WO2017208907A1 - 樹脂組成物及び積層体の製造方法 - Google Patents
樹脂組成物及び積層体の製造方法 Download PDFInfo
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- WO2017208907A1 WO2017208907A1 PCT/JP2017/019240 JP2017019240W WO2017208907A1 WO 2017208907 A1 WO2017208907 A1 WO 2017208907A1 JP 2017019240 W JP2017019240 W JP 2017019240W WO 2017208907 A1 WO2017208907 A1 WO 2017208907A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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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
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/22—Di-epoxy compounds
- C08G59/24—Di-epoxy compounds carbocyclic
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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
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/22—Di-epoxy compounds
- C08G59/24—Di-epoxy compounds carbocyclic
- C08G59/245—Di-epoxy compounds carbocyclic aromatic
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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
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/62—Alcohols or phenols
- C08G59/621—Phenols
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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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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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
- C08J2363/04—Epoxynovolacs
Definitions
- the present invention relates to a resin composition and a method for producing a laminate.
- a laminate in which a resin layer for insulation or the like is disposed between a pair of members is used for various applications as a component of an electronic device and an electric device (see, for example, Patent Document 1).
- Such a laminated body was manufactured by affixing both members through a film-form resin composition.
- the properties required for the resin composition used in the above method are that a resin layer having excellent adhesion to the member can be formed without unevenness (applicability), and spreads outside the applied region after application to the member. It is difficult (shape retention).
- the applicability of the resin composition is generally improved as the viscosity is low, and the shape retention is generally improved as the viscosity is high. Therefore, there is room for study in designing a resin composition satisfying both characteristics.
- thermal conductivity is required for the resin layer formed from the resin composition.
- a technique of highly filling a filler in a resin composition has been studied.
- the viscosity increases and the coatability may be impaired.
- the present invention has a coating composition and shape retention suitable for forming a resin layer of a laminate, and a resin composition capable of forming a resin layer having good thermal conductivity, and this It is an object of the present invention to provide a method for manufacturing a laminate using the above.
- a thixotropic index at 25 ° C. is 3 to 10, and is formed by applying the resin layer of a laminate including a pair of members and a resin layer disposed between the pair of members.
- the resin composition For the resin composition.
- R 1 to R 4 each independently represents a hydrogen atom or an alkyl group having 1 to 3 carbon atoms.
- the resin composition which can form the resin layer which has the applicability
- a method for producing a laminate is provided.
- the present invention is not limited to the following embodiments.
- the components including element steps and the like are not essential unless otherwise specified.
- the term “process” includes a process that is independent of other processes and includes the process if the purpose of the process is achieved even if it cannot be clearly distinguished from the other processes. It is.
- numerical values indicated by using “to” include numerical values described before and after “to” as the minimum value and the maximum value, respectively.
- the upper limit value or the lower limit value described in one numerical range may be replaced with the upper limit value or the lower limit value of another numerical range. Good. Further, in the numerical ranges described in this specification, the upper limit value or the lower limit value of the numerical range may be replaced with the values shown in the examples.
- the content of each component in the composition is the sum of the plurality of substances present in the composition unless there is a specific indication when there are a plurality of substances corresponding to each component in the composition. It means the content rate of.
- the particle diameter of each component in the composition is a mixture of the plurality of types of particles present in the composition unless there is a specific indication when there are a plurality of types of particles corresponding to each component in the composition. Means the value of.
- the term “layer” or “film” refers to a part of the region in addition to the case where the layer or the film is formed when the region where the layer or film exists is observed. It is also included when it is formed only.
- laminate indicates that layers are stacked, and two or more layers may be combined, or two or more layers may be detachable.
- the number of structural units indicates an integer value for a single molecule, but indicates a rational number that is an average value as an aggregate of a plurality of types of molecules.
- a resin sheet obtained by further heating and pressing a resin sheet obtained by drying a resin composition layer formed from the resin composition may be referred to as a B stage sheet.
- B stage refer to the provisions of JIS K6900: 1994.
- surface roughness (Rz) refer to the definition of (Rzjis) in JIS B 0601-2001.
- the resin composition of the present embodiment has a thixotropic index of 3 to 10 at 25 ° C., the resin layer of the laminate having a pair of members and a resin layer disposed between the pair of members. It is for apply
- the resin composition of this embodiment has a thixotropic index at 25 ° C. of 3 to 10, so that it has excellent applicability to members constituting the laminate and excellent shape retention after application. For this reason, the resin layer excellent in the adhesiveness with respect to a member can be formed in a predetermined position. Therefore, for example, even when the members constituting the laminate are separated into pieces in advance, a resin layer having excellent adhesion can be formed at a predetermined position.
- the members constituting the laminate are “individualized” means that the size and shape of the member before the resin layer is formed are the size of the member in the finally obtained laminate and It means that it has a shape.
- Thixotropic index at 25 ° C. 25 °C, 25 °C for viscosity A (Pa ⁇ s) measured under conditions of 5min -1 (rpm), under the conditions of 0.5 min -1 (rpm) It is the ratio (viscosity B / viscosity A) of the measured viscosity B (Pa ⁇ s).
- the thixotropic index at 25 ° C. is preferably 3 to 10, and more preferably 5 to 7.
- the viscosity of the resin composition at 25 ° C. and 5 min ⁇ 1 (rpm) is preferably 0.6 Pa ⁇ s to 3.5 Pa ⁇ s, preferably 0.8 Pa ⁇ s to 3 Pa ⁇ s. More preferably, it is more preferably 1 Pa ⁇ s to 2.5 Pa ⁇ s.
- the viscosity and thixotropic index of the resin composition can be adjusted by changing, for example, the type and amount of the components of the resin composition.
- Resins contained in the resin composition include thermosetting resins such as epoxy resins, phenol resins, urea resins, melamine resins, urethane resins, silicone resins, and unsaturated polyester resins.
- the resin contained in the resin composition may be one type or two or more types. From the viewpoint of electrical insulation and adhesiveness, the resin composition preferably contains an epoxy resin.
- the resin composition may contain components other than the resin, such as a filler, as necessary.
- the material of the pair of members in the laminate formed using the resin composition is not particularly limited, and examples thereof include metals, semiconductors, glasses, resins, and composites thereof.
- the shape in particular of a pair of member is not restrict
- the materials and shapes of the pair of members may be the same or different.
- the thickness of the resin layer formed using the resin composition is not particularly limited. From the viewpoint of sufficiently obtaining the effects (insulating properties, etc.) obtained by providing the resin layer, it is preferable that the thickness is large, and from the viewpoint of manufacturing cost, the thickness is preferable. For example, it may be in the range of 80 ⁇ m to 300 ⁇ m. In this specification, the thickness of the resin layer can be measured by a known method, and is the number average value of the values measured at five points.
- the use of the laminate having a resin layer formed using the resin composition of the present embodiment is not particularly limited.
- a semiconductor device can be given.
- semiconductor devices it is suitably used for components with particularly high heat generation density.
- the method for producing a laminate using the resin composition of the present embodiment is not particularly limited.
- the resin composition comprises a resin layer forming step of forming a resin layer on the first member, and a member arranging step of arranging a second member on the resin layer. Used in the method.
- a resin composition is applied on the first member to form a resin layer.
- the method for applying the resin composition is not particularly limited, and methods such as a dispensing method, a printing method, a transfer method, a spray method, and an electrostatic coating method can be applied depending on the application. From the viewpoint of the adhesion of the resin layer to the first member, there is a method in which the resin composition is applied on the first member in a composition (varnish) containing a resin and a solvent, and dried to remove the solvent. preferable.
- the resin layer forming step preferably includes a step of heating the resin layer.
- a step of heating the resin layer volatile components such as a solvent contained in the resin layer are efficiently removed.
- the resin component in the resin layer reacts to increase the viscosity and the followability to the second member is reduced to some extent, but it is good by bringing the second member having a small surface roughness into contact with the resin layer. Good adhesion can be ensured.
- the method of heating the resin layer is not particularly limited, but a method of bringing the resin layer into a B-stage state is preferable.
- the method and conditions for bringing the resin layer into the B stage state are not particularly limited. From the viewpoint of forming a resin layer having a smooth surface and reduced thickness unevenness, a method of heating while pressing the first member and the resin layer formed thereon with a pair of hot plates is preferable.
- the second member is placed on the resin layer formed on the first member.
- the method for arranging the second member is not particularly limited.
- the resin layer After disposing the second member on the resin layer formed on the first member, the resin layer is cured to obtain a laminate.
- the method for curing the resin layer is not particularly limited.
- the second member may be sandwiched between a pair of hot plates in a state where the second member is disposed on the resin layer and heated while being pressed.
- a resin composition is applied on the first member 1 to form a resin layer 2.
- the first member 1 on which the resin layer 2 is formed is sandwiched between a pair of hot plates 3 and 4 and heated while being pressed to bring the resin layer 2 into a B-stage state.
- the second member 5 is disposed on the resin layer 2, sandwiched between the pair of hot plates 6 and 7 in this state, and heated while being pressurized to cure the resin layer 2, A laminate is obtained.
