WO2022034872A1 - 樹脂層付き銅箔、及び、これを用いた積層体 - Google Patents
樹脂層付き銅箔、及び、これを用いた積層体 Download PDFInfo
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- WO2022034872A1 WO2022034872A1 PCT/JP2021/029459 JP2021029459W WO2022034872A1 WO 2022034872 A1 WO2022034872 A1 WO 2022034872A1 JP 2021029459 W JP2021029459 W JP 2021029459W WO 2022034872 A1 WO2022034872 A1 WO 2022034872A1
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- copper foil
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- 0 [O-][N+](*12[N+]([O-])O[N+]1[O-])O[N+]2[O-] Chemical compound [O-][N+](*12[N+]([O-])O[N+]1[O-])O[N+]2[O-] 0.000 description 1
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Classifications
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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
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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
- B32B15/088—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 polyamides
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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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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/013—Fillers, pigments or reinforcing additives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/34—Heterocyclic compounds having nitrogen in the ring
- C08K5/3412—Heterocyclic compounds having nitrogen in the ring having one nitrogen atom in the ring
- C08K5/3415—Five-membered rings
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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
- C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
- C08L71/02—Polyalkylene oxides
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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
- C08L79/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen or carbon only, not provided for in groups C08L61/00 - C08L77/00
- C08L79/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
- C08L79/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/46—Manufacturing multilayer circuits
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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
- B32B2311/00—Metals, their alloys or their compounds
- B32B2311/12—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
- B32B2371/00—Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
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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
- B32B2379/00—Other polymers having nitrogen, with or without oxygen or carbon only, in the main chain
- B32B2379/08—Polyimides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/08—PCBs, i.e. printed circuit boards
Definitions
- the present invention relates to a copper foil with a resin layer and a laminated body using the same. More specifically, the present invention relates to a copper foil with a resin layer useful for a printed wiring board or a substrate for mounting a semiconductor element, and a laminate using the same.
- printed wiring boards or substrates for mounting semiconductor elements which are widely used in electronic devices, communication devices, personal computers, etc.
- a method for manufacturing a printed wiring board or a substrate for mounting a semiconductor element a build-up method in which circuit-formed conductor layers and insulating layers (interlayer insulating layers) are alternately stacked is widely used, and wiring is used.
- a semi-additive method that can form a fine pattern is often used for forming a pattern.
- Patent Document 1 As an insulating layer used for such a printed wiring board, a multi-layered resin composition layer is known (see, for example, Patent Document 1).
- Patent Document 1 relates to a resin insulating sheet in which the etching amount of each layer is controlled in order to improve the performance of the multi-layered insulating layer.
- the resin insulating sheet described in Patent Document 1 is required to have a total thickness of at least 12 ⁇ m or more for each layer. Therefore, there has been a demand for the development of a technique that can further reduce the thickness (for example, less than 10 ⁇ m) and satisfy the requirements of insulation, plating adhesion, hygroscopic heat resistance, and the like.
- the present invention has been made based on such a problem, and provides a copper foil with a resin layer having excellent insulation, plating adhesion, and moisture absorption and heat resistance, and a laminate using the same. The purpose.
- the present inventors adjust the composition of the first resin layer and the surface roughness of the copper foil in the copper foil with a resin layer having the copper foil and the first resin layer laminated on the surface of the copper foil. As a result, it was found that the above problems could be solved, and the present invention was completed.
- the first resin layer contains a polyphenylene ether compound (A), a polyimide resin (B), and a maleimide compound (C).
- the inorganic filler contains at least one selected from magnesium hydroxide, magnesium oxide, silica, molybdenum compound, alumina, aluminum nitride, glass, talc, titanium compound, and zirconium oxide.
- the second resin layer is a group consisting of an epoxy compound, a cyanate ester compound, a maleimide compound, a phenol compound, a polyphenylene ether compound, a benzoxazine compound, an organic group-modified silicone compound, and a compound having a polymerizable unsaturated group.
- With copper foil [10] The copper foil with a resin layer according to [2], wherein the thickness of the second resin layer is 1 ⁇ m or more and 15 ⁇ m or less.
- the present invention it is possible to provide a copper foil with a resin layer having excellent insulation, plating adhesion, and hygroscopic heat resistance, and a laminate using the same.
- the present embodiment will be described in detail, but the present invention is not limited thereto, and various modifications are made without departing from the gist thereof. Is possible.
- the laminated bodies are those in which the layers are adhered to each other, but the layers may be peelable from each other, if necessary.
- the “resin solid content” refers to the components of the first resin layer 12 or the second resin layer 13 excluding the solvent and the inorganic filler, unless otherwise specified, and refers to the “resin solid content”. "100 parts by mass” means that the total of the components of the first resin layer 12 or the second resin layer 13 excluding the solvent and the inorganic filler is 100 parts by mass.
- FIG. 1 shows the configuration of a copper foil 10 with a resin layer according to an embodiment of the present invention.
- the copper foil 10 with a resin layer includes a copper foil 11 and a first resin layer 12 laminated on the surface of the copper foil 11, and further, a second resin is placed on the first resin layer 12. It is preferable that the layer 13 is provided.
- the copper foil 10 with a resin layer is useful, for example, as a material for forming an insulating layer provided on a circuit pattern (conductor layer), and is used, for example, in the manufacture of electronic devices, communication devices, personal computers, and the like. It can be used as a material for forming an insulating layer of a printed wiring board or a substrate for mounting a semiconductor element.
- a copper foil 10 with a resin layer is arranged on a substrate on which a conductor layer such as a circuit pattern is formed so that the second resin layer 13 and the conductor layer are in contact with each other. After that, the first resin layer 12 and the second resin layer 13 are cured by heating and pressing (pressing) to form an insulating layer on the conductor layer.
- the first resin layer 12 maintains the distance between the copper foil 11 and the conductor layer even after a press treatment such as when forming a laminate. It is a layer.
- the second resin layer 13 is a layer containing a resin having fluidity at the time of press processing, and is a layer in which uneven portions such as a conductor layer of a circuit pattern are embedded. Since the second resin layer 13 functions as an embedded layer, it is preferable that at least one of the constituent components and physical properties is different from that of the first resin layer 12.
- the first resin layer 12 is a polyimide resin and the second resin layer 13 is an epoxy compound.
- the first resin layer 12 can be obtained by changing the composition ratio of the components contained in each layer or the cured state (for example, by changing the coating conditions of each layer).
- the physical properties are different depending on (such as completely curing the second resin layer 13 to make the second resin layer 13 in a semi-cured state), and there are cases where these are combined.
- the copper foil 11 may be any one used for ordinary printed wiring boards, and examples thereof include electrolytic copper foil, rolled copper foil, and copper alloy film.
- the copper foil 11 may be subjected to known surface treatments such as matte treatment, corona treatment, nickel treatment and cobalt treatment.
- commercially available products can be used, for example, "GHY5" (trade name, 12 ⁇ m thick copper foil) and "JXUT-I" (trade name, 1) manufactured by JX Nippon Mining & Metals Co., Ltd.
- the ten-point average roughness Rz of the surface of the copper foil 11, that is, the ten-point average roughness Rz of the surface of the copper foil 11 on the side where the first resin layer 12 is formed may be 0.3 ⁇ m or more and 10 ⁇ m or less. preferable. This is because the plating adhesion can be improved by setting the thickness to 0.3 ⁇ m or more. Further, if it is larger than 10 ⁇ m, the thickness of the first resin layer 12 must be increased in order to secure the insulating property. A more preferable range of the ten-point average roughness Rz of the surface of the copper foil 11 is, for example, 0.6 ⁇ m or more and 2.5 ⁇ m or less.
- the ten-point average roughness Rz of the surface of the copper foil 11 is preferably smaller than the thickness of the first resin layer 12. This is to improve the insulation.
- the ten-point average roughness Rz of the surface of the copper foil 11 can be measured using a commercially available shape measuring microscope (laser microscope, for example, "VK-X1000" (trade name) manufactured by KEYENCE CORPORATION).
- the thickness of the copper foil 11 is not particularly limited, but is preferably in the range of 1 ⁇ m to 18 ⁇ m in consideration of the surface roughening treatment, and a thin printed wiring board and a substrate for mounting a semiconductor element can be preferably obtained. It is more preferably in the range of 2 ⁇ m to 15 ⁇ m.
- the first resin layer 12 contains a polyphenylene ether compound (A), a polyimide resin (B), and a maleimide compound (C). Further, the first resin layer 12 may contain at least one of other resin components, an inorganic filler, and other components, if necessary.
- the thickness of the first resin layer 12 is not particularly limited, but is preferably 5 ⁇ m or less from the viewpoint of thinning, and is preferably 1.5 ⁇ m or more in consideration of ensuring insulation.
- a copper foil 10 with a resin layer is hardened with a resin to prepare a sample for measurement, cut so as to have a vertical cross section, polished, and the vertical cross section is observed with a microscope. The thickness can be calculated.
- the length measuring method is the distance from the surface of the first resin layer 12 opposite to the copper foil 11 to the interface with the copper foil 11 in the vertical direction, and the uneven interface between the first resin layer 12 and the copper foil 11 is set.
- the distance from the average position of the first resin layer 12 to the surface of the first resin layer 12 on the opposite side of the copper foil 11 is defined as the thickness of the first resin layer 12.
- the first resin layer 12 may be in a semi-cured state (B-Stage) or a completely cured state (C-Stage).
- the first resin layer 12 can be formed by a known means such as coating.
- the polyphenylene ether compound (A) according to the present embodiment is a compound represented by the general formula (1).
- the polyphenylene ether compound (A) represented by the general formula (1) used in the present embodiment preferably has a number average molecular weight of 1000 or more and 7000 or less. By setting the number average molecular weight to 7,000 or less, the compatibility between the resins can be controlled.
- the number average molecular weight of the polyphenylene ether compound (A) is preferably 1100 or more and 5000 or less. More preferably, the number average molecular weight of the polyphenylene ether compound (A) is 4500 or less, and even more preferably, the number average molecular weight of the polyphenylene ether compound (A) is 3000 or less. The number average molecular weight is measured using gel permeation chromatography according to a routine method.
- X represents an aryl group (aromatic group)
- ⁇ (YO) n 2 ⁇ represents a polyphenylene ether moiety
- R 1 , R 2 and R 3 are independent of each other. It represents a hydrogen atom, an alkyl group, an alkenyl group or an alkynyl group
- n 2 represents an integer of 1 to 100
- n 1 represents an integer of 1 to 6
- n 3 represents an integer of 1 to 4.
- n 1 is preferably an integer of 1 or more and 4 or less, more preferably n 1 is 1 or 2, ideally n 1 is 1 and preferably n 3 is. It is preferably an integer of 1 or more and 3 or less, more preferably n 3 is 1 or 2, and ideally n 3 is 2.
- the polyphenylene ether compound (A) represented by the general formula (1) preferably contains a polymer of the structural unit represented by the following general formula (2).
- R 901 , R 902 , R 903 , and R 904 each independently represent an alkyl group, an aryl group, a halogen atom, or a hydrogen atom having 6 or less carbon atoms.
- the polymer may further contain at least one structural unit selected from the group consisting of the structural units represented by the general formula (3) and the general formula (4).
- R 905 , R 906 , R 907 , R 911 , and R 912 each independently represent an alkyl group or a phenyl group having 6 or less carbon atoms.
- R 908 , R 909 , and R 910 are.
- R 913 , R 914 , R 915 , R 916 , R 917 , R 918 , R 919 , and R 920 each independently have a hydrogen atom and an alkyl group or a phenyl group having 6 or less carbon atoms.
- -A- is a linear, branched or cyclic divalent hydrocarbon group having 20 or less carbon atoms.
- the general formulas (2), (3) and (4) are preferably ⁇ (YO) ⁇ of the general formula (1).
- an aromatic hydrocarbon group can be used as the aryl group in X of the general formula (1).
- a group for example, a phenyl group, a biphenyl group, etc.
- a group obtained by removing n3 hydrogen atoms from one ring structure selected from a benzene ring structure , a biphenyl structure, an indenyl ring structure, and a naphthalene ring structure.
