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  • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
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  • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
  • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
  • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
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  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
  • C04B35/583—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on boron nitride
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  • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
  • C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
  • C04B38/0074—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores expressed as porosity percentage
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  • C04B41/0063—Cooling, e.g. freezing
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
  • C04B41/4521—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application application under increased pressure
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
  • C04B41/4523—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied from the molten state ; Thermal spraying, e.g. plasma spraying
  • C04B41/4525—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied from the molten state ; Thermal spraying, e.g. plasma spraying using a molten bath as vehicle, e.g. molten borax
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
  • C04B41/81—Coating or impregnation
  • C04B41/82—Coating or impregnation with organic materials
  • C04B41/83—Macromolecular compounds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
  • B29K2709/02—Ceramics
  • B29K2709/04—Carbides; Nitrides
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  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00844—Uses not provided for elsewhere in C04B2111/00 for electronic applications
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
  • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
  • H10H20/80—Constructional details
  • H10H20/85—Packages
  • H10H20/858—Means for heat extraction or cooling
  • H10H20/8581—Means for heat extraction or cooling characterised by their material

Definitions

• the present disclosure relates to a complex and a method for producing the complex.
• thermo interface material For electronic components such as LED lighting devices and in-vehicle power modules, it is an issue to efficiently dissipate heat generated during use.
• a composite heat dissipation member
• a resin and ceramics such as boron nitride
• the step of impregnating the ceramics with the resin or the composition containing the resin-imparting monomer is set as a pressure condition, and the pressure thereof is controlled to improve the resin impregnation rate in the pores.
• the pressure is adjusted as described above, the produced complex may not reach the desired resin impregnation rate, and the pore volume may not be reached. It can be difficult to obtain a complex containing a semi-cured product in a high proportion.
• An object of the present disclosure is to provide a method for producing a complex capable of increasing the content ratio of a semi-cured product in the pores of a nitride sintered body.
• One aspect of the present disclosure comprises a cooling step of cooling the thermosetting composition in contact with the heat-curable composition under pressurized conditions, and the resin-impregnated body has a porous structure.
• a method for producing a composite having a nitride sintered body and a semi-cured product of a thermosetting composition impregnated in the nitride sintered body is provided.
• the content ratio of the semi-cured product in the obtained complex can be increased by performing the cooling step under pressurized conditions.
• the pressure adjustment when impregnating the nitride sintered body with the thermosetting composition in the conventional method for producing a composite is effective for improving the resin impregnation rate.
• the heat-curable composition is semi-cured by heating, and the shrinkage (curing shrinkage) accompanying the curing of the heat-curable composition continuously progresses in the subsequent cooling process.
• Shrinkage (solidification shrinkage) associated with cooling of the semi-cured product may cause a decrease in the ratio of the semi-cured product to the total pore volume of the nitride sintered body.
• thermosetting composition by semi-curing the thermosetting composition and setting the pressure in the subsequent cooling process as a pressurizing condition, the thermosetting composition or the thermosetting composition is further semi-cured from the outside in response to the above-mentioned shrinkage. It has been found that the material can be supplied to reduce the decrease in the ratio of the semi-cured material to the total pore volume of the nitride sintered body, which is generated by the curing shrinkage and the solidification shrinkage. Based on this finding, the present inventors have reached the method for producing the complex of the present disclosure. Since the method for producing the complex of the present disclosure uses the above findings, the thermosetting composition is further semi-cured with respect to the complex produced by the conventional method and having a low content ratio of the semi-cured product. By introducing a substance, a complex having a high content ratio of the semi-cured product can also be prepared.
• the pressure in the cooling step may be 2.0 MPa or more.
• the heat-curable composition is heated and semi-cured in a state where the nitride sintered body having a porous structure is in contact with the heated melt of the thermosetting composition, and the resin is semi-cured.
• a step of preparing a resin-impregnated body for obtaining the impregnated body may be further provided.
• the preparation step may include placing the nitride sintered body under pressurized conditions in a state of being in contact with the heated melt of the thermosetting composition.
• pressurizing the nitride sintered body in contact with the heated melt of the thermosetting composition the pores of the nitride sintered body can be more sufficiently impregnated with the thermosetting composition. ..
• the characteristics of the obtained complex for example, insulation
• the pressure in the cooling step may be larger than the pressure in the preparation step. Since the pressure in the cooling step is higher than the pressure in the preparation step, the pores of the nitride sintered body can be more sufficiently impregnated with the thermosetting composition, and the curing of the thermosetting composition proceeds. However, even when the viscosity increases, the decrease in the impregnation rate can be suppressed more sufficiently.
• One aspect of the present disclosure comprises a nitride sintered body having a porous structure and a semi-cured product of a thermosetting composition impregnated in the nitride sintered body, and all of the nitride sintered bodies.
• a composite in which the ratio of the semi-cured product to the pore volume is 99.0% by volume or more.
• the composite has 99% by volume or more of the semi-cured product in the total pore volume of the nitride sintered body, and sufficiently contains the semi-cured product.
• the method for producing a complex it is possible to produce a complex in which the content ratio of the semi-cured product in the pores of the nitride sintered body is increased. According to the present disclosure, it is also possible to provide a complex having a semi-cured product in an extremely high proportion.
• each component in the composition means the total amount of the plurality of substances present in the composition when a plurality of substances corresponding to each component in the composition are present, unless otherwise specified. ..
• the "process" in the present specification may be a process independent of each other or a process performed at the same time.
• the present disclosure relates to a method for producing a composite having a nitride sintered body having a porous structure and a semi-cured product of a thermosetting composition impregnated in the nitride sintered body.