- the laminate manufactured using the resin composition of the present embodiment may be used as it is or may be cut into a desired shape and separated.
- a method for obtaining an individualized laminate (1) a method in which a first member before forming a resin layer and a second member before being arranged on the resin layer are individually separated, (2) (3) Resin layer, after forming a resin layer on the first member and then separating the laminate of the first member and the resin layer into individual pieces and placing the separated second member on the resin layer Examples include a method in which the second member is disposed on the substrate and the laminate obtained by curing the resin layer is singulated.
- a method in which the first member before the resin layer is formed and the second member before the resin layer is arranged on the resin layer is preferably divided into pieces.
- the first member in the state of being separated It is preferable to form a resin layer according to the shape of the member. Since the resin composition of this embodiment has a thixotropic index at 25 ° C. of 3 to 10, a resin layer can be formed at a predetermined position even in such a case.
- the resin composition includes a resin layer forming step of forming a resin layer on the first member, and a member arranging step of arranging a second member on the resin layer, and the following conditions ( It is suitably used in a method for producing a laminate satisfying at least one of 1) and (2).
- the surface roughness (Rz) of the surface in contact with the resin layer of the first member is larger than the surface roughness (Rz) of the surface in contact with the resin layer of the second member.
- the surface roughness (Rz) of the surface in contact with the resin layer of the second member is 30 ⁇ m or less.
- the surface roughness (Rz) of the first member and the second member is not particularly limited as long as at least one of the conditions (1) and (2) is satisfied, and is included in the resin layer. It can be selected according to the type of resin to be obtained, the degree of adhesion required for the laminate, and the like.
- the surface roughness of the portion having the maximum surface roughness is defined as the surface roughness of the member.
- the surface roughness (Rz) of the first member may be, for example, 5 ⁇ m or more, 10 ⁇ m, or 20 ⁇ m or more.
- the surface roughness (Rz) of the first member may be, for example, 80 ⁇ m or less.
- the surface roughness (Rz) of the second member may be, for example, 20 ⁇ m or less, 10 ⁇ m or less, or 5 ⁇ m or less.
- the surface roughness (Rz) of the second member may be 3 ⁇ m or more, for example.
- the first member and the second member may be subjected to a surface roughening treatment.
- a surface roughening treatment In general, as the surface roughness of the surface where the member is in contact with the resin layer is larger, the anchor effect that is manifested by the resin layer entering into the irregularities on the surface of the member increases, and the adhesive strength tends to increase. As a result, it can be expected to improve the shear strength for evaluating the adhesive force mainly applied in the planar direction of the resin layer, and the peel strength for evaluating the adhesive force mainly applied in the vertical direction of the resin layer.
- the member subjected to the surface roughening treatment may be obtained using a material having a rough surface or may be obtained by roughening a material having a smooth surface.
- the surface roughening treatment method is not particularly limited, and may be performed by a physical method or a chemical method. Physical methods include file processing, sandblasting, laser irradiation, and the like. Examples of the chemical treatment include magnesium treatment, CZ treatment, blackening treatment, etching treatment and the like when the material is copper. When the material is aluminum, alumite treatment is exemplified.
- the method of surface treatment is not limited to these, and physical treatment or chemical treatment is performed alone, physical treatment and chemical treatment are combined, or two or more chemical treatments are combined. Or two or more physical processes may be combined.
- the surface which contacts the resin layer of the first member and the second member may be provided with a surface treatment agent.
- Surface treatment agents include solid or liquid thermosetting resin monomer coating and thermoplastic resin solvent coating, silanol coupling agent, titanate coupling agent, aluminosilicate agent, leveling for the purpose of improving the wettability of the resin. And surface protecting agents such as agents.
- the resin composition of the present embodiment may be an epoxy resin composition that includes an epoxy monomer and a curing agent.
- Epoxy monomer The epoxy monomer contained in the epoxy resin composition may be one type alone or two or more types. Moreover, what the epoxy monomer was in the state of the oligomer or the prepolymer may be included.
- the type of epoxy monomer is not particularly limited, and can be selected according to the use of the laminate.
- an epoxy monomer having a mesogenic skeleton and having two glycidyl groups in one molecule (hereinafter also referred to as a specific epoxy monomer) may be used.
- a resin layer formed using an epoxy resin composition containing a specific epoxy monomer tends to exhibit high thermal conductivity.
- the “mesogen skeleton” indicates a molecular structure that may exhibit liquid crystallinity. Specific examples include a biphenyl skeleton, a phenylbenzoate skeleton, an azobenzene skeleton, a stilbene skeleton, and derivatives thereof.
- An epoxy resin composition containing an epoxy monomer having a mesogenic skeleton tends to form a higher-order structure at the time of curing and tends to achieve higher thermal conductivity when a cured product is produced.
- Specific epoxy monomers include, for example, biphenyl type epoxy monomers and tricyclic type epoxy monomers.
- Biphenyl type epoxy monomers include 4,4'-bis (2,3-epoxypropoxy) biphenyl, 4,4'-bis (2,3-epoxypropoxy) -3,3 ', 5,5'-tetramethyl An epoxy monomer obtained by reacting biphenyl, epichlorohydrin and 4,4′-biphenol or 4,4 ′-(3,3 ′, 5,5′-tetramethyl) biphenol, ⁇ -hydroxyphenyl- ⁇ -hydropoly ( Biphenyldimethylene-hydroxyphenylene) and the like.
- Biphenyl type epoxy resins are named according to product names such as “YX4000”, “YL6121H” (Mitsubishi Chemical Corporation), “NC-3000”, “NC-3100” (Nippon Kayaku Co., Ltd.). The thing marketed is mentioned.
- Examples of the tricyclic epoxy monomer include epoxy monomers having a terphenyl skeleton, 1- (3-methyl-4-oxiranylmethoxyphenyl) -4- (4-oxiranylmethoxyphenyl) -1-cyclohexene, 1- Examples include (3-methyl-4-oxiranylmethoxyphenyl) -4- (4-oxiranylmethoxyphenyl) -benzene, compounds represented by the following general formula (I), and the like.
- the specific epoxy monomer is preferably capable of forming a higher order structure and capable of forming a smectic structure when used alone as an epoxy monomer and cured. Is more preferable.
- examples of such an epoxy monomer include compounds represented by the following general formula (I).
- the epoxy resin composition contains a compound represented by the following general formula (I)
- higher thermal conductivity can be achieved.
- R 1 to R 4 each independently represents a hydrogen atom or an alkyl group having 1 to 3 carbon atoms.
- R 1 to R 4 are each independently preferably a hydrogen atom or an alkyl group having 1 or 2 carbon atoms, more preferably a hydrogen atom or a methyl group, and even more preferably a hydrogen atom.
- 2 to 4 of R 1 to R 4 are preferably hydrogen atoms, more preferably 3 or 4 are hydrogen atoms, and all 4 are further hydrogen atoms. preferable.
- any of R 1 to R 4 is an alkyl group having 1 to 3 carbon atoms
- at least one of R 1 and R 4 is preferably an alkyl group having 1 to 3 carbon atoms.
- the higher order structure is a state in which the constituent elements are arranged microscopically, and corresponds to, for example, a crystal phase and a liquid crystal phase. Whether or not such a higher-order structure exists can be easily determined by observation with a polarizing microscope. That is, when an interference pattern due to depolarization is observed in the observation in the crossed Nicol state, it can be determined that a higher order structure exists.
- the higher order structure usually exists in an island shape in the resin, and forms a domain structure. Each island forming the domain structure is called a higher-order structure.
- the structural units constituting the higher order structure are generally bonded by a covalent bond.
- High-order structures with high regularity derived from the mesogenic skeleton include nematic structures and smectic structures.
- the nematic structure is a liquid crystal structure in which the molecular long axis is oriented in a uniform direction and has only alignment order.
- the smectic structure is a liquid crystal structure having a one-dimensional positional order in addition to the orientation order and having a layer structure with a constant period.
- the direction of the period of the layer structure is uniform inside the structure having the same period of the smectic structure. That is, the order of molecules is higher in the smectic structure than in the nematic structure.
- the smectic structure has a higher thermal conductivity than the nematic structure. That is, the order of the molecule is higher in the smectic structure than in the nematic structure, and the thermal conductivity of the cured product is higher in the case of showing the smectic structure. Since the epoxy resin composition containing the compound represented by the general formula (I) can react with a curing agent to form a smectic structure, it is considered that high thermal conductivity can be exhibited.
- Whether or not a smectic structure can be formed using the epoxy resin composition can be determined by the following method.
- X-ray diffraction measurement is performed using an X-ray analyzer (for example, manufactured by Rigaku Corporation) using a CuK ⁇ 1 line and a tube voltage of 40 kV, a tube current of 20 mA, and 2 ⁇ in the range of 0.5 ° to 30 °.
- a diffraction peak exists in the range of 2 ⁇ of 1 ° to 10 °, it is determined that the periodic structure includes a smectic structure. Note that in the case of a highly ordered high-order structure derived from a mesogenic structure, a diffraction peak appears in the range of 2 ⁇ of 1 ° to 30 °.