- Indenyl group and naphthyl group can be used, and it is preferable to use a biphenyl group.
- the aryl group includes a diphenyl ether group in which the above aryl group is bonded with an oxygen atom, a benzophenone group bonded with a carbonyl group, a 2,2-diphenylpropane group bonded with an alkylene group, and the like. But it may be. Further, the aryl group may be substituted with a general substituent such as an alkyl group (preferably an alkyl group having 1 to 6 carbon atoms, particularly a methyl group), an alkenyl group, an alkynyl group or a halogen atom. However, since the "aryl group" is substituted with a polyphenylene ether moiety via an oxygen atom, the limit on the number of general substituents depends on the number of polyphenylene ether moieties.
- the polyphenylene ether compound (A) contains a polyphenylene ether represented by the structure of the following general formula (5).
- X is an aryl group (aromatic group)
- ⁇ (YO) n 2 ⁇ indicates a polyphenylene ether moiety
- n 2 is an integer of 1 to 100, respectively.
- Shows.) -(YO) n 2- and n 2 are synonymous with those in the general formula (1). It may contain a plurality of kinds of compounds having different n2 .
- X in the general formula (1) and the general formula (5) is preferably the general formula (6), the general formula (7), or the general formula (8), and the general formula (1) and the general formula (5).
- -(YO) n 2 - is a structure in which the general formula (9) or the general formula (10) is arranged, or a structure in which the general formula (9) and the general formula (10) are randomly arranged. More preferred.
- R 921 , R 922 , R 923 , and R 924 each independently represent a hydrogen atom or a methyl group.
- -B- is a linear, branched, or cyclic group having 20 or less carbon atoms. It is a divalent hydrocarbon group of.
- -B- is a linear, branched or cyclic divalent hydrocarbon group having 20 or less carbon atoms.
- the method for producing the modified polyphenylene ether having the structure represented by the general formula (5) is not particularly limited, and is, for example, a bifunctional phenylene obtained by oxidation-coupling a bifunctional phenol compound and a monofunctional phenol compound. It can be produced by converting the terminal phenolic hydroxyl group of the ether oligomer into vinylbenzyl ether.
- a modified polyphenylene ether a commercially available product can be used, and for example, OPE-2St1200 and OPE-2St2200 manufactured by Mitsubishi Gas Chemical Company, Inc. can be preferably used.
- the ratio of the polyphenylene ether compound (A) in the present embodiment is preferably 1 part by mass or more, more preferably 3 parts by mass or more, with respect to 100 parts by mass of the resin solid content of the first resin layer 12. ..
- the upper limit of the content is preferably less than 20 parts by mass. Within such a range, the interlayer adhesion, the plating adhesion, and the hygroscopic heat resistance can be effectively improved.
- the first resin layer 12 may contain only one type of the polyphenylene ether compound (A), or may contain two or more types of the polyphenylene ether compound (A). When two or more kinds are contained, it is preferable that the total amount is within the above range.
- the polyimide resin (B) As the polyimide resin (B), a commercially available product can be appropriately selected and used.
- a solvent-soluble polyimide resin synthesized by the production method described in JP-A-2005-15629 can be used.
- the solvent-soluble polyimide resin includes an aliphatic tetracarboxylic acid dianhydride represented by the following formula (11), an aliphatic tetracarboxylic acid represented by the following formula (12), and the aliphatic tetracarboxylic acid. It can be obtained by polycondensing one or more selected from acid derivatives and one or more diamine compounds in a solvent in the presence of a tertiary amine compound.
- R is a tetravalent aliphatic hydrocarbon group having 4 to 16 carbon atoms.
- R is a tetravalent aliphatic hydrocarbon group having 4 to 16 carbon atoms
- Y 1 to Y 4 are independently hydrogen or a hydrocarbon group having 1 to 8 carbon atoms.
- a substantially equal molar amount of the aliphatic tetracarboxylic acid and the diamine compound can be heated in a solvent in the presence of a tertiary amine compound and polycondensed.
- the reaction molar ratio of the aliphatic tetracarboxylic acids and the diamine compound is preferably in the range of 95 to 105 mol% with respect to one of them.
- tetracarboxylic acid dianhydride is usually used as the tetracarboxylic acid, but in the above production method, in addition to the aliphatic tetracarboxylic acid dianhydride, the aliphatic tetra is used.
- a practical polyimide resin can be produced by using an ester of a carboxylic acid or an aliphatic tetracarboxylic acid and an alcohol. If the aliphatic tetracarboxylic acid can be used as it is, it is advantageous in terms of production equipment and cost.
- Examples of the aliphatic tetracarboxylic acid dianhydride represented by the formula (11) include 1,2,3,4-cyclobutanetetracarboxylic acid dianhydride and 1,2,4,5-cyclopentanetetra.
- examples of the aliphatic tetracarboxylic acid represented by the formula (12) and its derivatives include 1,2,3,4-cyclobutanetetracarboxylic acid and 1,2,4,5-cyclopentanetetracarboxylic acid.
- 1,2,4,5-Cyclohexanetetracarboxylic acid 1,2,4,5-Cyclohexanetetracarboxylic acid, bicyclo [2.2.2] octo-7-en-2,3,5,6-tetracarboxylic acid, etc., and their alcohol esters. Can be done. These can be used alone or in admixture of two or more. Of these, 1,2,4,5-cyclohexanetetracarboxylic dianhydride and 1,2,4,5-cyclohexanetetracarboxylic acid are preferred.
- tetracarboxylic dians and derivatives thereof can be mixed and used as long as the solvent solubility is not impaired.
- pyromellitic acid 3,3', 4,4'-biphenyltetracarboxylic acid, 2,3,3', 4'-biphenyltetracarboxylic acid, 2,2-bis (3,4-dicarboxyphenyl).
- the diamine compound is preferably an aromatic diamine compound containing 6 to 28 carbon atoms or an aliphatic diamine compound containing 2 to 28 carbon atoms.
- Examples of the diamine compound include p-phenylenediamine, m-phenylenediamine, 4,4'-diaminobiphenyl, 4,4'-diamino-2,2'-dimethylbiphenyl, and 4,4'-diamino-3,3.
- aromatic diamine compounds are 4,4'-diamino-3,3'-dimethylbiphenyl, 4,4'-diamino-2,2'-ditrifluoromethylbiphenyl, 4,4'-diamino.
- the aliphatic diamine compound 4,4'-diaminodicyclohexylmethane, 3 (4), 8 (9) -bis (aminomethyl) -tricyclo [5.2.1.02,6] decane are preferable.
- tertiary amine compound examples include trimethylamine, triethylamine, tripropylamine, tributylamine, triethanolamine, N, N-dimethylethanolamine, N, N-diethylethanolamine, triethylenediamine, N-methylpyrrolidin, and N.
- -Ethylpyrolidin, N-methylpiperidine, N-ethylpiperidine, imidazole, pyridine, quinoline, isoquinoline and the like can be mentioned.
- triethylamine is particularly preferred.
- Examples of the solvent used in the above-mentioned production method include ⁇ -butyrolactone, N, N-dimethylacetamide, N-methyl-2-pyrrolidone, N, N-dimethylformamide, dimethyl sulfoxide, hexamethylphosphoramide, and tetramethylene sulfone. , P-Chlorphenol, m-Cresol, 2-Chlor-4-hydroxytoluene and the like. These can be used alone or in admixture of two or more.
- ⁇ -butyrolactone, N, N-dimethylacetamide and N-methyl-2-pyrrolidone are preferable, and ⁇ -butyrolactone and N, N-dimethylacetamide are even more preferable.
- a poor solvent of the polyimide resin can be used in combination to the extent that the polymer does not precipitate.
- the poor solvent include hexane, heptane, benzene, toluene, xylene, chlorbenzene, o-dichlorobenzene and the like.
- the total weight of the aliphatic tetracarboxylic acid component and the diamine component is preferably 1 to 50% by mass, more preferably 20 to 45% by mass with respect to the total mass of the reaction solution.
- the method of charging the aliphatic tetracarboxylic acid component and the diamine compound component is not particularly limited, and the method of charging both components at once or in a solution containing either component (it does not have to be completely dissolved) is already used.
- a method of gradually charging one of the components in a solid state or a solution state can be performed.
- the method of charging both components at once is advantageous in terms of productivity because the charging time can be shortened.
- the tertiary amine compound it is preferable to charge the tertiary amine compound by raising the temperature and reaching the target temperature in order to fully exert its catalytic effect.
- the method for charging the solvent is also not particularly limited, and a method of charging in advance into a reaction vessel, a method of charging into a reaction vessel in which either one or both of an aliphatic tetracarboxylic acid component or a diamine compound is present, and an aliphatic tetra
- a method of charging into a reaction vessel in which either one or both of an aliphatic tetracarboxylic acid component or a diamine compound is present and an aliphatic tetra
- the solvent as described above may be added to the solvent-soluble polyimide resin solution in the state during the reaction, in the state of staying in the reaction tank after the reaction, or in the state of being taken out from the reaction tank after the reaction, depending on the purpose. can.
- the polyimide resin (B) used in this embodiment for example, a block copolymer polyimide resin can also be used.
- the block copolymer polyimide resin include the block copolymer polyimide resin described in International Publication No. WO2010-073952.
- the block copolymer polyimide resin is composed of a structure B1 in which an imide oligomer composed of a second structural unit is bonded to the end of an imide oligomer composed of a first structural unit, and a second structural unit.
- the copolymerized polyimide resin is not particularly limited as long as it has a structure in which the structure B2 in which the imide oligomer composed of the first structural unit is bonded to the end of the imide oligomer is alternately repeated.
- the second structural unit is different from the first structural unit.
- These block copolymerized polyimide resins are obtained by reacting a tetracarboxylic acid dianhydride with a diamine in a polar solvent to form an imide oligomer, and then further diamine or another tetracarboxylic acid with the tetracarboxylic acid dianhydride. It can be synthesized by a step-growth polymerization reaction in which acid dianhydride and diamine are added and imidized.
- the ratio of the polyimide resin (B) in the first resin layer 12 is not particularly limited, but is 10 parts by mass with respect to 100 parts by mass of the resin solid content of the first resin layer 12 from the viewpoint of heat resistance and curability.
- the range of 80 parts by mass or less is preferable, and the range of 30 parts by mass or more and 70 parts by mass or less is particularly preferable.
- the first resin layer 12 may contain only one type of polyimide resin (B), or may contain two or more types of polyimide resin (B). When two or more kinds are contained, it is preferable that the total amount is within the above range.
- ⁇ Maleimide compound (C)> By containing the maleimide compound (C), the interlayer adhesion, the insulating property, the plating adhesion, and the hygroscopic heat resistance can be improved.
- the maleimide compound (C) 1 or more (preferably 2 to 12, more preferably 2 to 6, still more preferably 2 to 4, more preferably 2 or 3, still more preferably 2) maleimide in one molecule.
- the compound is not particularly limited as long as it has a group, and any conventionally known maleimide compound can be used.
- maleimide compound (C) examples include, for example, bis (4-maleimidephenyl) methane, 2,2-bis ⁇ 4- (4-maleimidephenoxy) -phenyl ⁇ propane, and bis (3,5-dimethyl-4).
- -Bismaleimide compounds such as maleimidephenyl) methane, bis (3-ethyl-5-methyl-4-maleimidephenyl) methane, bis (3,5-diethyl-4-maleimidephenyl) methane; polyphenylmethane maleimide, etc. ..
- the maleimide compound (C) can also be blended in the form of a prepolymer of these compounds, or a prepolymer of these compounds and an amine compound. These maleimide compounds (C) can be used alone or in admixture of two or more.
- bismaleimide compounds are preferable from the viewpoint of heat resistance, and among them, 2,2-bis [4- (4-maleimidephenoxy) phenyl] propane and bis (3-ethyl-5-methyl-4-maleimidephenyl) are preferable. Methane is more preferred.
