WO2022113962A1 - 液晶ポリマーフィルム、ポリマーフィルム、及び、積層体 - Google Patents
液晶ポリマーフィルム、ポリマーフィルム、及び、積層体 Download PDFInfo
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- WO2022113962A1 WO2022113962A1 PCT/JP2021/042878 JP2021042878W WO2022113962A1 WO 2022113962 A1 WO2022113962 A1 WO 2022113962A1 JP 2021042878 W JP2021042878 W JP 2021042878W WO 2022113962 A1 WO2022113962 A1 WO 2022113962A1
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- liquid crystal
- polymer film
- crystal polymer
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Classifications
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
- B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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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
- C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
- C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L27/12—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
-
- 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
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0313—Organic insulating material
- H05K1/0353—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/02—2 layers
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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
- B32B2255/00—Coating on the layer surface
- B32B2255/06—Coating on the layer surface on metal layer
- B32B2255/062—Coating on the layer surface on metal layer metal layer being a foamed layer
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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
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/55—Liquid crystals
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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
-
- 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
- B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
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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
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0137—Materials
- H05K2201/0141—Liquid crystal polymer [LCP]
Definitions
- the present disclosure relates to liquid crystal polymer films, polymer films, and laminates.
- Patent Document 1 contains a solvent, a soluble liquid crystal polymer dissolved in the solvent, and at least one organic polymer or an inorganic filler, and is an addition dispersed or dissolved in the solvent.
- a liquid crystal polymer composition comprising the same is described.
- Patent Document 2 describes a method for producing a liquid crystal polymer film in which a liquid crystal polymer film is sandwiched between heat-resistant laminated films, stretched near the melting point of the liquid crystal polymer, and then the laminated film is peeled off, and a liquid crystal polymer film.
- Patent Document 3 describes a liquid crystal polyester film obtained by applying a dispersion liquid of liquid crystal polyester fine particle powder, removing a solvent, and then fusing by heat treatment.
- JP-A-2019-52288 Japanese Patent Application Laid-Open No. 2003-340918 International Publication No. 2020/166644
- An object to be solved by one embodiment of the present invention is to provide a liquid crystal polymer film or a polymer film having a small dielectric loss tangent and excellent breaking strength. Further, an object to be solved by another embodiment of the present invention is to provide the liquid crystal polymer film or a laminate using the polymer film.
- the means for solving the above problems include the following aspects.
- ⁇ 1> A liquid crystal polymer film containing a liquid crystal polymer A and a compound having a melting point lower than that of the liquid crystal polymer A and having a dielectric loss tangent of less than 0.01.
- ⁇ 2> The liquid crystal polymer film according to ⁇ 1>, wherein the melting point of the liquid crystal polymer A is 280 ° C. or higher.
- ⁇ 3> The liquid crystal polymer film according to ⁇ 1> or ⁇ 2>, wherein the liquid crystal polymer A has a structural unit represented by any of the formulas (1) to (3).
- Ar 1 represents a phenylene group, a naphthylene group or a biphenylylene group
- Ar 2 and Ar 3 independently represent a phenylene group, a naphthylene group, a biphenylylene group or the following formula (4).
- Equation (4) -Ar 4 -Z-Ar 5- Ar 4 and Ar 5 independently represent a phenylene group or a naphthylene group, and Z represents an oxygen atom, a sulfur atom, a carbonyl group, a sulfonyl group or an alkylene group.
- Z represents an oxygen atom, a sulfur atom, a carbonyl group, a sulfonyl group or an alkylene group.
- the content of the compound having a dielectric loss tangent of less than 0.01 is 10% by mass to 90% by mass with respect to the total mass of the liquid crystal polymer film.
- ⁇ 9> The liquid crystal polymer film according to any one of ⁇ 1> to ⁇ 8>, wherein the dielectric loss tangent of the liquid crystal polymer film is 0.001 or less.
- ⁇ 10> The liquid crystal polymer film according to any one of ⁇ 1> to ⁇ 9>, wherein the coefficient of linear expansion of the liquid crystal polymer film is ⁇ 20 ppm / K to 50 ppm / K.
- ⁇ 11> At least one polymer selected from the group consisting of a fluoropolymer, a polymer of a compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond, a polyphenylene ether, and an aromatic polyether ketone.
- the liquid crystal polymer film according to any one of ⁇ 1> to ⁇ 10> or the polymer film according to ⁇ 11> is arranged on at least one surface of the liquid crystal polymer film or the polymer film.
- a laminate having a metal layer At least one polymer selected from the group consisting of a fluoropolymer, a polymer of a compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond, a polyphenylene ether, and an aromatic
- ⁇ 13> The laminate according to ⁇ 12>, which has a metal layer arranged on both sides of the liquid crystal polymer film or the polymer film.
- ⁇ 14> The laminate according to ⁇ 12> or ⁇ 13>, wherein the metal layer is a copper layer, and the peel strength between the liquid crystal polymer film or the polymer film and the copper layer is 0.5 kN / m or more. body.
- liquid crystal polymer film or a polymer film having a small dielectric loss tangent and excellent breaking strength it is possible to provide a liquid crystal polymer film or a polymer film having a small dielectric loss tangent and excellent breaking strength. Further, according to another embodiment of the present invention, the liquid crystal polymer film or a laminate using the polymer film can be provided.
- the notation that does not describe substitution or non-substitution includes those having no substituent as well as those having a substituent.
- the "alkyl group” includes not only an alkyl group having no substituent (unsubstituted alkyl group) but also an alkyl group having a substituent (substituted alkyl group).
- (meth) acrylic is a term used in a concept that includes both acrylic and methacrylic
- (meth) acryloyl is a term that is used as a concept that includes both acryloyl and methacrylic. Is.
- the term "process” in the present specification is not limited to an independent process, and even if it cannot be clearly distinguished from other processes, the term “process” will be used as long as the intended purpose of the process is achieved. included.
- “% by mass” and “% by weight” are synonymous, and “parts by mass” and “parts by weight” are synonymous.
- a combination of two or more preferred embodiments is a more preferred embodiment.
- the first embodiment of the polymer film according to the present disclosure is a polymer film containing a liquid crystal polymer A and a compound having a melting point lower than that of the liquid crystal polymer A and having a dielectric loss tangent of less than 0.01.
- the second embodiment of the polymer film according to the present disclosure comprises a fluoropolymer, a polymer of a compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond, a polyphenylene ether, and an aromatic polyether ketone.
- the polymer film containing the liquid crystal polymer A is also referred to as a liquid crystal polymer film.
- polymer film according to the present disclosure refers to both the first embodiment and the second embodiment. Further, in the present specification, unless otherwise specified, the term “liquid crystal polymer film according to the present disclosure” shall be used to describe the first embodiment.
- the present inventor has found that many conventional polymer films do not have sufficient dielectric loss tangent, and that among conventional polymer films having small dielectric loss tangent, the breaking strength is not sufficient. As a result of diligent studies by the present inventor, it has been found that a polymer film having a small dielectric loss tangent and excellent breaking strength can be provided by adopting the above configuration. The detailed mechanism by which the above effect is obtained is unknown, but it is presumed as follows.
- the dielectric positive contact of the polymer film can be reduced, and the liquid crystal polymer A, a fluoropolymer, or a group having an ethylenically unsaturated bond with a cyclic aliphatic hydrocarbon group.
- the liquid crystal polymer A having a melting point of the above liquid crystal polymer A or at least one polymer selected from the group consisting of a polymer of a compound having a Lower than at least one polymer selected from the group consisting of fluoropolymers, polymers of compounds having cyclic aliphatic hydrocarbon groups and groups having ethylenically unsaturated bonds, polyphenylene ethers and aromatic polyether ketones, and It is presumed that the breaking strength is excellent by fusing the polymers having a dielectric positive contact of less than 0.01.
- the first embodiment of the polymer film according to the present disclosure comprises a liquid crystal polymer A.
- the type of the liquid crystal polymer A is not particularly limited, and known liquid crystal polymers can be used.
- the liquid crystal polymer A may be a thermotropic liquid crystal polymer that exhibits liquid crystallinity in a molten state, or may be a lyotropic liquid crystal polymer that exhibits liquid crystallinity in a solution state.
- the liquid crystal polymer A is a thermotropic liquid crystal polymer, it is preferably a liquid crystal polymer that melts at a temperature of 450 ° C. or lower.
- the melting point of the liquid crystal polymer A is the peak temperature, and is preferably 280 ° C. or higher, more preferably 300 ° C. or higher, and further preferably 315 ° C. or higher, from the viewpoint of ensuring the mechanical strength of the web during the manufacturing process. It is preferably 330 ° C to 400 ° C, and particularly preferably.
- the melting point shall be measured using a differential scanning calorimetry (DSC) device.
- DSC differential scanning calorimetry
- the peak temperature of the endothermic peak that appears when 5 mg of the sample is placed in the measuring pan of the DSC and the temperature is raised from 30 ° C. at 10 ° C./min in a nitrogen stream is defined as the melting point (Tm) of the liquid crystal polymer A.
- Tm melting point
- the metal layer can be etched with an aqueous solution of ferric chloride, and the removed polymer film can be washed with water and dried for measurement.
- liquid crystal polymer A examples include liquid crystal polyester, liquid crystal polyester amide having an amide bond introduced into the liquid crystal polyester, liquid crystal polyester ether having an ether bond introduced into the liquid crystal polyester, and liquid crystal polyester carbonate having a carbonate bond introduced into the liquid crystal polyester.
- the liquid crystal polymer A is preferably a polymer having an aromatic ring, and more preferably an aromatic polyester or an aromatic polyester amide, from the viewpoint of liquid crystal property and thermal expansion coefficient.
- the liquid crystal polymer A may be a polymer in which an imide bond, a carbodiimide bond, an isocyanate-derived bond such as an isocyanurate bond, or the like is further introduced into an aromatic polyester or an aromatic polyester amide.
- the liquid crystal polymer A is preferably a total aromatic liquid crystal polymer using only an aromatic compound as a raw material monomer.
- liquid crystal polymer A examples include the following liquid crystal polymers. 1) (i) Aromatic hydroxycarboxylic acid, (ii) Aromatic dicarboxylic acid, and (iii) At least one compound selected from the group consisting of aromatic diols, aromatic hydroxyamines and aromatic diamines. It is made by polycondensing. 2) Polycondensation of multiple types of aromatic hydroxycarboxylic acids. 3) A compound obtained by polycondensing (i) an aromatic dicarboxylic acid and (ii) at least one compound selected from the group consisting of aromatic diols, aromatic hydroxyamines and aromatic diamines.
- Polyester such as polyethylene terephthalate
- aromatic hydroxycarboxylic acid are polycondensed.
- the aromatic hydroxycarboxylic acid, the aromatic dicarboxylic acid, the aromatic diol, the aromatic hydroxyamine and the aromatic diamine may be independently replaced with a polycondensable derivative.
- the aromatic hydroxycarboxylic acid and the aromatic dicarboxylic acid can be replaced with the aromatic hydroxycarboxylic acid ester and the aromatic dicarboxylic acid ester by converting the carboxy group into an alkoxycarbonyl group or an aryloxycarbonyl group.
- the aromatic hydroxycarboxylic acid and the aromatic dicarboxylic acid can be replaced with the aromatic hydroxycarboxylic acid halide and the aromatic dicarboxylic acid halide.
- the aromatic hydroxycarboxylic acid and the aromatic dicarboxylic acid can be replaced with the aromatic hydroxycarboxylic acid anhydride and the aromatic dicarboxylic acid anhydride.
- polymerizable derivatives of compounds having a hydroxy group such as aromatic hydroxycarboxylic acids, aromatic diols and aromatic hydroxyamines, are those obtained by acylating a hydroxy group and converting it into an acyloxy group (acylated product). Can be mentioned.
- the aromatic hydroxycarboxylic acid, the aromatic diol, and the aromatic hydroxyamine can each be replaced with an acylated product.
- polymerizable derivatives of compounds having an amino group such as aromatic hydroxyamines and aromatic diamines, include those obtained by acylating an amino group and converting it into an acylamino group (acylated product).
- aromatic hydroxyamines and aromatic diamines can each be replaced with acylated products by acylating the amino group to convert it to an acylamino group.
- the liquid crystal polymer A is a structural unit represented by any of the following formulas (1) to (3) from the viewpoint of liquid crystal property, coefficient of thermal expansion, and adhesion to a metal layer (hereinafter, formula (1)).
- the structural unit represented by the above is preferably referred to as a structural unit (1) or the like, more preferably a structural unit represented by the following formula (1), and the following formula (1). It is particularly preferable to have a structural unit represented by the following formula (2), a structural unit represented by the following formula (2), and a structural unit represented by the following formula (3).
- Ar 1 represents a phenylene group, a naphthylene group or a biphenylylene group
- Ar 2 and Ar 3 independently represent a phenylene group, a naphthylene group, a biphenylylene group or the following formula (4).
- Ar 4 and Ar 5 independently represent a phenylene group or a naphthylene group, and Z represents an oxygen atom, a sulfur atom, a carbonyl group, a sulfonyl group or an alkylene group.
- halogen atom examples include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom.
- alkyl groups include methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, s-butyl group, t-butyl group, n-hexyl group and 2-ethylhexyl group. Examples thereof include an n-octyl group and an n-decyl group.
- the alkyl group preferably has 1 to 10 carbon atoms.
- aryl group examples include a phenyl group, an o-tolyl group, an m-tolyl group, a p-tolyl group, a 1-naphthyl group and a 2-naphthyl group.
- the aryl group preferably has 6 to 20 carbon atoms.
- the number of substitutions is independently, preferably 2 or less, and more preferably 1 in Ar 1 , Ar 2 or Ar 3 , respectively.
- alkylene group examples include a methylene group, a 1,1-ethanediyl group, a 1-methyl-1,1-ethanediyl group, a 1,1-butandyl group and a 2-ethyl-1,1-hexanediyl group.
- the alkylene group preferably has 1 to 10 carbon atoms.
- the structural unit (1) is a structural unit derived from an aromatic hydroxycarboxylic acid.
- Ar 1 is a p-phenylene group (a structural unit derived from p-hydroxyacousic acid) and an embodiment in which Ar 1 is a 2,6-naphthylene group (6-hydroxy-).
- a structural unit derived from 2-naphthoic acid) or an embodiment having a 4,4'-biphenylylene group (constituent unit derived from 4'-hydroxy-4-biphenylcarboxylic acid) is preferable.
- the structural unit (2) is a structural unit derived from an aromatic dicarboxylic acid.
- Ar 2 is a p-phenylene group (constituent unit derived from terephthalic acid)
- Ar 2 is an m-phenylene group (constituent unit derived from isophthalic acid)
- Ar 2 Is a 2,6-naphthylene group (a structural unit derived from 2,6-naphthalenedicarboxylic acid)
- Ar 2 is a diphenyl ether-4,4'-diyl group (diphenyl ether-4,4'-.
- a structural unit derived from a dicarboxylic acid) is preferable.
- the structural unit (3) is a structural unit derived from an aromatic diol, an aromatic hydroxylamine or an aromatic diamine.
- Ar 3 is a p-phenylene group (a structural unit derived from hydroquinone, p-aminophenol or p-phenylenediamine) and an embodiment in which Ar 3 is an m-phenylene group (isophthalic acid).
- the structural unit to be used) is preferable.
- the content of the structural unit (1) is determined by dividing the total amount of all the structural units (the mass of each structural unit (also referred to as “monomer unit”) constituting the liquid crystal polymer by the formula amount of each structural unit.
- the amount equivalent to the amount of the substance (mol) of the constituent unit is determined, and the total value thereof) is preferably 30 mol% or more, more preferably 30 mol% to 80 mol%, still more preferably 30 mol% to 60 mol. %, Especially preferably 30 mol% to 40 mol%.
- the content of the structural unit (2) is preferably 35 mol% or less, more preferably 10 mol% to 35 mol%, still more preferably 20 mol% to 35 mol%, particularly, with respect to the total amount of all the structural units.
- the content of the structural unit (3) is preferably 35 mol% or less, more preferably 10 mol% to 35 mol%, still more preferably 20 mol% to 35 mol%, particularly, with respect to the total amount of all the structural units. It is preferably 30 mol% to 35 mol%.
- the larger the content of the structural unit (1) the easier it is to improve the heat resistance, strength and rigidity, but if it is too large, the solubility in a solvent tends to be low.
- the ratio between the content of the constituent unit (2) and the content of the constituent unit (3) is expressed by [content of the constituent unit (2)] / [content of the constituent unit (3)] (mol / mol). It is preferably 0.9 / 1 to 1 / 0.9, more preferably 0.95 / 1 to 1 / 0.95, and further preferably 0.98 / 1 to 1 / 0.98.
- the liquid crystal polymer A may independently have two or more structural units (1) to (3). Further, the liquid crystal polymer A may have a structural unit other than the structural units (1) to (3), but the content thereof is preferably 10 mol% or less with respect to the total amount of all the structural units. More preferably, it is 5 mol% or less.
- the liquid crystal polymer A has a structural unit (3) in which at least one of X and Y is an imino group as the structural unit (3), that is, the aromatic unit (3) is aromatic. It is preferable to have at least one of the structural unit derived from the group hydroxylamine and the structural unit derived from the aromatic diamine, and it is more preferable to have only the structural unit (3) in which at least one of X and Y is an imino group.
- the liquid crystal polymer A is preferably produced by melt-polymerizing a raw material monomer corresponding to a constituent unit constituting the liquid crystal polymer A.
