化ビニリデン、ポリテトラフルオルエチレン、ジビニルベンゼン樹脂、フェノール樹脂、ウレタン樹脂、酢酸セルロース、ナイロン、セルロース、ベンゾグアナミン樹脂、メラミン樹脂等;無機粒子として、シリカ、酸化チタン、酸化アルミニウム、酸化亜鉛、酸化マグネシウム、炭化ケイ素、窒化珪素、窒化硼素、硫酸バリウム、硫酸マグネシウム、水酸化アルミニウム、水酸化マグネシウム、窒化ホウ素等の金属塩、カオリン、クレー、タルク、亜鉛華、鉛白、ジークライト、石英、ケイソウ土、パーライト、ベントナイト、雲母、合成雲母等;および、繊維状充填材として、ガラス繊維、アラミド繊維、炭化ケイ素繊維、アルミナ繊維等が挙げられる。
上記の充填材は、1種を単独で使用してもよいし、2種以上を併用してもよい。配合量については、接着剤組成物の総体積を100体積部とした場合、充填材の好ましい配合量は0.1~200体積部、より好ましくは0.5~150体積部、より更に好ましくは1~100体積部である。
本発明の接着剤組成物には、種々の特性を調整する目的のため、必要に応じて公知の難燃剤、反応促進剤、架橋剤、重合禁止剤、カップリング剤、熱硬化性樹脂、熱可塑性樹脂、染料、顔料、増粘剤、滑剤、消泡剤、紫外線吸収剤等を添加できる。
ただし、接着フィルムの半田耐熱性向上の観点から、本発明の接着剤組成物はエポキシ樹脂を含有しないことが好ましい。
本発明の接着剤組成物溶液について説明する。本発明の接着剤組成物溶液は、本発明の接着剤組成物の原料である成分(A)、(B)、(C)等の各成分を溶剤に溶解、または分散することで得ることができる。
接着剤組成物の各成分は、それぞれ個別に溶剤に溶解したのち、各溶液の所定量を配合しても良く、あるいは接着剤組成物の原料である各成分を予め混合したものに所定量の溶剤を追加して溶解してもよい。
本発明では、接着剤組成物溶液の固形分は、10~50重量%、好ましくは15~40重量%に設定することが望ましい。固形分が10重量%以上であると、接着剤組成物溶液の粘度が低くなりすぎることを防ぎ、例えば、基材フィルムへ塗布した際に流れ出ることなく、所望する厚さおよび形状のフィルムが形成されやすくなる傾向にある。一方、固形分が50重量%以下であると、接着剤組成物溶液の粘度が高くなりすぎることを防ぎ、塗布作業がより容易になり、各成分の分離や結晶化を防ぎ、接着剤組成物溶液の保存安定性が向上する傾向にある。
次に、本発明の接着剤組成物を、プラスチックフィルム、金属箔、紙、織布、不織布等の基材に積層し、基材付き接着フィルムを得る方法について説明する。なお、本発明においては、プラスチックフィルム、金属箔、紙、織布、不織布等に加えて、これらの一面または両面に離型処理を施したものについても基材と称する。
本発明の基材付き接着フィルムは、接着剤組成物溶液を基材に塗布、乾燥して得てもよいし、あらかじめ離型フィルムまたは離型紙に接着フィルムを作製しておき、これを基材に貼り合せて得てもよい。
乾燥時間についても特に制限は無いが、実用性を考慮すると1~10分の処理が好ましい。
接着フィルムの厚みは、接着剤組成物溶液の濃度と塗布厚みとによって調整できる。
上記の基材付き接着フィルムの形態としては、シートまたはロールが挙げられる。生産性の見地からは、接着剤組成物溶液を公知のコーティング機等を用いてロール状態に巻き取られた基材に連続塗布し、接着剤組成物溶液が塗布された基材を乾燥炉に通し、60~150℃で1~10分間かけて乾燥させ、乾燥炉から出た時点でロールラミネータを用いて保護層を貼着することで基材付き接着フィルムを形成し、ロール状に巻き取って貯蔵することが好ましい。
本発明の接着剤組成物を150~180℃に加熱すると、硬化物が得られる。加熱時間は20分~5時間、好ましくは30分~2時間である。