- the ratio of the maleimide compound (C) in the first resin layer 12 is not particularly limited, but is 5% by mass with respect to 100 parts by mass of the resin solid content of the first resin layer 12 from the viewpoint of heat resistance and plating adhesion.
- the range of 5 parts by mass or more and 75 parts by mass or less is preferable, and the range of 5 parts by mass or more and 45 parts by mass or less is further preferable.
- the first resin layer 12 may contain only one type of maleimide compound (C), or may contain two or more types of maleimide compound (C). When two or more kinds are contained, it is preferable that the total amount is within the above range.
- ⁇ Other resin components examples include liquid crystal polyesters, epoxy compounds, cyanate ester compounds, phenol compounds, benzoxazine compounds, organic group-modified silicone compounds, and compounds having a polymerizable unsaturated group.
- the first resin layer 12 may contain one or more of these.
- the liquid crystal polyester is an aromatic polyester that exhibits liquid crystal properties when melted.
- a known one can be appropriately selected and used.
- the aromatic polyester described in JP-A-2001-11296 can be used. Specific examples thereof include aromatic polyesters containing 90 mol% or more of structural units represented by the following formula (13).
- the aromatic polyester containing the structural unit represented by the above formula (13) for example, from the viewpoint of availability, polyoxybenzoate which is a homopolymer of the structural unit represented by the formula (13) is used. Can be used.
- a method for producing the aromatic polyester a known method can be adopted. It should be noted that the aromatic polyester containing the structural unit represented by the above formula (13) is often sparingly or insoluble in a normal solvent, and is also sparingly or insoluble, and therefore has a liquid crystallinity. Does not show. Therefore, the aromatic polyester containing the structural unit represented by the above formula (13) is preferably used as a powder. The powder is obtained by pulverizing an aromatic polyester resin or fiber.
- the molecular weight of the liquid crystal polyester is usually 1000 to 100,000, preferably 10,000 to 50,000.
- liquid crystal polyester a commercially available product can be appropriately selected and used, and for example, "Econol E101-F” manufactured by Sumitomo Chemical Co., Ltd. can be used.
- the content thereof is not particularly limited, but from the viewpoint of heat resistance and curability, the resin solid content of the first resin layer 12 is 100 parts by mass.
- the range of 10 to 90 parts by mass is preferable, and the range of 30 to 80 parts by mass is particularly preferable.
- the epoxy compound has 1 or more (preferably 2 to 12, more preferably 2 to 6, still more preferably 2 to 4, more preferably 2 or 3, even more preferably 2) epoxy groups in one molecule.
- the compound is not particularly limited as long as it is a compound, and any conventionally known epoxy compound can be used.
- the epoxy equivalent of the epoxy compound is preferably 250 g / eq to 850 g / eq, more preferably 250 g / eq to 450 g / eq, from the viewpoint of improving the adhesiveness and flexibility.
- the epoxy equivalent can be measured by a conventional method.
- epoxy compound examples include polyoxynaphthylene type epoxy resin, biphenyl aralkyl type epoxy resin, naphthalene tetrafunctional epoxy resin, xylene type epoxy resin, naphthol aralkyl type epoxy resin, bisphenol A type epoxy resin, and bisphenol F.
- Type epoxy resin bisphenol A novolak type epoxy resin, trifunctional phenol type epoxy resin, tetrafunctional phenol type epoxy resin, naphthalene type epoxy resin, biphenyl type epoxy resin, aralkylnovolac type epoxy resin, alicyclic epoxy resin, polyol type epoxy
- examples thereof include a resin, a glycidylamine type epoxy resin, a glycidyl ester type epoxy resin, a compound obtained by epoxidizing a double bond such as butadiene, and a compound obtained by reacting a hydroxyl group-containing silicone resin with epichlorohydrin.
- polyoxynaphthylene type epoxy resin biphenyl aralkyl type epoxy resin, naphthalene tetrafunctional epoxy resin, xylene type epoxy resin, and naphthol aralkyl type epoxy resin are particularly from the viewpoint of adhesiveness to plated copper and flame retardancy. Is preferable.
- These epoxy compounds may be used alone or in admixture of two or more.
- the content thereof is not particularly limited, but from the viewpoint of heat resistance and curability, the resin solid content of the first resin layer 12 is 100 parts by mass.
- the range of 1 to 60 parts by mass is preferable, and the range of 1 to 30 parts by mass is particularly preferable.
- the cyanic acid ester compound has excellent chemical resistance, adhesiveness, and the like, and the excellent chemical resistance makes it possible to form a uniform roughened surface. Therefore, the resin layer in the present embodiment. Can be suitably used as a component of.
- the cyanate ester compound has one or more cyanate groups (cyanato groups) in the molecule (preferably 2 to 12, more preferably 2 to 6, still more preferably 2 to 4, more preferably 2 or 3, still more preferably. 2)
- the compound is not particularly limited as long as it is contained, and a compound usually used in the field of printed wiring board can be widely used.
- Specific examples of the cyanate ester compound include, for example, an ⁇ -naphthol aralkyl type cyanate ester compound represented by the formula (14), a phenol novolac type cyanate ester compound represented by the formula (15), and a formula (16).
- Biphenyl aralkyl type cyanic acid ester compound naphthylene ether type cyanic acid ester compound, xylene resin type cyanic acid ester compound, trisphenol methane type cyanic acid ester compound, adamantan skeleton type cyanic acid ester compound, bisphenol M type cyanide.
- At least one selected from the group consisting of an acid ester compound, a bisphenol A type cyanate ester compound, and a diallyl bisphenol A type cyanate ester compound can be mentioned.
- These cyanate ester compounds may be prepared by a known method, or commercially available products may be used.
- Cyanic acid ester compounds are preferable because they have excellent flame retardancy, high curability, and a low thermal expansion coefficient of the cured product.
- R 1 represents a hydrogen atom or a methyl group, and n 1 represents an integer of 1 or more. n 1 is preferably an integer of 1 to 50.
- R 2 represents a hydrogen atom or a methyl group
- n 2 represents an integer of 1 or more.
- n 2 is preferably an integer of 1 to 50.
- R 3 represents a hydrogen atom or a methyl group, and n 3 represents an integer of 1 or more. n 3 is preferably an integer of 1 to 50.
- the content thereof is not particularly limited, but from the viewpoint of heat resistance and adhesion to the copper foil, the first resin layer 12 has a content thereof.
- the range of 1 to 60 parts by mass is preferable, and the range of 1 to 30 parts by mass is more preferable with respect to 100 parts by mass of the resin solid content.
- the phenolic compound includes 1 or more (preferably 2 to 12, more preferably 2 to 6, still more preferably 2 to 4, more preferably 2 or 3, even more preferably 2) phenolic hydroxy groups in one molecule.
- the phenol compound is not particularly limited as long as it has, and any conventionally known phenol compound can be used.
- Specific examples of the phenol compound include, for example, bisphenol A type phenol resin, bisphenol E type phenol resin, bisphenol F type phenol resin, bisphenol S type phenol resin, phenol novolac resin, bisphenol A novolak type phenol resin, and glycidyl ester type phenol resin.
- the benzoxazine compound is not particularly limited as long as it is a compound having two or more dihydrobenzoxazine rings in one molecule, and generally known compounds can be used.
- Specific examples of the benzoxazine compound include, for example, bisphenol A type benzoxazine BA-BXZ (trade name manufactured by Konishi Chemical Co., Ltd.), bisphenol F type benzoxazine BF-BXZ (trade name manufactured by Konishi Chemical Co., Ltd.), and bisphenol S type benzoxazine BS-BXZ. (Product name manufactured by Konishi Chemical Co., Ltd.) and the like. These benzoxazine compounds may be used alone or in admixture of two or more.
- organic group-modified silicone compound is not particularly limited, and specific examples thereof include di (methylamino) polydimethylsiloxane, di (ethylamino) polydimethylsiloxane, di (propylamino) polydimethylsiloxane, and di (epoxypropyl). Examples thereof include polydimethylsiloxane and di (epoxybutyl) polydimethylsiloxane. These organic-modified silicone compounds may be used alone or in admixture of two or more.
- the compound having a polymerizable unsaturated group is not particularly limited, and generally known compounds can be used. Specific examples of the compound having a polymerizable unsaturated group include vinyl compounds such as ethylene, propylene, styrene, divinylbenzene and divinylbiphenyl; methyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-.
- Hydroxypropyl (meth) acrylate polypropylene glycol di (meth) acrylate, trimethylolpropane di (meth) acrylate, trimethylolpropanetri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate, etc.
- Methoda) acrylates of monovalent or polyhydric alcohols; epoxy (meth) acrylates such as bisphenol A type epoxy (meth) acrylate and bisphenol F type epoxy (meth) acrylate; benzocyclobutene resin and the like can be mentioned. These compounds having a polymerizable unsaturated group can be used alone or in admixture of two or more.
- the first resin layer 12 may not contain the inorganic filler, but may contain the inorganic filler.
- the content is preferably 35% by volume or less, and more preferably 31% by volume or less. This is because the addition of the inorganic filler improves the workability, but if the content is too large, the flexibility is lowered, cracks are generated, and the insulating property is lowered.
- the content of the inorganic filler is the content of the inorganic filler with respect to the first resin layer 12 (inorganic filler / first resin layer ⁇ 100).
- a spherical filler can be used from the viewpoint of low thermal expansion rate, moldability, filling property and rigidity, and is not particularly limited as long as it is a spherical filler used for the insulating layer of the printed wiring board.
- the inorganic filler examples include magnesium hydroxide; magnesium oxide; silica such as natural silica, molten silica, amorphous silica, and hollow silica; molybdenum compounds such as molybdenum disulfide, molybdenum oxide, and zinc molybdenate; alumina; aluminum nitride; Glass; talc; titanium compounds such as titanium oxide, barium titanate, and strontium titanate; zirconium oxide and the like. These can be used by appropriately mixing one kind or two or more kinds.
- silica is preferable as the inorganic filler from the viewpoint of low thermal expansion, and specifically, spherical molten silica is preferable.
- Commercially available spherical fused silicas include SO-C1, SO-E1, YC100C, SC2500-SQ, K180SQ-C1, CIK Nanotech Co., Ltd., and Denka Co., Ltd. Examples include SFP-20M and SFP-130MC.
- the particle size of the inorganic filler is not particularly limited, but is preferably 5 ⁇ m or less, more preferably 3 ⁇ m or less, further preferably 2 ⁇ m or less, and even more preferably 1.0 ⁇ m or less.
- the particle size of the inorganic filler can be measured by a laser diffraction / scattering method based on the Mie scattering theory.
- As the measurement sample an inorganic filler dispersed in water by ultrasonic waves can be preferably used.
- the laser diffraction / scattering type particle size distribution measuring device "MT3000II" manufactured by Microtrac Bell Co., Ltd. or the like can be used.
- the inorganic filler may be surface-treated with a silane coupling agent or the like.
- a silane coupling agent the silane coupling agent described later can be used.
- a silane coupling agent may be contained for the purpose of improving hygroscopic heat resistance.
- the silane coupling agent is not particularly limited as long as it is a silane coupling agent generally used for surface treatment of inorganic substances. Specific examples include aminosilane-based silane coupling agents (eg, ⁇ -aminopropyltriethoxysilane, N- ⁇ - (aminoethyl) - ⁇ -aminopropyltrimethoxysilane), and epoxysilane-based silane coupling agents (eg, ⁇ -aminopropyltriethoxysilane).
- aminosilane-based silane coupling agents eg, ⁇ -aminopropyltriethoxysilane, N- ⁇ - (aminoethyl) - ⁇ -aminopropyltrimethoxysilane
- epoxysilane-based silane coupling agents eg, ⁇ -aminopropyltriethoxysi
- silane-based silane coupling agent eg, ⁇ -acryloxypropyltrimethoxysilane, vinylsilane-based silane coupling agent (eg, ⁇ -methacryloxypropyltrimethoxysilane)).
- Cationic silane-based silane coupling agent for example, N- ⁇ - (N-vinylbenzylaminoethyl) - ⁇ -aminopropyltrimethoxysilane hydrochloride
- phenylsilane-based silane coupling agent one kind or two or more kinds can be appropriately mixed and used.