- the epoxy resin composition contains two or more types of specific epoxy monomers and a curing agent, and the two or more types of specific epoxy monomers are compatible with each other, and react with the curing agent to form a smectic structure.
- An epoxy resin composition that can be formed (hereinafter, also referred to as “specific epoxy resin composition”) may be used.
- the specific epoxy resin composition has a low melting point and excellent thermal conductivity after curing.
- two or more types of epoxy monomers mean two or more types of epoxy monomers having different molecular structures. However, epoxy monomers having a stereoisomer (optical isomer, geometric isomer, etc.) relationship do not fall under “two or more epoxy monomers” and are regarded as the same type of epoxy monomer.
- the specific epoxy resin composition has a low melting point and excellent thermal conductivity after curing is not clear, but two or more specific epoxy monomers are compatible with each other to form a smectic structure. It is considered that the melting point of the previous specific epoxy resin composition can be lowered and high thermal conductivity can be exhibited after curing.
- the specific epoxy resin composition contains two or more specific epoxy monomers, and the specific epoxy monomers are compatible with each other.
- the melting point of a mixture of two or more types of specific epoxy monomers compatible with each other (hereinafter also referred to as “epoxy monomer mixture”) is the specific epoxy having the highest melting point among the specific epoxy monomers constituting the epoxy monomer mixture. There is a phenomenon that the melting point of the monomer becomes lower. Therefore, it becomes possible to exhibit the low melting point of the specific epoxy resin composition.
- the thermal conductivity when the specific epoxy resin composition is semi-cured or cured is higher than the thermal conductivity when the specific epoxy monomer alone constituting the epoxy monomer mixture is semi-cured or cured. It becomes possible to do.
- the epoxy monomer mixture includes three or more types of specific epoxy monomers, it is sufficient that the epoxy monomer mixture composed of all the specific epoxy monomers constituting the epoxy monomer mixture is compatible as a whole. Any two selected specific epoxy monomers may not be compatible with each other.
- compatible means phase separation derived from a specific epoxy monomer when the specific epoxy resin composition is semi-cured or cured after the epoxy monomer mixture is melted and naturally cooled. Means that no condition is observed. Moreover, even if each specific epoxy monomer is phase-separated in the epoxy monomer mixture before making a semi-cured product or a cured product, when a phase-separated state is not observed when making a semi-cured product or a cured product, It is determined that the specific epoxy monomers contained in the monomer mixture are compatible with each other.
- Whether or not the specific epoxy monomers are compatible with each other can be determined by the presence or absence of a phase separation state when the specific epoxy resin composition is made into a semi-cured product or a cured product. For example, it can be judged by observing a semi-cured product or a cured product of a specific epoxy resin composition at a curing temperature described later using an optical microscope. More specifically, the determination can be made by the following method. The epoxy monomer mixture is melted by heating above the temperature at which the epoxy monomer mixture transitions to the isotropic phase, and then the molten epoxy monomer mixture is allowed to cool naturally.
- the curing temperature can be appropriately selected according to the specific epoxy resin composition.
- the curing temperature is preferably 100 ° C. or higher, more preferably 100 ° C. to 250 ° C., and still more preferably 120 ° C. to 210 ° C.
- the melting point of the epoxy monomer mixture composed of the specific epoxy monomers in a compatible combination is lower than the melting point of the specific epoxy monomer having the highest melting point among the specific epoxy monomers constituting the epoxy monomer mixture.
- the melting point refers to the temperature at which an epoxy monomer undergoes a phase transition from a liquid crystal phase to an isotropic phase in an epoxy monomer having a liquid crystal phase.
- an epoxy monomer having no liquid crystal phase it indicates the temperature at which the state of the substance changes from a solid (crystalline phase) to a liquid (isotropic phase).
- the liquid crystal phase is one of the phases located between the crystalline state (crystalline phase) and the liquid state (isotropic phase).
- the presence or absence of a liquid crystal phase can be determined by a method of observing a change in the state of a substance in the process of raising the temperature from room temperature (for example, 25 ° C.) using a polarizing microscope. In the observation in the crossed Nicols state, interference fringes due to depolarization are seen in the crystal phase and the liquid crystal phase, and the isotropic phase appears in the dark field. The transition from the crystal phase to the liquid crystal phase can be confirmed by the presence or absence of fluidity. In other words, the expression of the liquid crystal phase means that the liquid crystal phase has a fluidity and has a temperature region where interference fringes due to depolarization are observed.
- the specific epoxy monomer or the epoxy monomer mixture has fluidity and has a temperature region where interference fringes due to depolarization are observed, the specific epoxy monomer Alternatively, it is determined that the epoxy monomer mixture has a liquid crystal phase.
- the temperature range is preferably 10 ° C. or higher, more preferably 20 ° C. or higher, and further preferably 40 ° C. or higher.
- the temperature region is 10 ° C. or higher, high thermal conductivity tends to be achieved. Furthermore, the wider the temperature region, the higher the thermal conductivity, which is preferable.
- the melting point of the specific epoxy monomer or epoxy monomer mixture can be determined by using a differential scanning calorimeter (DSC) in a temperature range from 25 ° C. to 350 ° C. under a temperature rising rate of 10 ° C./min. It is measured as a temperature at which an energy change (endothermic reaction) occurs with a phase transition.
- DSC differential scanning calorimeter
- the two or more types of specific epoxy monomers contained in the specific epoxy resin composition are compatible with each other, and are not particularly limited as long as they can form a smectic structure by reacting with a curing agent described later. It can be selected from epoxy monomers having a skeleton.
- the specific epoxy monomer can be selected from those exemplified above.
- the specific epoxy resin composition is different from the compound represented by the general formula (I) and the compound represented by the general formula (I) as two or more kinds of specific epoxy monomers, and is represented by the general formula (I). It is preferable to contain a specific epoxy monomer that is compatible with the compound (hereinafter referred to as “specific epoxy monomer different from the compound represented by the general formula (I)”).
- the epoxy resin composition contains a compound represented by the general formula (I) and a specific epoxy monomer different from the compound represented by the general formula (I), thereby effectively reducing the melting point and heat conductivity. It is possible to achieve both improvements.
- the content of the specific epoxy monomer in the epoxy monomer mixture is not particularly limited as long as it can form a smectic structure by reaction between the epoxy monomer mixture and a curing agent described later, and can be selected as appropriate. From the viewpoint of lowering the melting point, the content of the specific epoxy monomer is preferably 5% by mass or more, more preferably 10% by mass to 90% by mass, more preferably 100% by mass with respect to the total mass of the epoxy monomer mixture. % Is more preferable.
- the total content of the specific epoxy monomer in the epoxy resin composition is not particularly limited. From the viewpoint of thermosetting and thermal conductivity, the total content of the specific epoxy monomer is preferably 3% by mass to 10% by mass with respect to the total mass of the epoxy resin composition, and 3% by mass to 8% by mass. It is more preferable that
- the epoxy resin composition contains a curing agent.
- the curing agent is not particularly limited as long as it is a compound capable of curing reaction with a specific epoxy monomer, and a commonly used curing agent can be appropriately selected and used.
- Specific examples of the curing agent include acid anhydride curing agents, amine curing agents, phenol curing agents, polyaddition curing agents such as mercaptan curing agents, and catalytic curing agents such as imidazole. These curing agents may be used alone or in combination of two or more.
- the amine-based curing agent those usually used as curing agents for epoxy monomers can be used without particular limitation, and commercially available ones may be used.
- the amine curing agent is preferably a polyfunctional curing agent having two or more functional groups, and from the viewpoint of thermal conductivity, is a polyfunctional curing agent having a rigid skeleton. It is more preferable.
- bifunctional amine curing agent examples include 4,4′-diaminodiphenylmethane, 4,4′-diaminodiphenyl ether, 4,4′-diaminodiphenyl sulfone, 4,4′-diamino-3,3.
- Examples include '-dimethoxybiphenyl, 4,4'-diaminophenyl benzoate, 1,5-diaminonaphthalene, 1,3-diaminonaphthalene, 1,4-diaminonaphthalene, 1,8-diaminonaphthalene and the like.
- thermo conductivity it is preferably at least one selected from the group consisting of 4,4′-diaminodiphenylmethane, 1,5-diaminonaphthalene and 4,4′-diaminodiphenylsulfone, More preferred is 5-diaminonaphthalene.
- phenol and a novolac phenol resin can be used.
- the phenol curing agent include monofunctional compounds such as phenol, o-cresol, m-cresol, and p-cresol; bifunctional compounds such as catechol, resorcinol, and hydroquinone; 1,2,3-trihydroxybenzene, 1, And trifunctional compounds such as 2,4-trihydroxybenzene and 1,3,5-trihydroxybenzene.
- a phenol novolak resin obtained by connecting these phenol curing agents with a methylene chain or the like to form a novolak can be used.
- the phenol novolak resin include resins obtained by novolacizing one phenol compound such as cresol novolak resin, catechol novolak resin, resorcinol novolak resin, hydroquinone novolak resin; catechol resorcinol novolak resin, resorcinol hydroquinone novolak resin, etc. Examples thereof include resins obtained by novolacizing two or more phenol compounds.