• One embodiment of the method for producing a composite comprises a cooling step of cooling the resin-impregnated body under pressurized conditions in a state where the heated melt of the thermosetting composition is in contact with the resin-impregnated body.
• the resin-impregnated body includes a nitride sintered body having a porous structure and a semi-cured product of a thermosetting composition impregnated in the nitride sintered body.
• the resin-impregnated body may be a complex obtained by a conventional production method, and the content ratio of the semi-cured product may be, for example, 98% by volume or less, or 80% by volume or less.
• the content ratio of the semi-cured product means the ratio of the semi-cured product to the total pore volume of the nitride sintered body.
• the heat-curable composition is heated in a state where the nitride sintered body having a porous structure is in contact with (for example, immersed) the heat-melted product of the thermosetting composition.
• a step of preparing a resin-impregnated body by curing to obtain the resin-impregnated body may be further provided.
• the preparation step is also referred to as a first step
• the cooling step of cooling the resin-impregnated body under pressurized conditions to obtain a complex is also referred to as a second step.
• the nitride sintered body having a porous structure may be obtained by sintering primary particles of a nitride.
• the nitride sintered body having a porous structure may be, for example, one obtained by sintering primary particles of boron nitride (boron nitride sintered body).
• the term "porous structure” means a structure having a plurality of fine pores (hereinafter, also referred to as pores), and at least a part of the pores is connected to form a continuous pore. Including things.
• the upper limit of the average pore diameter of the pores may be, for example, 7 ⁇ m or less, 6 ⁇ m or less, or 5 ⁇ m or less. When the upper limit of the average pore diameter is within the above range, the thermal conductivity of the composite can be improved.
• the lower limit of the average pore diameter of the pores may be, for example, 0.3 ⁇ m or more, 0.5 ⁇ m or more, or 0.7 ⁇ m or more. When the lower limit of the average pore diameter is within the above range, the thermosetting composition can be easily impregnated into the pores, and the adhesiveness of the complex to the adherend can be further improved.
• the average pore diameter of the pores may be adjusted within the above range, and may be, for example, 0.3 to 7 ⁇ m, 0.5 to 6 ⁇ m, or 0.7 to 5 ⁇ m.
• the "average pore diameter” means that the cumulative pore volume is 50 of the total pore volume in the pore diameter distribution (horizontal axis: pore diameter, vertical axis: cumulative pore volume) measured using a mercury porosimeter. It means the pore diameter reaching%.
• the mercury porosimeter for example, a mercury porosimeter manufactured by Shimadzu Corporation can be used. The measurement range is 0.03 to 4000 atm, and the measurement is performed while gradually pressurizing while increasing the pressure.
• the total pore volume of the nitride sintered body may be adjusted according to the application of the complex and the like.
• the total pore volume of the nitride sintered body can be calculated as a value obtained by multiplying the volume of the nitride sintered body by the porosity of the nitride sintered body described later.
• the lower limit of the ratio of pores (porosity) in the nitride sintered body is, for example, 10% by volume or more, 30% by volume or more, or 50% by volume or more based on the total volume of the nitride sintered body. It may be there. When the lower limit of the ratio of the pores to the nitride sintered body is within the above range, the content of the semi-cured product can be improved and the mechanical strength can be sufficiently secured.
• the upper limit of the ratio of pores to the nitride sintered body may be, for example, 70% by volume or less, 60% by volume or less, or 55% by volume or less based on the total volume of the nitride sintered body.
• the insulating property and the thermal conductivity of the complex can be compatible at a higher level.
• the ratio of pores to the nitride sintered body may be adjusted within the above range, and may be, for example, 10 to 70% by volume, 30 to 60% by volume, or 50 to 55% by volume. ..
• the ratio of pores (porosity) to the nitride sintered body in the present specification is the bulk density D (unit: g / cm 3 ) obtained from the volume and mass of the nitride sintered body, and the theory of the nitride.
• D 0 when the nitride is boron nitride, D 0 is 2.28 g / cm 3 ), it means a value calculated based on the following formula (I).
• the complex can be measured by burning and removing the semi-cured product.
• the nitride sintered body may be obtained by molding a nitride powder and then sintering it, or may be prepared by itself. That is, the above-mentioned method for producing a composite is a molding step of molding a powder containing a nitride to obtain a nitride molded body, and a sintering process of sintering a nitride molded body to obtain a nitride sintered body. Further steps may be provided.
• a slurry containing a nitride powder is spheroidized by a spray dryer or the like, and the obtained spherical nitride granules are molded by a press molding method and a cold isotropic pressurization method (CIP). It may be a step of obtaining a molded product.
• the pressure during molding in the molding process is not particularly limited, but the higher the pressure, the smaller the average pore diameter of the obtained nitride sintered body, and the lower the pressure, the larger the average pore diameter of the obtained nitride sintered body. It tends to be.
• the nitride may contain, for example, at least one nitride selected from the group consisting of boron nitride, aluminum nitride, and silicon nitride, and preferably contains boron nitride.
• boron nitride either amorphous boron nitride or hexagonal boron nitride can be used.
• the thermal conductivity of the nitride may be, for example, 20 W / (m ⁇ K) or more, 50 W / (m ⁇ K) or more, or 60 W / (m ⁇ K) or more.
• the powder containing a nitride may further contain a sintering aid or the like in addition to the nitride.
• the sintering aid may be, for example, an oxide of a rare earth element such as ittoria oxide, alumina oxide and magnesium oxide, a carbonate of an alkali metal such as lithium carbonate and sodium carbonate, and boric acid.