- the content of the silane coupling agent is not particularly limited, but is preferably in the range of 0.05 to 5 parts by mass with respect to 100 parts by mass of the inorganic filler from the viewpoint of improving moisture absorption and heat resistance, and is 0.
- the range of 1 to 3 parts by mass is more preferable.
- the total amount of these silane coupling agents satisfies the above range.
- a wet dispersant may be contained, for example, for the purpose of improving manufacturability.
- the wet dispersant is not particularly limited as long as it is a wet dispersant generally used for paints and the like.
- Disperbyk registered trademark
- -110, -111, -118, -180, -161, BYK registered trademark
- BYK registered trademark
- These wet dispersants can be used alone or in admixture of two or more.
- the content of the wet dispersant is not particularly limited, but is preferably in the range of 0.1 to 5 parts by mass with respect to 100 parts by mass of the inorganic filler from the viewpoint of improving manufacturability, and is preferably 0.5. A range of up to 3 parts by mass is more preferable. When two or more kinds of wet dispersants are used in combination, it is preferable that the total amount thereof satisfies the above range.
- a curing accelerator may be further contained, for example, for the purpose of adjusting the curing rate.
- the curing accelerator is not particularly limited, but is an organic metal salt containing a metal such as copper, zinc, cobalt, nickel, manganese, etc. (for example, lead naphthenate, lead stearate, zinc naphthenate, zinc octylate, tin oleate).
- Inorganic metal salts such as tin chloride, zinc chloride, aluminum chloride; dioctyl tin oxide, other alkyl tin, alkyl tin oxide), imidazoles and derivatives thereof (eg, 2-ethyl-4-methylimidazole, 1-benzyl- 2-Phenylimidazole, 2,4,5-triphenylimidazole), tertiary amines (eg, triethylamine, N, N-dimethylbenzylamine, N, N-dimethylaniline, N, N-dimethyltoluidine, 2-N -Ethylanilinoethanol, tri-n-butylamine, pyridine, quinoline, N-methylmorpholine, triethanolamine, triethylenediamine, tetramethylbutanediamine, N-methylpiperidine, etc.), organic peroxides (eg, benzoyl peroxide) , Lauroyl peroxide, acetyl peroxid
- the content of the curing accelerator is not particularly limited, but is 0.001 to 5% by mass with respect to 100 parts by mass of the resin solid content of the first resin layer 12 from the viewpoint of obtaining a high glass transition temperature.
- the range of parts is preferable, and the range of 0.01 to 3 parts by mass is more preferable.
- the total amount thereof satisfies the above range.
- various other polymer compounds and / or flame-retardant compounds may be contained.
- the polymer compound and the flame-retardant compound are not particularly limited as long as they are generally used.
- polymer compound examples include various thermosetting resins and thermoplastic resins, oligomers thereof, elastomers and the like.
- polyamide-imide resin polystyrene, polyolefin, styrene-butadiene rubber (SBR), isoprene rubber (IR), butadiene rubber (BR), acrylonitrile butadiene rubber (NBR), polyurethane, polypropylene, (meth) acrylic oligomer
- SBR styrene-butadiene rubber
- IR isoprene rubber
- BR butadiene rubber
- NBR acrylonitrile butadiene rubber
- polyurethane polypropylene
- acrylic oligomer examples thereof include (meth) acrylic polymers and silicone resins. From the viewpoint of compatibility, acrylonitrile butadiene rubber or styrene-butadiene rubber is preferable.
- the flame-retardant compound examples include phosphorus-containing compounds (for example, phosphoric acid ester, phosphoric acid melamine, phosphorus-containing epoxy compound), nitrogen-containing compounds (for example, melamine and benzoguanamine), oxazine ring-containing compounds, silicone-based compounds and the like. Can be mentioned. These polymer compounds and / or flame-retardant compounds may be used alone or in admixture of two or more.
- the first resin layer 12 may contain various other additives for various purposes.
- additives include UV absorbers, antioxidants, photopolymerization initiators, optical brighteners, photosensitizers, dyes, pigments, thickeners, lubricants, defoaming agents, dispersants, and leveling agents. And brighteners. These additives may be used alone or in admixture of two or more.
- the second resin layer 13 contains a thermosetting resin.
- the thermosetting resin is not particularly limited, and is, for example, an epoxy compound, a cyanate ester compound, a maleimide compound, a phenol compound, a polyphenylene ether compound, a benzoxazine compound, an organic group-modified silicone compound, and a non-polymerizable resin. Examples include compounds having a saturated group. As these compounds, the same compounds as those exemplified in the first resin layer 12 can be used.
- the thermosetting resin can be used by appropriately mixing one or more of these. Above all, it is preferable to include an epoxy compound and a phenol compound because excellent peel strength can be obtained, and it is more preferable to further contain a maleimide compound together with the epoxy compound and the phenol compound.
- the content thereof is not particularly limited, but from the viewpoint of heat resistance and curability, the resin solid content of the second resin layer 13 is 100 parts by mass.
- the range of 10 to 80 parts by mass is preferable, and the range of 30 to 70 parts by mass is particularly preferable.
- the content thereof is not particularly limited, but from the viewpoint of heat resistance and adhesion to the copper foil, the resin solid of the second resin layer 13 is used.
- the range of 10 to 80 parts by mass is preferable, and the range of 20 to 60 parts by mass is more preferable with respect to 100 parts by mass.
- the maleimide compound when used for the second resin layer 13, the content thereof is not particularly limited, but from the viewpoint of heat resistance and adhesion to the copper foil, the resin solid of the second resin layer 13 is used.
- the range of 10 to 80 parts by mass is preferable, and the range of 10 to 50 parts by mass is more preferable with respect to 100 parts by mass.
- the thickness of the second resin layer 13 is not particularly limited, but is preferably 15 ⁇ m or less, and more preferably 10 ⁇ m or less, from the viewpoint of thinning. Further, the thickness of the second resin layer 13 is preferably 1 ⁇ m or more in consideration of ensuring the insulating property.
- the second resin layer 13 is preferably in a semi-cured state (B-Stage).
- the second resin layer 13 can be formed by a known means such as coating.
- the second resin layer 13 may also contain at least one of an inorganic filler and other components, if necessary.
- an inorganic filler and other components for example, the same ones as described in the first resin layer 12 can be used.
- the second resin layer 13 may not contain the inorganic filler, but may contain the inorganic filler, and the content thereof is preferably 35% by volume or less. This is because adding an inorganic filler improves workability, but if the content is too large, the flexibility is reduced and cracks are likely to occur.
- the content of the inorganic filler is the content of the inorganic filler with respect to the second resin layer 13 (inorganic filler / first resin layer ⁇ 100).
- the method for producing the copper foil 10 with a resin layer of the present embodiment is not particularly limited.
- a manufacturing method for example, first, a solution (varnish) in which the composition of the first resin layer 12 is dissolved or dispersed in an organic solvent is applied to the surface of the copper foil 11 and dried under heating and / or reduced pressure. Then, the solvent is removed and solidified to form the first resin layer 12.
- the first resin layer 12 may be in a completely cured state as well as in a semi-cured state.
- a solution (varnish) in which the composition of the second resin layer 13 is dissolved or dispersed in an organic solvent is applied onto the first resin layer 12, and dried under heating and / or reduced pressure to remove the solvent. It is preferable to remove and solidify to form the second resin layer 13. At this time, it is preferable that the second resin layer 13 is in a B-stage (semi-cured state). Further, a protective layer such as a plastic film may be provided on the second resin layer 13. The protective layer is appropriately removed at the time of producing the laminate described later.
- the drying conditions are not particularly limited, but the first resin layer 12 or the second resin layer 13 is dried so that the amount of the organic solvent is usually 10 parts by mass or less, preferably 5 parts by mass or less, based on 100 parts by mass. Let me.
- the conditions for achieving drying differ depending on the amount of the organic solvent in the varnish. For example, in the case of a varnish containing 30 to 60 parts by mass of an organic solvent with respect to 100 parts by mass of the varnish, the heating conditions are 50 ° C. to 200 ° C. It may be dried underneath for about 3 to 10 minutes.
- the organic solvent is not particularly limited as long as each component can be suitably dissolved or dispersed and the effect of the first resin layer 12 or the second resin layer 13 is exhibited.
- organic solvents include alcohols (eg, methanol, ethanol and propanol), ketones (eg, acetone, methylethylketone and methylisobutylketone), amides (eg, dimethylacetamide and dimethylformamide), aromatic hydrocarbons. Classes (eg, toluene and xylene), N-methyl-2-pyrrolidone, ⁇ -butyrolactone and the like can be mentioned. These organic solvents may be used alone or in admixture of two or more.
- the method of coating is also not particularly limited, but for example, bar coater coating, air knife coating, gravure coating, reverse gravure coating, micro gravure coating, micro reverse gravure coater coating, die coater coating, dip coating, spin coating coating. , A coating method known for spray coating and the like can be used.
- the laminate using the copper foil 10 with a resin layer of the present embodiment (hereinafter, may be simply referred to as “the laminate of the present embodiment”) is, for example, a build-up of a printed wiring board or a substrate for mounting a semiconductor element. It can be used for materials and for manufacturing coreless substrates.
- the laminate of the present embodiment can be configured as a laminate having a build-up layer in which a conductor layer and an insulating layer formed by using a copper foil 10 with a resin layer are alternately laminated, for example.
- the "insulating layer formed by using the copper foil 10 with a resin layer” means, for example, such that the second resin layer 13 of the copper foil 10 with a resin layer is in contact with the substrate on which the conductor layer is formed. Can be laminated and configured.
- the conductor layer may be the copper foil 11 of the copper foil 10 with a resin layer, or another conductor (copper foil or the like) such as the copper foil of the copper-clad laminate may be separately laminated to form the conductor layer. May be formed.
- the laminated body 20 is formed by laminating a copper foil 10 with a resin layer on a substrate 22 on which a conductor layer 21 is formed so that a second resin layer 13 is in contact with the first resin layer 12. And the second resin layer 13 form an insulating layer 23.
- the build-up layer has a plurality of conductor layers and an insulating layer, and the conductor layer is between the insulating layers and of the build-up layer. It can be configured to be arranged on the surface of the outermost layer.
- the number of insulating layers is not particularly limited, but may be, for example, 3 layers or 4 layers.
- a coreless substrate can be produced by using the laminated body of the present embodiment. Examples of the coreless substrate include a coreless substrate having two or more layers, and examples thereof include a three-layer coreless substrate. The configuration of the coreless substrate will be described later.
- the laminate of this embodiment can be used as a printed wiring board.
- a laminate using the copper foil 10 with a resin layer of the present embodiment is used as a build-up material for a metal foil-clad laminate in which an insulating resin layer called a core base material is completely cured.
- an insulating resin layer called a core base material is completely cured.
- the copper foil 10 (laminated body) with a resin layer of the present embodiment for example, it is possible to manufacture a thin printed wiring board without using a thick support substrate (carrier substrate).
- a conductor circuit is formed by a conductor layer obtained by peeling off the metal foil and / or the metal foil of a commonly used metal foil-clad laminate and then plating.
- the base material of the metal foil-clad laminate is not particularly limited, but is mainly a glass epoxy substrate, a metal substrate, a polyester substrate, a polyimide substrate, a BT resin substrate, and a thermosetting polyphenylene ether substrate.
- build-up refers to the first resin layer 12 in the copper foil 10 with a resin layer and, if necessary, a second, with respect to the metal foil and / or the conductor layer on the surface of the metal foil-clad laminate.
- the resin layer 13 is laminated. Even if the copper foil 11 is etched and then plated when the printed wiring board or the substrate for mounting the semiconductor element is manufactured, the first resin layer 12 has excellent plating adhesion, so that the plating adhesion is improved.
- holes such as via holes and / or through holes are machined in order to electrically connect each conductor layer as needed. Drilling is usually performed using a mechanical drill, a carbon dioxide laser, a UV laser, a YAG laser, or the like.
- the roughening treatment usually consists of a swelling step, a surface roughening and smear melting step, and a neutralization step.