- the melt polymerization may be carried out in the presence of a catalyst.
- catalysts include metal compounds such as magnesium acetate, stannous acetate, tetrabutyl titanate, lead acetate, sodium acetate, potassium acetate and antimony trioxide, 4- (dimethylamino) pyridine and 1-methylimidazole.
- examples thereof include nitrogen heterocyclic compounds, and nitrogen-containing heterocyclic compounds are preferably mentioned.
- the melt polymerization may be further solid-phase polymerized, if necessary.
- the lower limit of the flow start temperature of the liquid crystal polymer A is preferably 180 ° C. or higher, more preferably 200 ° C. or higher, still more preferably 250 ° C. or higher, and the upper limit of the flow start temperature is preferably 350 ° C. or higher, 330 ° C. ° C is more preferred, and 300 ° C is even more preferred.
- the solubility, heat resistance, strength and rigidity are excellent, and the viscosity of the solution is appropriate.
- the flow start temperature also called the flow temperature or the flow temperature, melts the liquid crystal polymer using a capillary leometer while raising the temperature at a rate of 4 ° C./min under a load of 9.8 MPa (100 kg / cm 2 ). It is a temperature that shows a viscosity of 4,800 Pa ⁇ s (48,000 poise) when extruded from a nozzle with an inner diameter of 1 mm and a length of 10 mm, and is a guideline for the molecular weight of the liquid crystal polymer (edited by Naoyuki Koide). , "Liquid Polymer-Synthesis / Molding / Application-", CMC Co., Ltd., June 5, 1987, p.95).
- the weight average molecular weight of the liquid crystal polymer A is preferably 1,000,000 or less, more preferably 3,000 to 300,000, and even more preferably 5,000 to 100,000. , 5,000 to 30,000 are particularly preferable.
- the film after heat treatment is excellent in thermal conductivity, heat resistance, strength and rigidity in the thickness direction.
- the liquid crystal polymer A is preferably a liquid crystal polymer (hereinafter, also referred to as “soluble liquid crystal polymer”) that is soluble in a specific organic solvent.
- the soluble liquid crystal polymer in the present disclosure is N-methylpyrrolidone, N-ethylpyrrolidone, dichloromethane, dichloroethane, chloroform, N, N-dimethylacetamide, ⁇ -butyrolactone, dimethylformamide, ethylene glycol mono at 25 ° C.
- a liquid crystal polymer that dissolves 0.1 g or more in 100 g of at least one solvent selected from the group consisting of butyl ether and ethylene glycol monoethyl ether is preferable.
- the second embodiment of the polymer film according to the present disclosure preferably contains a fluorinated polymer from the viewpoint of heat resistance and mechanical strength.
- the type of the fluoropolymer is not particularly limited, and a known fluoropolymer can be used.
- the fluorinated polymer is a fluorinated ⁇ -olefin monomer, that is, an ⁇ -olefin monomer containing at least one fluorine atom, and, if necessary, a non-fluorinated ethylene that is reactive with the fluorinated ⁇ -olefin monomer.
- fluorinated ⁇ -olefin monomer that is, an ⁇ -olefin monomer containing at least one fluorine atom, and, if necessary, a non-fluorinated ethylene that is reactive with the fluorinated ⁇ -olefin monomer.
- Examples include homopolymers and copolymers containing building blocks derived from sex unsaturated monomers.
- Examples thereof include perfluoro (alkyl having 2 to 8 carbon atoms) vinyl ether (for example, perfluoromethyl vinyl ether, perfluoropropyl vinyl ether, perfluorooctyl vinyl ether) and the like.
- tetrafluoroethylene CF 2
- (perfluorobutyl) ethylene vinylidene fluoride
- CH 2 CF 2
- hexafluoropropylene CF 2 ).
- At least one monomer selected from the group consisting of CFCF 3 ) is preferred.
- the non-fluorinated monoethylenically unsaturated monomer include ethylene, propylene, butene, and an ethylenically unsaturated aromatic monomer (for example, styrene and ⁇ -methylstyrene).
- the fluorinated ⁇ -olefin monomer may be used alone or in combination of two or more.
- the non-fluorinated ethylenically unsaturated monomer may be used alone or in combination of two or more.
- fluoropolymer examples include polychlorotrifluoroethylene (PCTFE), poly (chlorotrifluoroethylene-propylene), poly (ethylene-tetrafluoroethylene) (ETFE), poly (ethylene-chlorotrifluoroethylene) (ECTFE), and the like.
- the fluoropolymer may be used alone or in combination of two
- the fluoropolymer is preferably at least one of FEP, PFA, ETFE, or PTFE.
- FEP is available under the trade name of Teflon (registered trademark) FEP (TEFLON (registered trademark) FEP) from DuPont, or the trade name of NEOFLON FEP from Daikin Industries, Ltd .
- PFA is the trade name of NEOFLON PFA from Daikin Industries, Ltd., the trade name of Teflon (registered trademark) PFA (TEFLON® PFA) from DuPont, or Solvay. It is available from Solexis) under the trade name of HYFLON PFA.
- the fluoropolymer preferably contains PTFE.
- the PTFE can include a PTFE homopolymer, a partially modified PTFE homopolymer, or a combination comprising one or both of these.
- Partially modified PTFE homopolymers preferably contain less than 1% by weight of building blocks derived from commonomers other than tetrafluoroethylene, based on the total weight of the polymer.
- the fluoropolymer may be a crosslinkable fluoropolymer having a crosslinkable group.
- the crosslinkable fluoropolymer can be crosslinked by a conventionally known crosslinking method.
- One of the typical crosslinkable fluoropolymers is a fluoropolymer having a (meth) acryloxy group.
- R is a fluorine-based oligomer chain having two or more structural units derived from an ⁇ -olefin monomer or a non-fluorinated monoethylenically unsaturated monomer, R'is H or -CH 3 , and n is 1 to 4.
- R may be a fluorine-based oligomer chain containing a structural unit derived from tetrafluoroethylene.
- Forming a crosslinked fluoropolymer network structure by exposing a fluoropolymer having a (meth) acryloxy group to a free radical source in order to initiate a radical crosslinking reaction via the (meth) acryloxy group on a fluoropolymer.
- the free radical source is not particularly limited, but a photoradical polymerization initiator or an organic peroxide is preferable. Suitable photoradical polymerization initiators and organic peroxides are well known in the art.
- Crosslinkable fluoropolymers are commercially available and include, for example, DuPont Byton B.
- the second embodiment of the polymer film according to the present disclosure preferably comprises a polymer of a compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond.
- polymers of compounds having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond include a structural unit formed of a monomer composed of a cyclic olefin such as norbornene or a polycyclic norbornene-based monomer. Examples thereof include thermoplastic resins having the above.
- the polymer of the compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond is the hydrogenation of the ring-opening polymer of the above cyclic olefin or the ring-opening copolymer using two or more kinds of cyclic olefins. It may be a product, or it may be an addition polymer of a cyclic olefin and an aromatic compound having an ethylenically unsaturated bond such as a chain olefin or a vinyl group.
- a polar group may be introduced into the polymer of the compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond.
- the polymer of the compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond may be used alone or in combination of two or more.
- the ring structure of the cyclic aliphatic hydrocarbon group may be a monocyclic ring, a condensed ring in which two or more rings are condensed, or a bridged ring.
- Examples of the ring structure of the cyclic aliphatic hydrocarbon group include a cyclopentane ring, a cyclohexane ring, a cyclooctane ring, an isovoron ring, a norbornane ring, and a dicyclopentane ring.
- the compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond may be a monofunctional ethylenically unsaturated compound or a polyfunctional ethylenically unsaturated compound.
- the number of cyclic aliphatic hydrocarbon groups in the compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond may be 1 or more, and may be 2 or more.
- a polymer of a compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond polymerizes a compound having at least one cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond.
- the polymer may be a polymer of a compound having two or more kinds of cyclic aliphatic hydrocarbon groups and a group having an ethylenically unsaturated bond, or may not have a cyclic aliphatic hydrocarbon group. It may be a copolymer with another ethylenically unsaturated compound.
- the polymer of the compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond is preferably a cycloolefin polymer.
- the second embodiment of the polymer film according to the present disclosure preferably contains polyphenylene ether.
- the weight average molecular weight (Mw) of the polyphenylene ether is preferably 500 to 5,000, preferably 500 to 3,000, from the viewpoint of heat resistance and film forming property when thermosetting after film formation. It is preferable to have. When it is not heat-cured, it is not particularly limited, but is preferably 3,000 to 100,000, and preferably 5,000 to 50,000.
- the average number of phenolic hydroxyl groups at the molecular terminal per molecule is preferably 1 to 5 from the viewpoint of dielectric loss tangent and heat resistance, and is preferably 1.5.
- the number is 3 to 3.
- the number of hydroxyl groups or phenolic hydroxyl groups of polyphenylene ether can be found, for example, from the standard values of polyphenylene ether products. Examples of the number of terminal hydroxyl groups or the number of terminal phenolic hydroxyl groups include numerical values representing the average value of hydroxyl groups or phenolic hydroxyl groups per molecule of all polyphenylene ethers present in 1 mol of polyphenylene ether.
- the polyphenylene ether may be used alone or in combination of two or more.
- polyphenylene ether examples include polyphenylene ether composed of 2,6-dimethylphenol and at least one of bifunctional phenol and trifunctional phenol, poly (2,6-dimethyl-1,4-phenylene oxide) and the like.
- examples thereof include those containing the polyphenylene ether of the above as a main component. More specifically, for example, a compound having a structure represented by the formula (PPE) is preferable.
- X represents an alkylene group or a single bond having 1 to 3 carbon atoms
- m represents an integer of 0 to 20
- n represents an integer of 0 to 20
- m and n The sum represents an integer from 1 to 30.
- alkylene group in the X include a dimethylmethylene group and the like.
- the second embodiment of the polymer film according to the present disclosure preferably comprises an aromatic polyetherketone.
- the aromatic polyetherketone is not particularly limited, and known aromatic polyetherketones can be used.
- the aromatic polyetherketone is preferably a polyetheretherketone.
- Polyetheretherketone is a kind of aromatic polyetherketone, and is a polymer in which bonds are arranged in the order of ether bond, ether bond, and carbonyl bond (ketone). It is preferable that each bond is linked by a divalent aromatic group.
- the aromatic polyetherketone may be used alone or in combination of two or more.
- aromatic polyether ketone examples include a polyether ether ketone having a chemical structure represented by the following formula (P1) (PEEK) and a polyether ketone having a chemical structure represented by the following formula (P2) (PEK).
- P1 polyether ether ketone having a chemical structure represented by the following formula (P1)
- P2 polyether ketone having a chemical structure represented by the following formula (P2)
- P3 Polyether ether ketone ketone
- PEEKK polyether ether ketone ketone
- P5 examples thereof include polyether ketones and ether ketone ketones (PEKEKK) having the represented chemical structure.
- n of the formulas (P1) to (P5) is preferably 10 or more, more preferably 20 or more, from the viewpoint of mechanical properties.
- n is preferably 5,000 or less, more preferably 1,000 or less, in that an aromatic polyetherketone can be easily produced. That is, n is preferably 10 to 5,000, more preferably 20 to 1,000.
- the polymer film is selected from the group consisting of liquid crystal polymer A, a fluoropolymer, a polymer of a compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond, a polyphenylene ether, and an aromatic polyether ketone.
- a polymer of at least one polymer (hereinafter, liquid crystal polymer A, a fluoropolymer, a polymer of a compound having a cyclic aliphatic hydrocarbon group and a group having an ethylenically unsaturated bond, a polyphenylene ether and an aromatic polyether ketone is referred to as " It may also contain only one kind of "specific polymer”) or two or more kinds.
- the content of the specific polymer in the polymer film is preferably 10% by mass to 90% by mass, preferably 20% by volume to 80% by mass, based on the total mass of the polymer film, from the viewpoint of ensuring the mechanical strength of the web during the manufacturing process. It is more preferably mass%, and particularly preferably 30% by volume to 70% by volume.
- the polymer film according to the present disclosure includes a compound having a melting point lower than that of a specific polymer and having a dielectric loss tangent of less than 0.01 (hereinafter, also simply referred to as "a compound having a dielectric loss tangent of less than 0.01").
- the dielectric loss tangent of the compound having a dielectric loss tangent of less than 0.01 is preferably 0.005 or less, more preferably 0.002 or less, from the viewpoint of the dielectric loss tangent of the polymer film and the breaking strength. It is more preferably 0.001 or less, and particularly preferably more than 0 and 0.001 or less.
- the melting point of a compound having a dielectric loss tangent of less than 0.01 shall be measured using a differential scanning calorimetry (DSC) device.
- the melting point Tm of the compound whose dielectric loss tangent is less than 0.01 is the peak temperature of the endothermic peak that appears when 5 mg of the sample is placed in the measuring pan of the DSC and the temperature is raised from 30 ° C. at 10 ° C./min in a nitrogen stream. And said. If a compound having a dielectric loss tangent of less than 0.01 does not show a melting point, the flow start temperature shall be used as the melting point.
- the flow start temperature also called the flow temperature or the flow temperature
- the flow start temperature is 0 in the dielectric positive contact while raising the temperature at a rate of 4 ° C./min under a load of 9.8 MPa (100 kg / cm 2 ) using a capillary reometer. It is a temperature showing a viscosity of 4,800 Pa ⁇ s (48,000 poises) when a compound having a diameter of less than 0.01 is melted and extruded from a nozzle having an inner diameter of 1 mm and a length of 10 mm.
- the metal layer is laminated on the polymer film, the metal layer is etched with an aqueous solution of ferric chloride, washed with water and dried to take out the film.
- the film is placed in a DSC measuring pan for measurement, and among the plurality of endothermic peaks that appear, the one that is not derived from the specific polymer can be identified and evaluated. Further, as another method when the peak in the DSC measurement does not appear clearly, the chemical structure of the compound having a dielectric loss tangent of less than 0.01 is specified, and the temperature of a plurality of particles made of the material is raised. It can also be evaluated as the fused temperature.
- the method for measuring the dielectric loss tangent in the present disclosure shall be the following method.
- the permittivity measurement is carried out by the resonance perturbation method at a frequency of 10 GHz.
- a 10 GHz hollow resonator (CP531 manufactured by Kanto Electronics Applied Development Co., Ltd.) is connected to a network analyzer (“E8633B” manufactured by Agent Technology), and a sample (width: 2 mm ⁇ length: 80 mm) is inserted into the cavity resonator.
- E8633B manufactured by Agent Technology
- the measurement of the dielectric loss tangent of the polymer in the present disclosure shall be carried out according to the above-mentioned method for measuring the dielectric loss tangent using a sample obtained by identifying or isolating the chemical structure of the polymer constituting each layer and measuring the polymer as a powder. do. The permittivity and dielectric loss tangent of the sample are measured from the change in frequency.
- the compound having a dielectric positive contact of less than 0.01 is not particularly limited except that the compound has a dielectric positive contact of less than 0.01, and may be a low molecular weight compound or a high molecular weight compound, and is high. It is preferably a molecular compound.
- the compound having a dielectric tangent of less than 0.01 is preferably a resin from the viewpoint of the dielectric tangent of the polymer film and the breaking strength, has a melting point lower than that of the specific polymer, and has a dielectric tangent of less than 0.01.
- the liquid crystal polymer B, the fluoropolymer, the cycloolefin polymer, the polyphenylene ether, or the aromatic vinyl resin is more preferable, and in the first embodiment, from the viewpoint of breaking strength, the liquid crystal polymer B is used. Is particularly preferable, and a fluoropolymer is particularly preferable from the viewpoint of the dielectric tangent of the polymer film, and in the second embodiment, the liquid crystal polymer B is particularly preferable from the viewpoint of breaking strength.
- the surface of the inorganic particles having a dielectric loss tangent of less than 0.01 may be coated with an organic substance having a melting point.
- Preferred examples of the fluoropolymer include polytetrafluoroethylene.
- the resin used as a compound having a dielectric tangent of less than 0.01 a resin having a weight average molecular weight of 1,000 or more is preferable, and a weight average molecular weight of 2,000 or more is preferable, from the viewpoint of breaking strength.
- a resin is more preferable, a resin having a weight average molecular weight of 3,000 or more is more preferable, and a resin having a weight average molecular weight of 5,000 or more and 200,000 or less is particularly preferable.
- the weight average molecular weight is preferably 13,000 or less.
- the liquid crystal polymer B having a melting point lower than that of the specific polymer and having a dielectric loss tangent of less than 0.01 is the same as the above-mentioned preferred embodiment of the liquid crystal polymer A except for the melting point.
- the melting point of the liquid crystal polymer B used as a compound having a dielectric loss tangent of less than 0.01 is preferably 200 ° C. or higher and less than the melting point Tm of the specific polymer contained, and is 250 ° C. or higher and the specific polymer contained. It is more preferably less than the melting point Tm of the above, and particularly preferably 280 ° C. or higher and less than the melting point Tm of the specific polymer.
- the upper limit of the melting point Tm of the liquid crystal polymer B is preferably less than 330 ° C, more preferably less than 315 ° C.
- the compound having a dielectric tangent of less than 0.01 a polymer having a melting point lower than the melting point of the specific polymer is preferable from the viewpoint of the dielectric tangent of the polymer film and the breaking strength, and the melting point is lower than that of the specific polymer.