• the content of the sintering aid is, for example, 0.5 to 25 parts by mass, 0.5 to 20 parts by mass, 0.5 to 15 parts by mass, and 0.5 to 10 parts by mass with respect to 100 parts by mass of the nitride powder. It may be parts by mass or 0.5 to 5 parts by mass.
• the lower limit of the sintering temperature in the sintering step may be, for example, 1600 ° C. or higher, or 1700 ° C. or higher.
• the upper limit of the sintering temperature in the sintering step may be, for example, 2200 ° C. or lower, or 2000 ° C. or lower.
• the sintering temperature in the sintering step may be adjusted within the above range, and may be, for example, 1600 to 2200 ° C. or 1700 to 2000 ° C.
• the sintering time may be, for example, 1 to 30 hours.
• the atmosphere at the time of sintering may be, for example, an atmosphere of an inert gas such as nitrogen, helium, and argon.
• a batch type furnace, a continuous type furnace, or the like can be used.
• the batch type furnace include a muffle furnace, a tube furnace, an atmosphere furnace, and the like.
• the continuous furnace include a rotary kiln, a screw conveyor furnace, a tunnel furnace, a belt furnace, a pusher furnace, a koto-shaped continuous furnace, and the like.
• thermosetting composition used in the method for producing the complex is, for example, at least one compound selected from the group consisting of a compound having a cyanate group, a compound having a bismaleimide group and a compound having an epoxy group, and phosphine. It may contain at least one curing agent selected from the group consisting of a system curing agent and an imidazole system curing agent.
• Examples of the compound having a cyanate group include dimethylmethylenebis (1,4-phenylene) biscyanate and bis (4-cyanatephenyl) methane.
• Dimethylmethylenebis (1,4-phenylene) biscyanate is commercially available, for example, as TACN (manufactured by Mitsubishi Gas Chemical Company, Inc., trade name).
• Compounds having a bismaleimide group include, for example, N, N'-[(1-methylethylidene) bis [(p-phenylene) oxy (p-phenylene)]] bismaleimide, and 4,4'-diphenylmethane bismaleimide. And so on.
• N, N'-[(1-methylethylidene) bis [(p-phenylene) oxy (p-phenylene)]] bismaleimide is commercially available, for example, as BMI-80 (manufactured by Keiai Kasei Co., Ltd., trade name). Is available.
• Examples of the compound having an epoxy group include 1,6-bis (2,3-epoxypropane-1-yloxy) naphthalene, a compound represented by the following general formula (1), and the like.
• the value of n is not particularly limited, but can be 0 or an integer of 1 or more, and is usually 1 to 10, preferably 2 to 5.
• the 1,6-bis (2,3-epoxypropane-1-yloxy) naphthalene is commercially available, for example, as HP-4032D (manufactured by DIC Corporation, trade name).
• the total amount of the compound having a cyanate group, the compound having a bismaleimide group and the compound having an epoxy group may be 50% by mass or more based on the total amount of the thermosetting composition. It may be 70% by mass or more, 80% by mass or more, and 90% by mass or more.
• the content of the compound having a cyanate group in the thermosetting composition is, for example, 50 parts by mass or more, 60 parts by mass or more, based on 100 parts by mass of the total amount of the compound having a cyanate group and the compound having a bismaleimide group. Alternatively, it may be 70 parts by mass or more.
• the content of the compound having a cyanate group in the thermosetting composition is within the above range, the curing reaction when the obtained composite is adhered to the adherend proceeds rapidly, and after adhesion to the adherend, the curing reaction proceeds rapidly.
• the breakdown voltage can be improved.
• the bonding condition to the adherend is set to the bonding condition in the embodiment, the effect of improving the dielectric breakdown voltage can be made more remarkable.
• the content of the compound having a bismaleimide group in the thermosetting composition is, for example, 15 parts by mass or more and 20 parts by mass or more with respect to 100 parts by mass of the total amount of the compound having a cyanate group and the compound having a bismaleimide group. , Or 25 parts by mass or more.
• the content of the compound having a bismaleimide group in the thermosetting composition is within the above range, the water absorption rate of the semi-cured product is lowered, and the reliability of the product can be improved.
• the content of the compound having an epoxy group in the thermosetting composition is, for example, 10 parts by mass or more, 20 parts by mass or more, based on 100 parts by mass of the total amount of the compound having a cyanate group and the compound having a bismaleimide group. Alternatively, it may be 30 parts by mass or more.
• the content of the compound having an epoxy group in the thermosetting composition is, for example, 70 parts by mass or less, or 60 parts by mass or less, based on 100 parts by mass of the total amount of the compound having a cyanate group and the compound having a bismaleimide group. May be.
• the content of the compound having an epoxy group in the thermosetting composition is within the above range, it is possible to suppress a decrease in the thermosetting start temperature of the thermosetting composition, and the nitride sintered body has thermosetting property. It becomes easier to impregnate the composition.
• the content of the compound having an epoxy group in the thermosetting composition may be adjusted within the above range, and for example, 10 parts by mass with respect to 100 parts by mass of the total amount of the compound having a cyanate group and the compound having a bismaleimide group. It may be up to 70 parts by mass or 30 to 60 parts by mass.
• the above-mentioned curing agent may contain a phosphine-based curing agent and an imidazole-based curing agent.
• the phosphine-based curing agent can promote the triazine formation reaction by the trimerization of the compound having a cyanate group or the cyanate resin.
• the phosphine-based curing agent include tetraphenylphosphonium tetra-p-tolylborate and tetraphenylphosphonium tetraphenylborate. Tetraphenylphosphonium tetra-p-tolylborate is commercially available, for example, as TPP-MK (manufactured by Hokuko Chemical Industry Co., Ltd., trade name).