加熱方法は任意であり、例えば、熱風循環型オーブン、プレス機、オートクレーブ等が使用できる。本発明の接着剤組成物の硬化物は、低温においても柔軟性が高く、かつ高温でも弾性率の低下が少ないことを特徴とする。具体的には、180℃/1時間の熱処理後の貯蔵弾性率が、25~150℃の範囲において最小値が1×105Pa以上、最大値が1×108Pa以下である。
上述した本発明の熱硬化性接着剤組成物は、基材と積層し、接着フィルムの形態で、FPCの各種部材に用いることができる。以下、各応用例について説明する。
ボンディングシートは、離型フィルム基材上に、本発明の熱硬化性接着剤組成物が積層された熱硬化性接着フィルムということができる。
本発明の基材付き接着フィルムのうち、基材としてプラスチックフィルムを母材に用いた離型フィルム、または紙を母材に用いた離型紙を使用したものは、ボンディングシートとして用いることができ、ボンディングシートに使用する基材としては、特に制限が無いが、厚さ10~100μmの離型フィルム、または厚さ50~200μmの離型紙が好ましい。
ボンディングシートの場合、接着フィルムの厚さは任意に設定できるが、乾燥状態で5~50μmが好ましく、5~25μmであることがさらに好ましい。
本発明の基材付き接着フィルムのうち、基材として銅箔を使用したものは、FRCCとして用いることができる。すなわち、FRCCは、銅箔の一面に本発明の熱硬化性接着剤組成物が積層された熱硬化性接着テープということができる。
FRCCに使用する銅箔としては、特に制限が無いが、電子材料部品用途向けに市販されている銅箔が好適である。銅箔の厚さは、5~50μmが好ましく、9~25μmがより好ましい。
FRCCに使用する場合、接着フィルムの厚さは任意に設定できるが、乾燥状態で1~50μmが好ましく、1~25μmであることがさらに好ましい。
本発明の基材付き接着フィルムのうち、基材として耐熱性プラスチックフィルムを使用したものは、カバーレイフィルムとして用いることができる。
カバーレイフィルムに使用する耐熱性フィルムとしては、電気絶縁性が高く、通常カバーレイフィルムに用いられるものであれば、特に制限は無い。具体例として、ポリイミドフィルム、ポリエチレンテレフタレートフィルム、ポリエチレンナフタレートフィルム、ポリブチレンテレフタレートフィルム、ポリパラバン酸フィルム、ポリエーテルエーテルケトンフィルム、ポリフェニレンサルファイドフィルム、液晶ポリマーフィルム、シンジオタクチックポリスチレンフィルム、ポリカーボネートフィルム等が挙げられ、液晶ポリマー(LCP)フィルムがより好ましく挙げられる。
カバーレイフィルムに使用する場合、接着フィルムの厚さは任意に設定できるが、乾燥状態で5~50μmが好ましく、5~38μmであることがさらに好ましく、5~25μmであることが特に好ましい。
本発明の基材付き熱硬化性接着フィルムは、耐熱性フィルム基材の一方の面に、本発明の熱硬化性接着剤組成物が積層され、もう一方の面に銅箔層を有するものである。この、本発明の接着フィルムと、耐熱性フィルムと、銅箔と、が順次積層された構造を有する接着剤付きFCCLは、FCCLの耐熱性フィルム面に予めボンディングシートが積層された構造を有している。この接着剤付きFCCLを用いることで、FPC製造工程の省力化、低コスト化を実現できる。
本発明の接着剤付きFCCLに使用する銅箔、および耐熱性フィルムとしては、前述のカバーレイフィルムおよびFRCCで例示したものが使用できる。FCCLとしては、市販されているものが本発明に使用できる。あるいは本発明の接着フィルムを用いて銅箔と耐熱性フィルムを貼り合せて作製してもよい。
上記のカバーレイフィルム、および接着剤組成物フィルムと、耐熱性フィルムと、銅箔と、が順次積層された構造を有する基材付き接着剤組成物フィルムにおいて、耐熱性フィルムとしてLCPフィルムを使用すれば、より低誘電率および低誘電正接のFPC材料が得られる。
本発明の接着剤組成物は、以下に示すとおり、特に、高周波用FPC材料、すなわちボンディングシート、カバーレイ、FRCC、接着剤付きFCCLとして好適な特性を有している。本発明の接着剤組成物は、150~180℃で30分~1時間加熱することによって、優れた電気特性、接着強度、耐熱性、および柔軟性を発現する。