- the liquid crystal polymer B has a dielectric tangent of less than 0.01.
- the melting point (preferably melting point Tm) of the compound having a dielectric tangent of less than 0.01 is preferably 10 ° C. or more lower than the melting point of the specific polymer from the viewpoint of the dielectric tangent of the polymer film and the breaking strength. It is more preferably 20 ° C. or higher than the melting point of the polymer, further preferably 30 ° C. to 100 ° C. lower than the melting point of the specific polymer, and particularly preferably 30 ° C. to 70 ° C. lower than the melting point of the specific polymer.
- the compound having a dielectric positive contact of less than 0.01 is preferably particles or fibrous, more preferably resin particles, and a fluoropolymer from the viewpoint of the dielectric positive contact of the polymer film and the breaking strength. Particles are more preferable, and polytetrafluoroethylene particles are particularly preferable. Further, from the viewpoint of promoting fusion between compounds having a dielectric loss tangent of less than 0.01, it is preferable to increase the surface area per mass, and for example, it is preferable to reduce the particle size.
- the average particle size of the particles is preferably 5 nm to 20 ⁇ m, more preferably 20 nm to 2 ⁇ m, and even more preferably 50 nm to 1 ⁇ m from the viewpoint of dielectric loss tangent and breaking strength of the polymer film. , 100 nm to 500 nm is particularly preferable.
- a polymer having a melting point larger than the melting point of the specific polymer is preferable from the viewpoint of mechanical strength.
- a fluorinated polymer is preferably mentioned. Examples of the fluoropolymer include those described above.
- the crystallization enthalpy ⁇ Hc of the compound having a dielectric loss tangent of less than 0.01 is preferably 3 J / g or less, and more preferably 2 J / g or less, from the viewpoint of the dielectric loss tangent of the polymer film and the breaking strength. It is more preferably 1 J / g or less, and particularly preferably more than 0 J / g and 0.6 J / g or less. Further, the crystallization enthalpy ⁇ Hc is preferably close to 0 J / g from the viewpoint of dielectric loss tangent of the polymer film and breaking strength.
- the method for measuring the crystallization enthalpy ⁇ Hc in the present disclosure shall be as follows. 2 mg of a film is placed in a measuring pan of a differential scanning calorimetry (DSC) device, and the calorific value of the exothermic peak that appears when the temperature is raised from 25 ° C. to 350 ° C. at 20 ° C./min in a nitrogen stream is defined as ⁇ Hc of the film. Attribution of the exothermic peak is carried out by isolating the material constituting the film and separately measuring the DSC under the above conditions to investigate the exothermic peak temperature derived from each material.
- DSC differential scanning calorimetry
- the polymer film may contain only one compound having a dielectric loss tangent of less than 0.01, or may contain two or more compounds.
- the content of the compound having a dielectric positive contact of less than 0.01 in the polymer film is preferably 10% by mass to 90% by mass with respect to the total mass of the polymer film from the viewpoint of the dielectric positive contact and the breaking strength. It is more preferably 20% by mass to 80% by mass, and particularly preferably 30% by mass to 70% by mass.
- the mass ratio MA / MB of the content MA of the specific polymer in the polymer film and the content MB of the compound having a dielectric positive contact of less than 0.01 is determined from the viewpoint of the dielectric positive contact and the breaking strength. It is preferably 0.1 to 10, more preferably 0.2 to 5, and particularly preferably 0.5 to 2.
- the polymer film according to the present disclosure is a filler other than the compound having a dielectric loss tangent of less than 0.01 (hereinafter, also simply referred to as “filler”) from the viewpoint of the coefficient of linear expansion and the adhesion to the metal layer. It is preferable to include it.
- the filler may be in the form of particles or fibers, and may be an inorganic filler or an organic filler. In the polymer film according to the present disclosure, it is preferable that the number density of the filler is larger inside than the surface of the polymer film from the viewpoint of the linear expansion coefficient and the adhesion to the metal layer.
- the inorganic filler a known inorganic filler can be used.
- the material of the inorganic filler include BN, Al 2 O 3 , Al N, TiO 2 , SiO 2 , barium titanate, strontium titanate, aluminum hydroxide, calcium carbonate, and a material containing two or more of these. Be done.
- metal oxide particles or fibers are preferable, silica particles, titania particles, or glass fibers are more preferable, and silica particles are preferable from the viewpoint of linear expansion coefficient and adhesion to a metal layer. , Or glass fiber is particularly preferred.
- the average particle size of the inorganic filler is preferably about 20% to about 40% of the thickness of the layer A, and for example, those having an average particle size of 25%, 30% or 35% of the thickness of the layer A may be selected. .. If the particle or fiber is flat, it indicates the length in the short side direction.
- the average particle size of the inorganic filler is preferably 5 nm to 20 ⁇ m, more preferably 10 nm to 10 ⁇ m, and more preferably 20 nm to 1 ⁇ m from the viewpoint of the coefficient of linear expansion and the adhesion to the metal layer. It is more preferably 25 nm to 500 nm, and particularly preferably 25 nm to 500 nm.
- the organic filler a known organic filler can be used.
- the material of the organic filler include polyethylene, polystyrene, urea-formalin filler, polyester, cellulose, acrylic resin, fluororesin, cured epoxy resin, crosslinked benzoguanamine resin, crosslinked acrylic resin, liquid crystal polymer, and two or more of these. Examples include materials.
- the organic filler may be in the form of fibers such as nanofibers, or may be hollow resin particles. Among them, the organic filler is a fluororesin particle, a polyester resin particle, a polyethylene particle, a liquid crystal polymer particle, or a cellulosic resin nanofiber from the viewpoint of the linear expansion coefficient and the adhesion to the metal layer.
- the average particle size of the organic filler is preferably 5 nm to 20 ⁇ m, more preferably 10 nm to 1 ⁇ m, and more preferably 20 nm to 500 nm from the viewpoint of the coefficient of linear expansion and the adhesion to the metal layer. It is more preferably 25 nm to 90 nm, and particularly preferably 25 nm to 90 nm.
- the polymer film may contain only one kind of filler or two or more kinds of fillers.
- the content of the filler in the polymer film is preferably 5% by volume to 80% by volume, preferably 10% by volume or more, based on the total volume of the polymer film, from the viewpoint of the coefficient of thermal expansion and the adhesion to the metal layer. It is more preferably 70% by volume, further preferably 15% by volume to 70% by volume, and particularly preferably 20% by volume to 60% by volume.
- the polymer film may contain other additives other than the above-mentioned components.
- additives known additives can be used. Specific examples thereof include leveling agents, antifoaming agents, antioxidants, ultraviolet absorbers, flame retardants, colorants and the like.
- the polymer film may contain, as other additives, a specific polymer and other resins other than the compound having a dielectric loss tangent of less than 0.01.
- resins include polypropylene, polyamide, polyester other than liquid crystal polyester, polyphenylene sulfide, polyether ketone, polycarbonate, polyether sulfone, polyphenylene ether and its modified products, and thermoplastic resins other than liquid crystal polyester such as polyetherimide.
- Elastomers such as copolymers of glycidyl methacrylate and polyethylene; thermocurable resins such as phenolic resins, epoxy resins, polyimide resins and cyanate resins.
- the total content of the other additives in the polymer film is preferably 25 parts by mass or less, more preferably 10 parts by mass or less, still more preferably 5 parts by mass, based on 100 parts by mass of the specific polymer. It is as follows.
- the polymer film according to the present disclosure may have a multilayer structure.
- the polymer film according to the present disclosure may have a structure having a layer A containing a specific polymer and a compound having a dielectric loss tangent of less than 0.01, and a layer B on at least one surface of the layer A.
- a layer containing the specific polymer and a compound having a dielectric loss tangent of less than 0.01, and a layer C may be provided in this order.
- the layer A contains particles or further contains a filler as a compound having a dielectric loss tangent of less than 0.01.
- the layer B and the layer C each independently preferably contain a specific polymer, and more preferably contain the specific polymer and a compound having a dielectric loss tangent of less than 0.01.
- the polymer contained in the layer B is preferably a polymer having a higher breaking strength (toughness) than the polymer contained in the layer A.
- the breaking strength shall be measured by the following method. A sample consisting of the polymer to be measured was prepared, and the stress on elongation was measured at a tensile speed of 10% / min in a universal tensile tester "STM T50BP" manufactured by Toyo Baldwin Co., Ltd. at 25 ° C. and 60% RH atmosphere. Find the breaking strength.
- a method for detecting or determining the layer structure of the polymer film and the thickness of each layer the following methods can be mentioned.
- a cross-sectional sample of a polymer film is cut out by a microtome, and the layer composition and the thickness of each layer are determined by an optical microscope.
- the determination may be made by morphological observation with a scanning electron microscope (SEM) or component analysis with a flight time type secondary ion mass spectrometry (TOF-SIMS) or the like.
- SEM scanning electron microscope
- TOF-SIMS flight time type secondary ion mass spectrometry
- the layer B or the layer C is a layer that comes into contact with the metal layer as a laminated body, it preferably contains a compound having a functional group described later, and more preferably contains a compound having a group capable of a curing reaction described later.
- the functional group is at least one selected from the group consisting of a covalent group, an ionic bondable group, a hydrogen bondable group, a bipolar element interactable group, and a curing reaction capable group. It is preferably a group.
- the compound having a functional group may be a low molecular weight compound or a high molecular weight compound.
- the compound having a functional group is preferably a low molecular weight compound from the viewpoint of compatibility between the polymer and the compound having a functional group and the dielectric rectification of the polymer film, and the heat resistance and dynamics of the polymer film. From the viewpoint of target strength, a polymer compound is preferable.
- the number of functional groups in the compound having a functional group may be 1 or more, may be 2 or more, but is preferably 2 or more, and the amount of functional groups is set to an appropriate amount in the polymer film. From the viewpoint of reducing the dielectric loss tangent, 10 or less is preferable. Further, the compound having a functional group may have only one kind of functional group or may have two or more kinds of functional groups.
- the low molecular weight compound used as the compound having a functional group preferably has a molecular weight of 50 or more and less than 2,000, and more preferably 100 or more and less than 1,000, from the viewpoint of adhesion to the metal layer. It is particularly preferable that the molecular weight is 200 or more and less than 1,000.
- the content of the compound having a functional group is 10% by mass with respect to the total mass of the layer B. It is preferable to include the above.
- the polymer compound used as the compound having a functional group is preferably a polymer having a weight average molecular weight of 1,000 or more, and a weight average molecular weight of 2,000 or more, from the viewpoint of adhesion to the metal layer. It is more preferable that the polymer has a weight average molecular weight of 3,000 or more and 1,000,000 or less, and a polymer having a weight average molecular weight of 5,000 or more and 200,000 or less. Especially preferable.
- the polymer having a dielectric loss tangent of 0.005 or less and the compound having a functional group are compatible with each other.
- the difference between the SP value of the polymer by the Hoy method and the SP value of the compound having a functional group by the Hoy method is the compatibility between the polymer having a dielectric loss tangent of 0.005 or less and the compound having a functional group, and the dielectric of the polymer film. From the viewpoint of direct contact and adhesion to the metal layer, it is preferably 5 MPa 0.5 or less. The lower limit is 0 MPa 0.5 .
- the SP value (solubility parameter value) by the Hoy method is calculated from the molecular structure of the resin by the method described in Polymer Handbook future edition.
- the SP value is calculated as the SP value of each constituent unit.
- the functional group in the compound having a functional group was selected from the group consisting of a covalent group, an ionic bondable group, a hydrogen bondable group, a bipolar element interactable group, and a curing reaction capable group. It is preferably at least one group. From the viewpoint of the adhesion between the layer C and the metal layer, the functional group is preferably a covalent group or a group capable of a curing reaction, and more preferably a covalent group. Further, from the viewpoint of storage stability and handleability, the functional group is preferably an ion-bondable group, a hydrogen-bondable group, or a dipole-interactable group.
- the group that can be covalently bonded is not particularly limited as long as it is a group that can form a covalent bond. , Iimide ester group, alkyl halide group, thiol group, hydroxy group, carboxy group, amino group, amide group, isocyanate group, aldehyde group, sulfonic acid group and the like.
- it is selected from the group consisting of an epoxy group, an oxetanyl group, an N-hydroxy ester group, an isocyanate group, an imide ester group, an alkyl halide group, and a thiol group. It is preferably at least one functional group, and an epoxy group is particularly preferable.
- the surface of the metal to be bonded to the layer C has a group paired with the functional group of the compound having a functional group.
- a covalent group and a group paired with the covalent group are, for example, an epoxy.
- the other group includes a hydroxy group, an amino group and the like.
- the other may be an amino group or the like.
- the group capable of ionic bonding include a cationic group and an anionic group.
- the cationic group is preferably an onium group.
- the onium group include an ammonium group, a pyridinium group, a phosphonium group, an oxonium group, a sulfonium group, a selenonium group, an iodonium group and the like.
- an ammonium group, a pyridinium group, a phosphonium group, or a sulfonium group is preferable, an ammonium group or a phosphonium group is more preferable, and an ammonium group is particularly preferable.
- the anionic group is not particularly limited, and is, for example, a phenolic hydroxyl group, a carboxy group, -SO 3 H, -OSO 3 H, -PO 3 H, -OPO 3 H 2 , -CONHSO 2- , -SO 2 NHSO. 2 -etc.
- a phosphoric acid group, a phosphonic acid group, a phosphinic acid group, a sulfate group, a sulfonic acid group, a sulfinic acid group or a carboxy group is preferable, and a phosphoric acid group or a carboxy group is more preferable. It is more preferably a carboxy group.
- an ionic bondable group and a group paired with the ionic bondable group (combination of a functional group of a compound having a functional group and a group having a group on the surface of a metal), for example, one of them is acidic. If it has a group, the other is a basic group. Examples of the acidic group include a carboxy group, a sulfo group, a phosphoric acid group and the like, and a carboxy group is preferable.
- examples of the group that can be ionically bonded to the carboxy group include a tertiary amino group, a pyridyl group, and a piperidyl group.
- the group capable of hydrogen bonding include a group having a hydrogen bond donating site and a group having a hydrogen bond accepting site.
- the hydrogen bond donating site may have a structure having an active hydrogen atom capable of hydrogen bonding, but is preferably a structure represented by XH.
- X represents a heteroatom, and is preferably a nitrogen atom or an oxygen atom.
- the hydrogen bond donating site includes a hydroxy group, a carboxy group, a primary amide group, a secondary amide group, a primary amino group, and a secondary amino from the viewpoint of adhesion between the layer C and the metal layer.
- It is preferably at least one structure selected from the group consisting of a group, a primary sulfonamide group, a secondary sulfonamide group, an imide group, a urea bond, and a urethane bond, and preferably has a hydroxy group, a carboxy group, and a first structure. It may be at least one structure selected from the group consisting of a primary amide group, a secondary amide group, a primary sulfonamide group, a secondary sulfonamide group, a maleimide group, a urea bond, and a urethane bond.
- At least one structure selected from the group consisting of a hydroxy group, a carboxy group, a primary amide group, a secondary amide group, a primary sulfonamide group, a secondary sulfonamide group, and a maleimide group is more preferable, and it is particularly preferable that the structure is at least one selected from the group consisting of a hydroxy group and a secondary amide group.
- the hydrogen bond accepting site preferably has a structure containing an atom having an unshared electron pair, preferably a structure containing an oxygen atom having an unshared electron pair, and has a carbonyl group (carboxy group, amide group, imide group).
- a carbonyl structure such as a urea bond and a urethane bond
- a sulfonyl group including a sulfonyl structure such as a sulfonamide group
- a carbonyl group is particularly preferable.
- the group capable of hydrogen bonding is preferably a group having both the hydrogen bond donating site and the hydrogen bond accepting site, and is preferably a carboxy group, an amide group, an imide group, a urea bond, a urethane bond, or a sulfonamide. It preferably has a group, and more preferably has a carboxy group, an amide group, an imide group, or a sulfonamide group.
- a group capable of hydrogen bonding and a group paired with the group capable of hydrogen bonding provides a hydrogen bond.
- the other includes a group having a hydrogen binding accepting site.
- one of the above combinations is a carboxy group, an amide group, a carboxy group and the like can be mentioned.
- one of the above combinations is, for example, a phenolic hydroxyl group, the other may be phenolic hydroxide or the like.
- the dipole interactable group had a polarized structure other than the structure represented by XH (X represents a hetero atom, a nitrogen atom, or an oxygen atom) in the hydrogen-bondable group. Any group may be used, and a group to which atoms having different electronegativity are bonded is preferable. As a combination of atoms having different electric negative degrees, a combination of at least one atom selected from the group consisting of an oxygen atom, a nitrogen atom, a sulfur atom, and a halogen atom and a carbon atom is preferable, and an oxygen atom, a nitrogen atom, and the like.
- a combination of at least one atom selected from the group consisting of sulfur atoms and a carbon atom is more preferable.
- a combination of a nitrogen atom and a carbon atom and a combination of a carbon atom and a nitrogen atom, an oxygen atom and a sulfur atom are preferable, and specifically, cyano A group, a cyanul group, and a sulfonic acid amide group are more preferable.
- the combination of the dipole-interactable group and the group paired with the dipole-interactable group (combination of the functional group of the compound having a functional group and the group having on the surface of the metal) is the same.
- a combination of dipole-interactable groups is preferred.
- one of the above combinations is, for example, a cyano group
- the other is a cyano group.
- one of the above combinations is, for example, a sulfonic acid amide group
- the other may be a sulfonic acid amide group.