• the imidazole-based curing agent produces oxazoline and promotes the curing reaction of the compound having an epoxy group or the epoxy resin.
• Examples of the imidazole-based curing agent include 1- (1-cyanomethyl) -2-ethyl-4-methyl-1H-imidazole, 2-ethyl-4-methylimidazole and the like.
• 1- (1-Cyanomethyl) -2-ethyl-4-methyl-1H-imidazole is commercially available, for example, as 2E4MZ-CN (manufactured by Shikoku Chemicals Corporation, trade name).
• the content of the phosphine-based curing agent is, for example, 5 parts by mass or less, 4 parts by mass or less, or 3 parts by mass with respect to 100 parts by mass of the total amount of the compound having a cyanate group, the compound having a bismaleimide group, and the compound having an epoxy group. It may be less than or equal to a mass part.
• the content of the phosphine-based curing agent is, for example, 0.1 part by mass or more or 0.5 part by mass with respect to 100 parts by mass of the total amount of the compound having a cyanate group, the compound having a bismaleimide group and the compound having an epoxy group. It may be more than one part.
• the complex When the content of the phosphine-based curing agent is within the above range, the complex can be easily produced, and the time required for adhering the adherend using the complex can be further shortened.
• the content of the phosphine-based curing agent may be adjusted within the above range, and for example, 0. It may be 1 to 5 parts by mass or 0.5 to 3 parts by mass.
• the content of the imidazole-based curing agent is, for example, 0.1 part by mass or less, 0.05 part by mass with respect to 100 parts by mass of the total amount of the compound having a cyanate group, the compound having a bismaleimide group and the compound having an epoxy group. It may be less than a part or 0.03 part by mass or less.
• the content of the imidazole-based curing agent is, for example, 0.001 part by mass or more, or 0.005 parts by mass with respect to 100 parts by mass of the total amount of the compound having a cyanate group, the compound having a bismaleimide group, and the compound having an epoxy group. It may be parts by mass or more.
• the complex When the content of the imidazole-based curing agent is within the above range, the complex can be easily produced, and the time required for adhering the adherend using the complex can be further shortened.
• the content of the imidazole-based curing agent may be adjusted within the above range, and for example, 0. It may be 001 to 0.1 parts by mass or 0.005 to 0.03 parts by mass.
• the thermosetting composition may contain a compound having a cyanate group, a compound having a bismaleimide group, a compound having an epoxy group, and other components of a curing agent.
• Other components further include, for example, other resins such as phenolic resins, melamine resins, urea resins, and alkyd resins, silane coupling agents, leveling agents, defoaming agents, surface modifiers, and wet dispersants. But it may be.
• the content of these other components may be, for example, 20% by mass or less, 10% by mass or less, or 5% by mass or less, based on the total amount of the thermosetting composition.
• the viscosity of the above-mentioned thermosetting composition can be adjusted as appropriate.
• the upper limit of the viscosity of the thermosetting composition at 100 ° C. may be, for example, 50 mPa ⁇ sec or less, 30 mPa ⁇ sec or less, 20 mPa ⁇ sec or less, 10 mPa ⁇ sec or less, or 5 mPa ⁇ sec or less.
• the lower limit of the viscosity of the thermosetting composition at 100 ° C. may be, for example, 3 mPa ⁇ sec or more. The viscosity of the thermosetting composition at 100 ° C.
• thermosetting composition is preferably maintained at 50 mPa ⁇ sec or less for, for example, 5 hours or more while the temperature of the thermosetting composition is maintained at 100 ° C.
• the viscosity of the thermosetting composition at 100 ° C. may be adjusted within the above range, and may be, for example, 3 to 50 mPa ⁇ sec or 3 to 5 mPa ⁇ sec.
• the viscosity of the thermosetting composition at 100 ° C. means a value measured under the condition of a shear rate of 10 (1 / sec) using a rotary viscometer.
• the viscosity of the thermosetting composition may be adjusted by adding a solvent, for example. That is, the object to be immersed in the nitride sintered body may be a heat-melt of a thermosetting composition or a heat-melt of a mixture containing a thermosetting composition and a solvent. In this case, the viscosity of the mixture is determined. It may be adjusted to have the above-mentioned viscosity for the above-mentioned thermosetting composition.
• the solvent include toluene, ethylene glycol, dimethyl sulfoxide (DMSO) and the like.
• the nitride sintered body is brought into contact with (for example, immersed) in the heated melt of the thermosetting composition described above by using an impregnating device or the like.
• the pores of the nitride sintered body are impregnated with the thermosetting composition.
• the thermosetting composition or the mixture containing the thermosetting composition may be heated.
• the heating temperature at this time may be, for example, higher than the heating temperature for semi-curing the thermosetting composition.
• the upper limit of the heating temperature may be, for example, a heating temperature of + 20 ° C. or lower for semi-curing the thermosetting composition.
• the heating temperature for semi-curing the thermosetting composition means the reaction start temperature of the thermosetting composition, and specifically, the curing temperature corresponding to each curing agent (when a plurality of curing agents are contained). Refers to the lowest curing temperature among those curing temperatures).
• the nitride sintered body may be held in contact with the thermosetting composition or the heated melt of the mixture containing the thermosetting composition for a predetermined time before starting heating. ..
• the holding time in the contact state (for example, the immersion state) may be, for example, 5 hours or more, 10 hours or more, 100 hours or more, or 150 hours or more.
• the first step may include placing the nitride sintered body in contact with the heated melt of the thermosetting composition under reduced pressure conditions and / or pressurized conditions.
• the reduced pressure condition when the reduced pressure condition is included, the gas component dissolved in the nitride sintered body and the thermosetting composition can be degassed, and the content of the semi-cured product of the thermosetting composition in the composite can be determined. It can be improved further.