- the phenol novolak resin When a phenol novolak resin is used as the phenolic curing agent, the phenol novolak resin has a structural unit represented by at least one selected from the group consisting of the following general formulas (II-1) and (II-2) It is preferable to include a compound.
- R 21 and R 24 each independently represents an alkyl group, an aryl group or an aralkyl group.
- R 22 , R 23 , R 25 and R 26 each independently represent a hydrogen atom, an alkyl group, an aryl group or an aralkyl group.
- m21 and m22 each independently represents an integer of 0-2.
- n21 and n22 each independently represents an integer of 1 to 7.
- the alkyl group may be linear, branched or cyclic.
- the aryl group may have a structure containing a hetero atom in the aromatic ring. In this case, a heteroaryl group in which the total number of heteroatoms and carbon is 6 to 12 is preferable.
- the alkylene group in the aralkyl group may be any of a chain, a branched chain, and a cyclic group.
- the aryl group in the aralkyl group may have a structure containing a hetero atom in the aromatic ring. In this case, a heteroaryl group in which the total number of heteroatoms and carbon is 6 to 12 is preferable.
- R 21 and R 24 each independently represents an alkyl group, an aromatic group (aryl group), or an aralkyl group. These alkyl group, aromatic group and aralkyl group may further have a substituent if possible. Examples of the substituent include an alkyl group (except when R 21 and R 24 are alkyl groups), an aromatic group, a halogen atom, and a hydroxyl group.
- m21 and m22 each independently represents an integer of 0 to 2, and when m21 or m22 is 2, two R 21 or R 24 may be the same or different.
- m21 and m22 are each independently preferably 0 or 1, and more preferably 0.
- n21 and n22 are the numbers of structural units represented by the above general formulas (II-1) and (II-2) contained in the phenol novolac resin, and each independently represents an integer of 1 to 7.
- R 22 , R 23 , R 25 and R 26 each independently represent a hydrogen atom, an alkyl group, an aryl group, or an aralkyl group.
- the alkyl group, aryl group and aralkyl group represented by R 22 , R 23 , R 25 and R 26 may further have a substituent, if possible.
- the substituent include an alkyl group (provided that R 22 , R 23 , R 25 and R 26 are alkyl groups), an aryl group, a halogen atom, a hydroxyl group and the like.
- R 22 , R 23 , R 25 and R 26 are each independently a hydrogen atom, an alkyl group, from the viewpoint of storage stability and thermal conductivity, Alternatively, it is preferably an aryl group, more preferably a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, or an aryl group having 6 to 12 carbon atoms, and further preferably a hydrogen atom. Furthermore, from the viewpoint of heat resistance, at least one of R 22 and R 23 is preferably an aryl group, more preferably an aryl group having 6 to 12 carbon atoms.
- R 25 and R 26 is preferably an aryl group, and more preferably an aryl group having 6 to 12 carbon atoms.
- the aryl group may have a structure containing a hetero atom in the aromatic ring. In this case, a heteroaryl group in which the total number of heteroatoms and carbon is 6 to 12 is preferable.
- the phenolic curing agent may contain one type of compound having the structural unit represented by the above general formula (II-1) or general formula (II-2) alone, or may contain two or more types. Preferably, it contains at least one compound having a structural unit derived from resorcinol represented by the general formula (II-1).
- the compound having the structural unit represented by the general formula (II-1) may further include at least one partial structure derived from a phenol compound other than resorcinol.
- examples of the partial structure derived from a phenol compound other than resorcinol include phenol, cresol, catechol, hydroquinone, 1,2,3-trihydroxybenzene, 1,2,4-trimethyl. Examples thereof include partial structures derived from hydroxybenzene and 1,3,5-trihydroxybenzene. The partial structures derived from these may be contained singly or in combination of two or more.
- the compound having the structural unit represented by the general formula (II-2) may include at least one partial structure derived from a phenol compound other than catechol.
- examples of the partial structure derived from a phenol compound other than catechol include, for example, phenol, cresol, resorcinol, hydroquinone, 1,2,3-trihydroxybenzene, 1,2,4-trimethyl. Examples thereof include partial structures derived from hydroxybenzene and 1,3,5-trihydroxybenzene. The partial structures derived from these may be contained singly or in combination of two or more.
- the partial structure derived from the phenol compound means a monovalent or divalent group constituted by removing one or two hydrogen atoms from the benzene ring portion of the phenol compound.
- the position where the hydrogen atom is removed is not particularly limited.
- the content of the partial structure derived from resorcinol is not particularly limited. From the viewpoint of the elastic modulus, the content of the partial structure derived from resorcinol is preferably 55% by mass or more based on the total mass of the compound having the structural unit represented by the general formula (II-1), and the glass transition temperature From the viewpoint of (Tg) and the linear expansion coefficient, it is more preferably 80% by mass or more, and from the viewpoint of thermal conductivity, it is further preferably 90% by mass or more.
- the phenol novolac resin more preferably includes a novolac resin having a partial structure represented by at least one selected from the group consisting of the following general formulas (III-1) to (III-4).
- n31 to n34 each independently represent a positive integer and represent the number of each structural unit contained.
- Ar 31 to Ar 34 each independently represent a group represented by the following general formula (III-a) or a group represented by the following general formula (III-b).
- R 31 and R 34 each independently represent a hydrogen atom or a hydroxyl group.
- R 32 and R 33 each independently represent a hydrogen atom or an alkyl group having 1 to 8 carbon atoms.
- a curing agent having a partial structure represented by at least one of general formula (III-1) to general formula (III-4) is produced as a by-product by a production method described later in which a divalent phenol compound is novolakized. It can be generated.
- the partial structures represented by the general formulas (III-1) to (III-4) may be included as the main chain skeleton of the compound, or may be included as a part of the side chain. Furthermore, each structural unit constituting the partial structure represented by any one of the above general formulas (III-1) to (III-4) may be included randomly or regularly. It may be contained in a block shape. In the above general formulas (III-1) to (III-4), the hydroxyl substitution position is not particularly limited as long as it is on the aromatic ring.
- a plurality of Ar 31 to Ar 34 may all be the same atomic group or include two or more atomic groups. Also good. Ar 31 to Ar 34 each independently represents a group represented by any one of the above general formulas (III-a) and (III-b).
- R 31 and R 34 are each independently a hydrogen atom or a hydroxyl group, but are preferably a hydroxyl group from the viewpoint of thermal conductivity. Further, the substitution positions of R 31 and R 34 are not particularly limited.
- R 32 and R 33 in the above general formula (III-a) and general formula (III-b) each independently represent a hydrogen atom or an alkyl group having 1 to 8 carbon atoms.
- the alkyl group having 1 to 8 carbon atoms in R 32 and R 33 include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a t-butyl group, and an n-pentyl group. , N-hexyl group, n-heptyl group, and n-octyl group.
- the substitution positions of R 32 and R 33 in general formula (III-a) and general formula (III-b) are not particularly limited.
- Ar 31 to Ar 34 in the general formula (III-a) and the general formula (III-b) are groups derived from dihydroxybenzene (in the general formula (III-a), from the viewpoint of achieving higher thermal conductivity.
- One type is preferable.
- group derived from dihydroxybenzene means a divalent group formed by removing two hydrogen atoms from the aromatic ring portion of dihydroxybenzene, and the position at which the hydrogen atom is removed is not particularly limited. Further, the “group derived from dihydroxynaphthalene” has the same meaning.
- Ar 31 to Ar 34 are more preferably each independently a group derived from dihydroxybenzene, and 1,2-dihydroxybenzene (catechol) More preferably, it is at least one selected from the group consisting of a group derived from the above and a group derived from 1,3-dihydroxybenzene (resorcinol).
- Ar 31 to Ar 34 preferably include at least a group derived from resorcinol from the viewpoint of particularly improving thermal conductivity.
- the structural unit represented by n31 to n34 preferably contains a group derived from resorcinol.
- the compound having a partial structure represented by at least one selected from the group consisting of general formula (III-1) to general formula (III-4) includes a structural unit derived from resorcinol, it is derived from resorcinol
- the content of the structural unit containing the group is, in terms of elastic modulus, in the whole compound having the structure represented by at least one of the above general formulas (III-1) to (III-4) It is preferably 55% by mass or more, more preferably 80% by mass or more from the viewpoint of Tg and linear expansion coefficient, and further preferably 90% by mass or more from the viewpoint of thermal conductivity.
- the total value of mx and nx is preferably 20 or less, more preferably 15 or less, and still more preferably 10 or less from the viewpoint of fluidity.
- the lower limit of the total value of m and n is not particularly limited.
- Mx and nx represent the number of structural units and indicate how much the corresponding structural unit is added in the molecule. Therefore, an integer value is shown for a single molecule. Note that mx and nx in (mx / nx) and (mx + nx) indicate rational numbers that are average values in the case of an assembly of a plurality of types of molecules.