- the group capable of a curing reaction examples include an ethylenically unsaturated group, a cyclic ether group, a cyanato group, a reactive silyl group, an oxazine ring group, a urethane group and the like.
- the compound having a group capable of a curing reaction the following curable compound may be used.
- the curable compound is a compound that is cured by irradiation with heat or light (for example, visible light, ultraviolet rays, near infrared rays, far infrared rays, electron beams, etc.), and may require a curing aid described later. ..
- curable compounds include epoxy compounds, cyanate ester compounds, vinyl compounds, silicone compounds, oxazine compounds, maleimide compounds, allyl compounds, acrylic compounds, methacrylic compounds, and urethane compounds. These may be used alone or in combination of two or more.
- the compound is at least one selected from the group consisting of an epoxy compound, a cyanate ester compound, a vinyl compound, an allyl compound, and a silicone compound.
- the content of the curable compound in the layer B is preferably 10% by mass or more and 90% by mass or less, and more preferably 20% by mass or more and 80% by mass or less with respect to the total mass of the layer C.
- Hardening aid examples include a polymerization initiator such as a photoreaction initiator (photoradical generator, photoacid generator, photobase generator).
- Specific examples of the curing aid include onium salt compounds, sulfone compounds, sulfonic acid ester compounds, sulfonimide compounds, disulfonyldiazomethane compounds, disulfonylmethane compounds, oxime sulfonate compounds, hydrazine sulfonate compounds, triazine compounds, and nitrobenzyl compounds. Examples thereof include benzyl imidazole compounds, organic halides, octylate metal salts, disulfones and the like.
- these curing aids may be used alone or in combination of two or more.
- the content of the curing aid in the layer B is preferably 5% by mass or more and 20% by mass or less, and more preferably 5% by mass or more and 10% by mass or less with respect to the total mass of the layer B.
- the functional group in the compound having a functional group include an epoxy group, an oxetanyl group, an isocyanate group, an acid anhydride group, a carbodiimide group, an N-hydroxyester group, a glyoxal group, an imide ester group and an alkyl halide group.
- an epoxy group, an oxetanyl group, an isocyanate group, an acid anhydride group, a carbodiimide group, an N-hydroxyester group, a glyoxal group, an imide ester group, an alkyl halide group or a thiol group is more preferable.
- bonds or interactions of the two functional groups are shown below, but the above-mentioned bonds or interactions in the present disclosure are not limited thereto.
- the compound having a functional group is preferably a polyfunctional epoxy compound or a polymer of a polyfunctional epoxy compound from the viewpoint of the dielectric tangent of the polymer film and the adhesion to the metal layer, and the bifunctional epoxy compound, Alternatively, it is more preferably a polymer of a bifunctional epoxy compound, and particularly preferably a bifunctional epoxy compound.
- the layer B or the layer C may contain only one kind of compound having a functional group, or may contain two or more kinds of compounds.
- the content of the compound having a functional group in the layer B or the layer C is 1% by mass to 80% by mass with respect to the total mass of the polymer film from the viewpoint of the dielectrically tangent of the polymer film and the adhesion to the metal layer. It is preferably 5% by mass to 70% by mass, more preferably 10% by mass to 60% by mass, and particularly preferably 20% by mass to 60% by mass.
- the average thickness of the layer A is not particularly limited, but is preferably 5 ⁇ m to 90 ⁇ m, more preferably 10 ⁇ m to 70 ⁇ m, and more preferably 15 ⁇ m to 15 ⁇ m from the viewpoint of the coefficient of thermal expansion and the adhesion to the metal layer. It is particularly preferably 50 ⁇ m.
- the method for measuring the average thickness of each layer in the polymer film according to the present disclosure is as follows.
- the polymer film is cut with a microtome and the cross section is observed with an optical microscope to evaluate the thickness of each layer.
- the cross-section sample is cut out at three or more places, the thickness is measured at three or more points in each cross-section, and the average value thereof is taken as the average thickness.
- the average thickness of the layers B and C is preferably thinner than the average thickness of the layer A independently from the viewpoint of the coefficient of thermal expansion and the adhesion to the metal layer.
- the value of TA / TB which is the ratio of the average thickness TA of the layer A to the average thickness TB of the layer B , may be larger than 1 from the viewpoint of the coefficient of thermal expansion and the adhesion to the metal layer. It is preferably 2 to 100, more preferably 2.5 to 20, and particularly preferably 3 to 10.
- the value of TA / TC which is the ratio of the average thickness TA of the layer A to the average thickness TC of the layer C , may be larger than 1 from the viewpoint of the coefficient of thermal expansion and the adhesion to the metal layer.
- the value of TC / TB which is the ratio of the average thickness TC of the layer C to the average thickness TB of the layer B , is 0.2 from the viewpoint of the coefficient of thermal expansion and the adhesion to the metal layer. It is preferably from 5 to 5, more preferably 0.5 to 2, and particularly preferably 0.8 to 1.2. Further, the average thickness of the layer B and the layer C is preferably 0.1 ⁇ m to 20 ⁇ m, preferably 0.5 ⁇ m to 15 ⁇ m, independently from the viewpoint of the coefficient of thermal expansion and the adhesion to the metal layer. Is more preferable, 1 ⁇ m to 10 ⁇ m is further preferable, and 3 ⁇ m to 8 ⁇ m is particularly preferable.
- the average thickness of the polymer film according to the present disclosure is preferably 6 ⁇ m to 200 ⁇ m, more preferably 12 ⁇ m to 100 ⁇ m, and more preferably 20 ⁇ m to 20 ⁇ m from the viewpoint of strength, coefficient of thermal expansion, and adhesion to the metal layer. It is particularly preferably 60 ⁇ m.
- the average thickness of the polymer film is measured at any five points using an adhesive film thickness meter, for example, an electronic micrometer (product name "KG3001A", manufactured by Anritsu Co., Ltd.), and is used as the average value thereof.
- an adhesive film thickness meter for example, an electronic micrometer (product name "KG3001A", manufactured by Anritsu Co., Ltd.), and is used as the average value thereof.
- the dielectric loss tangent of the polymer film according to the present disclosure is preferably 0.005 or less, more preferably 0.002 or less, further preferably 0.001 or less, and 0. It is particularly preferable that it exceeds 0.001 and is 0.001 or less.
- the coefficient of linear expansion of the polymer film according to the present disclosure is preferably -20 ppm / K to 50 ppm / K, more preferably -10 ppm / K to 40 ppm / K, and 0 ppm / K from the viewpoint of the coefficient of thermal expansion. It is more preferably K to 35 ppm / K, and particularly preferably 10 ppm / K to 30 ppm / K.
- the method for measuring the coefficient of linear expansion in the present disclosure shall be as follows. Using a thermomechanical analyzer (TMA), a tensile load of 1 g is applied to both ends of a polymer film having a width of 5 mm and a length of 20 mm or a measurement sample of each layer, and the temperature rises from 25 ° C to 200 ° C at a rate of 5 ° C / min. Then, the linear expansion coefficient is calculated from the slope of the TMA curve between 30 ° C. and 150 ° C. when the temperature is cooled to 30 ° C. at a rate of 20 ° C./min and the temperature is raised again at a rate of 5 ° C./min.
- TMA thermomechanical analyzer
- the layer to be measured may be scraped off with a razor or the like to prepare a measurement sample. If it is difficult to measure the coefficient of linear expansion by the above method, it shall be measured by the following method.
- a section sample is prepared by cutting the polymer film with a microtome and set in an optical microscope equipped with a heating stage system (HS82, manufactured by Metler Toledo), followed by 25 ° C to 200 ° C at a rate of 5 ° C / min. After the temperature was raised to 30 ° C., the temperature was cooled to 30 ° C. at a rate of 20 ° C./min, and the temperature was raised again at a rate of 5 ° C./min.
- HS82 heating stage system
- the thickness (ts150) of the polymer film or each layer at ° C. is evaluated, the value obtained by dividing the dimensional change by the temperature change ((ts150-ts30) / (150-30)) is calculated, and the linear expansion coefficient of the polymer film or each layer is calculated. May be calculated.
- the method for producing the polymer film according to the present disclosure is not particularly limited, and known methods can be referred to.
- a method for producing a polymer film according to the present disclosure for example, a casting method, a coating method, an extrusion method and the like are preferably mentioned. Of these, the hypersalivation method is particularly preferable.
- the polymer film according to the present disclosure has a multi-layer structure, for example, a co-flow spreading method, a multi-layer coating method, a co-extrusion method and the like are preferably mentioned. Of these, the coextrusion method is particularly preferable for relatively thin film formation, and the coextrusion method is particularly preferable for thick film formation.
- the composition for forming layer A in which the components of each layer such as a specific polymer and a compound having a dielectric loss tangent of less than 0.01 are dissolved or dispersed in a solvent, respectively. It is preferable to carry out a co-current spreading method or a multi-layer coating method using a substance, a composition for forming a layer B, a composition for forming a layer C, or the like.
- the solvent examples include halogenated hydrocarbons such as dichloromethane, chloroform, 1,1-dichloroethane, 1,2-dichloroethane, 1,1,2,2-tetrachloroethane, 1-chlorobutane, chlorobenzene and o-dichlorobenzene; Halogenized phenols such as p-chlorophenol, pentachlorophenol and pentafluorophenol; ethers such as diethyl ether, tetrahydrofuran and 1,4-dioxane; ketones such as acetone and cyclohexanone; esters such as ethyl acetate and ⁇ -butyrolactone; ethylene Phenols such as carbonates and propylene carbonates; amines such as triethylamine; nitrogen-containing heterocyclic aromatic compounds such as pyridines; nitriles such as acetonitrile and succinonitriles; N, N-d
- the solvent preferably contains an aprotic compound (particularly preferably an aprotic compound having no halogen atom) because it is less corrosive and easy to handle.
- the proportion of the aprotic compound in the whole solvent is preferably 50% by mass to 100% by mass, more preferably 70% by mass to 100% by mass, and particularly preferably 90% by mass to 100% by mass.
- an amide such as N, N-dimethylformamide, N, N-dimethylacetamide, tetramethylurea, N-methylpyrrolidone or ⁇ -butyrolactone may be used. It preferably contains an ester, more preferably N, N-dimethylformamide, N, N-dimethylacetamide, or N-methylpyrrolidone.
- the solvent preferably contains a compound having a dipole moment of 3 to 5 because it easily dissolves the specific polymer.
- the proportion of the compound having a dipole moment of 3 to 5 in the entire solvent is preferably 50% by mass to 100% by mass, more preferably 70% by mass to 100% by mass, and particularly preferably 90% by mass to 100% by mass. be.
- the aprotic compound it is preferable to use a compound having a dipole moment of 3 to 5.
- the solvent preferably contains a compound having a boiling point of 220 ° C. or lower at 1 atm because it is easy to remove.
- the proportion of the compound having a boiling point of 220 ° C. or lower at 1 atm in the whole solvent is preferably 50% by mass to 100% by mass, more preferably 70% by mass to 100% by mass, and particularly preferably 90% by mass to 100% by mass.
- the aprotic compound it is preferable to use a compound having a boiling point of 220 ° C. or lower at 1 atm.
- a support may be used when the polymer film is produced by the above-mentioned co-flow spreading method, multi-layer coating method, co-extrusion method or the like. Further, when a metal layer (metal foil) or the like used for the laminate described later is used as a support, it may be used as it is without peeling. Examples of the support include a metal drum, a metal band, a glass plate, a resin film or a metal foil. Of these, metal drums, metal bands, and resin films are preferable.
- the resin film examples include a polyimide (PI) film, and examples of commercially available products include U-Pylex S and U-Pylex R manufactured by Ube Kosan Co., Ltd., Kapton manufactured by Toray DuPont Co., Ltd., and Examples thereof include IF30, IF70 and LV300 manufactured by SKC Koron PI.
- the support may have a surface treatment layer formed on the surface thereof so that the support can be easily peeled off.
- the surface treatment layer hard chrome plating, fluororesin or the like can be used.
- the average thickness of the support is not particularly limited, but is preferably 25 ⁇ m or more and 75 ⁇ m or less, and more preferably 50 ⁇ m or more and 75 ⁇ m or less.
- the method for removing at least a part of the solvent from the cast or coated film-like composition is not particularly limited, and a known drying method can be used. ..
- the polymer film according to the present disclosure can be appropriately combined with stretching from the viewpoint of controlling the molecular orientation and adjusting the coefficient of linear expansion and the mechanical properties.
- the stretching method is not particularly limited, and a known method can be referred to, and the stretching method may be carried out in a solvent-containing state or in a dry film state. Stretching in a solvent-containing state may be carried out by gripping the film and stretching it, or by utilizing the self-shrinking force of the web due to drying without stretching, or a combination thereof. Stretching is particularly effective for the purpose of improving the elongation at break and the strength at break when the brittleness of the film is reduced by the addition of an inorganic filler or the like.
- the method for producing a polymer film according to the present disclosure preferably includes a step of heat-treating (annealing) the polymer film.
- the heat treatment temperature in the heat treatment step is preferably a temperature less than the melting point Tm of the specific polymer from the viewpoint of the mechanical strength of the web during the manufacturing process and the breaking strength of the manufactured polymer film, and the dielectric adrect contact is preferable. More preferably, the temperature is above the melting point of the compound, which is less than 0.01, and below the melting point of the specific polymer.
- the heat treatment temperature in the heat treatment step exceeds the melting point of the specific polymer from the viewpoint of breaking strength. It is preferably a temperature, and more preferably a temperature of less than the melting point Tm of the compound which exceeds the melting point of the specific polymer and has a dielectric adduct of less than 0.01. Further, the heat treatment temperature in the heat treatment step is more preferably 260 ° C. to 370 ° C., and particularly preferably 310 ° C. to 350 ° C. from the viewpoint of breaking strength. The annealing time is preferably 30 minutes to 5 hours, more preferably 30 minutes to 3 hours. Further, the method for producing a polymer film according to the present disclosure may include other known steps, if necessary.
- the polymer film according to the present disclosure can be used for various purposes, and above all, it can be suitably used for a film for electronic parts such as a printed wiring board, and can be preferably used for a flexible printed circuit board. Further, the polymer film according to the present disclosure can be suitably used as a polymer film for metal adhesion.
- the laminate according to the present disclosure may be a laminate of the polymer films according to the present disclosure, but has a polymer film according to the present disclosure and a metal layer arranged on at least one surface of the polymer film. It is more preferable to have the polymer film according to the present disclosure and copper layers arranged on both sides of the polymer film. Further, it is more preferable that the metal layer is a copper layer. Further, the laminate according to the present disclosure includes a polymer film according to the present disclosure having a layer B, a layer A, and a layer C in this order, and a metal layer arranged on the surface of the polymer film on the layer B side.
- the metal layer arranged on the surface on the layer B side is preferably a metal layer arranged on the surface of the layer B.
- the metal layer arranged on the surface on the layer C side is preferably a metal layer arranged on the surface of the layer C, and the metal layer arranged on the surface on the layer B side is the surface of the layer B. It is more preferable that the metal layer arranged on the surface of the layer C and the metal layer arranged on the surface of the layer C is a metal layer arranged on the surface of the layer C.
- the metal layer arranged on the surface on the layer B side and the metal layer arranged on the surface on the layer C side are different materials and thicknesses even if they are metal layers having the same material, thickness and shape. And may be a metal layer of shape. From the viewpoint of characteristic impedance adjustment, the metal layer arranged on the surface on the layer B side and the metal layer arranged on the surface on the layer C side may be metal layers of different materials and thicknesses. A metal layer may be laminated on only one side of B or C.
- the method for attaching the polymer film and the metal layer according to the present disclosure is not particularly limited, and a known laminating method can be used.
- the peel strength between the polymer film and the copper layer is preferably 0.5 kN / m or more, more preferably 0.7 kN / m or more, and 0.7 kN / m to 2.0 kN / m. It is more preferably 0.9 kN / m to 1.5 kN / m, and particularly preferably 0.9 kN / m to 1.5 kN / m.
- the peel strength between the polymer film and the metal layer shall be measured by the following method.
- a 1.0 cm wide peeling test piece was prepared from the laminate of the polymer film and the metal layer, the polymer film was fixed to a flat plate with double-sided adhesive tape, and 50 mm by the 180 ° method according to JIS C 5016 (1994).
- the strength (kN / m) when the polymer film is peeled from the metal layer at a rate of / minute is measured.
- the surface roughness Rz of the metal layer on the side in contact with the polymer film is preferably 1 ⁇ m to 10 ⁇ m, more preferably 1 ⁇ m to 5 ⁇ m, and more preferably 1.5 ⁇ m to 1.5 ⁇ m when the layer C containing the compound having the functional group is not present. 3 ⁇ m is particularly preferable, and when the layer C containing the compound having the above functional group is provided, it is preferably less than 1 ⁇ m, more preferably 0.5 ⁇ m or less, and more preferably 0.3 ⁇ m or less from the viewpoint of reducing the transmission loss of the high frequency signal. Especially preferable.
- surface roughness Rz is a value expressed in micrometers, which is the total value of the maximum value of the height of the peak and the maximum value of the depth of the valley observed in the roughness curve at the reference length. means.
- the surface roughness Rz of the metal layer shall be measured by the following method. Using the non-contact surface / layer cross-sectional shape measurement system VertScan (manufactured by Ryoka System Co., Ltd.), measure 465.48 ⁇ m in length and 620.64 ⁇ m in width, and measure the roughness curve on the surface of the object to be measured (metal layer) and the above. Create an average line of the roughness curve.