• the pressure in the impregnation device may be, for example, 1000 MPa or less, 500 MPa or less, 100 MPa or less, 50 MPa or less, or 20 MPa or less.
• the pressure in the impregnation device may be, for example, 0.5 MPa or more, 3 MPa or more, 10 MPa or more, or 30 MPa or more.
• the pressure in the impregnation device when impregnating the thermosetting composition under reduced pressure conditions may be adjusted within the above range, for example, 0.5 to 1000 MPa, 3 to 500 MPa, 10 to 100 MPa, or 30 to 50 MPa. May be.
• thermosetting composition is impregnated into the pores of the nitride sintered body, and then heat-treated to semi-cure the thermosetting composition to prepare a resin-impregnated body.
• the semi-cured state of the thermosetting composition in the complex can be adjusted.
• the heating temperature in the first step can be adjusted according to the components and composition of the thermosetting composition, and may be, for example, 80 to 130 ° C.
• the heat treatment in the first step may be performed under atmospheric pressure or under pressurized conditions.
• the state of "semi-hardening" means that the state can be further cured by the subsequent curing treatment. Utilizing the fact that it is in a semi-cured state, it can be temporarily pressure-bonded to an adherend such as a metal substrate and then heated to adhere to the adherend.
• the semi-cured product is in a semi-cured state, and can be further cured to a "completely cured" state (also referred to as C stage). Whether or not the semi-cured product in the complex is in a semi-cured state that can be further cured can be confirmed by, for example, a differential scanning calorimeter.
• thermosetting composition A semi-cured product of a thermosetting composition (hereinafter, may be simply referred to as a "semi-cured product") means a thermosetting composition in which the curing reaction has progressed beyond a certain level. Therefore, the semi-cured product of the thermosetting composition may contain a thermosetting resin or the like obtained by reacting the raw material components (compounds and the like contained in the thermosetting composition) in the thermosetting composition. In addition to the thermosetting resin, the semi-cured product may contain unreacted compounds and the like among the raw material components.
• the degree of curing of the semi-cured product may be, for example, an index of the curing rate of the thermosetting composition having a curing rate of 100% when it is in a completely cured state.
• the curing rate of the semi-cured product may be, for example, 70% or less, 65% or less, or 60% or less.
• the adhesiveness of the composite to the adherend can be improved.
• the curing rate of the semi-cured resin may be, for example, 5% or more, 15% or more, 30% or more, or 40% or more.
• the curing rate of the semi-cured product When the curing rate of the semi-cured product is within the above range, the semi-cured product can be suppressed from flowing out of the resin composite, and the semi-cured product can be sufficiently retained in the pores of the nitride sintered body.
• the curing rate of the semi-cured product may be adjusted within the above range, and may be, for example, 5 to 70%, 30 to 65%, or 40 to 60%.
• the curing rate can be determined by measurement using a differential scanning calorimeter. First, the amount of heat Q generated when 1 g of the uncured thermosetting composition is completely cured is measured. Next, 1 g of a semi-cured product is collected from the complex to be measured, and the calorific value R generated when the collected semi-cured product is completely cured is measured. A differential scanning calorimeter is used for the measurement. After that, the curing rate of the semi-cured product can be calculated according to the following formula (A). Whether or not the semi-cured product is completely cured can be confirmed by the end of heat generation in the heat generation curve obtained by the differential scanning calorimetry.
• Curing rate of semi-cured product [%] [(QR) / R] x 100 ... (A)
• the above curing rate may be calculated as follows. That is, the curing rate of the semi-cured product impregnated in the nitride sintered body can be obtained by the following method. First, the calorific value Q2 generated when the uncured thermosetting composition is heated to a high temperature and completely cured is obtained. Then, the temperature of the sample collected from the semi-cured product provided in the composite is raised in the same manner, and the calorific value R2 generated when the sample is completely cured is obtained. At this time, the mass of the sample used for the measurement by the differential scanning calorimeter is the same as that of the thermosetting composition used for the measurement of the calorific value Q2.
• the calorific value Q2 and the calorific value R2 may be converted into the calorific value per unit mass.
• the curing rate of the thermosetting composition impregnated in the complex can be obtained by the following formula (B).
• Curing rate of the impregnated semi-cured product [%] ⁇ 1-[(R2 / c) x 100] / Q2 ⁇ x 100 ... (B)
• the resin impregnated body obtained by heat treatment has a semi-cured product of a thermosetting composition.
• the semi-cured product may contain at least one thermosetting resin selected from the group consisting of cyanate resin, bismaleimide resin and epoxy resin, and a curing agent.
• the semi-cured product includes other resins such as phenol resin, melamine resin, urea resin, and alkyd resin, as well as silane coupling agents, leveling agents, and defoaming agents. It may contain a component derived from an agent, a surface conditioner, a wet dispersant, or the like.
• the total content of the other resin and the component may be, for example, 20% by mass or less, 10% by mass or less, or 5% by mass or less based on the total amount of the semi-cured product.
• the second step is a step of cooling the resin-impregnated body in a heated state under pressurized conditions in order to semi-cure the thermosetting composition to obtain a composite. That is, the second step is a step in which the thermosetting composition is semi-cured in a state where the thermosetting composition is brought into contact with the resin impregnated body, and then cooled under pressurized conditions. It's okay.
• the thermosetting composition or the thermosetting composition are supplied from the surroundings, and the content of the semi-cured product in the pores of the obtained composite can be made extremely high.
• the resin-impregnated body is impregnated with the resin by performing a cooling step (second step) while bringing the resin-impregnated body into contact with the heated melt of the thermosetting composition.