具体的には、周波数10GHzにおける誘電率(ε)が3.0以下かつ誘電正接(tanδ)が0.005以下、LPCフィルムおよび銅箔に対するピール強度が4N/cm以上、LCPフィルムおよび銅箔との積層構造による300℃/60秒間の半田フロート試験において異状なし、銅箔との積層構造において耐折回数が5回以上である。
(1)製造方法1:〔実施例1~18、比較例1~6〕
表1~4に示す接着剤組成物の原料である各成分および溶剤を投入し、次いで温度計および攪拌装置をフラスコにセットして2時間の攪拌によってすべての成分を溶解した。最後にナイロンメッシュ(線径30μm、255メッシュ)を使って溶解液を濾過し、接着剤組成物溶液を得た。なお、作業中は液温が30℃を超えないように管理した。
(2)製造方法2:〔実施例19(充填材あり)〕
ガラスフラスコ中に、表1~4に示す成分(D)充填材および溶剤を投入し、超音波洗浄装置を使って充填材を分散した。
次いで充填材および溶剤以外の各成分をフラスコに追加投入し、温度計および攪拌装置をフラスコにセットして2時間の攪拌により各成分を溶解した。
最後にナイロンメッシュ(線径30μm、255メッシュ)を使って溶解液を濾過し、接着剤組成物溶液を得た。なお、作業中は液温が30℃を超えないように管理した。
成分(A)
ビニル化合物1:オリゴフェニレンエーテル(構造式(4)で示される化合物)(OPE2St-1200、三菱ガス化学株式会社製、数平均分子量=1200)
ビニル化合物2:オリゴフェニレンエーテル(構造式(4)で示される化合物)(OPE2St-2200、三菱ガス化学株式会社製、数平均分子量=2200)
成分(B)
BMI1:構造式(10)で示される化合物(4,4’-ジフェニルメタンビスマレイミド)
BMI2:構造式(12)で示される化合物(ビスフェノールAフェニルエーテルビスマレイミド)
BMI3:構造式(13)で示される化合物(ノボラック型多官能マレイミド)
BMI4:構造式(14)で示される化合物(1,6'-ビスマレイミド-(2,2,4-トリメチル)ヘキサン)
成分(C)
エラストマー1:ポリスチレン-ポリ(エチレン/プロピレン)ブロック共重合体。スチレン含有量20重量%、100%伸び引張応力=2.4MPa、切断時伸び=670%。
エラストマー2:ポリスチレン-ポリ(エチレン/プロピレン)ブロック共重合体。スチレン含有量30重量%、100%伸び引張応力=値なし、切断時伸び=100未満。
エラストマー3:ポリスチレン-ポリ(エチレン/プロピレン)ブロック共重合体。スチレン含有量15重量%、100%伸び引張応力=0.3MPa、切断時伸び=1400%。
エラストマー4:ポリスチレン-ポリ(エチレン/プロピレン)ブロック共重合体。スチレン含有量65重量%、100%伸び引張応力=値なし、切断時伸び=100未満。
エラストマー5:ポリスチレン-ポリ(エチレン/ブチレン)ブロック共重合体。スチレン含有量30重量%、100%伸び引張応力=1.0MPa、切断時伸び=580%。
エラストマー7:ポリスチレン-ポリイソプレンブロック共重合体。スチレン含有量20重量%、100%伸び引張応力=2.8MPa、切断時伸び=730%。
エラストマー8:ポリスチレン-ポリ(ブタジエン/ブチレン)ブロック共重合体。スチレン含有量30重量%、100%伸び引張応力=0.7MPa、切断時伸び=780%。
エラストマー9:水添ポリスチレン-ポリ(イソプレン/ブタジエン)ブロック共重合体。スチレン含有量12重量%、100%伸び引張応力=0.7MPa、切断時伸び=980%。
成分(D)
アエロジルRX200:疎水性シリカ(日本アエロジル株式会社製)
その他の成分
NC3000H:ビフェニル型エポキシ樹脂
2E4MZ :2-エチル-4-メチルイミダゾール
溶媒
THF:テトラヒドロフラン