- the phenol novolak resin having a partial structure represented by at least one selected from the group consisting of the above general formulas (III-1) to (III-4) is particularly substituted or unsubstituted in Ar 31 to Ar 34
- a curing agent having a low melting point can be obtained as compared with a novolak phenol resin or the like.
- Whether or not the phenol novolac resin has a partial structure represented by any one of the general formulas (III-1) to (III-4) is determined by field desorption ionization mass spectrometry (FD-MS). The determination can be made based on whether or not the fragment component includes a component corresponding to the partial structure represented by any of the general formulas (II-1) to (II-4).
- FD-MS field desorption ionization mass spectrometry
- the molecular weight of the phenol novolac resin having a partial structure represented by at least one selected from the group consisting of general formula (III-1) to general formula (III-4) is not particularly limited.
- the number average molecular weight (Mn) is preferably 2000 or less, more preferably 1500 or less, and even more preferably 350 to 1500.
- the weight average molecular weight (Mw) is preferably 2000 or less, more preferably 1500 or less, and further preferably 400 to 1500.
- Mn and Mw are measured by a usual method using GPC (gel permeation chromatography).
- the hydroxyl equivalent of the phenol novolac resin having a partial structure represented by at least one selected from the group consisting of general formula (III-1) to general formula (III-4) is not particularly limited. From the viewpoint of the crosslinking density involved in heat resistance, the hydroxyl group equivalent is preferably 45 g / eq to 150 g / eq on average, more preferably 50 g / eq to 120 g / eq, and 55 g / eq to 120 g / eq. More preferably, it is eq.
- a hydroxyl equivalent means the value measured based on JISK0070: 1992.
- the phenol novolac resin may contain a monomer that is a phenol compound constituting the phenol novolac resin.
- the content of the monomer that is a phenol compound constituting the phenol novolac resin (hereinafter also referred to as “monomer content”) is not particularly limited. From the viewpoint of thermal conductivity and moldability, the monomer content in the phenol novolac resin is preferably 5% by mass to 80% by mass, more preferably 15% by mass to 60% by mass, and 20% by mass. More preferably, it is ⁇ 50 mass%.
- the monomer content is 80% by mass or less, the amount of monomers that do not contribute to crosslinking decreases during the curing reaction, and the high molecular weight material that contributes to crosslinking occupies a large amount. It is formed and the thermal conductivity is improved.
- the monomer content is 5% by mass or more, it is easy to flow during molding, so that the adhesion with the inorganic filler contained as necessary is further improved, and more excellent thermal conductivity and heat resistance. Tend to be achieved.
- the content of the curing agent in the epoxy resin composition is not particularly limited.
- the ratio of the number of active hydrogen equivalents of the amine curing agent (amine equivalent number) to the number of epoxy groups equivalent of the epoxy monomer (amine equivalent number / epoxy equivalent number) Is preferably 0.5 to 2.0, more preferably 0.8 to 1.2.
- the curing agent is a phenolic curing agent
- the number of equivalents of epoxy groups is preferably 0.5 to 2.0, and more preferably 0.8 to 1.2.
- the epoxy resin composition may contain a curing accelerator.
- a curing agent and a curing accelerator in combination, it can be further sufficiently cured.
- the kind and content of the curing accelerator are not particularly limited, and an appropriate one can be selected from the viewpoint of reaction rate, reaction temperature, and storage property.
- Specific examples include imidazole compounds, tertiary amine compounds, organic phosphine compounds, complexes of organic phosphine compounds and organic boron compounds, and the like.
- it is preferably at least one selected from the group consisting of an organic phosphine compound and a complex of an organic phosphine compound and an organic boron compound.
- organic phosphine compound examples include triphenylphosphine, diphenyl (p-tolyl) phosphine, tris (alkylphenyl) phosphine, tris (alkoxyphenyl) phosphine, tris (alkylalkoxyphenyl) phosphine, and tris (dialkylphenyl).
- Phosphine tris (trialkylphenyl) phosphine, tris (tetraalkylphenyl) phosphine, tris (dialkoxyphenyl) phosphine, tris (trialkoxyphenyl) phosphine, tris (tetraalkoxyphenyl) phosphine, trialkylphosphine, dialkylarylphosphine And alkyldiarylphosphine.
- an organic phosphine compound and an organic boron compound include tetraphenylphosphonium / tetraphenylborate, tetraphenylphosphonium / tetra-p-tolylborate, tetrabutylphosphonium / tetraphenylborate, and tetraphenylphosphonium.
- One of these curing accelerators may be used alone, or two or more thereof may be used in combination.
- the mixing ratio should be determined without any particular restrictions depending on the characteristics (for example, how much flexibility is required) required for the semi-cured epoxy resin composition. Can do.
- the content of the curing accelerator in the epoxy resin composition is not particularly limited.
- the content of the curing accelerator is preferably 0.5% by mass to 1.5% by mass of the total mass of the epoxy monomer and the curing agent, and 0.5% by mass to 1% by mass. More preferably, the content is 0.6% by mass to 1% by mass.
- the epoxy resin composition may include an inorganic filler. By including the inorganic filler, the epoxy resin composition can achieve high thermal conductivity.
- the inorganic filler may be non-conductive or conductive. Use of a non-conductive inorganic filler tends to suppress a decrease in insulation. Moreover, it exists in the tendency for thermal conductivity to improve more by using a conductive inorganic filler.
- non-conductive inorganic filler examples include aluminum oxide (alumina), magnesium oxide, aluminum nitride, boron nitride, silicon nitride, silica (silicon oxide), silicon oxide, aluminum hydroxide, and barium sulfate.
- conductive inorganic filler examples include gold, silver, nickel, and copper.
- the inorganic filler is preferably at least one selected from the group consisting of aluminum oxide (alumina), boron nitride, magnesium oxide, aluminum nitride, and silica (silicon oxide). More preferably, it is at least one selected from the group consisting of boron nitride and aluminum oxide (alumina).
- These inorganic fillers may be used alone or in combination of two or more.
- the inorganic filler having a small particle diameter is packed in the voids of the inorganic filler having a large particle diameter, thereby filling the inorganic filler more densely than using only the inorganic filler having a single particle diameter. It becomes possible to exhibit higher thermal conductivity.
- aluminum oxide when aluminum oxide is used as the inorganic filler, aluminum oxide having a volume average particle diameter of 16 ⁇ m to 20 ⁇ m is oxidized in the inorganic filler by 60 volume% to 75 volume% and volume average particle diameter of 2 ⁇ m to 4 ⁇ m.
- the volume average particle diameter (D50) of the inorganic filler can be measured using a laser diffraction method.
- the inorganic filler in the epoxy resin composition is extracted and measured using a laser diffraction / scattering particle size distribution analyzer (for example, trade name: LS230, manufactured by Beckman Coulter, Inc.).
- LS230 laser diffraction / scattering particle size distribution analyzer
- the inorganic filler component is extracted from the epoxy resin composition and sufficiently dispersed with an ultrasonic disperser, etc., and the weight cumulative particle size distribution curve of this dispersion liquid Measure.
- the volume average particle diameter (D50) refers to the particle diameter at which accumulation is 50% from the small diameter side in the volume cumulative distribution curve obtained from the above measurement.
- the content of the inorganic filler is preferably more than 50% by volume, more than 70% by volume, and 90% by volume when the total volume of the epoxy resin composition is 100% by volume. The following is more preferable.
- the content of the inorganic filler exceeds 50% by volume, higher thermal conductivity can be achieved.
- the content of the inorganic filler is 90% by volume or less, the flexibility of the epoxy resin composition and the insulating property tend to be suppressed.
- the epoxy resin composition may contain at least one silane coupling agent.
- the silane coupling agent has a role of forming a covalent bond between the surface of the inorganic filler and the surrounding resin (equivalent to a binder agent), an improvement in thermal conductivity, and prevents moisture penetration. It can be thought that it plays a role of improving sex.
- the type of silane coupling agent is not particularly limited, and a commercially available product may be used.
- the terminal is an epoxy group, an amino group, a mercapto group. It is preferable to use a silane coupling agent having a ureido group and a hydroxyl group.
- silane coupling agent examples include 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, 3-glycidoxypropylmethyldimethoxysilane.
- silane coupling agent oligomers manufactured by Hitachi Chemical Techno Service Co., Ltd. represented by trade name: SC-6000KS2. These silane coupling agents may be used alone or in combination of two or more.
- the epoxy resin composition may contain other components in addition to the above components, if necessary.
- examples of other components include a solvent, an elastomer, a dispersant, and an anti-settling agent.
- the solvent is not particularly limited as long as it does not inhibit the curing reaction of the epoxy resin composition, and a commonly used organic solvent can be appropriately selected and used.
- Mn and Mw weight average molecular weight were measured as follows. Mn and Mw were measured using a high performance liquid chromatography (manufactured by Hitachi, Ltd., trade name: L6000) and a data analyzer (manufactured by Shimadzu Corporation, trade name: C-R4A). As analytical GPC columns, G2000HXL and G3000HXL (trade names) manufactured by Tosoh Corporation were used. The sample concentration was 0.2% by mass, tetrahydrofuran was used as the mobile phase, and the measurement was performed at a flow rate of 1.0 mL / min. A calibration curve was prepared using a polystyrene standard sample, and Mn and Mw were calculated using polystyrene conversion values.