• the thermosetting composition melted from the periphery of the body is supplied to the unimpregnated portion of the resin-impregnated body.
• the semi-cured product in the resin-impregnated body prepared in advance can also be melted by receiving heat supply from the surroundings, it is possible to reduce the voids and the like initially formed, and it is also possible to further improve the impregnation rate. can.
• the thermosetting composition constituting the semi-cured product contained in the resin impregnated body and the thermosetting composition constituting the heated melt to be brought into contact with the resin impregnated body are the same. May also be different.
• a complex having an improved content ratio of the semi-cured product can be produced.
• the resin-impregnated body may be immersed in a thermosetting composition contained in a container and cooled under pressure.
• the viscosity of this thermosetting composition at 120 ° C. may be, for example, 1000 to 3000000 mPa ⁇ sec or 1000 to 300,000 mPa ⁇ sec.
• the viscosity of the thermosetting composition at 120 ° C. means a value measured under the condition of a shear rate of 10 (1 / sec) using a rotary viscometer.
• the pressure in the second step may be larger than the pressure in the first step (preparation step). Since the pressure in the second step is higher than the pressure in the first step, the pores of the nitride sintered body can be more sufficiently impregnated with the thermosetting composition even in the cooling step, and the heat can be further impregnated. Even when the curable composition is cured and the viscosity is increased, the decrease in the impregnation rate can be more sufficiently suppressed.
• the pressure in the second step can be adjusted according to the composition, viscosity, etc. of the semi-cured product.
• the lower limit of the pressure in the second step may be, for example, 2.0 MPa or more, 3.0 MPa or more, 4.0 MPa or more, 10 MPa or more, 15 MPa or more, or 30 MPa or more.
• the upper limit of the pressure in the second step is not particularly limited, but may be, for example, 1000 MPa or less, 500 MPa or less, 100 MPa or less, 50 MPa or less, or 20 MPa or less.
• the pressure in the second step may be adjusted within the above range, and may be, for example, 2.0 to 1000 MPa, 2.0 to 100 MPa, 2.0 to 20 MPa, or 3.0 to 20 MPa.
• the cooling of the resin impregnated body in the second step may be, for example, cooling to room temperature.
• the upper limit of the temperature lowering rate in the second step may be, for example, 15 ° C./min or less, 5 ° C./min or less, 3 ° C./min or less, or 2 ° C./min or less.
• the lower limit of the temperature lowering rate in the second step is not particularly limited, and may be, for example, 0.2 ° C./min or more, or 0.5 ° C./min or more.
• the temperature lowering rate in the second step may be adjusted within the above range, and may be, for example, 0.2 to 15 ° C./min or 0.5 to 10 ° C./min.
• the above-mentioned method for producing a complex may include other steps in addition to the first step and the second step. Examples of other steps include a step of cutting the obtained complex into a desired size.
• the obtained composite can be obtained.
• a layer containing a semi-cured product of the thermosetting composition can be formed around the nitride sintered body. Therefore, the layer containing the surrounding semi-cured material may be cut and removed, or the complex may be cut to a predetermined thickness to prepare a complex sheet.
• a nitride sintered body adjusted to a desired thickness in advance may be used instead of cutting the composite after production and forming it into a sheet. That is, in the above-mentioned production method, a composite sheet may be produced by impregnating a sheet-shaped nitride sintered body with a thermosetting composition.
• the upper limit of the thickness of the complex sheet is, for example, 1.00 mm or less, 0.90 mm or less, 0.80 mm or less, 0.70 mm or less, 0.50 mm or less, or 0.40 mm. It may be: When the upper limit of the thickness of the complex sheet is within the above range, the thermal resistance of the complex sheet itself can be further reduced.
• the lower limit of the thickness of the complex sheet may be, for example, 0.15 mm or more, or 0.20 mm or more. When the lower limit of the thickness of the complex sheet is within the above range, more sufficient insulating properties can be exhibited even when the laminate obtained by using the composite sheet is used at a high voltage. can.
• the thickness of the complex sheet may be adjusted within the above range, and may be, for example, 0.15 to 1.0 mm or 0.20 to 0.50 mm.
• a complex having a high proportion of semi-cured product can be produced.
• the composite for example, a nitride sintered body having a porous structure and a semi-cured product of a thermosetting composition impregnated in the nitride sintered body are provided, and the entire fine details of the nitride sintered body are provided. It is possible to provide a composite in which the ratio of the semi-cured product to the pore volume is 80% by volume or more.
• the ratio of the semi-cured product to the total pore volume of the nitride sintered body can be, for example, 99.0% by volume or more, or 99.5% by volume or more.
• a complex having an extremely high content of the semi-cured product can be produced. ..
• the content ratio of the semi-cured product in the complex can be, for example, 99.0% by volume or more, or 99.5% by volume or more.
• the sufficiently high pressure may be 2.0 MPa or more, or 3.0 MPa or more, although it depends on the viscosity of the thermosetting composition used.
• the sufficiently small temperature lowering rate may be 15 ° C./min or less, 10 ° C./min or less, 8 ° C./min or less, 5 ° C./min or less, or 2 ° C./min or less.
• the ratio of the semi-cured product to the total pore volume of the nitride sintered body is the theoretical density D 1 (unit: g /) when the semi-cured product is impregnated in all the pores of the nitride sintered body. cm 3) and then, the bulk density D (units or determined from the volume and mass of the nitride sintered body: g / cm 3) and then, the complex volume and bulk density D 2 is determined from the mass (unit: g / cm 3 ), and means a value calculated based on the following formula (II) using these.
