Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
  • C08G65/44—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols by oxidation of phenols
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/48—Polymers modified by chemical after-treatment
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/48—Polymers modified by chemical after-treatment
  • C08G65/485—Polyphenylene oxides
• • 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
  • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
  • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
  • C08J5/244—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using glass fibres
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
  • C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
  • C08L71/12—Polyphenylene oxides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
  • C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
  • C08L71/12—Polyphenylene oxides
  • C08L71/123—Polyphenylene oxides not modified by chemical after-treatment
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
  • C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
  • C08L71/12—Polyphenylene oxides
  • C08L71/126—Polyphenylene oxides modified by chemical after-treatment
• • 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
  • C08J2371/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
  • C08J2371/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08J2371/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
  • C08J2371/12—Polyphenylene oxides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/02—Fibres or whiskers
  • C08K7/04—Fibres or whiskers inorganic
  • C08K7/14—Glass

Definitions

• the present invention relates to polyphenylene ether, its manufacturing method, thermosetting composition, prepreg, and laminate.
• Polyphenylene ether (hereinafter also referred to as "PPE") has excellent high-frequency characteristics, flame retardancy, and heat resistance. It is widely used as a material in various industrial material fields. In recent years, in particular, its low dielectric properties and heat resistance have led to its application as a modifier in electronic material applications such as substrate materials and various other applications.
• Patent Documents 4 and 6 propose low-molecular polyfunctional polyphenylene ethers obtained by polymerization in the presence of polyfunctional phenol compounds. These multifunctional polyphenylene ethers have a branched structure, so they have lower solution viscosity than linear polymers at the same molecular weight, and have higher fluidity than linear polymers even at the same molecular weight.
• a polymer having a relatively high molecular weight can be used, and improvement in the physical properties of the cured product can be expected.
• the number of cross-linking reaction sites increases, in addition to contributing to the improvement of the above physical properties, it is expected that the cross-linking reaction can be easily controlled.
• JP-A-2004-99824 Japanese Patent Application Laid-Open No. 2004-339328 Japanese Patent Publication No. 2008-510059 U.S. Pat. No. 9,012,572 JP 2007-308685 A Japanese Patent Application Laid-Open No. 2007-070598
• Patent Document 1 discloses a method for producing a polyphenylene ether with a low molecular weight or a polyfunctional polyphenylene ether in order to improve the solvent solubility of the polyphenylene ether, but simply lowering the molecular weight of the polyphenylene ether
• solubility in general-purpose ketone solvents such as methyl ethyl ketone at room temperature has not been significantly improved, and is still insufficient.
• the present invention has been made in view of the above problems, and aims to provide a polyphenylene ether excellent in solubility in general-purpose ketone solvents and a method for producing the same.
• Another object of the present invention is to provide a thermosetting composition, a prepreg, and a laminate using the polyphenylene ether.
• the present invention is as follows. [1] characterized by comprising a repeating unit derived from a phenol of the following formula (1), a repeating unit derived from a phenol of the following formula (2), and a structural unit derived from a phenol of the following formula (3) , polyphenylene ether.
• each R 11 is independently an optionally substituted saturated hydrocarbon group having 1 to 6 carbon atoms, an optionally substituted aryl group having 6 to 12 carbon atoms, or a halogen atom; and each R 12 is independently a hydrogen atom, an optionally substituted hydrocarbon group having 1 to 6 carbon atoms, an optionally substituted aryl group having 6 to 12 carbon atoms, or a halogen atom.
• each R 22 is independently a hydrogen atom, an optionally substituted saturated or unsaturated hydrocarbon group having 1 to 20 carbon atoms, an optionally substituted aryl having 6 to 12 carbon atoms, is a group or a halogen atom, two R 22 are not both hydrogen atoms, and R 21 is a partial structure represented by the following formula (4).
• X is an a-valent linking group
• a is an integer of 2 to 6
• R 3 is a linear alkyl group having 1 to 8 carbon atoms and the following formula (4) , wherein the carbon atom of the benzene ring to which -O- is bonded is the 1st position, and is bonded to at least one carbon atom at the 2nd or 6th position, and k are each independently It is an integer from 1 to 4.