- the swelling step is performed by swelling the surface of the insulating resin layer with a swelling agent.
- the swelling agent As the swelling agent, the wettability of the surface of the insulating resin layer is improved, and the surface of the insulating resin layer can be swelled to the extent that oxidative decomposition is promoted in the next surface roughening and smear dissolution steps. If so, it is not particularly limited. Examples include an alkaline solution, a surfactant solution and the like.
- the surface roughening and smear dissolution steps are carried out using an oxidizing agent.
- the oxidizing agent include an alkaline permanganate solution and the like, and suitable specific examples thereof include an aqueous solution of potassium permanganate and an aqueous solution of sodium permanganate.
- Such an oxidant treatment is called wet desmear, and in addition to the wet desmear, other known roughening treatments such as plasma treatment, dry desmear by UV treatment, mechanical polishing by buffing, and sandblasting are appropriately combined. May be.
- the neutralization step is to neutralize the oxidizing agent used in the previous step with a reducing agent.
- the reducing agent examples include amine-based reducing agents, and suitable specific examples thereof include acidic aqueous solutions such as a hydroxylamine sulfate aqueous solution, an ethylenediamine tetraacetic acid aqueous solution, and a nitrilotriacetic acid aqueous solution.
- acidic aqueous solutions such as a hydroxylamine sulfate aqueous solution, an ethylenediamine tetraacetic acid aqueous solution, and a nitrilotriacetic acid aqueous solution.
- the via hole and / or the through hole is provided, or after the via hole and / or the through hole is desmeared, it is preferable to perform a metal plating treatment to electrically connect each conductor layer.
- the method of the metal plating treatment is not particularly limited, and a method of the metal plating treatment in the production of a normal multilayer printed wiring board can be appropriately used.
- the method of metal plating treatment and the type of chemical solution used for plating are not particularly limited, and the metal plating treatment method and chemical solution in the production of a normal multilayer printed wiring board can be appropriately used.
- the chemical solution used for the metal plating treatment may be a commercially available product.
- the metal plating treatment method is not particularly limited, and is, for example, a treatment with a degreasing liquid, a treatment with a soft etching liquid, an acid cleaning, a treatment with a predip liquid, a treatment with a catalyst liquid, a treatment with an accelerator liquid, and a chemical copper liquid.
- a treatment with a degreasing liquid a treatment with a soft etching liquid
- an acid cleaning a treatment with a predip liquid
- a treatment with a catalyst liquid a treatment with an accelerator liquid
- chemical copper liquid examples thereof include treatment, pickling, and treatment of immersing in a copper sulfate solution and passing a current.
- the first resin layer 12 or the second resin layer 13 in the semi-cured state is usually heat-treated.
- a printed wiring board can be obtained by completely curing.
- another copper foil 10 with a resin layer may be further laminated on the obtained printed wiring board.
- the laminating method in the build-up method is not particularly limited, but a vacuum-pressurized laminator can be preferably used.
- the copper foil 10 with a resin layer can be laminated via an elastic body such as rubber.
- the laminating conditions are not particularly limited as long as they are conditions used in laminating ordinary printed wiring boards, but for example, a temperature of 70 ° C. to 140 ° C., a contact pressure in the range of 1 kgf / cm 2 to 11 kgf / cm 2 , and a contact pressure of 1 kgf / cm 2 to 11 kgf / cm 2. It is carried out under an atmospheric reduced pressure of 20 hPa or less.
- the laminated adhesive film may be smoothed by hot pressing with a metal plate.
- the laminating step and the smoothing step can be continuously performed by a commercially available vacuum pressurizing laminator.
- the first resin layer 12 and the second resin layer 13 can be completely cured.
- the thermosetting conditions differ depending on the types of components contained in the first resin layer 12 and the second resin layer 13, but usually the curing temperature is 100 ° C to 300 ° C and the pressure is 0.1 kgf / cm 2 to 100 kgf. / Cm 2 (about 9.8 kPa to about 9.8 MPa), curing time is 30 seconds to 5 hours.
- Examples of the method for forming a circuit pattern on the copper foil on one side or both sides of the printed wiring board in the present embodiment include a semi-additive method, a full additive method, and a subtractive method. Above all, the semi-additive method is preferable from the viewpoint of forming a fine wiring pattern.
- a method of selectively electroplating using a plating resist pattern plating
- pattern plating a method of selectively electroplating using a plating resist
- etching an appropriate amount of the whole to form a wiring pattern can be mentioned.
- electroless plating and electrolytic plating are combined, and at that time, it is preferable to perform drying after electroless plating and after electrolytic plating, respectively. Drying after electroless plating is not particularly limited, but is preferably performed at 80 ° C. to 180 ° C. for 10 minutes to 120 minutes, and drying after electrolytic plating is not particularly limited, but is, for example, at 130 ° C. to 220 ° C. It is preferably performed for 10 to 120 minutes. Copper plating is preferable as the plating.
- An example of a method of forming a circuit pattern by the subtractive method is a method of forming a wiring pattern by selectively removing a conductor layer using an etching resist.
- a dry film resist (Hitachi Kasei RD-1225 (trade name)) is laminated and bonded (laminated) on the entire surface of the copper foil at a temperature of 110 ⁇ 10 ° C. and a pressure of 0.50 ⁇ 0.02 MPa. Then, exposure is performed according to the circuit pattern and masking is performed. Then, the dry film resist is developed with a 1% aqueous sodium carbonate solution, and finally the dry film resist is peeled off with an amine-based resist stripping solution. This makes it possible to form circuit patterning on the copper foil.
- a multilayer printed wiring board can be obtained by further laminating an insulating resin layer and / or a conductor layer on the printed wiring board.
- a circuit board may be provided in the inner layer of the multilayer printed wiring board.
- the copper foil 10 with a resin layer constitutes one of the insulating resin layer and the conductor layer of the multilayer printed wiring board.
- the laminating method is not particularly limited, and a method generally used for laminating and forming a normal printed wiring board can be used.
- Examples of the laminating method include a multi-stage press, a multi-stage vacuum press, a laminator, a vacuum laminator, an autoclave forming machine, and the like.
- the temperature at the time of stacking is not particularly limited, but is not particularly limited, for example, 100 ° C. to 300 ° C.
- the pressure is not particularly limited, for example, 0.1 kgf / cm 2 to 100 kgf / cm 2 (about 9.8 kPa to about 9.8 MPa).
- the heating time is not particularly limited, but is appropriately selected in the range of, for example, 30 seconds to 5 hours. Further, if necessary, for example, post-curing may be performed in a temperature range of 150 ° C. to 300 ° C. to adjust the degree of curing.
- the laminate of this embodiment can be used as a substrate for mounting a semiconductor element.
- a substrate for mounting a semiconductor element is produced, for example, by laminating a copper foil 10 with a resin layer on a metal foil-clad laminate and masking and patterning the copper foil on the surface or one side of the obtained laminate.
- the masking and patterning known masking and patterning performed in the manufacture of the printed wiring board can be used, and the circuit pattern is preferably formed by the above-mentioned subtractive method without particular limitation.
- the circuit pattern may be formed on only one side of the laminate, or may be formed on both sides.
- the laminate of this embodiment can be a coreless substrate as described above.
- An example of the coreless substrate is a multilayer coreless substrate.
- the multilayer coreless substrate is, for example, a plurality of insulating layers composed of a first insulating layer, one or a plurality of second insulating layers laminated on one side of the first insulating layer, and a plurality of insulating layers.
- FIG. 3 is a schematic diagram showing an example of a multilayer coreless substrate in this embodiment.
- the first conductor layer 113 arranged between each of the plurality of insulating layers (first insulating layer 111 and the second insulating layer 112) and their respective insulating layers 113. It has a plurality of conductor layers composed of a second conductor layer 114 arranged on the outermost layer of the plurality of insulating layers (first insulating layer 111 and second insulating layer 112).
- Terminal styrene polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.) 15.0 parts by mass, polyimide resin (product name: Neoprim (registered trademark) S100, manufactured by Mitsubishi Gas Chemical Company, Inc.) 49 .9 parts by mass, 2,2-bis- (4- (4-maleimidephenoxy) phenyl) propane (product name: BMI-80, manufactured by KI Kasei Co., Ltd.) 34.9 parts by mass, 2,4 0.2 parts by mass of 5-triphenylimidazole (manufactured by Tokyo Kasei Kogyo Co., Ltd.) was blended (mixed) to obtain the composition of the first resin layer 12.
- the composition of the first resin layer 12 was diluted with N-methyl-2-pyrrolidone (hereinafter referred to as “NMP”) to obtain varnish A.
- NMP N-methyl-2-pyrrolidone
- the obtained varnish A was applied to the surface mat surface side of a copper foil 11 (product name: 3EC-M2S-VLP, manufactured by Mitsui Mining & Smelting Co., Ltd.) having a thickness of 12 ⁇ m by a bar coater.
- the matte surface side of the copper foil 11 was set as the surface, and the ten-point average roughness Rz of the surface was 1.7 ⁇ m in Examples 1 to 5, 0.3 ⁇ m in Example 6, and 4.5 ⁇ m in Example 7. ..
- the coating film was heated and dried at 180 ° C. for 10 minutes to form the first resin layer 12 on the copper foil 11.
- biphenyl aralkyl type phenol resin product name: KAYAHARD GPH-103, hydroxyl group equivalent: 230 g / eq, manufactured by Nippon Kayaku Co., Ltd. 35.8 parts by mass, bis (3-ethyl-5-methyl-4-maleimide).
- Diphenyl) methane (product name: BMI-70, manufactured by KAI Kasei Co., Ltd.) 17.9 parts by mass, naphthalene aralkyl type epoxy resin (product name: HP-9900-75M, epoxy equivalent: 274 g / eq., DIC 7.0 parts by mass, biphenyl aralkyl type epoxy resin (product name: NC-3000-FH-75M, manufactured by Nippon Kayaku Co., Ltd., epoxy equivalent: 320 g / eq.) 38.8 parts by mass,
- the composition of the second resin layer 13 was obtained by blending (mixing) 0.5 parts by mass of 2,4,5-triphenylimidazole (manufactured by Tokyo Kasei Kogyo Co., Ltd.).
- the composition of the second resin layer 13 was diluted with methyl ethyl ketone to obtain varnish B.
- the obtained varnish B was applied by a bar coater onto the first resin layer 12 obtained by the above method.
- the coating film was heated and dried at 150 ° C. for 10 minutes to obtain a copper foil 10 with a resin layer having a first resin layer 12 and a second resin layer 13.
- the thickness of the first resin layer 12 and the thickness of the second resin layer 13 were changed as follows in each example.
- the thickness of the first resin layer 12 is 1.5 ⁇ m
- the thickness of the second resin layer 13 is 2.5 ⁇ m
- the thickness of the first resin layer 12 is 2.5 ⁇ m.
- the thickness of the resin layer 13 of 2 is 2.5 ⁇ m
- the thickness of the first resin layer 12 is 5.0 ⁇ m in Example 3
- the thickness of the second resin layer 13 is 2.5 ⁇ m
- the thickness of Example 4 is the first.
- the thickness of the resin layer 12 is 2.5 ⁇ m, the thickness of the second resin layer 13 is 1.5 ⁇ m, and in Example 5, the thickness of the first resin layer 12 is 2.5 ⁇ m and the thickness of the second resin layer 13 is In Example 6, the thickness of the first resin layer 12 is 2.5 ⁇ m, the thickness of the second resin layer 13 is 2.5 ⁇ m, and in Example 7, the thickness of the first resin layer 12 is 2. The thickness of the second resin layer 13 is 5 ⁇ m, and the thickness of the second resin layer 13 is 5.0 ⁇ m.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.) 18.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemical Company, Inc.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.), 10.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemical Company, Inc.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed.
- the composition of the first resin layer 12 is a terminal styrated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemicals Co., Ltd.), 15.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemicals Co., Ltd.
- the second resin layer 13 was formed on the first resin layer 12 in the same manner as in Example 2 except that the composition of the second resin layer 13 was changed.