シリコーンで離型処理された厚み38μmのポリエチレンテレフタレートフィルム(商標名:ピューレックスA43。帝人デュポンフィルム株式会社製)に、アプリケータを用いて、乾燥後の厚さが25μmとなるように接着剤組成物溶液を塗布した。
次いで100℃に設定した通風オーブン内で5分間乾燥させ、厚さ25μmの接着剤組成物フィルムを得た。
(1)ピール強度測定用サンプルの作製
ピール強度の測定には、LCPフィルムに対する強度と、銅箔に対する強度とを個別に計測するために、下記のとおり、LCPフィルム同士、および銅箔同士を貼り合わせたサンプルを用いた。ここで、2種類の基材についてピール強度を独立に測定する理由は、性質の異なる2種類の基材に対して高い接着性を両立することが求められるため、それぞれの基材に対する正確なピール強度を知る必要があるためである。仮に一方の基材としてLCPを、もう一方の基材として銅箔を用いてサンプルを作成し、ピール強度を測定したとしても、どちらか一方の基材に対するピール強度しか知ることができないため、不十分である。
ロールラミネータを使って、厚さ25μmのLCPフィルム(商標名:ベクスターCT-Z。株式会社クラレ製)と接着剤組成物フィルムとを積層した。このときの作業条件は、ロール温度は120℃、加圧は30N/cm、速度は0.5m/分とした。
次いで、さらに上記と同じLCPフィルムを積層し、2枚のLCPフィルムが接着剤組成物を介して貼り合わされた積層体を得た。
上記の積層体を160℃×0.5MPa×2分の熱プレス処理し、次いで通風オーブン内で180℃×1時間加熱硬化させたのち、10mm×100mmにカットしてLCPフィルムに対するピール強度測定用サンプルを作製した。
LCPフィルムを、厚さ18μmの銅箔(商標名:FQ-VLP。三井金属鉱業株式会社製)に代えた以外は上記(1-1.ピールテスト1)と同条件とし、銅箔に対するピール強度測定用サンプルを作製した。なお、銅箔の接着面は、シャイン面とした。
(2-1.半田テスト1):LCPフィルムを使った場合の半田耐熱温度測定用
カットするサイズを25mm×25mmに代えた以外は(1-1.ピールテスト1)と同条件として、LCPフィルムを使った場合の半田耐熱温度測定用サンプルを作製した。
(2-2.半田テスト2):銅箔を使った場合の半田耐熱温度測定用
カットするサイズを25mm×25mmに代えた以外は(1-2.ピールテスト2)と同条件として、銅箔を使った場合の半田耐熱温度測定用サンプルを作製した。
カットするサイズを20mm×100mmに代えた以外は(1-2.ピールテスト2)と同条件として、はぜ折り試験用サンプルを作製した。
ロールラミネータを使って厚さ25μmの接着剤組成物フィルムを順次積層し、厚さ200μmの接着剤組成物を得た。
次にこれを通風オーブン内で180℃×1時間加熱硬化させたのち、2mm×50mmにカットして誘電率および誘電正接測定用サンプルを作製した。
なお、積層および加熱硬化の際は、接着剤組成物の両面にピューレックスA43を積層した状態で作業し、測定の直前にピューレックスA43を除去した。
ロールラミネータを使って厚さ25μmの接着剤組成物フィルムを積層し、厚さ50μmの接着剤組成物を得た。
次にこれを通風オーブン内で180℃×1時間加熱硬化させたのち、4mm×30mmにカットして誘電率および貯蔵弾性率測定用サンプルを作製した。
なお、積層および加熱硬化の際は、接着剤組成物の両面にピューレックスA43を積層した状態で作業し、測定の直前にピューレックスA43を除去した。
(1)接着剤組成物フィルムの状態
乾燥後の接着剤組成物フィルムの外観で評価した。表面が平滑であって、ひび割れ、オレンジピール、ブラッシング等の欠陥が無い場合を○、なんらかの異状が見られる場合を×とした。
(2)ピール強度の測定
万能引張試験機(オリンテック社製)を用いて基材を90°方向に引き剥がし、ピール強度を測定した。引張速度は50mm/分とした。