• each R 41 is independently an optionally substituted linear alkyl group having 1 to 8 carbon atoms, or a cyclic alkyl structure having 1 to 8 carbon atoms in which two R 41 are bonded.
• R 42 are each independently an optionally substituted alkylene group having 1 to 8 carbon atoms, each b is independently 0 or 1, R 43 is a hydrogen atom, optionally substituted It is either an alkyl group having 1 to 8 carbon atoms or an optionally substituted phenyl group.
• the partial structure represented by the formula (4), which is R 21 in the formula (2), and the partial structure represented by the formula (4) in the R 3 of the formula (3) may be the same, can be different.
• R 8 is a saturated or unsaturated divalent hydrocarbon group having 1 to 10 carbon atoms, and the saturated or unsaturated divalent hydrocarbon has 1 to 10 carbon atoms.
• R 9 is a hydrogen atom or a saturated or unsaturated hydrocarbon group having 1 to 10 carbon atoms, and the saturated or unsaturated hydrocarbon has 1 carbon atom. It may have a substituent as long as it satisfies the conditions of ⁇ 10.
• [5] The polyphenylene ether according to any one of [1] to [4], which has a polystyrene-equivalent number average molecular weight of 500 to 15,000.
• [6] The method for producing a polyphenylene ether according to any one of [1] to [5], comprising a step of oxidatively polymerizing the phenol of the formula (1), the phenol of the formula (2), and the phenol of the formula (3). .
• a thermosetting composition comprising the polyphenylene ether according to any one of [1] to [6].
• a prepreg which is a composite comprising a substrate and the thermosetting composition according to [7].
• the prepreg according to [8] wherein the base material is glass cloth.
• a laminate comprising a cured product of the prepreg according to [8] or [9] and a metal foil.
• thermosetting composition a prepreg, and a laminate using the polyphenylene ether can be provided.
• this embodiment the form for carrying out the present invention (hereinafter referred to as "this embodiment") will be described in detail.
• the following embodiments are exemplifications for explaining the present invention, and the present invention is not limited only to these embodiments, and the present invention can be appropriately modified within the scope of the gist thereof. can be implemented.
• polyphenylene ether in which some or all of the hydroxyl groups contained in the polyphenylene ether are modified is sometimes simply referred to as "polyphenylene ether". Therefore, the expression “polyphenylene ether” includes both unmodified polyphenylene ether and modified polyphenylene ether, unless otherwise contradicted.
• a (numerical value) to B (numerical value) mean A or more and B or less.
• substituents include, for example, saturated or unsaturated hydrocarbon groups having 1 to 10 carbon atoms, aryl groups having 6 to 10 carbon atoms, and halogen atoms.
• the polyphenylene ether of the present embodiment includes a repeating unit derived from a phenol of the following formula (1), a repeating unit derived from a phenol of the following formula (2), and a structure derived from a phenol of the following formula (3)
• R 42 are each independently an optionally substituted alkylene group having 1 to 8 carbon atoms, each b is independently 0 or 1, R 43 is a hydrogen atom, optionally substituted It is either an alkyl group having 1 to 8 carbon atoms or an optionally substituted phenyl group.
• each R 11 is preferably a saturated hydrocarbon group having 1 to 6 carbon atoms or an aryl group having 6 to 12 carbon atoms, more preferably a methyl group or a phenyl group, still more preferably is a methyl group.
• two R 11 preferably have the same structure.
• the substituent for the saturated hydrocarbon group having 1 to 6 carbon atoms and the aryl group having 6 to 12 carbon atoms for R 11 includes a saturated or unsaturated hydrocarbon group having 1 to 10 carbon atoms and an aryl group having 6 to 10 carbon atoms. groups and halogen atoms.
• each R 12 is preferably a hydrogen atom or a hydrocarbon group having 1 to 6 carbon atoms, more preferably a hydrogen atom or a methyl group.