- the composition of the second resin layer 13 is a biphenyl aralkyl type phenol resin (product name: KAYAHARD GPH-103, hydroxyl group equivalent: 230 g / eq, manufactured by Nippon Kayaku Co., Ltd.), 35.8 parts by mass, bis (3-).
- Ethyl-5-methyl-4-maleimidediphenyl) methane (product name: BMI-70, manufactured by Keiai Kasei Co., Ltd.) 17.9 parts by mass, naphthalene aralkyl type epoxy resin (product name: HP-9900-75M, Epoxy equivalent: 274 g / eq., manufactured by DIC Co., Ltd.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.) 10.0 parts by mass, polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemical Company, Inc.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.), 7.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemical Company, Inc.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.), 3.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemical Company, Inc.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrenated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.), 50.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemical Company, Ltd.) 50.0 parts by mass was blended (mixed) to obtain the product.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrenated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.), 30.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). S100, manufactured by Mitsubishi Gas Chemical Company, Ltd.) 70.0 parts by mass was blended (mixed) to obtain the product.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a terminal styrenated polyphenylene ether compound (product name: OPE-2St2200, manufactured by Mitsubishi Gas Chemical Company, Inc.), 15.0 parts by mass, and a polyimide resin (product name: Neoprim (registered trademark)). It was obtained by blending (mixing) 50.0 parts by mass of S100, manufactured by Mitsubishi Gas Chemical Company, Ltd. and 35.0 parts by mass of an epoxy compound (product name: LCE-2615, manufactured by Nippon Kayaku Co., Ltd.).
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 2 except that the composition of the first resin layer 12 was changed, and the first resin layer 12 was formed on the first resin layer 12.
- a second resin layer 13 was formed on the surface.
- the composition of the first resin layer 12 is a polyimide resin (product name: Neoprim (registered trademark) S100, manufactured by Mitsubishi Gas Chemical Company, Inc.), 50.0 parts by mass, 2,2-bis- (4- (4- (4- (4- (4- (4-) Maleimide phenoxy) Phenyl) Propane (Product name: BMI-80, manufactured by KI Kasei Co., Ltd.) 50.0 parts by mass was blended (mixed) to obtain the product.
- the first resin layer 12 was formed on the surface of the copper foil 11 in the same manner as in Example 7 except that the ten-point average roughness Rz of the surface of the copper foil 11 was set to 10.5 ⁇ m.
- a second resin layer 13 was formed on the resin layer 12 of the above.
- the resistance value of the obtained insulation evaluation substrate was measured in a HAST test tank (130 ° C., 85% RH, 5.0 V) for 300 hours, and then the resistance value after being taken out of the HAST test tank was measured. did.
- a HAST test tank 130 ° C., 85% RH, 5.0 V
- the resistance value after being taken out of the HAST test tank was measured. did.
- the resistance value after being taken out of the HAST test tank is 1 ⁇ 10 8 ⁇ or more, it is evaluated as ⁇ as good, and in other cases, it is evaluated as ⁇ . did.
- the copper foil 10 with a resin layer obtained in each example and each comparative example was etched with the copper foil 10 and then electroless plated and electrolytic copper plated to obtain a test piece having a plating layer having a thickness of 20 ⁇ m. rice field.
- the peel strength was measured using this test piece.
- the lower layer of the test piece was fixed to a plate or the like, the end of the plating layer was pulled perpendicular to the direction of the fixed plate, and the load value required for peeling was set as the adhesion strength at the interface between the upper layer and the lower layer. When this peel strength is 0.5 kN / m or more, it is judged to be good.
- the obtained copper-clad laminate was cut into a size of 50 mm ⁇ 50 mm to obtain a test piece for measurement.
- the obtained test piece for measurement was left in a constant temperature bath at 120 ° C. for 3 hours as a pretreatment, and then immersed in a solder bath at 260 ° C. for 30 seconds to evaluate heat resistance. After 30 seconds have elapsed, (1) the layer between the copper foil on the surface of the copper foil-clad laminate and the layer containing the cured product of the first resin layer 12 and the second resin layer 13, and (2) the first.
- a layer containing a cured product of the resin layer 12 and the second resin layer 13, and a cured product of a resin composition in a copper foil-clad laminate (HL832NS (trade name) T / T 0.2 mmt, manufactured by Mitsubishi Gas Chemicals Co., Ltd.). It was confirmed whether or not each delamination occurred between the layers containing the above. For (1) and (2), the case where delamination did not occur was evaluated as ⁇ , and the case where delamination occurred in at least one of them was evaluated as x.
- Tables 1 and 2 show the conditions and evaluation results of each example and each comparative example.
- the first resin layer 12 contains the polyphenylene ether compound (A), the polyimide resin (B), and the maleimide compound (C), and the ten-point average roughness Rz of the surface of the copper foil 11 is 0.3 ⁇ m or more. It was found that when the thickness is 10 ⁇ m or less, excellent insulating property, plating adhesion, and moisture absorption heat resistance can be obtained.
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Abstract
Description
[1]
銅箔と、前記銅箔の表面に積層された第1の樹脂層とを有する樹脂層付き銅箔であって、
前記第1の樹脂層は、ポリフェニレンエーテル化合物(A)、ポリイミド樹脂(B)、及び、マレイミド化合物(C)を含み、
前記銅箔の表面の十点平均粗さRzは0.3μm以上10μm以下である
ことを特徴とする樹脂層付き銅箔。
[2]
前記第1の樹脂層の上に、熱硬化性樹脂を含む第2の樹脂層が設けられた、[1]に記載の樹脂層付き銅箔。
[3]
前記第1の樹脂層におけるポリフェニレンエーテル化合物(A)の割合は、樹脂固形分100質量部に対して3質量部以上20質量部未満である、[1]に記載の樹脂層付き銅箔。
[4]
前記第1の樹脂層は、無機充填材を含まないか、又は、35体積%以下の含有量で無機充填材を含む、[1]に記載の樹脂層付き銅箔。
[5]
前記無機充填材は水酸化マグネシウム、酸化マグネシウム、シリカ、モリブデン化合物、アルミナ、窒化アルミニウム、ガラス、タルク、チタン化合物、酸化ジルコニウムから選択される少なくとも1種を含有する、[4]に記載の樹脂層付き銅箔。
[6]
前記第1の樹脂層の厚みは1.5μm以上5μm以下である、[1]に記載の樹脂層付き銅箔。
[7]
前記第2の樹脂層は、エポキシ化合物、シアン酸エステル化合物、マレイミド化合物、フェノール化合物、ポリフェニレンエーテル化合物、ベンゾオキサジン化合物、有機基変性シリコーン化合物、及び、重合可能な不飽和基を有する化合物からなる群より選択される少なくとも1種を含有する、[2]に記載の樹脂層付き銅箔。
[8]
前記第2の樹脂層は、無機充填材を含まないか、又は、36体積%以下の含有量で無機充填材を含む、[2]に記載の樹脂層付き銅箔。
[9]
前記無機充填材は水酸化マグネシウム、酸化マグネシウム、シリカ、モリブデン化合物、アルミナ、窒化アルミニウム、ガラス、タルク、チタン化合物、酸化ジルコニウムから選択される少なくとも1種を含有する、[8]に記載の樹脂層付き銅箔。
[10]
前記第2の樹脂層の厚みは1μm以上15μm以下である、[2]に記載の樹脂層付き銅箔。
[11]
導体層と、[1]に記載の樹脂層付き銅箔を用いて形成されたビルドアップ層を有する積層体。
図1は、本発明の一実施の形態に係る樹脂層付き銅箔10の構成を表すものである。この樹脂層付き銅箔10は、銅箔11と、銅箔11の表面に積層された第1の樹脂層12とを備えており、更に、第1の樹脂層12の上に第2の樹脂層13が設けられていることが好ましい。