• Ratio of the semi-cured material to the total pore volume of a nitride sintered body [(D 2 -D ) / (D 1 -D)] ⁇ 100 ⁇ (II)
• the theoretical density D 1 in the above equation (II) means a value obtained by the following equation.
• Theoretical density of composite true density of boron nitride + true density of resin x (1-bulk density of boron nitride / true density of boron nitride)
• the above complex has an excellent breakdown voltage.
• the lower limit of the breakdown voltage of the complex is, for example, 4.5 kV or more, 5.0 kV or more, 6.0 kV or more, 7.0 kV or more, 8.0 kV or more, 9.0 kV or more, or 10.0 kV or more. be able to.
• the upper limit of the dielectric breakdown voltage of the complex may be, for example, 15 kV or less, or 13 kV or less.
• the dielectric breakdown voltage of the complex can be adjusted, for example, by the composition of the thermosetting composition, the content of the semi-cured product, and the like.
• conductive tapes of the same size are attached to both sides at a position 2 mm away from the creeping surface of the composite sheet, a measurement sample is prepared, and JIS C2110-1 is used for the sample.
• JIS C2110-1 is used for the sample.
• As the withstand voltage tester for example, "TOS-8700" (device name) manufactured by Kikusui Electronics Co., Ltd. can be used.
• the above-mentioned composite is useful as an adhesive member (for example, an adhesive sheet) that is required to have thermal conductivity and insulation.
• the above-mentioned complex can be used as an adhesive member for adhering a metal circuit board and other layers in a power module structure, an LED light emitting device, or the like. That is, the above-mentioned complex is suitable for producing a laminated body.
• One embodiment of the laminate is a first metal substrate, an intermediate layer provided on the first metal substrate, and a first metal substrate provided on the opposite side of the intermediate layer from the first metal substrate side.
• the second metal substrate is provided, and the first metal substrate and the second metal substrate are connected by the intermediate layer.
• the intermediate layer is a cured product of the above-mentioned complex.
• the thickness of the first metal substrate and the second metal substrate may be independently of each other, for example, 0.035 mm or more, and may be 10 mm or less.
• the first metal substrate and the second metal substrate may form a circuit, for example.
• the first metal substrate and the second metal substrate may be the same metal substrate or different metal substrates.
• the first metal substrate and the second metal substrate may contain, for example, at least one selected from the group consisting of copper and aluminum, and may be copper or aluminum.
• the first metal substrate and the second metal substrate may contain metals other than copper and aluminum.
• the above-mentioned laminated body can be manufactured by, for example, the following method.
• a first metal substrate and a second metal substrate are arranged and laminated so as to face the pair of main surfaces of the composite sheet described above, and the first metal substrate is laminated.
• the composite sheet, the first metal substrate, and the second metal substrate are heated by heating the metal substrate and the second metal substrate in a state of being pressurized in the laminating direction to cure the thermosetting composition. It has a step of connecting to a metal substrate.
• the first metal substrate and the second metal substrate can be bonded in a short time.
• the bonding time can be 2 hours or less, 1 hour or less, or 0.5 hours or less.
• Example 1 Preparation of nitride sintered body having a porous structure
• amorphous boron nitride powder manufactured by Denka Co., Ltd., oxygen content: 1.5%, boron nitride purity: 97.6%, average particle size: 6.0 ⁇ m
• Measure the powder manufactured by Denka Co., Ltd., oxygen content: 0.3%, boron nitride purity: 99.0%, average particle size: 30.0 ⁇ m
• After adding the agent boric acid, calcium carbonate
• an organic binder and water were added and mixed, and then dry granulation was performed to prepare a mixed powder of nitride.
• the above mixed powder was filled in a mold and press-molded at a pressure of 5 MPa to obtain a molded product.
• the molded product was compressed by applying a pressure of 20 to 100 MPa using a cold isotropic pressurizing (CIP) device (manufactured by Kobe Steel, Ltd., trade name: ADW800).
• CIP cold isotropic pressurizing
• a nitride sintered body is obtained by holding the compressed molded body at 2000 ° C. for 10 hours using a batch type high frequency furnace (manufactured by Fuji Dempa Kogyo Co., Ltd., trade name: FTH-300-1H) and sintering it. Was prepared.
• the porosity of the obtained nitride sintered body was 45% by volume.
• the firing was carried out by adjusting the inside of the furnace under a nitrogen atmosphere while flowing nitrogen into the furnace in a standard state so that the flow rate was 10 L / min.
• thermosetting composition Measure so that the compound having a cyanate group is 80 parts by mass, the compound having a bismaleimide group is 20 parts by mass, and the compound having an epoxy group is 50 parts by mass in a container, and the total amount of the above three compounds is 100 parts by mass. 1 part by mass of a phosphine-based curing agent and 0.01 part by mass of an imidazole-based curing agent were added and mixed. Since the epoxy resin was in a solid state at room temperature, it was mixed in a state of being heated to about 80 ° C. The viscosity of the obtained thermosetting composition at 100 ° C. was 10 mPa ⁇ sec.
• thermosetting composition The following compounds were used to prepare the thermosetting composition.