- the metal layer is preferably a copper layer.
- a rolled copper foil formed by a rolling method or an electrolytic copper foil formed by an electrolytic method is preferable, and a rolled copper foil is more preferable from the viewpoint of bending resistance.
- the average thickness of the metal layer is not particularly limited, but is preferably 2 ⁇ m to 20 ⁇ m, more preferably 3 ⁇ m to 18 ⁇ m, and even more preferably 5 ⁇ m to 12 ⁇ m.
- the metal layer may be a metal layer with a carrier formed on a support (carrier) so as to be peelable.
- a carrier a known carrier can be used.
- the average thickness of the carrier is not particularly limited, but is preferably 10 ⁇ m to 100 ⁇ m, and more preferably 18 ⁇ m to 50 ⁇ m.
- the metal layer in the laminate according to the present disclosure may be a metal layer having a circuit pattern. It is also preferable that the metal layer in the laminate according to the present disclosure is processed into a desired circuit pattern by etching, for example, to form a flexible printed circuit board.
- the etching method is not particularly limited, and a known etching method can be used.
- the permittivity measurement was carried out by the resonance perturbation method at a frequency of 10 GHz.
- a 10 GHz hollow resonator (CP531 manufactured by Kanto Denshi Applied Development Co., Ltd.) is connected to a network analyzer (“E8633B” manufactured by Agent Technology), and a polymer film or a sample of each layer (width: 2.0 mm ⁇ length) is connected to the cavity resonator.
- the diameter of the polymer film or each layer was measured from the change in the resonance frequency before and after the insertion for 96 hours under a temperature of 25 ° C. and a humidity of 60% RH.
- LC-A Liquid crystal polymer produced by adjusting the monomer addition ratio and thermal polymerization conditions with reference to the production of the liquid crystal polyester (B) described in Comparative Example 2 of International Publication No. 2020/166644
- LC-C The following production Liquid crystal polymer produced according to the method (dielectric loss tangent 0.004)
- the liquid crystal polyester (C1) obtained above is heated in a nitrogen atmosphere from room temperature to 160 ° C. over 2 hours and 20 minutes, then from 160 ° C. to 180 ° C. over 3 hours and 20 minutes, and at 180 ° C. By holding for 5 hours, solid-phase polymerization was carried out, the mixture was cooled, and then the mixture was pulverized with a pulverizer to obtain a powdery liquid crystal polyester (C2).
- the liquid crystal polyester (C2) obtained above was heated in a nitrogen atmosphere from room temperature (23 ° C.) to 180 ° C. over 1 hour and 20 minutes, and then from 180 ° C. to 240 ° C. over 5 hours to 240.
- the liquid crystal polyester (C) (LC-C) in the form of powder was obtained by solid-phase polymerization by holding at ° C. for 5 hours and then cooling.
- LC-D Liquid crystal polymer produced according to the following manufacturing method (dielectric loss tangent 0.004)
- the liquid crystal polyester (D1) obtained above was subjected to solid phase polymerization in a nitrogen atmosphere at 250 ° C. for 3 hours, cooled, and then pulverized with a pulverizer to obtain a powdery liquid crystal polyester (D1). LC-D) was obtained.
- LC-E Commercially available liquid crystal polymer resin (A-8100, manufactured by Ueno Fine Chemicals Industry Co., Ltd.)
- LC-B Commercially available liquid crystal polymer resin powder (Vectra A950, manufactured by Polyplastics Co., Ltd., liquid crystal polyester)
- A-1 A polymer film in which the solvent of commercially available polytetrafluoroethylene (PTFE) nanoparticles (polyflon PTFE D-210C, average particle size 0.25 ⁇ m, manufactured by Daikin Industries, Ltd.) is replaced with an N-methylpyrrolidone solvent.
- PTFE polytetrafluoroethylene
- A-2 Copolymer (PFA) particles of ethylene tetrafluoride and perfluoroalkoxy ethylene (melting point 280 ° C., average particle diameter 0.2 ⁇ m to 0.5 ⁇ m, dielectric loss tangent 0.001)
- A-3 Commercially available ultra-high molecular weight polyethylene particles having an average particle size of 10 ⁇ m (Miperon PM200, manufactured by Mitsui Chemicals, Inc.) were used so that the solid content was the amount shown in Table 1.
- ⁇ Curable compound> M-1 A commercially available aminophenol type epoxy resin (jER630LSD, manufactured by Mitsubishi Chemical Corporation) was used.
- a film was formed according to the following flow.
- a sintered fiber metal filter having a nominal pore diameter of 10 ⁇ m was passed, and then a sintered fiber metal filter having a nominal pore diameter of 10 ⁇ m was also passed to obtain a polymer solution.
- a liquid crystal polymer solution was prepared without adding the additive, passed through the sintered fiber metal filter, and then the additive was added and stirred.
- the polymer films of Examples 1 to 13 which are the polymer films according to the present disclosure, have a smaller dielectric loss tangent and excellent breaking strength than the polymer films of Comparative Example 1. Further, in Comparative Example 2, the layers A and C could not maintain their shapes during the heat treatment, and the polymer film could not be produced.
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Abstract
Description
従来、回路基板に用いられる絶縁材料として、ポリイミドが多く用いられてきたが、高耐熱性及び低吸水性であり、かつ、高周波帯域での損失が小さい液晶ポリマーが注目されている。
また、本発明の他の実施形態が解決しようとする課題は、上記液晶ポリマーフィルム又は上記ポリマーフィルムを用いた積層体を提供することである。
<1> 液晶ポリマーA、及び、融点が上記液晶ポリマーAより低く、かつ、誘電正接が0.01未満である化合物を含む液晶ポリマーフィルム。
<2> 上記液晶ポリマーAの融点が、280℃以上である<1>に記載の液晶ポリマーフィルム。
<3> 上記液晶ポリマーAが、式(1)~式(3)のいずれかで表される構成単位を有する<1>又は<2>に記載の液晶ポリマーフィルム。
式(1) -O-Ar1-CO-
式(2) -CO-Ar2-CO-
式(3) -X-Ar3-Y-
式(1)~式(3)中、Ar1は、フェニレン基、ナフチレン基又はビフェニリレン基を表し、Ar2及びAr3はそれぞれ独立に、フェニレン基、ナフチレン基、ビフェニリレン基又は下記式(4)で表される基を表し、X及びYはそれぞれ独立に、酸素原子又はイミノ基を表し、Ar1~Ar3における水素原子は、それぞれ独立に、ハロゲン原子、アルキル基又はアリール基で置換されていてもよい。
式(4) -Ar4-Z-Ar5-
式(4)中、Ar4及びAr5はそれぞれ独立に、フェニレン基又はナフチレン基を表し、Zは、酸素原子、硫黄原子、カルボニル基、スルホニル基又はアルキレン基を表す。<4> 上記誘電正接が0.01未満である化合物が、ポリマーである<1>~<3>のいずれか1つに記載の液晶ポリマーフィルム。
<5> 上記誘電正接が0.01未満である化合物が、融点が上記液晶ポリマーAより低く、かつ、誘電正接が0.01未満である液晶ポリマーBである<1>~<4>のいずれか1つに記載の液晶ポリマーフィルム。
<6> 上記誘電正接が0.01未満である化合物が、粒子である<1>~<5>のいずれか1つに記載の液晶ポリマーフィルム。
<7> 上記誘電正接が0.01未満である化合物が、フッ素系ポリマーである<1>~<6>のいずれか1つに記載の液晶ポリマーフィルム。
<8> 上記誘電正接が0.01未満である化合物の含有量が、液晶ポリマーフィルムの全質量に対し、10質量%~90質量%である<1>~<7>のいずれか1つに記載の液晶ポリマーフィルム。
<9> 上記液晶ポリマーフィルムの誘電正接が、0.001以下である<1>~<8>のいずれか1つに記載の液晶ポリマーフィルム。
<10> 上記液晶ポリマーフィルムの線膨張係数が、-20ppm/K~50ppm/Kである<1>~<9>のいずれか1つに記載の液晶ポリマーフィルム。
<11> フッ素系ポリマー、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物、ポリフェニレンエーテル及び芳香族ポリエーテルケトンよりなる群から選ばれる少なくとも1種のポリマー、並びに、融点が上記ポリマーより低く、かつ、誘電正接が0.01未満である化合物を含むポリマーフィルム。
<12> <1>~<10>のいずれか1つに記載の液晶ポリマーフィルム、又は、<11>に記載のポリマーフィルムと、上記液晶ポリマーフィルム又は上記ポリマーフィルムの少なくとも一方の面に配置された金属層とを有する積層体。
<13> 上記液晶ポリマーフィルム又は上記ポリマーフィルムの両面にそれぞれ配置された金属層を有する<12>に記載の積層体。
<14> 上記金属層が、銅層であり、上記液晶ポリマーフィルム又は上記ポリマーフィルムと上記銅層との剥離強度が、0.5kN/m以上である<12>又は<13>に記載の積層体。
また、本発明の他の実施形態によれば、上記液晶ポリマーフィルム又は上記ポリマーフィルムを用いた積層体を提供することができる。
なお、本明細書において、数値範囲を示す「~」とはその前後に記載される数値を下限値及び上限値として含む意味で使用される。
本開示中に段階的に記載されている数値範囲において、一つの数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本開示中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
また、本明細書における基(原子団)の表記において、置換及び無置換を記していない表記は、置換基を有さないものと共に置換基を有するものをも包含するものである。例えば「アルキル基」とは、置換基を有さないアルキル基(無置換アルキル基)のみならず、置換基を有するアルキル基(置換アルキル基)をも包含するものである。
本明細書において、「(メタ)アクリル」は、アクリル及びメタクリルの両方を包含する概念で用いられる語であり、「(メタ)アクリロイル」は、アクリロイル及びメタクリロイルの両方を包含する概念として用いられる語である。
また、本明細書中の「工程」の用語は、独立した工程だけではなく、他の工程と明確に区別できない場合であっても、その工程の所期の目的が達成されれば本用語に含まれる。
また、本開示において、「質量%」と「重量%」とは同義であり、「質量部」と「重量部」とは同義である。
更に、本開示において、2以上の好ましい態様の組み合わせは、より好ましい態様である。
また、本開示における重量平均分子量(Mw)及び数平均分子量(Mn)は、特に断りのない限り、TSKgel SuperHM-H(東ソー(株)製の商品名)のカラムを使用したゲルパーミエーションクロマトグラフィ(GPC)分析装置により、溶剤PFP(ペンタフルオロフェノール)/クロロホルム=1/2(質量比)、示差屈折計により検出し、標準物質としてポリスチレンを用いて換算した分子量である。
本開示に係るポリマーフィルムの第一の実施形態は、液晶ポリマーA、及び、融点が上記液晶ポリマーAより低く、かつ、誘電正接が0.01未満である化合物を含むポリマーフィルムである。
本開示に係るポリマーフィルムの第二の実施形態は、フッ素系ポリマー、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物、ポリフェニレンエーテル及び芳香族ポリエーテルケトンよりなる群から選ばれる少なくとも1種のポリマー、並びに、融点が上記ポリマーより低く、かつ、誘電正接が0.01未満である化合物を含む液晶ポリマーフィルムである。
なお、本開示において、液晶ポリマーAを含む上記ポリマーフィルムを液晶ポリマーフィルムともいう。
また、本明細書において、特に断りなく、単に「本開示に係る液晶ポリマーフィルム」という場合は、上記第一の実施態様について述べるものとする。
本発明者が鋭意検討した結果、上記構成をとることにより、誘電正接が小さく、かつ破断強度に優れるポリマーフィルムを提供できることを見出した。
上記効果が得られる詳細なメカニズムは不明であるが、以下のように推測される。