- the hydroxyl equivalent was measured as follows.
- the hydroxyl equivalent was measured by acetyl chloride-potassium hydroxide titration method.
- the determination of the titration end point was performed by potentiometric titration instead of the coloring method using an indicator because the solution color was dark.
- the hydroxyl group of the measurement resin is acetylated in a pyridine solution, the excess reagent is decomposed with water, and the resulting acetic acid is titrated with a potassium hydroxide / methanol solution.
- the obtained CRN is a mixture of compounds having a partial structure represented by at least one of the general formulas (III-1) to (III-4), and Ar is represented by the general formula (III-a )
- R 31 is a hydroxyl group
- R 32 and R 33 are hydrogen atoms, a group derived from 1,2-dihydroxybenzene (catechol) and a group derived from 1,3-dihydroxybenzene (resorcinol)
- TPP Triphenylphosphine [Wako Pure Chemical Industries, Ltd., trade name]
- KBM-573 3-phenylaminopropyltrimethoxysilane [silane coupling agent, manufactured by Shin-Etsu Chemical Co., Ltd., trade name]
- Example 1 (Preparation of epoxy resin composition)
- monomer A and monomer B were mixed so that an epoxy equivalent was 8: 2, and an epoxy monomer mixture 1 was obtained.
- the epoxy monomer mixture 1 was compatible at 140 ° C., which is the curing temperature of the epoxy resin composition.
- the density of boron nitride (HP-40) is 2.20 g / cm 3
- the density of alumina (AA-3 and AA-04) is 3.98 g / cm 3
- epoxy monomers (monomer A and monomer B) and curing agent When the density of the mixture with (CRN) was 1.20 g / cm 3 and the ratio of the inorganic filler to the total volume of the total solid content of the epoxy resin composition was calculated, it was 72% by volume.
- PET polyethylene terephthalate
- the PET film was peeled off from the B-stage resin layer, and a copper foil was placed thereon so that the roughened surface was opposed to the resin layer.
- vacuum thermocompression bonding press temperature: 180 ° C., degree of vacuum: 1 kPa, press pressure: 15 MPa, pressurization time: 6 minutes
- the copper foil of the produced cured epoxy resin composition with copper foil was removed by etching to obtain a sheet-like cured epoxy resin composition (cured resin sheet).
- the obtained resin sheet cured product was cut into 10 mm length and 10 mm width to obtain a sample.
- the thermal diffusivity was evaluated by a xenon flash method (trade name: LFA447 nanoflash, manufactured by NETZSCH). From the product of this value, the density measured by the Archimedes method, and the specific heat measured by DSC (Differential Scanning Calorimeter; product name: DSC Pyris 1 manufactured by Perkin Elmer), the thickness of the cured resin sheet is determined. The thermal conductivity was determined. The results are shown in Table 1.
- the copper foil of the produced cured epoxy resin composition with copper foil was removed by etching to obtain a sheet-like cured epoxy resin composition (cured resin sheet).
- the obtained resin sheet cured product was cut into 10 mm length and 10 mm width to obtain a sample.
- the sample was subjected to X-ray diffraction measurement (using an X-ray diffractometer manufactured by Rigaku Corporation) with a tube voltage of 40 kV, a tube current of 20 mA, and 2 ⁇ of 2 ° to 30 ° using a CuK ⁇ 1 wire. It was confirmed that a smectic structure was formed depending on the presence or absence of a diffraction peak in a range of ⁇ 10 °.
- Examples 2 to 8, Comparative Examples 1 and 2 Epoxy resin compositions of Examples 2 to 8 and Comparative Examples 1 and 2 were prepared in the same manner as in Example 1 except that the amount of the solvent (CHN) was changed. Using the prepared epoxy resin composition, the viscosity, coatability, shape retention, and thermal conductivity were measured or evaluated in the same manner as in Example 1. The results are shown in Table 1.
- the epoxy resin compositions of the examples having a thixotropic index of 3 to 10 at 25 ° C. had good evaluations of coatability and shape retention.
- the epoxy resin composition of Comparative Example 1 having a thixotropic index at 25 ° C. of less than 3 had a low applicability evaluation.
- the epoxy resin composition of Comparative Example 2 having a thixotropic index of 10 at 25 ° C. had a low evaluation of shape retention. From the above results, it was found that the resin composition of the present embodiment has applicability and shape retention suitable for forming the resin layer of the laminate.
Abstract
Description
<1>25℃でのチクソトロピック指数が3~10であり、一対の部材と、前記一対の部材の間に配置される樹脂層と、を有する積層体の前記樹脂層を塗布して形成するための、樹脂組成物。
<2>25℃、5min-1(rpm)での粘度が0.6Pa・s~3.5Pa・sである、<1>に記載の樹脂組成物。