LCPフィルムおよび銅箔に対して、4N/cm以上の場合を良好、4N/cmに満たない場合を不良と判定した。
(3)半田耐熱試験
サンプルを20℃/65%RH/96時間(表1~4では処理1と記載)、または40℃/90%RH/96時間(表1~4では処理2と記載)で調湿処理した
のち、300℃の半田浴で60秒間フロートさせた。
60秒間フロート中に異状が発生しなかった場合を○、フロート中に膨れ、破れ、めくれ等の異状が見られた場合を×とした。
(4)はぜ折り試験
まず20mm×100mmのサンプルを長手方向で軽く2つ折りにしたのち、厚さ5mm、300mm×300mmのSUS304板の上に置き、JIS C-2107 附属書Aで規定される手動ローラ(以下、ローラという)を長手方向に1往復させて荷重を加え、折り目を形成した。
次に、サンプルSUS板上に置き、2枚重ねになったうちの1枚を持ち上げながら、もう1枚の端部から長手方向にローラを1往復させて荷重を加えてサンプルを伸ばした。
この一連の作業を1回のはぜ折りとし、1回のはぜ折りが終わるごとに銅箔の状態を確認して、銅箔にクラックが生じなかった回数をはぜ折り回数とした。
(5)誘電率および誘電正接の測定
空洞共振器摂動法により、10GHzにおける誘電率(ε)および誘電正接(tanδ)を測定した。
(6)貯蔵弾性率測定用サンプルの作製
動的粘弾性測定により貯蔵弾性率を測定した。測定周波数は11Hzとした。測定は25℃から開始し、10℃/分で昇温しながら150℃まで測定し、25℃~150℃における最大値及び最小値を計測した。
実施例1~6:
スチレン含有量が10~40重量%であり、100%伸び引張応力が0.1~2.9MPaの範囲にあり、切断時伸びが100%以上であるエラストマー1、3、5、7、8および9を用いており、各材料の誘電率(ε)が3.0以下かつ誘電正接(tanδ)が0.005以下、LPCフィルムおよび銅箔に対するピール強度が4N/cm以上、300℃/60秒間の半田フロート試験において異状なし、銅箔との積層構造において耐折回数が5回以上であり、良好な特性を有していた。
切断時伸びが100%未満であるエラストマー2を用いた場合、接着剤組成物を基材に塗布、乾燥してフィルム化した際にひび割れが発生し、評価用サンプルが作製できなかった。
スチレン含有量が40重量%を超えるエラストマー4を用いた場合、接着剤組成物フィルムが硬くなり、曲げた際に簡単に割れるため、評価用サンプルが作製できなかった。
比較例4: 成分(A)、成分(B),及び成分(C)の総重量における成分(C)(エラストマー)の含有量を97.5重量%とした場合、40℃/90%RH/96時間処理後の半田耐熱試験において、LCPフィルムサンプルおよび銅箔サンプルのいずれも膨れが発生した。
比較例6: 成分(A)に含まれるビニル基と上記成分(B)に含まれるマレイミド基との当量比を1.0:5.0として、マレイミド基を多くした場合、LCPフィルム対するピール強度が4N/cm未満であった。
実施例19: 実施例2に、充填材を加えた場合にも、すべての評価で良好な値を示した。
Claims (14)
- 成分(A)下記構造式(1)で示されるポリフェニレンエーテル骨格を有するビニル化合物、成分(B)分子内に2個以上のマレイミド基を有するマレイミド樹脂、および成分(C)ポリオレフィン骨格を主成分とし、ポリオレフィンブロックとポリスチレンブロックの共重合体である熱可塑性エラストマー、を含有し、
上記成分(A)に含まれるビニル基と上記成分(B)に含まれるマレイミド基との当量比が、1.0:0.5~1.0:4.0であり、
上記成分(A)、上記成分(B)、及び上記成分(C)の総重量に占める上記成分(C)の割合が55~95重量%であり、
上記成分(C)の総重量に対する上記成分(C)のスチレン単位の比率が10~40重量%、100%伸び引張応力が0.1~2.9MPa、切断時伸びが100%以上であることを特徴とする熱硬化性接着剤組成物。