銅箔11は、通常のプリント配線板に用いられるものであればどのようなものでもよく、例えば、電解銅箔、圧延銅箔及び銅合金フィルムが挙げられる。銅箔11には、例えば、マット処理、コロナ処理、ニッケル処理及びコバルト処理等の公知の表面処理が施されていてもよい。本実施形態における銅箔11としては、市販品を用いることができ、例えば、JX金属(株)製の「GHY5」(商品名、12μm厚銅箔)及び「JXUT-I」(商品名、1.5μm厚銅箔)、三井金属鉱業(株)製の「MT-FL」(商品名、3μm厚銅箔)、「3EC-VLP」(商品名、12μm厚銅箔)、「3EC-III」(商品名、12μm厚銅箔)及び「3EC-M2S-VLP」(商品名、12μm厚銅箔)、並びに、古河電気工業(株)製の銅箔「GTS-MP」(商品名、12μm厚銅箔)を挙げることができる。
第1の樹脂層12は、ポリフェニレンエーテル化合物(A)、ポリイミド樹脂(B)、及び、マレイミド化合物(C)を含んでいる。また、第1の樹脂層12は、必要に応じて、他の樹脂成分、無機充填材、及び、他の成分の少なくとも1種を含んでいてもよい。第1の樹脂層12の厚みは、特に限定されるものではないが、薄膜化の観点から5μm以下であることが好ましく、絶縁性の確保も考慮すると1.5μm以上であることが好ましい。第1の樹脂層12の厚みは、例えば、樹脂層付き銅箔10を樹脂で固めて測定用試料を作製し、垂直断面がでるように切断して研磨を行い、垂直断面を顕微鏡で観察して厚さを求めることができる。例えば、測長方法は第1の樹脂層12の銅箔11と反対側の表面から垂直方向に銅箔11との界面までの距離とし、第1の樹脂層12と銅箔11との凹凸界面の平均位置から第1の樹脂層12の銅箔11と反対側の表面までの距離を第1の樹脂層12の厚みとする。第1の樹脂層12は、半硬化状態(B-Stage)であってもよいし、完全硬化状態(C-Stage)であってもよい。第1の樹脂層12は、例えば、塗布等の公知の手段により形成することができる。
本実施形態に係るポリフェニレンエーテル化合物(A)は、一般式(1)で表される化合物である。ポリフェニレンエーテル化合物(A)を含有することにより、絶縁性、めっき密着性、及び、吸湿耐熱性を向上させることができる。本実施形態に用いられる一般式(1)で表されるポリフェニレンエーテル化合物(A)は、数平均分子量が1000以上7000以下であることが好ましい。数平均分子量を7000以下とすることで樹脂同士の相溶性をコントロールできる。また数平均分子量を1000以上とすることで、ポリフェニレンエーテル樹脂本来の優れた絶縁性及び吸湿耐熱性が得られる。その中でも、より優れた相溶性、絶縁性、及び、吸湿耐熱性を得るためには、ポリフェニレンエーテル化合物(A)の数平均分子量が1100以上5000以下であるとよい。より好ましくは、ポリフェニレンエーテル化合物(A)の数平均分子量が4500以下であるとよく、さらに好ましくは、ポリフェニレンエーテル化合物(A)の数平均分子量が3000以下である。数平均分子量は、定法に従ってゲル浸透クロマトグラフィーを使用して測定される。
一般式(1)との関係でいうと、上記一般式(2)、(3)、(4)は一般式(1)の-(Y-O)-であることが好ましい。-(Y-O)-はn2の数(1~100)の繰り返し単位を有する。
-(Y-O)n2-及びn2は、一般式(1)におけるものと同義である。n2の異なる化合物を複数種含んでいてもよい。
また、このような変性ポリフェニレンエーテルは市販品を用いることができ、例えば、三菱ガス化学(株)製OPE-2St1200、OPE-2St2200を好適に使用することができる。
ポリイミド樹脂(B)としては、市販の製品を適宜選定して用いることができ、例えば、特開2005-15629号公報に記載の製造方法によって合成される溶媒可溶性ポリイミド樹脂を用いることができる。具体的には、溶媒可溶性ポリイミド樹脂は、下記式(11)で表される脂肪族テトラカルボン酸二無水物、下記式(12)で表される脂肪族テトラカルボン酸、及び当該脂肪族テトラカルボン酸の誘導体から選ばれる1種以上と、ジアミン化合物の1種以上とを、3級アミン化合物存在下に溶媒中にて重縮合させることで得ることができる。
また、式(11)で表される脂肪族テトラカルボン酸二無水物としては、例えば、1,2,3,4-シクロブタンテトラカルボン酸二無水物、1,2,4,5-シクロペンタンテトラカルボン酸二無水物、1,2,4,5-シクロヘキサンテトラカルボン酸二無水物、ビシクロ[2.2.2]オクト-7-エン-2,3,5,6-テトラカルボン酸二無水物などを挙げることができる。
さらに、式(12)で表される脂肪族テトラカルボン酸、及びその誘導体としては、例えば、1,2,3,4-シクロブタンテトラカルボン酸、1,2,4,5-シクロペンタンテトラカルボン酸、1,2,4,5-シクロヘキサンテトラカルボン酸、ビシクロ[2.2.2]オクト-7-エン-2,3,5,6-テトラカルボン酸など、及びそれらのアルコールエステル類を挙げることができる。これらは1種類単独かあるいは2種類以上を混合して使用することができる。これらのうち、好ましいのは1,2,4,5-シクロヘキサンテトラカルボン酸二無水物、1,2,4,5-シクロヘキサンテトラカルボン酸が挙げられる。
前記製造方法における溶媒の使用量は、脂肪族テトラカルボン酸成分及びジアミン成分の総重量が反応液全体の質量に対して1~50質量%が好ましく、20~45重量%がさらに好ましい。
第1の樹脂層12は、ポリイミド樹脂(B)を、1種のみ含んでいてもよいし、2種以上含んでいてもよい。2種以上含む場合、合計量が上記範囲となることが好ましい。
マレイミド化合物(C)を含有することにより、層間密着性、絶縁性、めっき密着性、及び、吸湿耐熱性を向上させることができる。マレイミド化合物(C)としては、1分子中に1以上(好ましくは2~12、より好ましくは2~6、さらに好ましくは2~4、一層好ましくは2または3、より一層好ましくは2)のマレイミド基を有する化合物であれば特に限定されず、従来公知の任意のマレイミド化合物が使用できる。
第1の樹脂層12は、マレイミド化合物(C)を、1種のみ含んでいてもよいし、2種以上含んでいてもよい。2種以上含む場合、合計量が上記範囲となることが好ましい。
その他の樹脂成分としては、例えば、液晶ポリエステル、エポキシ化合物、シアン酸エステル化合物、フェノール化合物、ベンゾオキサジン化合物、有機基変性シリコーン化合物、及び、重合可能な不飽和基を有する化合物が挙げられる。第1の樹脂層12は、これらの1種又は2種以上を含んでいてもよい。
液晶ポリエステルは、溶融時に液晶性を示す芳香族ポリエステルである。液晶ポリエステルとしては公知のものを適宜選定して用いることができる。公知の液晶ポリエステルとしては、例えば、特開2001-11296号公報に記載の芳香族ポリエステルなどを用いることができる。具体的には、下記式(13)で表される構造単位を90モル%以上含む芳香族ポリエステルなどが挙げられる。
エポキシ化合物としては、1分子中に1以上(好ましくは2~12、より好ましくは2~6、さらに好ましくは2~4、一層好ましくは2または3、より一層好ましくは2)のエポキシ基を有する化合物であれば特に限定されず、従来公知の任意のエポキシ化合物が使用できる。エポキシ化合物のエポキシ当量は、接着性及び可撓性をより良好にする点から、250g/eq~850g/eqが好ましく、より好ましくは250g/eq~450g/eqである。エポキシ当量は、常法により測定することができる。
シアン酸エステル化合物は、耐薬品性、接着性等に優れた特性を有し、その優れた耐薬品性により、均一な粗化面を形成することが可能であるため、本実施形態における樹脂層の成分として好適に使用することができる。
フェノール化合物としては、1分子中に1以上(好ましくは2~12、より好ましくは2~6、さらに好ましくは2~4、一層好ましくは2または3、より一層好ましくは2)のフェノール性ヒドロキシ基を有するフェノール化合物であれば特に限定されず、従来公知の任意のフェノール化合物が使用できる。フェノール化合物の具体例としては、例えば、ビスフェノールA型フェノール樹脂、ビスフェノールE型フェノール樹脂、ビスフェノールF型フェノール樹脂、ビスフェノールS型フェノール樹脂、フェノールノボラック樹脂、ビスフェノールAノボラック型フェノール樹脂、グリシジルエステル型フェノール樹脂、アラルキルノボラックフェノール樹脂、ビフェニルアラルキル型フェノール樹脂、クレゾールノボラック型フェノール樹脂、多官能フェノール樹脂、ナフトール樹脂、ナフトールノボラック樹脂、多官能ナフトール樹脂、アントラセン型フェノール樹脂、ナフタレン骨格変性ノボラック型フェノール樹脂、フェノールアラルキル型フェノール樹脂、ナフトールアラルキル型フェノール樹脂、ジシクロペンタジエン型フェノール樹脂、ビフェニル型フェノール樹脂、脂環式フェノール樹脂、ポリオール型フェノール樹脂、リン含有フェノール樹脂、水酸基含有シリコーン樹脂類等が挙げられる。これらのフェノール化合物は、1種又は2種以上を適宜混合して使用することができる。
ベンゾオキサジン化合物としては、1分子中に2個以上のジヒドロベンゾオキサジン環を有する化合物であれば、特に限定されず、一般に公知のものを用いることができる。ベンゾオキサジン化合物の具体例としては、例えば、ビスフェノールA型ベンゾオキサジンBA-BXZ(小西化学製商品名)ビスフェノールF型ベンゾオキサジンBF-BXZ(小西化学製商品名)、ビスフェノールS型ベンゾオキサジンBS-BXZ(小西化学製商品名)等が挙げられる。これらのベンゾオキサジン化合物は、1種を単独で又は2種以上混合して用いることができる。
有機基変性シリコーン化合物としては、特に限定されず、具体例としては、ジ(メチルアミノ)ポリジメチルシロキサン、ジ(エチルアミノ)ポリジメチルシロキサン、ジ(プロピルアミノ)ポリジメチルシロキサン、ジ(エポキシプロピル)ポリジメチルシロキサン、ジ(エポキシブチル)ポリジメチルシロキサンが挙げられる。これらの有機基変性シリコーン化合物は、1種又は2種以上を適宜混合して使用することができる。
重合可能な不飽和基を有する化合物としては、特に限定されず、一般に公知のものを使用できる。重合可能な不飽和基を有する化合物の具体例としては、例えば、エチレン、プロピレン、スチレン、ジビニルベンゼン、ジビニルビフェニル等のビニル化合物;メチル(メタ)アクリレート、2-ヒドロキシエチル(メタ)アクリレート、2-ヒドロキシプロピル(メタ)アクリレート、ポリプロピレングリコールジ(メタ)アクリレート、トリメチロールプロパンジ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、ペンタエリスリトールテトラ(メタ)アクリレート、ジペンタエリスリトールヘキサ(メタ)アクリレート等の1価又は多価アルコールの(メタ)アクリレート類;ビスフェノールA型エポキシ(メタ)アクリレート、ビスフェノールF型エポキシ(メタ)アクリレート等のエポキシ(メタ)アクリレート類;ベンゾシクロブテン樹脂等が挙げられる。これらの重合可能な不飽和基を有する化合物は、1種又は2種以上を適宜混合して使用することができる。
第1の樹脂層12は、無機充填材を含んでいなくてもよいが、含んでいてもよい。含む場合には、その含有量は35体積%以下であることが好ましく、31体積%以下であればより好ましい。無機充填材を添加すると加工性は向上するが、含有量が多くなりすぎると柔軟性が低下しクラックの発生や絶縁性の低下が生じてしまうからである。なお、無機充填材の含有量というのは、第1の樹脂層12に対する無機充填材の含有量(無機充填材/第1の樹脂層×100)である。
その他の成分としては、例えば、吸湿耐熱性向上の目的で、シランカップリング剤を含有してもよい。シランカップリング剤としては、一般に無機物の表面処理に使用されるシランカップリング剤であれば、特に限定されない。具体例としては、アミノシラン系シランカップリング剤(例えば、γ-アミノプロピルトリエトキシシラン、N-β-(アミノエチル)-γ-アミノプロピルトリメトキシシラン)、エポキシシラン系シランカップリング剤(例えば、γ-グリシドキシプロピルトリメトキシシラン)、アクリルシラン系シランカップリング剤(たとえは、γ-アクリロキシプロピルトリメトキシシラン、ビニルシラン系シランカップリング剤(例えば、γ-メタアクリロキシプロピルトリメトキシシラン)、カチオン性シラン系シランカップリング剤(例えば、N-β-(N-ビニルベンジルアミノエチル)-γ-アミノプロピルトリメトキシシラン塩酸塩)、フェニルシラン系シランカップリング剤等が挙げられる。これらのシランカップリング剤は、1種又は2種以上を適宜混合して使用することができる。
第2の樹脂層13は、熱硬化性樹脂を含んでいる。熱硬化性樹脂は特に限定されるものではないが、例えば、エポキシ化合物、シアン酸エステル化合物、マレイミド化合物、フェノール化合物、ポリフェニレンエーテル化合物、ベンゾオキサジン化合物、有機基変性シリコーン化合物、及び、重合可能な不飽和基を有する化合物が挙げられる。これら化合物としては第1の樹脂層12で例示したものと同様のものを用いることができる。熱硬化性樹脂は、これらの1種又は2種以上を適宜混合して使用することができる。中でも、エポキシ化合物及びフェノール化合物を含むようにすれば、優れたピール強度を得ることができるので好ましく、エポキシ化合物及びフェノール化合物と共に、マレイミド化合物を更に含むことがより好ましい。
本実施形態の樹脂層付き銅箔10を製造する方法は、特に限定されない。製造方法としては、例えば、まず、第1の樹脂層12の組成物を有機溶剤に溶解又は分散させた溶液(ワニス)を、銅箔11の表面に塗布し、加熱及び/又は減圧下で乾燥し、溶媒を除去して固化させ、第1の樹脂層12を形成する。上述のように、第1の樹脂層12は半硬化状態のみならず完全に硬化した状態であってもよい。その後、第1の樹脂層12の上に、第2の樹脂層13の組成物を有機溶剤に溶解又は分散させた溶液(ワニス)を塗布し、加熱及び/又は減圧下で乾燥し、溶媒を除去して固化させ、第2の樹脂層13を形成することが好ましい。この際、第2の樹脂層13はB-stage(半硬化状態)とすることが好ましい。また、第2の樹脂層13の上には、プラスチックフィルムなどの保護層を設けてもよい。当該保護層は、後述の積層体作製時に適宜除去される。
本実施形態の樹脂層付き銅箔10を用いた積層体(以下、単に「本実施形態の積層体」と称することがある。)は、例えば、プリント配線板又は半導体素子搭載用基板のビルドアップ材料用途、コアレス基板の作製用途に用いることができる。
本実施形態の積層体は、例えば、導体層と、樹脂層付き銅箔10を用いて形成された絶縁層と、を交互に積層されたビルドアップ層を有する積層体として構成することができる。ここで、「樹脂層付き銅箔10を用いて形成された絶縁層」とは、例えば、導体層が形成された基板上に、樹脂層付き銅箔10の第2の樹脂層13が接するように積層して構成することができる。また、絶縁層を3つ以上の樹脂層付き銅箔10を用いて形成する場合には、必要に応じて銅箔11を除去し、第1の樹脂層12及び第2の樹脂層13を積層して、絶縁層を形成することができる。また、前記導体層は、樹脂層付き銅箔10の銅箔11がその役割を担ってもよいし、銅張積層板の銅箔など他の導体(銅箔等)を別に積層して導体層を形成してもよい。図2は本実施形態の積層体20の一例を示すものである。この積層体20は、導体層21が形成された基板22の上に、1つの樹脂層付き銅箔10を第2の樹脂層13が接するように積層したものであり、第1の樹脂層12と第2の樹脂層13により絶縁層23が形成されている。
また、本実施形態の積層体を用いて、コアレス基板を作製することができる。前記コアレス基板としては、例えば、2層以上のコアレス基板が挙げられ、例えば、3層コアレス基板が挙げられる。コアレス基板の構成については後述する。