<3>エポキシ樹脂を含む、<1>又は<2>に記載の樹脂組成物。
<4>メソゲン骨格を有するエポキシモノマーと、硬化剤と、を含む、<1>~<3>のいずれか1項に記載の樹脂組成物。
<5>前記メソゲン骨格を有するエポキシモノマーは下記一般式(I)で表される化合物を含む、<4>に記載の樹脂組成物。
<6>前記硬化剤はフェノールノボラック樹脂を含む、<4>又は<5>に記載の樹脂組成物。
<7>第一部材の上に<1>~<6>のいずれか1項に記載の樹脂組成物を用いて樹脂層を形成する樹脂層形成工程と、前記樹脂層の上に第二部材を配置する部材配置工程と、を含む積層体の製造方法。
本明細書において「工程」との語には、他の工程から独立した工程に加え、他の工程と明確に区別できない場合であってもその工程の目的が達成されれば、当該工程も含まれる。
また本明細書において「~」を用いて示された数値範囲には、「~」の前後に記載される数値がそれぞれ最小値及び最大値として含まれる。
本明細書中に段階的に記載されている数値範囲において、一つの数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本明細書中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
本明細書において組成物中の各成分の含有率は、組成物中に各成分に該当する物質が複数種存在する場合、特に断らない限り、組成物中に存在する当該複数種の物質の合計の含有率を意味する。
本明細書において組成物中の各成分の粒子径は、組成物中に各成分に該当する粒子が複数種存在する場合、特に断らない限り、組成物中に存在する当該複数種の粒子の混合物についての値を意味する。
本明細書において「層」又は「膜」との語には、当該層又は膜が存在する領域を観察したときに、当該領域の全体に形成されている場合に加え、当該領域の一部にのみ形成されている場合も含まれる。
本明細書において「積層」との語は、層を積み重ねることを示し、二以上の層が結合されていてもよく、二以上の層が着脱可能であってもよい。
樹脂組成物から形成された樹脂組成物層を乾燥して得られる樹脂シートを更に加熱加圧処理して得られる樹脂シートをBステージシートと称する場合がある。
なお、Bステージについては、JIS K6900:1994の規定を参照するものとする。
本明細書において表面粗さ(Rz)の定義については、JIS B 0601-2001の(Rzjis)の規定を参照する。
本実施形態の樹脂組成物は、25℃でのチクソトロピック指数が3~10であり、一対の部材と、前記一対の部材の間に配置される樹脂層と、を有する積層体の前記樹脂層を塗布して形成するためのものである。
本実施形態の樹脂組成物を用いて積層体を製造する方法は、特に制限されない。ある実施態様では、樹脂組成物は、第一部材の上に樹脂層を形成する樹脂層形成工程と、前記樹脂層の上に第二部材を配置する部材配置工程と、を含む積層体の製造方法に用いられる。
(1)第一部材の樹脂層と接する面の表面粗さ(Rz)が、第二部材の樹脂層と接する面の表面粗さ(Rz)よりも大きい。
(2)第二部材の樹脂層と接する面の表面粗さ(Rz)が30μm以下である。
第一部材の表面粗さ(Rz)は、例えば、5μm以上であってよく、10μmであってよく、20μm以上であってよい。第一部材の表面粗さ(Rz)は、例えば、80μm以下であってよい。
第二部材の表面粗さ(Rz)は、例えば、20μm以下であってよく、10μm以下であってよく、5μm以下であってよい。第二部材の表面粗さ(Rz)は、例えば、3μm以上であってよい。
本実施形態の樹脂組成物は、エポキシモノマーと、硬化剤と、を含むエポキシ樹脂組成物であってもよい。
エポキシ樹脂組成物に含まれるエポキシモノマーは、1種単独でも、2種以上であってもよい。また、エポキシモノマーがオリゴマー又はプレポリマーの状態になったものを含んでいてもよい。
すなわち、分子の秩序性はネマチック構造よりもスメクチック構造の方が高く、硬化物の熱伝導性もスメクチック構造を示す場合の方が高くなる。一般式(I)で表される化合物を含むエポキシ樹脂組成物は、硬化剤と反応して、スメクチック構造を形成できるので、高い熱伝導率を発揮できると考えられる。
CuKα1線を用い、管電圧40kV、管電流20mA、2θが0.5°~30°の範囲で、X線解析装置(例えば、株式会社リガク製)を用いてX線回折測定を行う。2θが1°~10°の範囲に回折ピークが存在する場合には、周期構造がスメクチック構造を含んでいると判断される。なお、メソゲン構造に由来する規則性の高い高次構造を有する場合には、2θが1°~30°の範囲に回折ピークが現れる。
また、特定エポキシ樹脂組成物を半硬化物又は硬化物にしたときの熱伝導率は、エポキシモノマー混合物を構成する特定エポキシモノマー単体を半硬化物又は硬化物にしたときの熱伝導率よりも高くすることが可能となる。
エポキシモノマー混合物が3種以上の特定エポキシモノマーを含む場合、エポキシモノマー混合物を構成する全ての特定エポキシモノマーからなるエポキシモノマー混合物の全体として相溶可能であればよく、3種以上の特定エポキシモノマーから選択される任意の2種の特定エポキシモノマーが互いに相溶可能でなくともよい。
液晶相とは、結晶状態(結晶相)と液体状態(等方相)との中間に位置する相のひとつであり、分子の配向方向は何らかの秩序は保っているものの、3次元的な位置の秩序を失った状態を指す。
すなわち、クロスニコル状態での観察において、特定エポキシモノマー又はエポキシモノマー混合物が流動性を有し、且つ偏光解消による干渉縞が観察される温度領域を持っていることが確認されれば、特定エポキシモノマー又はエポキシモノマー混合物は液晶相を有すると判断する。
エポキシ樹脂組成物は、硬化剤を含有する。硬化剤は、特定エポキシモノマーと硬化反応が可能な化合物であれば特に制限されず、通常用いられる硬化剤を適宜選択して用いることができる。硬化剤の具体例としては、酸無水物系硬化剤、アミン系硬化剤、フェノール系硬化剤、メルカプタン系硬化剤等の重付加型硬化剤、イミダゾール等の触媒型硬化剤などが挙げられる。これらの硬化剤は、1種を単独で用いてもよく、2種以上を組み合わせてもよい。
中でも耐熱性の観点から、硬化剤としては、アミン系硬化剤及びフェノール系硬化剤からなる群より選択される少なくとも1種を用いることが好ましく、更に、保存安定性の観点から、フェノール系硬化剤の少なくとも1種を用いることがより好ましい。
中でも、熱伝導率の観点から、4,4’-ジアミノジフェニルメタン及び1,5-ジアミノナフタレン及び4,4’-ジアミノジフェニルスルフォンからなる群より選択される少なくとも1種であることが好ましく、1,5-ジアミノナフタレンであることがより好ましい。
フェノール硬化剤としては、フェノール、o-クレゾール、m-クレゾール、p-クレゾール等の単官能の化合物;カテコール、レゾルシノール、ハイドロキノン等の2官能の化合物;1,2,3-トリヒドロキシベンゼン、1,2,4-トリヒドロキシベンゼン、1,3,5-トリヒドロキシベンゼン等の3官能の化合物などが挙げられる。また、硬化剤としては、これらフェノール硬化剤をメチレン鎖等で連結してノボラック化したフェノールノボラック樹脂を用いることができる。
アリール基は、芳香族環にヘテロ原子を含む構造であってもよい。この場合、ヘテロ原子と炭素の合計数が6~12となるヘテロアリール基であることが好ましい。
アラルキル基におけるアルキレン基は、鎖状、分岐鎖状、及び環状のいずれであってもよい。アラルキル基におけるアリール基は、芳香族環にヘテロ原子を含む構造であってもよい。この場合、ヘテロ原子と炭素の合計数が6~12となるヘテロアリール基であることが好ましい。
m21及びm22はそれぞれ独立に、0~2の整数を表し、m21又はm22が2の場合、2つのR21又はR24は同一であっても異なっていてもよい。m21及びm22は、それぞれ独立に、0又は1であることが好ましく、0であることがより好ましい。
n21及びn22はフェノールノボラック樹脂に含まれる上記一般式(II-1)及び(II-2)で表される構造単位の数であり、それぞれ独立に、1~7の整数を表す。
更に、耐熱性の観点から、R22及びR23の少なくとも一方はアリール基であることが好ましく、炭素数6~12であるアリール基であることがより好ましい。また、R25及びR26の少なくとも一方は、同様にアリール基であることが好ましく、炭素数6~12であるアリール基であることがより好ましい。
なお、上記アリール基は芳香族環にヘテロ原子を含む構造であってもよい。この場合、ヘテロ原子と炭素の合計数が6~12となるヘテロアリール基であることが好ましい。
また、上記一般式(II-2)で表される構造単位を有する化合物は、カテコール以外のフェノール化合物に由来する部分構造の少なくとも1種を含んでいてもよい。上記一般式(II-2)において、カテコール以外のフェノール化合物に由来する部分構造としては、例えば、フェノール、クレゾール、レゾルシノール、ヒドロキノン、1,2,3-トリヒドロキシベンゼン、1,2,4-トリヒドロキシベンゼン、及び1,3,5-トリヒドロキシベンゼンに由来する部分構造が挙げられる。これらに由来する部分構造は、1種単独でも、2種以上を組み合わせて含んでいてもよい。
なお、フェノールノボラック樹脂が一般式(III-1)~一般式(III-4)のいずれかで表される部分構造を有するか否かは、電界脱離イオン化質量分析法(FD-MS)によって、そのフラグメント成分として、上記一般式(II-1)~一般式(II-4)のいずれかで表される部分構造に相当する成分が含まれるか否かによって判断することができる。
エポキシ樹脂組成物は、硬化促進剤を含んでもよい。硬化剤と硬化促進剤とを併用することで、更に十分に硬化させることができる。硬化促進剤の種類及び含有量は特に制限されず、反応速度、反応温度及び保管性の観点から、適切なものを選択することができる。
これら硬化促進剤は、1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。
エポキシ樹脂組成物は、無機充填材を含んでもよい。無機充填材を含むことにより、エポキシ樹脂組成物は、高い熱伝導率を達成することができる。
無機充填材は非導電性であっても、導電性であってもよい。非導電性の無機充填材を使用することによって絶縁性の低下が抑制される傾向にある。また、導電性の無機充填材を使用することによって熱伝導性がより向上する傾向にある。
これら無機充填材は、1種を単独で用いてもよく、2種以上を組み合わせて用いることができる。
具体的には、無機充填材として酸化アルミニウムを使用する場合、無機充填材中に、体積平均粒子径16μm~20μmの酸化アルミニウムを60体積%~75体積%、体積平均粒子径2μm~4μmの酸化アルミニウムを10体積%~20体積%、体積平均粒子径0.3μm~0.5μmの酸化アルミニウムを10体積%~20体積%の範囲の割合で混合することによって、より最密充填化が可能となる。