誘電正接が0.01未満である化合物を含むことにより、ポリマーフィルムの誘電正接が小さくできるとともに、液晶ポリマーA、又は、フッ素系ポリマー、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物、ポリフェニレンエーテル及び芳香族ポリエーテルケトンよりなる群から選ばれる少なくとも1種のポリマーで製造プロセス中のウェブの機械強度を確保しつつ、融点が上記液晶ポリマーA、又は、フッ素系ポリマー、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物、ポリフェニレンエーテル及び芳香族ポリエーテルケトンよりなる群から選ばれる少なくとも1種のポリマーより低く、かつ、誘電正接が0.01未満である化合物同士を融着させることにより、破断強度に優れると推定している。
本開示に係るポリマーフィルムの第一の実施態様は、液晶ポリマーAを含む。
本開示において、液晶ポリマーAの種類は特に限定されず、公知の液晶ポリマーを用いることができる。
また、液晶ポリマーAは、溶融状態で液晶性を示すサーモトロピック液晶ポリマーであってもよく、溶液状態で液晶性を示すリオトロピック液晶ポリマーであってもよい。また、液晶ポリマーAがサーモトロピック液晶ポリマーである場合には、450℃以下の温度で溶融する液晶ポリマーであることが好ましい。
また、液晶ポリマーAは、液晶性、及び、熱膨張係数の観点から、芳香環を有するポリマーであることが好ましく、芳香族ポリエステル又は芳香族ポリエステルアミドであることがより好ましい。
更に、液晶ポリマーAは、芳香族ポリエステル又は芳香族ポリエステルアミドに、更にイミド結合、カルボジイミド結合やイソシアヌレート結合などのイソシアネート由来の結合等が導入されたポリマーであってもよい。
また、液晶ポリマーAは、原料モノマーとして芳香族化合物のみを用いてなる全芳香族液晶ポリマーであることが好ましい。
1)(i)芳香族ヒドロキシカルボン酸と、(ii)芳香族ジカルボン酸と、(iii)芳香族ジオール、芳香族ヒドロキシアミン及び芳香族ジアミンよりなる群から選ばれる少なくとも1種の化合物と、を重縮合させてなるもの。
2)複数種の芳香族ヒドロキシカルボン酸を重縮合させてなるもの。
3)(i)芳香族ジカルボン酸と、(ii)芳香族ジオール、芳香族ヒドロキシアミン及び芳香族ジアミンよりなる群から選ばれる少なくとも1種の化合物と、を重縮合させてなるもの。
4)(i)ポリエチレンテレフタレート等のポリエステルと、(ii)芳香族ヒドロキシカルボン酸と、を重縮合させてなるもの。
ここで、芳香族ヒドロキシカルボン酸、芳香族ジカルボン酸、芳香族ジオール、芳香族ヒドロキシアミン及び芳香族ジアミンはそれぞれ独立に、重縮合可能な誘導体に置き換えてもよい。
カルボキシ基をハロホルミル基に変換することにより、芳香族ヒドロキシカルボン酸及び芳香族ジカルボン酸を、芳香族ヒドロキシカルボン酸ハロゲン化物及び芳香族ジカルボン酸ハロゲン化物に置き換えることができる。
カルボキシ基をアシルオキシカルボニル基に変換することにより、芳香族ヒドロキシカルボン酸及び芳香族ジカルボン酸を、芳香族ヒドロキシカルボン酸無水物及び芳香族ジカルボン酸無水物に置き換えることができる。
芳香族ヒドロキシカルボン酸、芳香族ジオール及び芳香族ヒドロキシアミンのようなヒドロキシ基を有する化合物の重合可能な誘導体の例としては、ヒドロキシ基をアシル化してアシルオキシ基に変換してなるもの(アシル化物)が挙げられる。
例えば、ヒドロキシ基をアシル化してアシルオキシ基に変換することにより、芳香族ヒドロキシカルボン酸、芳香族ジオール、及び芳香族ヒドロキシアミンをそれぞれ、アシル化物に置き換えることができる。
芳香族ヒドロキシアミン及び芳香族ジアミンのようなアミノ基を有する化合物の重合可能な誘導体の例としては、アミノ基をアシル化してアシルアミノ基に変換してなるもの(アシル化物)が挙げられる。
例えば、アミノ基をアシル化してアシルアミノ基に変換することにより、芳香族ヒドロキシアミン及び芳香族ジアミンをそれぞれ、アシル化物に置き換えることができる。
式(1) -O-Ar1-CO-
式(2) -CO-Ar2-CO-
式(3) -X-Ar3-Y-
式(1)~式(3)中、Ar1は、フェニレン基、ナフチレン基又はビフェニリレン基を表し、Ar2及びAr3はそれぞれ独立に、フェニレン基、ナフチレン基、ビフェニリレン基又は下記式(4)で表される基を表し、X及びYはそれぞれ独立に、酸素原子又はイミノ基を表し、Ar1~Ar3における水素原子は、それぞれ独立に、ハロゲン原子、アルキル基又はアリール基で置換されていてもよい。
式(4) -Ar4-Z-Ar5-
式(4)中、Ar4及びAr5はそれぞれ独立に、フェニレン基又はナフチレン基を表し、Zは、酸素原子、硫黄原子、カルボニル基、スルホニル基又はアルキレン基を表す。
上記アルキル基の例としては、メチル基、エチル基、n-プロピル基、イソプロピル基、n-ブチル基、イソブチル基、s-ブチル基、t-ブチル基、n-ヘキシル基、2-エチルヘキシル基、n-オクチル基及びn-デシル基が挙げられる。上記アルキル基の炭素数は、好ましくは1~10である。
上記アリール基としては、フェニル基、o-トリル基、m-トリル基、p-トリル基、1-ナフチル基及び2-ナフチル基が挙げられる。上記アリール基の炭素数は、好ましくは6~20である。
上記水素原子がこれらの基で置換されている場合、その置換数は、Ar1、Ar2又はAr3において、それぞれ独立に、好ましくは2個以下であり、より好ましくは1個である。
構成単位(1)としては、Ar1がp-フェニレン基である態様(p-ヒドロキシ安香酸に由来する構成単位)、及びAr1が2,6-ナフチレン基である態様(6-ヒドロキシ-2-ナフトエ酸に由来する構成単位)、又は、4,4’-ビフェニリレン基である態様(4’-ヒドロキシ-4-ビフェニルカルボン酸に由来する構成単位)が好ましい。
構成単位(2)としては、Ar2がp-フェニレン基である態様(テレフタル酸に由来する構成単位)、Ar2がm-フェニレン基である態様(イソフタル酸に由来する構成単位)、Ar2が2,6-ナフチレン基である態様(2,6-ナフタレンジカルボン酸に由来する構成単位)、又は、Ar2がジフェニルエーテル-4,4’-ジイル基である態様(ジフェニルエーテル-4,4’-ジカルボン酸に由来する構成単位)が好ましい。
構成単位(3)としては、Ar3がp-フェニレン基である態様(ヒドロキノン、p-アミノフェノール又はp-フェニレンジアミンに由来する構成単位)、Ar3がm-フェニレン基である態様(イソフタル酸に由来する構成単位)、又は、Ar3が4,4’-ビフェニリレン基である態様(4,4’-ジヒドロキシビフェニル、4-アミノ-4’-ヒドロキシビフェニル又は4,4’-ジアミノビフェニルに由来する構成単位)が好ましい。
構成単位(2)の含有量は、全構成単位の合計量に対して、好ましくは35モル%以下、より好ましくは10モル%~35モル%、更に好ましくは20モル%~35モル%、特に好ましくは30モル%~35モル%である。
構成単位(3)の含有量は、全構成単位の合計量に対して、好ましくは35モル%以下、より好ましくは10モル%~35モル%、更に好ましくは20モル%~35モル%、特に好ましくは30モル%~35モル%である。
構成単位(1)の含有量が多いほど、耐熱性、強度及び剛性が向上し易いが、あまり多いと、溶媒に対する溶解性が低くなり易い。
具体的には、本開示における可溶性液晶ポリマーは、25℃において、N-メチルピロリドン、N-エチルピロリドン、ジクロロメタン、ジクロロエタン、クロロホルム、N,N-ジメチルアセトアミド、γ-ブチロラクトン、ジメチルホルムアミド、エチレングリコールモノブチルエーテル及びエチレングリコールモノエチルエーテルよりなる群から選ばれる少なくとも1種の溶媒100gに、0.1g以上溶解する液晶ポリマーであることが好ましい。
本開示に係るポリマーフィルムの第二の実施態様は、耐熱性、及び、力学的強度の観点から、フッ素系ポリマーを含むことが好ましい。
フッ素系ポリマーは、その種類等は特に限定されず、公知のフッ素系ポリマーを用いることができる。
フッ素化α-オレフィンモノマーとしては、CF2=CF2、CHF=CF2、CH2=CF2、CHCl=CHF、CClF=CF2、CCl2=CF2、CClF=CClF、CHF=CCl2、CH2=CClF、CCl2=CClF、CF3CF=CF2、CF3CF=CHF、CF3CH=CF2、CF3CH=CH2、CHF2CH=CHF、CF3CF=CF2、パーフルオロ(炭素数2~8のアルキル)ビニルエーテル(例えば、パーフルオロメチルビニルエーテル、パーフルオロプロピルビニルエーテル、パーフルオロオクチルビニルエーテル)等が挙げられる。中でも、テトラフルオロエチレン(CF2=CF2)、クロロトリフルオロエチレン(CClF=CF2)、(パーフルオロブチル)エチレン、フッ化ビニリデン(CH2=CF2)、及び、ヘキサフルオロプロピレン(CF2=CFCF3)よりなる群から選ばれた少なくとも1種のモノマーが好ましい。
非フッ素化モノエチレン性不飽和モノマーとしては、エチレン、プロピレン、ブテン、エチレン性不飽和芳香族モノマー(例えば、スチレン及びα-メチルスチレン)等が挙げられる。
フッ素化α-オレフィンモノマーは、1種単独で使用してもよいし、2種以上を併用してもよい。
また、非フッ素化エチレン性不飽和モノマーは、1種単独で使用してもよいし、2種以上を併用してもよい。
フッ素系ポリマーは、1種単独で使用してもよいし、2種以上を併用してもよい。
本開示に係るポリマーフィルムの第二の実施態様は、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物を含むことが好ましい。
環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物の例としては、例えば、ノルボルネン又は多環ノルボルネン系モノマーのような環状オレフィンからなるモノマーから形成される構成単位を有する熱可塑性の樹脂が挙げられる。
環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物は、上記環状オレフィンの開環重合体や2種以上の環状オレフィンを用いた開環共重合体の水素添加物であってもよく、環状オレフィンと、鎖状オレフィン又はビニル基の如きエチレン性不飽和結合を有する芳香族化合物などとの付加重合体であってもよい。また、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物には、極性基が導入されていてもよい。
環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物は、1種単独で使用してもよいし、2種以上を併用してもよい。
環状脂肪族炭化水素基の環構造としては、シクロペンタン環、シクロヘキサン環、シクロオクタン環、イソボロン環、ノルボルナン環、ジシクロペンタン環等が挙げられる。
環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物は、単官能エチレン性不飽和化合物であっても、多官能エチレン性不飽和化合物であってもよい。
環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物における環状脂肪族炭化水素基の数は、1以上であればよく、2以上有していてもよい。
環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物は、少なくとも1種の環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物を重合してなる重合体であればよく、2種以上環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物であってもよいし、環状脂肪族炭化水素基を有しない他のエチレン性不飽和化合物との共重合体であってもよい。
また、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物は、シクロオレフィンポリマーであることが好ましい。
本開示に係るポリマーフィルムの第二の実施態様は、ポリフェニレンエーテルを含むことが好ましい。
ポリフェニレンエーテルの重量平均分子量(Mw)は、製膜後に熱硬化する場合には、耐熱性、及び、膜形成性の観点から、500~5,000であることが好ましく、500~3,000であることが好ましい。また、熱硬化しない場合には、特に限定されないが、3,000~100,000であることが好ましく、5,000~50,000であることが好ましい。
ポリフェニレンエーテルとしては、分子末端のフェノール性水酸基の1分子当たりの平均個数(末端水酸基数)が、誘電正接、及び、耐熱性の観点から、1個~5個であることが好ましく、1.5個~3個であることがより好ましい。
ポリフェニレンエーテルの水酸基数又はフェノール性水酸基は、例えば、ポリフェニレンエーテルの製品の規格値からわかる。また、末端水酸基数又は末端フェノール性水酸基数としては、例えば、ポリフェニレンエーテル1モル中に存在する全てのポリフェニレンエーテルの1分子あたりの水酸基又はフェノール性水酸基の平均値を表した数値等が挙げられる。
ポリフェニレンエーテルは、1種単独で使用してもよいし、2種以上を併用してもよい。
上記Xにおける上記アルキレン基としては、例えば、ジメチルメチレン基等が挙げられる。
本開示に係るポリマーフィルムの第二の実施態様は、芳香族ポリエーテルケトンを含むことが好ましい。
芳香族ポリエーテルケトンとしては、特に限定されず、公知の芳香族ポリエーテルケトンを用いることができる。
芳香族ポリエーテルケトンは、ポリエーテルエーテルケトンであることが好ましい。
ポリエーテルエーテルケトンは、芳香族ポリエーテルケトンの1種であり、エーテル結合、エーテル結合、カルボニル結合(ケトン)の順に結合が配置されたポリマーである。各結合間は、2価の芳香族基により連結されていることが好ましい。
芳香族ポリエーテルケトンは、1種単独で使用してもよいし、2種以上を併用してもよい。
ポリマーフィルムにおける特定ポリマーの含有量は、製造プロセス中のウェブの機械強度を確保する観点から、ポリマーフィルムの全質量に対し、10質量%~90質量%であることが好ましく、20体積%~80質量%であることがより好ましく、30体積%~70体積%であることが特に好ましい。
本開示に係るポリマーフィルムは、融点が特定ポリマーより低く、かつ、誘電正接が0.01未満である化合物(以下、単に「誘電正接が0.01未満である化合物」ともいう。)を含む。
誘電正接が0.01未満である化合物の誘電正接は、ポリマーフィルムの誘電正接、及び、破断強度の観点から、0.005以下であることが好ましく、0.002以下であることがより好ましく、0.001以下であることが更に好ましく、0を超え0.001以下であることが特に好ましい。
また、誘電正接が0.01未満である化合物が融点を示さない場合は、融点として、流動開始温度を用いるものとする。流動開始温度は、フロー温度又は流動温度とも呼ばれ、毛細管レオメーターを用いて、9.8MPa(100kg/cm2)の荷重下、4℃/分の速度で昇温しながら、誘電正接が0.01未満である化合物を溶融させ、内径1mm及び長さ10mmのノズルから押し出すときに、4,800Pa・s(48,000ポイズ)の粘度を示す温度である。
なお、ポリマーフィルムに金属層が積層されている場合には、金属層を塩化第二鉄水溶液でエッチングし、水洗及び乾燥してフィルムを取り出す。続けて、フィルムをDSCの測定パンに入れて測定し、現れた複数の吸熱ピークのうち、特定ポリマー由来でない方を特定して評価することができる。
また、DSC測定でのピークが明瞭に現れない場合の別の方法として、誘電正接が0.01未満である化合物の化学構造を特定し、当該素材からなる複数の粒子を昇温させていき、融着した温度として評価することもできる。
誘電率測定は、周波数10GHzで共振摂動法により実施する。ネットワークアナライザ(Agilent Technology社製「E8363B」)に10GHzの空洞共振器((株)関東電子応用開発製 CP531)を接続し、空洞共振器に試料(幅:2mm×長さ:80mm)を挿入し、温度20℃、湿度65%RH環境下、96時間の挿入前後の共振周波数の変化から試料の誘電率及び誘電正接を測定する。
各層の誘電正接を測定する場合は、カミソリ等で不要な層を削り出し、目的の層だけの評価用サンプルを作製してもよい。また、層の厚みが薄い等の理由で、単膜の取り出しが困難な場合には、カミソリ等で測定する層を削り取り、得られた粉末状の試料を用いてもよい。本開示におけるポリマーの誘電正接の測定は、各層を構成するポリマーの化学構造を特定するか又は単離し、測定するポリマーを粉末としたサンプルを用いて、上記の誘電正接の測定方法に従って行うものとする。周波数の変化から試料の誘電率及び誘電正接を測定する。
誘電正接が0.01未満である化合物としては、ポリマーフィルムの誘電正接、及び、破断強度の観点から、樹脂であることが好ましく、融点が特定ポリマーより低く、かつ、誘電正接が0.01未満である液晶ポリマーB、フッ素系ポリマー、シクロオレフィンポリマー、ポリフェニレンエーテル、又は、芳香族ビニル樹脂であることがより好ましく、上記第一の実施態様においては、破断強度の観点からは、上記液晶ポリマーBが特に好ましく、また、ポリマーフィルムの誘電正接の観点からは、フッ素系ポリマーが特に好ましく、上記第二の実施態様においては、破断強度の観点から、上記液晶ポリマーBが特に好ましい。あるいは、誘電正接が0.01未満の無機粒子の表面を、融点を示す有機物で被覆したものを用いることもできる。
フッ素系ポリマーとしては、ポリテトラフルオロエチレンが好ましく挙げられる。
また、誘電正接が0.01未満である化合物として用いられる樹脂としては、破断強度の観点から、重量平均分子量が1,000以上の樹脂であることが好ましく、重量平均分子量が2,000以上の樹脂であることがより好ましく、重量平均分子量が3,000以上の樹脂であることが更に好ましく、重量平均分子量が5,000以上200,000以下の樹脂であることが特に好ましい。また、液晶ポリマーである場合は、重量平均分子量が13,000以下であることが好ましい。
誘電正接が0.01未満である化合物として用いられる液晶ポリマーBの融点は、200℃以上、かつ含有される特定ポリマーの融点Tm未満であることが好ましく、250℃以上、かつ含有される特定ポリマーの融点Tm未満であることがより好ましく、280℃以上、かつ特定ポリマーの融点Tm未満であることが特に好ましい。
また、液晶ポリマーBの融点Tmの上限値は、330℃未満であることが好ましく、315℃未満であることがより好ましい。
また、誘電正接が0.01未満である化合物の融点(好ましくは融点Tm)は、ポリマーフィルムの誘電正接、及び、破断強度の観点から、特定ポリマーの融点より10℃以上低いことが好ましく、特定ポリマーの融点より20℃以上低いことがより好ましく、特定ポリマーの融点より30℃~100℃低いことが更に好ましく、特定ポリマーの融点より30℃~70℃低いことが特に好ましい。