• Compound having a specific functional group Compound having cyanate group: Dimethylmethylenebis (1,4-phenylene) Biscyanate (manufactured by Mitsubishi Gas Chemical Company, Inc., trade name: TA-CN) Compounds with a bismaleimide group: N, N'-[(1-methylethylidene) bis [(p-phenylene) oxy (p-phenylene)]] bismaleimide (manufactured by Keiai Kasei Co., Ltd., trade name: BMI- 80) Compound having an epoxy group: 1,6-bis (2,3-epoxypropane-1-yloxy) naphthalene (manufactured by DIC Corporation, trade name: HP-4032D) Compound having benzoxazine group: Bisphenol F type benzoxazine (manufactured by Shikoku Chemicals Corporation, trade name: FA type benzoxazine)
• Phosphine-based curing agent Tetraphenylphosphonium Tetra-p-tolylbolate (manufactured by Chemical Co., Ltd., trade name: TPP-MK)
• Imidazole-based curing agent 1- (1-cyanomethyl) -2-ethyl-4-methyl-1H-imidazole (manufactured by Shikoku Chemicals Corporation, trade name: 2E4MZ-CN)
• Metal catalyst Bis (2,4-pentanionato) Zinc (II) (Tokyo Kasei Co., Ltd.)
• thermosetting composition prepared as described above by the following method. First, the nitride sintered body and the thermosetting composition in a container were housed in a vacuum heating impregnation device (manufactured by Kyoshin Engineering Co., Ltd., trade name: G-555AT-R). Next, the inside of the apparatus was degassed for 10 minutes under the conditions of temperature: 100 ° C. and pressure: 15 Pa.
• the nitride sintered body After degassing, the nitride sintered body is immersed in the heated melt of the thermosetting composition for 40 minutes while maintaining the same conditions, and the thermosetting composition is impregnated into the nitride sintered body (vacuum). Impregnated).
• the container containing the nitride sintered body and the thermosetting composition was taken out, and the container was put into a pressure heating impregnation device (manufactured by Kyoshin Engineering Co., Ltd., trade name: HP-4030AA-H45).
• the heat-curable composition was impregnated into a nitride sintered body (pressurized impregnation) by holding for 120 minutes under the conditions of a temperature of 100 ° C. and a pressure of 3.5 MPa.
• thermosetting composition was semi-cured to obtain a resin-impregnated body.
• the semi-cured material of the resin impregnated body and the surrounding thermosetting composition remains heated (before the system is cooled), and the pressure heating impregnated device (Kyo Co., Ltd.)
• a composite was prepared by putting it in a product manufactured by Shin Engineering Co., Ltd., trade name: HP-4030AA-H45) and cooling it to room temperature (25 ° C.) for 90 minutes under the condition of pressure: 4.0 MPa.
• a layer of semi-cured material provided around the complex was cut and removed, and then a 0.4 mm thick complex sheet was cut out.
• Example 2 Example 1 except that after vacuum impregnation, heat treatment for semi-curing was performed without pressure impregnation, and the pressure conditions and temperature lowering rate in the cooling step were changed as shown in Table 1.
• the complex was prepared in the same manner as above.
• Example 3 A complex was prepared in the same manner as in Example 1 except that the pressure conditions and the temperature lowering rate in the cooling step were changed as shown in Table 1.
• Example 1 The complex was prepared in the same manner as in Example 1 except that the cooling after the heat treatment for 8 hours was performed under atmospheric pressure instead of under pressurized conditions.
• Example 2 The complex was cooled in the same manner as in Example 1 except that the cooling after the heat treatment for 8 hours was performed under atmospheric pressure instead of under pressurized conditions, and the temperature lowering rate was changed as shown in Table 1. Was prepared.
• the ratio of the semi-cured product to the total pore volume of the boron nitride sintered body was determined. Specifically, it is obtained from the theoretical density D 0 (unit: g / cm 3 ) when all the pores of the nitride sintered body are impregnated with the semi-cured product, and the volume and mass of the nitride sintered body. Calculated based on the above formula (II) using the bulk density D (unit: g / cm 3 ) and the bulk density D (unit: g / cm 3) obtained from the volume and mass of the complex. bottom.
• the breakdown voltage was evaluated for each complex sheet obtained as described above. Specifically, two conductive tapes were attached to both sides of the complex sheet to prepare a measurement sample. The dielectric breakdown voltage of the obtained measurement sample was measured using a withstand voltage tester (manufactured by Kikusui Electronics Co., Ltd., device name: TOS-8700) according to JIS C2110-1: 2016. From the measurement results, the insulation was evaluated according to the following criteria. The results are shown in Table 1. A: The dielectric breakdown voltage is 11 kV or more. B: The dielectric breakdown voltage is 8.0 kV or more and less than 11 kV. C: The dielectric breakdown voltage is 4.5 kV or more and less than 8.0 kV. D: The dielectric breakdown voltage is less than 4.5 kV.
• the measurement was carried out under the conditions of a test speed: 50 mm / min, a load cell: 5 kN, and a measurement temperature: room temperature (20 ° C.), and the area of the aggregated fracture portion was measured. From the measurement results, the adhesiveness was evaluated according to the following criteria. The results are shown in Table 1.
• the cohesive failure portion is the area of the portion where the complex is broken.
• B The area ratio of the agglomerated fracture portion is 95 area% or more and less than 96 area%.
• C The area ratio of the agglomerated fracture portion is 70 area% or more and less than 95 area%.
• D The area ratio of the agglomerated fracture portion is less than 70 area%.
• the method for producing a complex it is possible to produce a complex in which the content ratio of the semi-cured product in the pores of the nitride sintered body is increased. According to the present disclosure, it is also possible to provide a complex having a semi-cured product in an extremely high proportion.

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• 2021
  • 2021-05-13 EP EP21804541.7A patent/EP4147845A4/en not_active Withdrawn
  • 2021-05-13 JP JP2022522200A patent/JP7458479B2/ja active Active
  • 2021-05-13 CN CN202180034018.1A patent/CN115551819A/zh active Pending
  • 2021-05-13 US US17/998,687 patent/US20230271888A1/en not_active Abandoned
  • 2021-05-13 WO PCT/JP2021/018244 patent/WO2021230323A1/ja not_active Ceased

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