• two R 12 are preferably different, and more preferably one is a hydrogen atom and the other is a hydrocarbon group having 1 to 6 carbon atoms (preferably a methyl group).
• Substituents for the hydrocarbon group having 1 to 6 carbon atoms and the aryl group having 6 to 12 carbon atoms for R 12 include a saturated or unsaturated hydrocarbon group having 1 to 10 carbon atoms and an aryl group having 6 to 10 carbon atoms. , and halogen atoms.
• two R 22 are preferably different, and more preferably one is a hydrogen atom and the other is a hydrocarbon group having 1 to 6 carbon atoms (preferably a methyl group).
• the substituents for the saturated or unsaturated hydrocarbon group having 1 to 20 carbon atoms and the aryl group having 6 to 12 carbon atoms for R 22 include a saturated or unsaturated hydrocarbon group having 1 to 10 carbon atoms, and a 10 aryl groups and halogen atoms.
• the respective proportions of the repeating unit derived from phenol of formula (1), the repeating unit derived from phenol of formula (2), and the structural unit derived from phenol of formula (3) can be determined, for example, by 1 H NMR, 13 It can be determined using an analysis method such as C NMR, and more specifically, it can be measured by the method described in Examples below.
• repeating units derived from formula (1) include repeating units having the structure of formula (9) below. (In formula (9), R 11 and R 12 are the same as in formula (1).)
• the structural unit derived from the phenol of formula (3) has the structure of formula (12) below, and the phenol of formula (3) is unsubstituted With the ortho position of substitution, the structure derived from the phenol of formula (3) has the structure of formula (12) below, the structure of formula (13) below, or a combination thereof.
• R3 in formulas (12) and (13) is the same as in formula ( 3 ).
• Examples of the monohydric phenol compound represented by the above formula (1) include 2,6-dimethylphenol, 2-methyl-6-ethylphenol, 2,6-diethylphenol, 2-ethyl-6-n- Propylphenol, 2-methyl-6-chlorophenol, 2-methyl-6-bromophenol, 2-methyl-6-n-propylphenol, 2-ethyl-6-bromophenol, 2-methyl-6-n-butylphenol , 2,6-di-n-propylphenol, 2-ethyl-6-chlorophenol, 2-methyl-6-phenylphenol, 2,6-diphenylphenol, 2-methyl-6-tolylphenol, 2,6- ditolylphenol, 2,3,6-trimethylphenol, 2,3-diethyl-6-n-propylphenol, 2,3,6-tributylphenol, 2,6-di-n-butyl-3-methylphenol, 2,6-dimethyl-3-n-butylphenol, 2,6-dimethyl-3-t-butylphenol and the like.
• 2,6-dimethylphenol, 2,3,6-trimethylphenol, and 2,6-diphenylphenol are particularly preferred because they are inexpensive and readily available.
• the monohydric phenol compound represented by the above formula (1) may be used singly or in combination of two or more.
• Examples of the monohydric phenol compound represented by the above formula (2) include 2-isopropyl-5-methylphenol, 2-cyclohexyl-5-methylphenol, 2-tert-butyl-5-methylphenol, 2- and isobutyl-5-methylphenol. 2-t-butyl-5-methylphenol and 2-cyclohexyl-5-methylphenol, which are bulky substituents, are more preferable from the viewpoint of suppressing hyperbranching and gelation.
• the monohydric phenol compound represented by the above formula (2) may be used singly or in combination of two or more.
• phenol compounds having two phenol units in the molecule include, for example, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl) Propane, 2,2-bis(4-hydroxy-3-methylphenyl)propane, 4,4′-methylenebis(2,6-dimethylphenol), bis(4-hydroxy-3-methylphenyl)sulfide, bis(4 -hydroxy-3,5-dimethylphenyl)sulfone, ⁇ , ⁇ '-bis(4-hydroxy-3,5-dimethylphenyl)-1,4-diisopropylbenzene, 9,9-bis(4-hydroxy-3- methylphenyl)fluorene, 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, 1,1-bis(2-methyl-4-hydroxy-5-t-butylphenyl)butane and the like.