本実施形態の積層体はプリント配線板として用いることができる。ここで、プリント配線板は、コア基材と呼ばれる絶縁性樹脂層が完全硬化した金属箔張積層板に対し、ビルドアップ材料として本実施形態の樹脂層付き銅箔10を用いた積層体を用いることにより得ることができる。本実施形態の樹脂層付き銅箔10(積層体)を用いると、例えば、厚い支持基板(キャリア基板)を用いずに薄型のプリント配線板を製造することが可能である。
上述のように、本実施形態の積層体は半導体素子搭載用基板として用いることができる。半導体素子搭載用基板は、例えば、金属箔張積層板に樹脂層付き銅箔10を積層させ、得られた積層体の表面又は片面における銅箔をマスキング及びパターニングすることで作製される。マスキング及びパターニングは、プリント配線板の製造において行われる公知のマスキング及びパターニングを用いることができ、特に限定されないが、前述のサブトラクティブ法によって、回路パターンを形成することが好ましい。回路パターンは、積層体の片面にだけ形成されてもよく、両面に形成されてもよい。
本実施形態の積層体は、上述のようにコアレス基板とすることができる。前記コアレス基板の一例として、多層コアレス基板が挙げられる。
多層コアレス基板は、例えば、第1の絶縁層と、第1の絶縁層の片面側に積層された1つ又は複数の第2の絶縁層とからなる複数の絶縁層と、複数の絶縁層の各々の間に配置された第1の導体層と、複数の絶縁層の最外層の表面に配置された第2の導体層とからなる複数の導体層とを有し、第1の絶縁層及び前記第2の絶縁層が、それぞれ、樹脂層付き銅箔10の第1の樹脂層12及び第2の樹脂層13の硬化物を有するように構成することができる。多層コアレス基板の具体例について図3を用いて説明する。図3は、本実施形態における多層コアレス基板の一例を示す模式図である。図3に示す多層コアレス基板100は、第1の絶縁層111と、第1の絶縁層111の片面方向(図示上面方向)に積層された2つの第2の絶縁層112を含み、第1の絶縁層111及び2つの第2の絶縁層112は、それぞれ1つの樹脂層付き銅箔10の第1の樹脂層12及び第2の樹脂層13を用いて形成されている。また、図3に示す多層コアレス基板100は、複数の絶縁層(第1の絶縁層111及び第2の絶縁層112)の各々の間に配置された第1の導体層113、及び、それらの複数の絶縁層(第1の絶縁層111及び第2の絶縁層112)の最外層に配置された第2の導体層114からなる複数の導体層を有する。
末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)15.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)49.9質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)34.9質量部、2,4,5-トリフェニルイミダゾール(東京化成工業(株)製)0.2質量部を配合(混合)して第1の樹脂層12の組成物を得た。次いで、第1の樹脂層12の組成物をN-メチル-2-ピロリドン(以下、“NMP”と称する)で希釈してワニスAを得た。得られたワニスAを、バーコーターによって12μm厚の銅箔11(製品名:3EC-M2S-VLP、三井金属鉱業(株)製)の表面マット面側に塗布した。その際、銅箔11のマット面側を表面とし、表面の十点平均粗さRzは実施例1~5が1.7μm、実施例6が0.3μm、実施例7が4.5μmとした。その後、塗布膜を180℃で10分間加熱乾燥することにより、銅箔11の上に第1の樹脂層12を形成した。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)18.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)49.9質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)31.9質量部、2,4,5-トリフェニルイミダゾール(東京化成工業(株)製)0.2質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)10.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)51.9質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)37.9質量部、2,4,5-トリフェニルイミダゾール(東京化成工業(株)製)0.2質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)15.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)49.9質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)34.9質量部、2,4,5-トリフェニルイミダゾール(東京化成工業(株)製)0.2質量部、無機充填材としてシリカ(製品名:K180SQ-C1、平均粒径0.18μm、(株)アドマテックス製)79.8質量部を配合(混合)して得た。第1の樹脂層12における無機充填材の含有量(無機充填材/第1の樹脂層×100)は30.3体積%である。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)10.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)49.9質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)39.9質量部、2,4,5-トリフェニルイミダゾール(東京化成工業(株)製)0.2質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)7.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)49.9質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)42.9質量部、2,4,5-トリフェニルイミダゾール(東京化成工業(株)製)0.2質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)3.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)49.9質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)46.9質量部、2,4,5-トリフェニルイミダゾール(東京化成工業(株)製)0.2質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)50.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)50.0質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)30.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)70.0質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、末端スチレン化ポリフェニレンエーテル化合物(製品名:OPE-2St2200、三菱ガス化学(株)製)15.0質量部、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)50.0質量部、エポキシ化合物(製品名:LCE-2615、日本化薬(株)製)35.0質量部を配合(混合)して得た。
第1の樹脂層12の組成物を変えたことを除き、他は実施例2と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。第1の樹脂層12の組成物は、ポリイミド樹脂(製品名:ネオプリム(登録商標)S100、三菱ガス化学(株)製)50.0質量部、2,2-ビス-(4-(4-マレイミドフェノキシ)フェニル)プロパン(製品名:BMI-80、ケイ・アイ化成(株)製)50.0質量部を配合(混合)して得た。
銅箔11の表面の十点平均粗さRzを10.5μmとしたことを除き、他は実施例7と同様にして、銅箔11の表面に第1の樹脂層12を形成し、第1の樹脂層12の上に第2の樹脂層13を形成した。
各実施例及び各比較例の特性を以下の方法により測定した。
銅箔張積層板(HL832NS(商品名)T/T0.2mmt、三菱ガス化学(株)製)における両面の銅箔面を0.5μm~1μm程度エッチング(内層粗化処理、CZ8101(商品名)、メック(株)製)し、その両面に、各実施例及び各比較例の樹脂層付き銅箔10を第2の樹脂層13が内側になるように配置し、圧力30kgf/cm2、温度220℃で120分間の積層成形(熱硬化)を行い、銅箔張積層板を得た。次いで、得られた銅張積層板に、サブトラクティブ法により絶縁性評価向けの外層回路を作製し、絶縁性評価用基板を得た。
各実施例及び各比較例で得られた樹脂層付き銅箔10について、銅箔10をエッチング後、無電解めっき、及び、電解銅めっきを行い、厚み20μmのめっき層を形成した試験片を得た。この試験片を用いピール強度を測定した。ピール強度は、試験片の下層を板などに固定し、めっき層の端を固定板方向に対して垂直に引っ張り、剥離に必要な荷重値を上層と下層の界面の密着強度とした。このピール強度が0.5kN/m以上の場合に良好と判断する。
銅箔張積層板(HL832NS(商品名)T/T0.2mmt、三菱ガス化学(株)製)における両面の銅箔面を0.5μm~1μm程度エッチング(内層粗化処理、CZ8101(商品名)、メック(株)製)し、その両面に、各実施例及び各比較例の樹脂層付き銅箔10を第2の樹脂層13が内側になるように配置し、圧力30kgf/cm2、温度220℃で120分間の積層成形(熱硬化)を行い、銅箔張積層板を得た。次いで、得られた銅張積層板をサイズ50mm×50mmに切断し、測定用試験片を得た。得られた測定用試験片を、前処理として、120℃の恒温槽にて3時間放置した後、260℃の半田槽に30秒浸漬することで、耐熱性の評価を行った。30秒経過後に(1)銅箔張積層板の表面の銅箔と、第1の樹脂層12及び第2の樹脂層13の硬化物を含む層との層間、及び、(2)第1の樹脂層12及び第2の樹脂層13の硬化物を含む層と、銅箔張積層板(HL832NS(商品名)T/T0.2mmt、三菱ガス化学(株)製)における樹脂組成物の硬化物を含む層との層間の、それぞれのデラミネーションの発生の有無を確認した。(1)及び(2)について、共にデラミネーションが発生しなかった場合を〇とし、少なくとも一方にデラミネーションが発生した場合を×とした。
Claims (11)
- 銅箔と、前記銅箔の表面に積層された第1の樹脂層とを有する樹脂層付き銅箔であって、
前記第1の樹脂層は、ポリフェニレンエーテル化合物(A)、ポリイミド樹脂(B)、及び、マレイミド化合物(C)を含み、
前記銅箔の表面の十点平均粗さRzは0.3μm以上10μm以下である
ことを特徴とする樹脂層付き銅箔。 - 前記第1の樹脂層の上に、熱硬化性樹脂を含む第2の樹脂層が設けられた、請求項1に記載の樹脂層付き銅箔。
- 前記第1の樹脂層におけるポリフェニレンエーテル化合物(A)の割合は、樹脂固形分100質量部に対して3質量部以上20質量部未満である、請求項1に記載の樹脂層付き銅箔。
- 前記第1の樹脂層は、無機充填材を含まないか、又は、35体積%以下の含有量で無機充填材を含む、請求項1に記載の樹脂層付き銅箔。
- 前記無機充填材は水酸化マグネシウム、酸化マグネシウム、シリカ、モリブデン化合物、アルミナ、窒化アルミニウム、ガラス、タルク、チタン化合物、酸化ジルコニウムから選択される少なくとも1種を含有する、請求項4に記載の樹脂層付き銅箔。
- 前記第1の樹脂層の厚みは1.5μm以上5μm以下である、請求項1に記載の樹脂層付き銅箔。
- 前記第2の樹脂層は、エポキシ化合物、シアン酸エステル化合物、マレイミド化合物、フェノール化合物、ポリフェニレンエーテル化合物、ベンゾオキサジン化合物、有機基変性シリコーン化合物、及び、重合可能な不飽和基を有する化合物からなる群より選択される少なくとも1種を含有する、請求項2に記載の樹脂層付き銅箔。
- 前記第2の樹脂層は、無機充填材を含まないか、又は、36体積%以下の含有量で無機充填材を含む、請求項2に記載の樹脂層付き銅箔。
- 前記無機充填材は水酸化マグネシウム、酸化マグネシウム、シリカ、モリブデン化合物、アルミナ、窒化アルミニウム、ガラス、タルク、チタン化合物、酸化ジルコニウムから選択される少なくとも1種を含有する、請求項8に記載の樹脂層付き銅箔。
- 前記第2の樹脂層の厚みは1μm以上15μm以下である、請求項2に記載の樹脂層付き銅箔。
- 導体層と、請求項1に記載の樹脂層付き銅箔を用いて形成されたビルドアップ層を有する積層体。
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EP4282902A1 (en) | 2022-05-27 | 2023-11-29 | Mitsubishi Gas Chemical Company, Inc. | Resin composition, cured product, sealing material, adhesive, insulating material, coating material, prepreg, multilayered body, and fiber-reinforced composite material |
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WO2010073952A1 (ja) * | 2008-12-26 | 2010-07-01 | 三菱瓦斯化学株式会社 | 樹脂複合銅箔 |
JP2012081586A (ja) * | 2010-10-06 | 2012-04-26 | Sumitomo Bakelite Co Ltd | 樹脂シート、積層板、電子部品、プリント配線板及び半導体装置 |
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WO2010073952A1 (ja) * | 2008-12-26 | 2010-07-01 | 三菱瓦斯化学株式会社 | 樹脂複合銅箔 |
JP2012081586A (ja) * | 2010-10-06 | 2012-04-26 | Sumitomo Bakelite Co Ltd | 樹脂シート、積層板、電子部品、プリント配線板及び半導体装置 |
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WO2022211071A1 (ja) * | 2021-03-31 | 2022-10-06 | 太陽ホールディングス株式会社 | 硬化性樹脂積層体、ドライフィルム、硬化物及び電子部品 |
EP4282902A1 (en) | 2022-05-27 | 2023-11-29 | Mitsubishi Gas Chemical Company, Inc. | Resin composition, cured product, sealing material, adhesive, insulating material, coating material, prepreg, multilayered body, and fiber-reinforced composite material |
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