Xは炭素数1以上の有機基であり、酸素原子、硫黄原子またはハロゲン原子を含んでもよく、
aおよびdは、それぞれ、0または1であり、
Yは下記構造式(2)で表され、
bおよびcは、それぞれ、その両方が0ではない0~20の整数であり、
Zは下記構造式(3)で表される。
R9、R10、R11、R12、R13、R14、R15およびR16はそれぞれ、水素原子、ハロゲン原子、炭素数1~6のアルキル基、またはフェニル基であり、
Aは、単結合または炭素数1~20の直鎖状、分岐状もしくは環状の炭化水素基であり、
*は酸素原子との結合部位を示す。 - 上記成分(C)が、ポリスチレン-ポリ(エチレン/プロピレン)ブロック共重合体、ポリスチレン-ポリ(エチレン/ブチレン)ブロック共重合体、ポリスチレン-ポリイソプレンブロック共重合体、ポリスチレン-ポリ(ブタジエン/ブチレン)ブロック共重合体、水添ポリスチレン-ポリ(イソプレン/ブタジエン)ブロック共重合体からなる群から選択される少なくとも1種である、請求項1~3のいずれかに記載の熱硬化性接着剤組成物。
- さらに成分(D)充填材を含む、請求項1~4のいずれかに記載の熱硬化性接着剤組成物。
- 180℃/1時間の加熱により硬化させた場合、25~150℃の範囲において、貯蔵弾性率の最小値が1×105Pa以上、最大値が1×108Pa以下である、請求項1~5のいずれかに記載の熱硬化性接着剤組成物。
- 離型フィルム基材、または離型紙基材上に請求項1~6のいずれかに記載の熱硬化性接着剤組成物が積層された熱硬化性接着フィルム。
- 銅箔基材の一方の面に請求項1~6のいずれかに記載の熱硬化性接着剤組成物が積層された基材付き熱硬化性接着フィルム。
- 耐熱性フィルム基材の少なくとも一方の面に請求項1~6のいずれかに記載の熱硬化性接着剤組成物が積層された基材付き熱硬化性接着フィルム。
- 耐熱性フィルム基材の一方の面に請求項1~6のいずれかに記載の熱硬化性接着剤組成物が積層され、もう一方の面に銅箔層を有する基材付き熱硬化性接着フィルム。
- 上記耐熱性フィルム基材が液晶ポリマーフィルムであることを特徴とする、請求項9または10に記載の基材付き熱硬化性接着フィルム。
- 請求項7に記載の熱硬化性樹脂フィルムを硬化させたフィルム。
- 請求項8~11のいずれかに記載の基材付き熱硬化性樹脂フィルムを硬化させたフィルム。
- 銅箔、耐熱性フィルム、または、銅箔および耐熱性フィルムの両方が積層されたフィルムからなる群から選択される少なくとも1種の基材と、請求項7に記載の熱硬化性接着フィルムおよび請求項8~10のいずれかに記載の基材付き熱硬化性接着フィルムからなる群から選択される少なくとも1種の熱硬化性接着フィルムとが、それぞれ少なくとも1枚積層された複合フィルム。
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JP2019112642A (ja) | 2019-07-11 |
TWI570200B (zh) | 2017-02-11 |
JP6483159B2 (ja) | 2019-03-13 |
CN107207932A (zh) | 2017-09-26 |
TW201631090A (zh) | 2016-09-01 |
US10822527B2 (en) | 2020-11-03 |
CN107207932B (zh) | 2019-10-25 |
KR20170090479A (ko) | 2017-08-07 |
JP6678788B2 (ja) | 2020-04-08 |
JPWO2016117554A1 (ja) | 2017-08-31 |
US20180258324A1 (en) | 2018-09-13 |
KR101989259B1 (ko) | 2019-06-13 |
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