• 2,2-bis(3,5-dimethyl-4-hydroxyphenyl) 2,2-bis(3,5-dimethyl-4-hydroxyphenyl
• phenol compounds having three or more phenol units in the molecule include, for example, 4,4′-[(3-hydroxyphenyl)methylene ] bis(2,6-dimethylphenol), 4,4′-[(3-hydroxyphenyl)methylene]bis(2,3,6-trimethylphenol), 4,4′-[(4-hydroxyphenyl)methylene ] bis(2,6-dimethylphenol), 4,4′-[(4-hydroxyphenyl)methylene]bis(2,3,6-trimethylphenol), 4,4′-[(2-hydroxy-3- methoxyphenyl)methylene]bis(2,6-dimethylphenol), 4,4'-[(4-hydroxy-3-ethoxyphenyl)methylene]bis(2,3,6-trimethylethylphenol), 4,4' -[(3,4-dihydroxyphenyl)methylene]bis(2,6-dimethylphenol), 4,4′-[(3,4-dihydroxyphenyl)methylene]bis(2,6-dimethylphenol), 4,4′-[
• 1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)butane is preferred because it is particularly inexpensive and readily available.
• the polyhydric phenol compound represented by the above formula (3) may be used singly or in combination of multiple types.
• the number of phenolic hydroxyl groups in the polyhydric phenol compound represented by the above formula (3) is not particularly limited as long as it is 2 to 6, but from the viewpoint of facilitating the control of the thermosetting speed, preferably 2 ⁇ 4.
• oxidative polymerization of phenol having a hydrogen atom at the ortho position can form an ether bond even at the ortho position, so during oxidative polymerization It becomes difficult to control the bonding position of the phenolic compound, resulting in a branched polymer having a high molecular weight, and finally a solvent-insoluble gel component is generated.
• an aromatic solvent that is a good solvent for polyphenylene ether can be used as a polymerization solvent in the oxidative polymerization step.
• the good solvent for polyphenylene ether is a solvent capable of dissolving polyphenylene ether.
• aromatic hydrocarbons such as ethylbenzene, halogenated hydrocarbons such as chlorobenzene and dichlorobenzene; nitro compounds such as nitrobenzene;
• a known catalyst system that can be generally used for the production of polyphenylene ether can be used.
• a generally known catalyst system one comprising a transition metal ion having oxidation-reduction ability and an amine compound capable of forming a complex with the transition metal ion is known.
• it comprises a copper compound and an amine compound.
• They include a catalyst system, a catalyst system comprising a manganese compound and an amine compound, a catalyst system comprising a cobalt compound and an amine compound, and the like. Since the polymerization reaction proceeds efficiently under slightly alkaline conditions, some alkali or additional amine compounds may be added here.
• the polymerization catalyst preferably used in the present embodiment is a catalyst comprising a copper compound, a halogen compound and an amine compound as constituent components of the catalyst, and more preferably a diamine compound represented by the following formula (14) as the amine compound. is a catalyst containing
• R 14 , R 15 , R 16 and R 17 are each independently a hydrogen atom, a linear or branched alkyl group having 1 to 6 carbon atoms, and are not all hydrogen atoms at the same time.
• R 18 is a linear or methyl-branched alkylene group having 2 to 5 carbon atoms.
• Suitable copper compounds may be cuprous compounds, cupric compounds or mixtures thereof.
• cupric compounds include cupric chloride, cupric bromide, cupric sulfate, and cupric nitrate.
• cuprous compounds include cuprous chloride, cuprous bromide, cuprous sulfate, and cuprous nitrate.
• particularly preferred metal compounds are cuprous chloride, cupric chloride, cuprous bromide and cupric bromide.
• These copper salts may also be synthesized at the time of use from oxides (eg, cuprous oxide), carbonates, hydroxides, etc. and the corresponding halogens or acids.
• a frequently used method is a method of mixing cuprous oxide and hydrogen halide (or a solution of hydrogen halide) as exemplified above.