上記粒子の平均粒径は、ポリマーフィルムの誘電正接、及び、破断強度の観点から、5nm~20μmであることが好ましく、20nm~2μmであることがより好ましく、50nm~1μmであることが更に好ましく、100nm~500nmであることが特に好ましい。
液晶ポリマーAの融点より大きい融点を有するポリマーとしては、フッ素系ポリマーが好ましく挙げられる。
フッ素系ポリマーとしては、上述したものが挙げられる。
示差走査熱量分析(DSC)装置の測定パンにフィルムを2mg入れ、窒素気流中で20℃/分で25℃から350℃まで昇温した際に現れた発熱ピークの熱量をフィルムのΔHcとする。また、発熱ピークの帰属は、フィルムを構成する素材を単離し、別途、上記条件でDSC測定することにより、各素材由来の発熱ピーク温度を調べ、実施する。
ポリマーフィルムにおける誘電正接が0.01未満である化合物の含有量は、誘電正接、及び、破断強度の観点から、ポリマーフィルムの全質量に対し、10質量%~90質量%であることが好ましく、20質量%~80質量%であることがより好ましく、30質量%~70質量%であることが特に好ましい。
また、ポリマーフィルムにおける特定ポリマーの含有量MAと誘電正接が0.01未満である化合物の含有量MBとの質量比MA/MBは、誘電正接、及び、破断強度の観点から、0.1~10であることが好ましく、0.2~5であることがより好ましく、0.5~2であることが特に好ましい。
本開示に係るポリマーフィルムは、線膨張係数、及び、金属層との密着性の観点から、上記誘電正接が0.01未満である化合物以外のフィラー(以下、単に「フィラー」ともいう。)を含むことが好ましい。
フィラーは、粒子状であっても、繊維状であってもよく、また、無機フィラーであっても、有機フィラーであってもよい。
本開示に係るポリマーフィルムにおいて、上記フィラーの数密度は、線膨張係数、及び、金属層との密着性の観点から、上記ポリマーフィルムの表面より内部の方が大きいことが好ましい。
無機フィラーの材質としては、例えば、BN、Al2O3、AlN、TiO2、SiO2、チタン酸バリウム、チタン酸ストロンチウム、水酸化アルミニウム、炭酸カルシウム、及び、これらを2種以上含む材質が挙げられる。
中でも、無機フィラーとしては、線膨張係数、及び、金属層との密着性の観点から、金属酸化物粒子、又は、繊維が好ましく、シリカ粒子、チタニア粒子、又は、ガラス繊維がより好ましく、シリカ粒子、又は、ガラス繊維が特に好ましい。
無機フィラーの平均粒径は、層Aの厚みの約20%~約40%であることが好ましく、例えば、層Aの厚みの25%、30%又は35%にあるものを選択してもよい。粒子、または繊維が扁平状の場合には、短辺方向の長さを示す。
また、無機フィラーの平均粒径は、線膨張係数、及び、金属層との密着性の観点から、5nm~20μmであることが好ましく、10nm~10μmであることがより好ましく、20nm~1μmであることが更に好ましく、25nm~500nmであることが特に好ましい。
有機フィラーの材質としては、例えば、ポリエチレン、ポリスチレン、尿素-ホルマリンフィラー、ポリエステル、セルロース、アクリル樹脂、フッ素樹脂、硬化エポキシ樹脂、架橋ベンゾグアナミン樹脂、架橋アクリル樹脂、液晶ポリマー、及び、これらを2種以上含む材質が挙げられる。
また、有機フィラーは、ナノファイバーのような繊維状であってもよく、中空樹脂粒子であってもよい。
中でも、有機フィラーとしては、線膨張係数、及び、金属層との密着性の観点から、フッ素樹脂粒子、ポリエステル系樹脂粒子、ポリエチレン粒子、液晶ポリマー粒子、又は、セルロース系樹脂のナノファイバーであることが好ましく、ポリテトラフルオロエチレン粒子、ポリエチレン粒子、又は、液晶ポリマー粒子であることがより好ましい。
有機フィラーの平均粒径は、線膨張係数、及び、金属層との密着性の観点から、5nm~20μmであることが好ましく、10nm~1μmであることがより好ましく、20nm~500nmであることが更に好ましく、25nm~90nmであることが特に好ましい。
ポリマーフィルムにおけるフィラーの含有量は、熱膨張係数、及び、金属層との密着性の観点から、ポリマーフィルムの全体積に対し、5体積%~80体積%であることが好ましく、10体積%~70体積%であることがより好ましく、15体積%~70体積%であることが更に好ましく、20体積%~60体積%であることが特に好ましい。
ポリマーフィルムは、上述した成分以外のその他の添加剤を含んでいてもよい。
その他の添加剤としては、公知の添加剤を用いることができる。具体的には、例えば、レベリング剤、消泡剤、酸化防止剤、紫外線吸収剤、難燃剤、着色剤等が挙げられる。
その他の樹脂の例としては、ポリプロピレン、ポリアミド、液晶ポリエステル以外のポリエステル、ポリフェニレンスルフィド、ポリエーテルケトン、ポリカーボネート、ポリエーテルスルホン、ポリフェニレンエーテル及びその変性物、ポリエーテルイミド等の液晶ポリエステル以外の熱可塑性樹脂;グリシジルメタクリレートとポリエチレンとの共重合体等のエラストマー;フェノール樹脂、エポキシ樹脂、ポリイミド樹脂、シアネート樹脂等の熱硬化性樹脂が挙げられる。
例えば、本開示に係るポリマーフィルムは、特定ポリマー及び誘電正接が0.01未満である化合物を含む層Aと、上記層Aの少なくとも一方の面に層Bとを有する構造であってもよいし、層Bと、特定ポリマー及び誘電正接が0.01未満である化合物を含む層Aと、層Cとをこの順で有する構造であってもよい。
中でも、上記層Aは、誘電正接が0.01未満である化合物として、粒子を含むか、フィラーを更に含むことが好ましい。
また、層B及び層Cはそれぞれ独立に、特定ポリマーを含むことが好ましく、特定ポリマー及び誘電正接が0.01未満である化合物を含むことがより好ましい。
また、層Bに含まれるポリマーは、層Aに含まれるポリマーよりも破断強度(靭性)が高いポリマーであることが好ましい。
破断強度の測定は、以下の方法により行うものとする。
測定するポリマーからなるサンプルを作製し、東洋ボールドウィン(株)製万能引っ張り試験機“STM T50BP”を用い、25℃、60%RH雰囲気中、引張速度10%/分で伸びに対する応力を測定し、破断強度を求める。
更に、ポリマーフィルムにおける層構成、及び、各層の厚み等の検出又は判定方法としては、以下の方法が挙げられる。
まず、ミクロトームによりポリマーフィルムの断面サンプルを切り出し、光学顕微鏡により層構成、及び、各層の厚みを判定する。光学顕微鏡での判定が困難な場合、走査型電子顕微鏡(SEM)による形態観察、又は、飛行時間型二次イオン質量分析法(TOF-SIMS)等による成分分析を行って判定してもよい。
上記官能基としては、共有結合可能な基、イオン結合可能な基、水素結合可能な基、双極子相互作用可能な基、及び、硬化反応可能な基よりなる群から選ばれた少なくとも1種の基であることが好ましい。
官能基を有する化合物は、低分子化合物であっても、高分子化合物であってもよい。
官能基を有する化合物は、上記ポリマーと官能基を有する化合物との相溶性、及び、ポリマーフィルムの誘電正接の観点からは、低分子化合物であることが好ましく、ポリマーフィルムの耐熱性、及び、力学的強度の観点からは、高分子化合物であることが好ましい。
官能基を有する化合物における官能基の数は、1以上であればよく、2以上であってもよいが、2以上であることが好ましく、また、官能基量を適度な量とし、ポリマーフィルムの誘電正接を小さくする観点から、10以下が好ましい。
また、官能基を有する化合物は、1種のみの官能基を有していても、2種以上の官能基を有していてもよい。
官能基を有する化合物が低分子化合物である場合、化合物の広がりが狭く、官能基同士の接触確率を上げるため、官能基を有する化合物の含有量は、層Bの全質量に対し、10質量%以上含むことが好ましい。
また、官能基を有する化合物として用いられる高分子化合物としては、金属層との密着性の観点から、重量平均分子量が1,000以上のポリマーであることが好ましく、重量平均分子量が2,000以上のポリマーであることがより好ましく、重量平均分子量が3,000以上1,000,000以下のポリマーであることが更に好ましく、重量平均分子量が5,000以上200,000以下のポリマーであることが特に好ましい。
上記ポリマーのHoy法によるSP値と官能基を有する化合物のHoy法によるSP値との差は、誘電正接が0.005以下であるポリマーと官能基を有する化合物との相溶性、ポリマーフィルムの誘電正接、及び、金属層との密着性の観点から、5MPa0.5以下であることが好ましい。なお、下限値は、0MPa0.5である。
官能基を有する化合物における官能基は、共有結合可能な基、イオン結合可能な基、水素結合可能な基、双極子相互作用可能な基、及び、硬化反応可能な基よりなる群から選ばれた少なくとも1種の基であることが好ましい。
層Cと金属層との密着性の観点からは、官能基は、共有結合可能な基、又は、硬化反応可能な基であることが好ましく、共有結合可能な基であることがより好ましい。
また、保存安定性、及び、取り扱い性の観点からは、官能基が、イオン結合可能な基、水素結合可能な基、又は、双極子相互作用可能な基であることが好ましい。
共有結合可能な基としては、共有結合が形成可能な基であれば特に制限はなく、例えば、エポキシ基、オキセタニル基、イソシアネート基、酸無水物基、カルボジイミド基、N-ヒドロキシエステル基、グリオキサール基、イミドエステル基、ハロゲン化アルキル基、チオール基、ヒドロキシ基、カルボキシ基、アミノ基、アミド基、イソシアネート基、アルデヒド基、スルホン酸基等を挙げることができる。これらの中でも、層Cと金属層との密着性の観点から、エポキシ基、オキセタニル基、N-ヒドロキシエステル基、イソシアネート基、イミドエステル基、ハロゲン化アルキル基、及び、チオール基よりなる群から選ばれる少なくとも1種の官能基であることが好ましく、エポキシ基が特に好ましい。
共有結合可能な基と上記共有結合可能な基と対になる基との組み合わせ(官能基を有する化合物の官能基と、金属の表面に有する基との組み合わせ)としては、一方が、例えば、エポキシ基又はオキセタニル基である場合、他方は、ヒドロキシ基、アミノ基等が挙げられる。
また、上記組み合わせの一方が、例えば、N-ヒドロキシエステル基又はイミドエステル基である場合、他方は、アミノ基等が挙げられる。
イオン結合可能な基としては、カチオン性基、アニオン性基等が挙げられる。
上記カチオン性基としては、オニウム基であることが好ましい。オニウム基の例は、アンモニウム基、ピリジニウム基、ホスホニウム基、オキソニウム基、スルホニウム基、セレノニウム基、ヨードニウム基等が挙げられる。中でも、層Cと金属層との密着性の観点から、アンモニウム基、ピリジニウム基、ホスホニウム基、又は、スルホニウム基が好ましく、アンモニウム基、又は、ホスホニウム基がより好ましく、アンモニウム基が特に好ましい。
アニオン性基としては、特に制限はなく、例えば、フェノール性水酸基、カルボキシ基、-SO3H、-OSO3H、-PO3H、-OPO3H2、-CONHSO2-、-SO2NHSO2-等が挙げられる。これらの中でも、リン酸基、ホスホン酸基、ホスフィン酸基、硫酸基、スルホン酸基、スルフィン酸基又はカルボキシ基であることが好ましく、リン酸基、又は、カルボキシ基であることがより好ましく、カルボキシ基であることが更に好ましい。
上記酸性基としては、例えば、カルボキシ基、スルホ基、リン酸基等が挙げられ、カルボキシ基であることが好ましい。
また、上記組み合わせの一方が、例えば、カルボキシ基である場合、カルボキシ基とイオン結合可能な基は、第三級アミノ基、ピリジル基、ピペリジル基等が挙げられる。
水素結合可能な基としては、水素結合供与性部位を有する基、水素結合受容性部位を有する基が挙げられる。
上記水素結合供与性部位は、水素結合可能な活性水素原子を有する構造であればよいが、X-Hで表される構造であることが好ましい。
Xは、ヘテロ原子を表し、窒素原子、又は、酸素原子であることが好ましい。
上記水素結合供与性部位としては、層Cと金属層との密着性の観点から、ヒドロキシ基、カルボキシ基、第一級アミド基、第二級アミド基、第一級アミノ基、第二級アミノ基、第一級スルホンアミド基、第二級スルホンアミド基、イミド基、ウレア結合、及び、ウレタン結合よりなる群から選ばれる少なくとも1種の構造であることが好ましく、ヒドロキシ基、カルボキシ基、第一級アミド基、第二級アミド基、第一級スルホンアミド基、第二級スルホンアミド基、マレイミド基、ウレア結合、及び、ウレタン結合よりなる群から選ばれる少なくとも1種の構造であることがより好ましく、ヒドロキシ基、カルボキシ基、第一級アミド基、第二級アミド基、第一級スルホンアミド基、第二級スルホンアミド基、及び、マレイミド基よりなる群から選ばれる少なくとも1種の構造であることが更に好ましく、ヒドロキシ基、及び、第二級アミド基よりなる群から選ばれる少なくとも1種の構造であることが特に好ましい。
例えば、上記組み合わせの一方がカルボキシ基である場合、アミド基、カルボキシ基等が挙げられる。
また、上記組み合わせの一方が、例えば、フェノール性水酸基である場合、他方は、フェノール性水酸等が挙げられる。
双極子相互作用可能な基としては、上記水素結合可能な基におけるX-H(Xは、ヘテロ原子を表し、窒素原子、又は、酸素原子)で表される構造以外の分極した構造を有した基であればよく、電気陰性度の異なる原子が結合された基が好適に挙げられる。
電気陰性度の異なる原子の組み合わせとしては、酸素原子、窒素原子、硫黄原子、及びハロゲン原子からなる群より選択される少なくとも1種の原子と炭素原子との組み合わせが好ましく、酸素原子、窒素原子、及び、硫黄原子からなる群より選択される少なくとも1種の原子と炭素原子との組み合わせがより好ましい。
これらの中でも、層Cと金属層との密着性の観点から、窒素原子と炭素原子との組み合わせ、炭素原子と、窒素原子、酸素原子及び硫黄原子との組み合わせが好ましく、具体的には、シアノ基、シアヌル基、スルホン酸アミド基がより好ましい。
上記組み合わせの一方が、例えば、シアノ基である場合、他方は、シアノ基が挙げられる。
また、上記組み合わせの一方が、例えば、スルホン酸アミド基である場合、他方は、スルホン酸アミド基が挙げられる。
硬化反応可能な基としては、エチレン性不飽和基、環状エーテル基、シアナト基、反応性シリル基、オキサジン環基、ウレタン基等が挙げられる。
硬化反応可能な基を有する化合物としては、下記の硬化性化合物を用いてもよい。
硬化性化合物は、熱や光(例えば、可視光、紫外線、近赤外線、遠赤外線、電子線等)の照射により硬化する化合物であり、後述する硬化助剤を必要とするものであってもよい。このような硬化性化合物としては、例えば、エポキシ化合物、シアネートエステル化合物、ビニル化合物、シリコーン化合物、オキサジン化合物、マレイミド化合物、アリル化合物、アクリル化合物、メタクリル化合物、ウレタン化合物が挙げられる。これらは、1種単独で用いられてもよいし、2種以上が併用されてもよい。これらの中でも、前記重合体との相溶性、耐熱性等の特性上の観点から、エポキシ化合物、シアネートエステル化合物、ビニル化合物、シリコーン化合物、オキサジン化合物、マレイミド化合物、及び、アリル化合物よりなる群から選ばれた少なくとも1種であることが好ましく、エポキシ化合物、シアネートエステル化合物、ビニル化合物、アリル化合物、及び、シリコーン化合物よりなる群から選ばれた少なくとも1種であることがより好ましい。
層B中の硬化性化合物の含有量は、層Cの全質量に対して、10質量%以上90質量%以下であることが好ましく、20質量%以上80質量%以下であることがより好ましい。
硬化助剤としては、例えば、光反応開始剤(光ラジカル発生剤、光酸発生剤、光塩基発生剤)等の重合開始剤を挙げることができる。硬化助剤の具体例としては、オニウム塩化合物、スルホン化合物、スルホン酸エステル化合物、スルホンイミド化合物、ジスルホニルジアゾメタン化合物、ジスルホニルメタン化合物、オキシムスルホネート化合物、ヒドラジンスルホネート化合物、トリアジン化合物、ニトロベンジル化合物、ベンジルイミダゾール化合物、有機ハロゲン化物類、オクチル酸金属塩、ジスルホン等が挙げられる。これらの硬化助剤は、種類を問わず、1種単独で用いてもよいし、2種以上を併用してもよい。
層B中の硬化助剤の含有量は、層Bの全質量に対して、5質量%以上20質量%以下であることが好ましく、5質量%以上10質量%以下であることがより好ましい。
層B又は層Cにおける官能基を有する化合物の含有量は、ポリマーフィルムの誘電正接、及び、金属層との密着性の観点から、ポリマーフィルムの全質量に対し、1質量%~80質量%であることが好ましく、5質量%~70質量%であることがより好ましく、10質量%~60質量%であることが更に好ましく、20質量%~60質量%であることが特に好ましい。
ポリマーフィルムをミクロトームで切削し、断面を光学顕微鏡で観察して、各層の厚みを評価する。断面サンプルは3ヶ所以上切り出し、各断面において、3点以上厚みを測定し、それらの平均値を平均厚みとする。
層Aの平均厚みTAと層Bの平均厚みTBとの比であるTA/TBの値は、熱膨張係数、及び、金属層との密着性の観点から、1より大きいことが好ましく、2~100であることがより好ましく、2.5~20であることが更に好ましく、3~10であることが特に好ましい。
層Aの平均厚みTAと層Cの平均厚みTCとの比であるTA/TCの値は、熱膨張係数、及び、金属層との密着性の観点から、1より大きいことが好ましく、2~100であることがより好ましく、2.5~20であることが更に好ましく、3~10であることが特に好ましい。
また、層Cの平均厚みTCと層Bの平均厚みTBとの比であるTC/TBの値は、熱膨張係数、及び、金属層との密着性の観点から、0.2~5であることが好ましく、0.5~2であることがより好ましく、0.8~1.2であることが特に好ましい。
更に、層B及び層Cの平均厚みはそれぞれ独立に、熱膨張係数、及び、金属層との密着性の観点から、0.1μm~20μmであることが好ましく、0.5μm~15μmであることがより好ましく、1μm~10μmであることが更に好ましく、3μm~8μmであることが特に好ましい。
熱機械分析装置(TMA)を用いて、幅5mm、長さ20mmのポリマーフィルム又は各層の測定サンプルの両端に1gの引張荷重をかけ、5℃/分の速度で25℃~200℃まで昇温した後、20℃/分の速度で30℃まで冷却し、再び5℃/分の速度で昇温したときの、30℃~150℃の間のTMA曲線の傾きから線膨張係数を算出する。
各層を測定する場合は、カミソリ等により、測定する層を削り取り測定サンプルを作製してもよい。
また、上記方法にて線膨張係数の測定が困難な場合は、以下の方法にて測定するものとする。