更に、無機充填材として窒化ホウ素及び酸化アルミニウムを併用する場合、無機充填材中に、体積平均粒子径20μm~100μmの窒化ホウ素を60体積%~90体積%、体積平均粒子径2μm~4μmの酸化アルミニウムを5体積%~20体積%、体積平均粒子径0.3μm~0.5μmの酸化アルミニウムを5体積%~20体積%の範囲の割合で混合することによって、より高熱伝導化が可能となる。無機充填材の体積平均粒子径は、レーザー回折式粒度分布測定装置を用いて通常の条件で測定される。
体積平均粒子径(D50)は、上記測定より得られた体積累積分布曲線において、小径側から累積が50%となる粒子径をいう。
無機充填剤の含有率が50体積%を超えると、より高い熱伝導率を達成することが可能となる。一方、無機充填剤の含有率が90体積%以下であると、エポキシ樹脂組成物の柔軟性の低下、及び絶縁性の低下を抑制する傾向にある。
エポキシ樹脂組成物は、シランカップリング剤の少なくとも1種を含んでいてもよい。シランカップリング剤は、無機充填材の表面とその周りを取り囲む樹脂との間で共有結合を形成する役割(バインダ剤に相当)、熱伝導率の向上、及び水分の侵入を妨げることによって絶縁信頼性を向上させる働きを果たすと考えることができる。
エポキシ樹脂組成物は、必要に応じて、上記成分に加えてその他の成分を含んでいてもよい。その他の成分としては、例えば、溶剤、エラストマ、分散剤、及び沈降防止剤を挙げることができる。
溶剤としては、エポキシ樹脂組成物の硬化反応を阻害しないものであれば特に制限はなく、通常用いられる有機溶剤を適宜選択して用いることができる。
(メソゲン骨格を有するエポキシモノマーA(モノマーA))
・[4-{4-(2,3-エポキシプロポキシ)フェニル}シクロヘキシル=4-(2,3-エポキシプロポキシ)ベンゾエート、エポキシ当量:212g/eq、特開2011-74366号公報に記載の方法により製造]
・AA-3[アルミナ粒子、住友化学株式会社製、D50:3μm]
・AA-04[アルミナ粒子、住友化学株式会社製、D50:0.40μm]
・HP-40[窒化ホウ素粒子、水島合金鉄株式会社製、D50:40μm]
・CRN[カテコールレゾルシノールノボラック(質量基準の仕込み比:カテコール/レゾルシノール=5/95)樹脂、シクロヘキサノン50質量%含有]
撹拌機、冷却器及び温度計を備えた3Lのセパラブルフラスコに、レゾルシノール627g、カテコール33g、37質量%ホルムアルデヒド水溶液316.2g、シュウ酸15g、水300gを入れ、オイルバスで加温しながら100℃に昇温した。104℃前後で還流し、還流温度で4時間反応を続けた。その後、水を留去しながらフラスコ内の温度を170℃に昇温した。170℃を保持しながら8時間反応を続けた。反応後、減圧下20分間濃縮を行い、系内の水等を除去し、目的であるフェノールノボラック樹脂CRNを得た。
また、得られたCRNについて、FD-MS(電界脱離イオン化質量分析法)により構造を確認したところ、一般式(III-1)~一般式(III-4)で表される部分構造すべての存在が確認できた。
Mn及びMwの測定は、高速液体クロマトグラフィ(株式会社日立製作所製、商品名:L6000)及びデータ解析装置(株式会社島津製作所製、商品名:C-R4A)を用いて行った。分析用GPCカラムは東ソー株式会社製のG2000HXL及びG3000HXL(以上、商品名)を使用した。試料濃度は0.2質量%、移動相にはテトラヒドロフランを用い、流速1.0mL/minで測定を行った。ポリスチレン標準サンプルを用いて検量線を作成し、それを用いてポリスチレン換算値でMn及びMwを計算した。
水酸基当量は、塩化アセチル-水酸化カリウム滴定法により測定した。なお、滴定終点の判断は溶液の色が暗色のため、指示薬による呈色法ではなく、電位差滴定によって行った。具体的には、測定樹脂の水酸基をピリジン溶液中塩化アセチル化した後に、過剰の試薬を水で分解し、生成した酢酸を水酸化カリウム/メタノール溶液で滴定したものである。
・TPP:トリフェニルホスフィン[和光純薬工業株式会社製、商品名]
・KBM-573:3-フェニルアミノプロピルトリメトキシシラン[シランカップリング剤、信越化学工業株式会社製、商品名]
・CHN:シクロヘキサノン
・PETフィルム[帝人デュポンフィルム株式会社製、商品名:A53、厚さ50μm]
・銅箔[古河電工株式会社製、厚さ:105μm、GTSグレード]
(エポキシ樹脂組成物の調製)
メソゲン骨格を有するエポキシモノマーとして、モノマーAとモノマーBとをエポキシ当量が8:2となるように混合してエポキシモノマー混合物1を得た。後述の方法により相溶性を確認したところ、エポキシモノマー混合物1は、エポキシ樹脂組成物の硬化温度である140℃において相溶性を有していた。
エポキシ樹脂組成物を、ディスペンサー(武蔵エンジニアリング株式会社製の商品名:SHOTMASTER300DS-S)を用いて、乾燥後の樹脂層の大きさが45mm×45mm、厚さが400μmとなるように、銅箔の粗化面上に付与した。その後、オーブン(ESPEC社製の商品名:SPHH-201)を用い、常温(20℃~30℃)で5分、更に130℃で5分間乾燥させた。
作製した銅箔付硬化エポキシ樹脂組成物の銅箔をエッチングして取り除き、シート状の硬化エポキシ樹脂組成物(樹脂シート硬化物)を得た。得られた樹脂シート硬化物を縦10mm、横10mmに切って試料を得た。試料をグラファイトスプレーにて黒化処理した後、キセノンフラッシュ法(NETZSCH社製の商品名:LFA447 nanoflash)にて熱拡散率を評価した。この値と、アルキメデス法で測定した密度と、DSC(示差走査熱量測定装置;Perkin Elmer社製の商品名:DSC Pyris1)にて測定した比熱との積から、樹脂シート硬化物の厚さ方向の熱伝導率を求めた。結果を表1に示す。
作製した銅箔付硬化エポキシ樹脂組成物の銅箔をエッチングして取り除き、シート状の硬化エポキシ樹脂組成物(樹脂シート硬化物)を得た。得られた樹脂シート硬化物を縦10mm、横10mmに切って試料を得た。試料をCuKα1線を用い、管電圧40kV、管電流20mA、2θが2°~30°の範囲でX線回折測定(株式会社リガク製X線回折装置を使用)を行い、2θが2°~10°の範囲での回折ピークの有無により、スメクチック構造が形成されていることを確認した。
上記で得られたエポキシモノマー混合物を加熱しながら、加熱中のエポキシモノマー混合物の状態変化を、偏光顕微鏡(オリンパス株式会社製、「BS51」)を用いてクロスニコル状態で観察(倍率:100倍)したところ、偏光解消による干渉縞を示したままで流動性を帯びた状態となる結晶相から液晶相への転移が、120℃で観察された。また、更に加熱を続けたところ、暗視野に変化する液晶相から等方相への転移が、170℃で観察された。以上の結果から、エポキシモノマー混合物は、120℃~170℃で液晶相を示すことを確認した。
上記で得られたエポキシモノマー混合物について、示差走査熱量測定装置(パーキンエルマ社製、「DSC7」)を用いて測定した。測定温度範囲25℃~350℃、昇温速度10℃/分、流量20±5ml/minの窒素雰囲気下の条件で、アルミニウム製のパンに密閉した3mg~5mgの試料の示差走査熱量測定を行い、相転移に伴うエネルギー変化が起こる温度(吸熱反応ピークの温度)を融点(相転移温度)とした。融点は111℃であり、モノマーA単独で測定した場合の融点(125℃)よりも低かった。
上記で得られたエポキシモノマー混合物について、等方相転移温度以上に加熱して溶融させた。その後、自然冷却しながら、エポキシ樹脂組成物の硬化温度である140℃における硬化物の状態を顕微鏡(オリンパス株式会社製、BS51)で観察(倍率:100倍)した。エポキシモノマー混合物の相分離は観察されなかった。以上の結果から、エポキシモノマー混合物は、エポキシ樹脂組成物の硬化温度である140℃において相溶性を示すことを確認した。
作製したエポキシ樹脂組成物の25℃、5min-1(rpm)における粘度Aと、25℃、0.5min-1(rpm)における粘度Bとを、E型粘度計(東機産業株式会社製の商品名:TV-33)を用いて測定した。また、得られた値からチクソトロピック指数(B/A)を算出した。結果を表1に示す。
エポキシ樹脂組成物の塗布性を下記の基準に従って評価した。結果を表1に示す。
「OK」・・・塗布した直後のエポキシ樹脂組成物の塗布面においてかすれが見られなかった場合
「NG」・・・塗布した直後のエポキシ樹脂組成物の塗布面においてかすれが見られた場合、又はエポキシ樹脂組成物がディスペンサーにて詰まってしまい、塗布できなかった場合
エポキシ樹脂組成物の形状保持性を下記の基準に従って評価した。結果を表1に示す。
「OK」・・・銅箔の光沢面に1mLのエポキシ樹脂組成物を銅箔の2cm上から滴下し、濡れ広がりが半径30mm未満であった場合
「NG」・・・銅箔の光沢面に1mLのエポキシ樹脂組成物を銅箔の2cm上から滴下し、濡れ広がりが半径30mm以上であった場合
溶剤(CHN)の量を変更した以外は実施例1と同様にして実施例2~8、比較例1、2のエポキシ樹脂組成物を調製した。
調製したエポキシ樹脂組成物を用いて、実施例1と同様にして粘度、塗布性、形状保持性及び熱伝導率を測定又は評価した。結果を表1に示す。
25℃でのチクソトロピック指数が3未満である比較例1のエポキシ樹脂組成物は、塗布性の評価が低かった。
25℃でのチクソトロピック指数が10を超える比較例2のエポキシ樹脂組成物は、形状保持性の評価が低かった。
以上の結果から、本実施形態の樹脂組成物は、積層体の樹脂層を形成するのに適した塗布性と形状保持性を有することがわかった。
2…樹脂層
3、4…熱板
5…第二部材
6、7…熱板
Claims (7)
- 25℃でのチクソトロピック指数が3~10であり、一対の部材と、前記一対の部材の間に配置される樹脂層と、を有する積層体の前記樹脂層を塗布して形成するための、樹脂組成物。
- 25℃、5min-1(rpm)での粘度が0.6Pa・s~3.5Pa・sである、請求項1に記載の樹脂組成物。
- エポキシ樹脂を含む、請求項1又は請求項2に記載の樹脂組成物。
- メソゲン骨格を有するエポキシモノマーと、硬化剤と、を含む、請求項1~請求項3のいずれか1項に記載の樹脂組成物。
- 前記硬化剤はフェノールノボラック樹脂を含む、請求項4又は請求項5に記載の樹脂組成物。
- 第一部材の上に請求項1~請求項6のいずれか1項に記載の樹脂組成物を用いて樹脂層を形成する樹脂層形成工程と、前記樹脂層の上に第二部材を配置する部材配置工程と、を含む積層体の製造方法。
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