ポリマーフィルムをミクロトームで切削して切片サンプルを作製し、加熱ステージシステム(HS82、メトラー・トレド社製)を備えた光学顕微鏡にセットし、続いて、5℃/分の速度で25℃~200℃まで昇温した後、20℃/分の速度で30℃まで冷却し、再び5℃/分の速度で昇温したときの、30℃でのポリマーフィルム又は各層の厚み(ts30)、及び、150℃でのポリマーフィルム又は各層の厚み(ts150)を評価し、寸法変化を温度変化で除した値((ts150-ts30)/(150-30))を算出し、ポリマーフィルム又は各層の線膨張係数を算出してもよい。
〔製膜〕
本開示に係るポリマーフィルムの製造方法は、特に制限はなく、公知の方法を参照することができる。
本開示に係るポリマーフィルムの製造方法としては、例えば、流延法、塗布法、押出法等が好適に挙げられる。中でも、流延法が特に好ましい。また、本開示に係るポリマーフィルムが、多層構造を有する場合には、例えば、共流延法、重層塗布法、共押出法等が好適に挙げられる。中でも、比較的薄手の製膜には共流延法が特に好ましく、厚手の製膜には共押出法が特に好ましい。
ポリマーフィルムにおける多層構造を共流延法及び重層塗布法により製造する場合、特定ポリマー及び誘電正接が0.01未満である化合物等の各層の成分をそれぞれ溶媒に溶解又は分散した層A形成用組成物、層B形成用組成物、層C形成用組成物等を用いて、共流延法又は重層塗布法を行うことが好ましい。
上記非プロトン性化合物として、双極子モーメントが3~5である化合物を用いることが好ましい。
上記非プロトン性化合物として、1気圧における沸点が220℃以下である化合物を用いることが好ましい。
支持体としては、例えば、金属ドラム、金属バンド、ガラス板、樹脂フィルム又は金属箔が挙げられる。中でも、金属ドラム、金属バンド、樹脂フィルムが好ましい。
樹脂フィルムとしては、例えばポリイミド(PI)フィルムを挙げることができ、市販品の例としては、宇部興産(株)製U-ピレックスS及びU-ピレックスR、東レデュポン(株)製カプトン、並びに、SKCコーロンPI社製IF30、IF70及びLV300等が挙げられる。
また、支持体は、容易に剥離できるように、表面に表面処理層が形成されていてもよい。表面処理層は、ハードクロムメッキ、フッ素樹脂等を用いることができる。
支持体の平均厚みは、特に制限はないが、好ましくは25μm以上75μm以下であり、より好ましくは50μm以上75μm以下である。
本開示に係るポリマーフィルムは、分子配向を制御し、線膨張係数や力学物性を調整する観点で、適宜、延伸を組み合わせることができる。延伸の方法は、特に制限はなく、公知の方法を参照することができ、溶媒を含んだ状態で実施してもよく、乾膜の状態で実施してもよい。溶媒を含んだ状態での延伸は、フィルムを把持して伸長してもよく、伸長せずに乾燥によるウェブの自己収縮力を利用して実施してもよく、それらの組み合わせでもよい。延伸は、無機フィラー等の添加によってフィルム脆性が低下した場合に、破断伸度や破断強度を改善する目的で特に有効である。
本開示に係るポリマーフィルムの製造方法は、ポリマーフィルムを熱処理(アニール)する工程を含むことが好ましい。
上記熱処理する工程における熱処理温度としては、製造プロセス中のウェブの機械強度、及び、製造されたポリマーフィルムの破断強度の観点から、特定ポリマーの融点Tm未満の温度であることが好ましく、誘電正接が0.01未満である化合物の融点を超え特定ポリマーの融点未満の温度であることがより好ましい。
また、誘電正接が0.01未満である化合物が、特定ポリマーの融点Tmより高い融点を有するポリマーである場合、上記熱処理する工程における熱処理温度は、破断強度の観点から、特定ポリマーの融点を超える温度であることが好ましく、特定ポリマーの融点を超え誘電正接が0.01未満である化合物の融点Tm未満の温度であることがより好ましい。
更に、上記熱処理する工程における熱処理温度として具体的には、破断強度の観点から、260℃~370℃であることが更に好ましく、310℃~350℃であることが特に好ましい。アニールの時間としては、30分~5時間が好ましく、30分~3時間が更に好ましい。
また、本開示に係るポリマーフィルムの製造方法は、必要に応じ、他の公知の工程を含んでいてもよい。
本開示に係るポリマーフィルムは、種々の用途に用いることができる、中でも、プリント配線板などの電子部品用フィルムに好適に用いることができ、フレキシブルプリント回路基板により好適に用いることができる。
また、本開示に係るポリマーフィルムは、金属接着用ポリマーフィルムとして好適に用いることができる。
本開示に係る積層体は、本開示に係るポリマーフィルムが積層したものであればよいが、本開示に係るポリマーフィルムと、上記ポリマーフィルムの少なくとも一方の面に配置された金属層とを有することが好ましく、本開示に係るポリマーフィルムと、上記ポリマーフィルムの両面にそれぞれ配置された銅層を有することがより好ましい。また、上記金属層が、銅層であることがより好ましい。
また、本開示に係る積層体は、層Bと、層Aと、層Cとをこの順で有する本開示に係るポリマーフィルムと、上記ポリマーフィルムの上記層B側の面に配置された金属層と、上記ポリマーフィルムの上記層C側の面に配置された金属層とを有することが好ましく、上記金属層がいずれも、銅層であることがより好ましい。
上記層B側の面に配置された金属層は、上記層Bの表面に配置された金属層であることが好ましい。
上記層C側の面に配置された金属層は、上記層Cの表面に配置された金属層であることが好ましく、上記層B側の面に配置された金属層は、上記層Bの表面に配置された金属層であり、かつ上記層C側の面に配置された金属層は、上記層Cの表面に配置された金属層であることがより好ましい。
また、上記層B側の面に配置された金属層と上記層C側の面に配置された金属層とは、同じ材質、厚さ及び形状の金属層であっても、異なる材質、厚さ及び形状の金属層であってもよい。特性インピーダンス調整の観点からは、上記層B側の面に配置された金属層と上記層C側の面に配置された金属層とは、異なる材質や厚みの金属層であってもよく、層B又はCのうち、片側だけに金属層が積層されていてもよい。
ポリマーフィルムと金属層との積層体から1.0cm幅の剥離用試験片を作製し、ポリマーフィルムを両面接着テープで平板に固定し、JIS C 5016(1994)に準じて180°法により、50mm/分の速度で金属層からポリマーフィルムを剥離したときの強度(kN/m)を測定する。
本開示において、金属層(例えば、銅層)の表面粗さRzは、以下の方法により測定するものとする。
非接触表面・層断面形状計測システムVertScan(菱化システム社製)を用い、縦465.48μm、横620.64μm四方を測定して、測定対象物(金属層)の表面における粗さ曲線及び上記粗さ曲線の平均線を作成する。粗さ曲線から基準長さに相当する部分を抜き取る。抜き出した粗さ曲線で観察される山の高さ(すなわち、平均線から山頂までの高さ)の最大値と谷の深さ(すなわち、平均線から谷底までの高さ)の最大値との合計値を求めることで、測定対象物の表面粗さRzを測定する。
本開示に係る積層体における金属層を、例えば、エッチングにより所望の回路パターンに加工し、フレキシブルプリント回路基板することも好ましい。エッチング方法としては、特に制限はなく、公知のエッチング方法を用いることができる。
〔誘電正接〕
誘電率測定は、周波数10GHzで共振摂動法により実施した。ネットワークアナライザ(Agilent Technology社製「E8363B」)に10GHzの空洞共振器((株)関東電子応用開発製CP531)を接続し、空洞共振器にポリマーフィルム又は各層のサンプル(幅:2.0mm×長さ:80mm)を挿入し、温度25℃、湿度60%RH環境下、96時間の挿入前後の共振周波数の変化からポリマーフィルム又は各層の誘電率及び誘電正接を測定した。
示差走査熱量分析(DSC)装置の測定パンにポリマーフィルムを2mg入れ、窒素気流中で20℃/分で25℃から350℃まで昇温した際に現れた発熱ピークの熱量をフィルムのΔHcとした。また、発熱ピークの帰属は、フィルムを構成する素材を単離し、別途、上記条件でDSC測定することにより、各素材由来の発熱ピーク温度を調べ、実施した。
作製したポリマーフィルムから150mm×10mmのサンプルを切り出し、東洋ボールドウィン(株)製万能引っ張り試験機“STM T50BP”を用い、25℃、60%RH雰囲気中、引張速度10%/分で伸びに対する応力を測定し、破断強度を求めた。
<液晶ポリマー>
LC-A:国際公開第2020/166644号の比較例2に記載の液晶ポリエステル(B)の製造を参考に、モノマー添加比率や熱重合条件を調整して作製した液晶ポリマー
LC-C:下記製造方法に従って作製した液晶ポリマー(誘電正接0.004)
撹拌装置、トルクメータ、窒素ガス導入管、温度計及び還流冷却器を備えた反応器に、6-ヒドロキシ-2-ナフトエ酸940.9g(5.0モル)、4-ヒドロキシアセトアミノフェン377.9g(2.5モル)、イソフタル酸415.3g(2.5モル)及び無水酢酸867.8g(8.4モル)を入れ、反応器内のガスを窒素ガスで置換した後、窒素ガス気流下、撹拌しながら、室温(23℃)から143℃まで60分かけて昇温し、143℃で1時間還流させた。
次いで、副生酢酸及び未反応の無水酢酸を留去しながら、150℃から300℃まで5時間かけて昇温し、300℃で30分保持した後、反応器から内容物を取り出し、室温まで冷却した。得られた固形物を、粉砕機で粉砕して、粉末状の液晶ポリエステル(C1)を得た。
撹拌装置、トルクメータ、窒素ガス導入管、温度計及び還流冷却器を備えた反応器に、6-ヒドロキシ-2-ナフトエ酸941g(5.0モル)、4-アミノフェノール273g(2.5モル)、イソフタル酸415g(2.5モル)及び無水酢酸1123g(11モル)を入れ、反応器内のガスを窒素ガスで置換した後、窒素ガス気流下、撹拌しながら、室温(23℃)から150℃まで15分かけて昇温し、150℃で3時間還流させた。
次いで、副生酢酸及び未反応の無水酢酸を留去しながら、150℃から320℃まで3時間かけて昇温し、粘度の上昇が認められるまで保持した後、反応器から内容物を取り出し、室温まで冷却した。得られた固形物を、粉砕機で粉砕して、粉末状の液晶ポリエステル(D1)を得た。
P-1:市販のポリフェニレンエーテルのペレット(SA120、SABIC社製、重量平均分子量Mw2,600)/ビスフェノールA型エポキシ樹脂(エピクロン850S、DIC(株)製、平均エポキシ基数2個)/ビスフェノールA型シアネートエステル樹脂(Badcy、ロンザジャパン(株)製)/芳香族縮合リン酸エステル(PX-200、大八化学工業(株)製)/トリスジエチルホスフィン酸アルミニウム(エクソリットOP-935、クラリアントジャパン(株)製)/オクタン酸亜鉛=25/34/25/8/8/0.01(質量比)の混合物
LC-B:市販の液晶ポリマー樹脂の粉末(ベクトラA950、ポリプラスチックス(株)製、液晶ポリエステル)
A-1:市販のポリテトラフルオロエチレン(PTFE)ナノ粒子(ポリフロンPTFE D-210C、平均粒径0.25μm、ダイキン工業(株)製)の溶媒をN-メチルピロリドン溶媒に置換し、ポリマーフィルムにおける固形分が表1に記載の量になるように用いた。
A-2:四フッ化エチレンとパーフルオロアルコキシエチレンとの共重合体(PFA)粒子(融点280℃、平均粒子径が0.2μm~0.5μm、誘電正接0.001)
A-3:市販の平均粒径10μmの超高分子量ポリエチレン粒子(ミペロンPM200、三井化学(株)製)を、固形分量が表1に記載の量となるように用いた。
M-1:市販のアミノフェノール型エポキシ樹脂(jER630LSD、三菱ケミカル(株)製)を用いた。
下記の流延に準じて製膜を行った。
-ポリマー溶液の調製-
表1に記載の特定ポリマー、及び、表1に記載の誘電正接が0.01未満である化合物をN-メチルピロリドンに加え、窒素雰囲気下、140℃で4時間撹拌し、液晶ポリマー溶液を得た。液晶ポリマーと誘電正接が0.01未満である化合物は、表1に記載の質量比率で添加し、固形分濃度は23質量%とした。
続いて、最初に、公称孔径10μmの焼結繊維金属フィルターを通過させ、ついで同じく公称孔径10μmの焼結繊維金属フィルターを通過させ、ポリマー溶液を得た。
なお、添加剤がN-メチルピロリドンに溶解しない場合は、添加剤を添加せずに液晶ポリマー溶液を調製し、上記焼結繊維金属フィルターに通過させた後に添加剤を添加して、撹拌した。
得られたポリマー溶液を流延ダイに送液し、銅箔(三井金属鉱業(株)製3EC-VLP、厚み18μm、粗化面の表面粗さRz3.0μm)の粗化面上に流延した。40℃にて4時間乾燥することにより、流延膜から溶媒を除去し、更に窒素雰囲気下で室温(25℃)から表1に記載のアニール温度まで1℃/分で昇温し、その温度で2時間保持する熱処理を行い、銅層を有するポリマーフィルム(積層体)を得た。
なお、表1に記載のように、比較例1では、アニール(熱処理)を行わなかった。
-ポリマー溶液Aの調製-
表1に記載の特定ポリマーをN-メチルピロリドンに加え、窒素雰囲気下、140℃4時間撹拌し、固形分濃度8質量%のポリマー溶液を得た。
続いて、公称孔径10μmの焼結繊維金属フィルターを通過させ、ついで同じく公称孔径10μmの焼結繊維金属フィルターを通過させた。更に、表1に記載の誘電正接が0.01未満である化合物を、表1に記載の質量比率で添加し、十分に撹拌して、ポリマー溶液Aを得た。
ポリマー溶液Aの調製において、誘電正接が0.01未満である化合物を、硬化性化合物M-1に変更し、表1に記載のポリマーとM-1との質量比を95:5とした以外はポリマー溶液Aの調製と同様に実施し、ポリマー溶液Cを得た。
得られたポリマー溶液A、及び、ポリマー溶液Cを流延ダイに送液し、銅箔(福田金属箔粉工業(株)製、CF-T9DA-SV-18、厚み18μm、処理面の表面粗さRz0.85μm)の処理面側に、銅箔/ポリマー溶液Cからなる層C(乾燥後厚み3μm)/ポリマー溶液Aからなる層Aの層構成になるように流延した。40℃にて4時間乾燥することにより、流延膜から溶媒を除去し、更に窒素雰囲気下で室温(25℃)から表1に記載のアニール温度まで1℃/分で昇温し、その温度で2時間保持する熱処理を行い、銅層を有するポリマーフィルム(積層体)を得た。なお、表1に記載の平均厚みには、層Cの厚みも含まれる。
-ポリマー溶液の調製-
表1に記載のポリマー、及び、表1に記載の誘電正接が0.01未満である化合物を、固形分濃度が80%になるようにトルエンに添加し、混合物を60分撹拌し、ポリマー溶液Aを得た。
得られたポリマー溶液を、スロットダイコーターに送液し、銅箔(福田金属箔粉工業(株)製、CF-T9DA-SV-18、厚み18μm、処理面の表面粗さRz0.85μm)の処理面上に塗布した。続けて、100℃にて3分間乾燥した後、170℃で3分間乾燥することにより、塗膜から溶媒を除去し、更に室温から200℃まで1℃/分で昇温し、その温度で2時間保持する熱処理を行い、銅層を有するポリマーフィルム(積層体)を得た。
作製した積層体から銅層を剥離したポリマーフィルムについて、上述の方法で評価を行い、結果を表1に記載した。
また、各実施例で作製したポリマーフィルムと銅層との積層体から1.0cm幅の剥離用試験片を切り出し、ポリマーフィルムを両面接着テープで平板に固定し、JIS C 5016(1994)に準じて180°法により、50mm/分の速度でポリマーフィルムから銅層を剥離し、5kN/m以上の十分な接着性が得られていることをそれぞれ確認した。
なお、実施例3~5のフィルムについて、前記ΔHcは、すべて0J/gであることを確認した。
Claims (14)
- 液晶ポリマーA、及び、
融点が前記液晶ポリマーAより低く、かつ、誘電正接が0.01未満である化合物を含む
液晶ポリマーフィルム。 - 前記液晶ポリマーAの融点が、280℃以上である請求項1に記載の液晶ポリマーフィルム。
- 前記液晶ポリマーAが、式(1)~式(3)のいずれかで表される構成単位を有する請求項1又は請求項2に記載の液晶ポリマーフィルム。
式(1) -O-Ar1-CO-
式(2) -CO-Ar2-CO-
式(3) -X-Ar3-Y-
式(1)~式(3)中、Ar1は、フェニレン基、ナフチレン基又はビフェニリレン基を表し、Ar2及びAr3はそれぞれ独立に、フェニレン基、ナフチレン基、ビフェニリレン基又は下記式(4)で表される基を表し、X及びYはそれぞれ独立に、酸素原子又はイミノ基を表し、Ar1~Ar3における水素原子は、それぞれ独立に、ハロゲン原子、アルキル基又はアリール基で置換されていてもよい。
式(4) -Ar4-Z-Ar5-
式(4)中、Ar4及びAr5はそれぞれ独立に、フェニレン基又はナフチレン基を表し、Zは、酸素原子、硫黄原子、カルボニル基、スルホニル基又はアルキレン基を表す。 - 前記誘電正接が0.01未満である化合物が、ポリマーである請求項1~請求項3のいずれか1項に記載の液晶ポリマーフィルム。
- 前記誘電正接が0.01未満である化合物が、融点が前記液晶ポリマーAより低く、かつ、誘電正接が0.01未満である液晶ポリマーBである請求項1~請求項4のいずれか1項に記載の液晶ポリマーフィルム。
- 前記誘電正接が0.01未満である化合物が、粒子である請求項1~請求項5のいずれか1項に記載の液晶ポリマーフィルム。
- 前記誘電正接が0.01未満である化合物が、フッ素系ポリマーである請求項1~請求項6のいずれか1項に記載の液晶ポリマーフィルム。
- 前記誘電正接が0.01未満である化合物の含有量が、液晶ポリマーフィルムの全質量に対し、10質量%~90質量%である請求項1~請求項7のいずれか1項に記載の液晶ポリマーフィルム。
- 前記液晶ポリマーフィルムの誘電正接が、0.001以下である請求項1~請求項8のいずれか1項に記載の液晶ポリマーフィルム。
- 前記液晶ポリマーフィルムの線膨張係数が、-20ppm/K~50ppm/Kである請求項1~請求項9のいずれか1項に記載の液晶ポリマーフィルム。
- フッ素系ポリマー、環状脂肪族炭化水素基とエチレン性不飽和結合を有する基とを有する化合物の重合物、ポリフェニレンエーテル及び芳香族ポリエーテルケトンよりなる群から選ばれる少なくとも1種のポリマー、並びに、
融点が前記ポリマーより低く、かつ、誘電正接が0.01未満である化合物を含む
ポリマーフィルム。 - 請求項1~請求項10のいずれか1項に記載の液晶ポリマーフィルム、又は、請求項11に記載のポリマーフィルムと、前記液晶ポリマーフィルム又は前記ポリマーフィルムの少なくとも一方の面に配置された金属層とを有する積層体。
- 前記液晶ポリマーフィルム又は前記ポリマーフィルムの両面にそれぞれ配置された金属層を有する請求項12に記載の積層体。
- 前記金属層が、銅層であり、
前記液晶ポリマーフィルム又は前記ポリマーフィルムと前記銅層との剥離強度が、0.5kN/m以上である請求項12又は請求項13に記載の積層体。
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