• halogen compounds include hydrogen chloride, hydrogen bromide, hydrogen iodide, sodium chloride, sodium bromide, sodium iodide, potassium chloride, potassium bromide, potassium iodide, tetramethylammonium chloride, and tetramethylammonium bromide. , tetramethylammonium iodide, tetraethylammonium chloride, tetraethylammonium bromide, tetraethylammonium iodide, and the like. Moreover, these can be used as an aqueous solution or a solution using a suitable solvent. These halogen compounds may be used alone as a component, or may be used in combination of two or more. Preferred halogen compounds are aqueous solutions of hydrogen chloride and hydrogen bromide.
• oxygen-containing gas in the polymerization of the present embodiment in addition to pure oxygen, a mixture of oxygen and an inert gas such as nitrogen at an arbitrary ratio, air, and air and an inert gas such as nitrogen are arbitrary. can be used. Normal pressure is sufficient for the system internal pressure during the polymerization reaction, but if necessary, either reduced pressure or increased pressure can be used.
• the polymerization temperature is not particularly limited, but if it is too low, the reaction will not progress easily, and if it is too high, the reaction selectivity may decrease or gel may be formed. It is in the range of 40°C.
• the organic phase containing the polyphenylene ether after the liquid-liquid separation may be concentrated and dried by volatilizing the solvent.
• the method for volatilizing the solvent contained in the organic phase is not particularly limited, but a method of transferring the organic phase to a high-temperature concentration tank and distilling off the solvent to concentrate, or distilling toluene using a device such as a rotary evaporator. A method of removing and concentrating is mentioned.
• the drying step preferably uses a dryer with a mixing function. Dryers having a mixing function include stirring-type and tumble-type dryers. As a result, the throughput can be increased, and productivity can be maintained at a high level.
• the polyphenylene ether of the present embodiment is obtained by equilibrating the polyphenylene ether derived from the phenol of the above formula (1) with the phenol compound of the above formula (2) and the phenol compound of the above formula (3) in the presence of an oxidizing agent. It can also be produced by a partition reaction. Redistribution reactions are known in the art and are described, for example, in US Pat. No. 3,496,236 to Cooper et al. and US Pat. No. 5,880,221 to Liska et al.
• the method for introducing a functional group to the hydroxyl group of the unmodified polyphenylene ether is not limited, for example, the hydroxyl group of the unmodified polyphenylene ether and a carboxylic acid having a carbon-carbon double bond (hereinafter, carboxylic acid) formation of an ester bond. Obtained by reaction.
• carboxylic acid a carboxylic acid halide with a polymer terminal hydroxyl group
• b. formation of an ester bond by reaction with a carboxylic anhydride c.
• a method by transesterification reaction and the like can be mentioned.
• the method for producing the modified polyphenylene ether of the present embodiment is not limited to the method for producing the modified polyphenylene ether of the present embodiment described above, and includes the oxidation polymerization step, copper extraction and by-product removal step, and liquid-liquid separation described above. The order and number of steps, concentration/drying steps, etc. may be adjusted as appropriate.
• the polyphenylene ether solution of the present embodiment contains at least the polyphenylene ether of the present embodiment and a ketone solvent, and may further contain other components. Moreover, as a solvent, a solvent other than the ketone solvent may be included. Examples of the ketone solvent include acetone, methyl ethyl ketone, methyl propyl ketone, methyl isobutyl ketone, diisobutyl ketone, cyclohexanone and the like.
• the polyphenylene ether of the present embodiment can be used as a raw material for thermosetting compositions.
• the thermosetting composition is not particularly limited as long as it contains polyphenylene ether, but preferably further contains a cross-linking agent and an organic peroxide, and if desired, a thermoplastic resin, a flame retardant, other additives, Silica fillers, solvents and the like can also be included.
• the constituent elements of the thermosetting composition of this embodiment are described below.
• crosslinking agent Any cross-linking agent capable of undergoing or promoting the cross-linking reaction can be used in the thermoset compositions of the present embodiments.
• the cross-linking agent preferably has a number average molecular weight of 4,000 or less. When the number average molecular weight of the cross-linking agent is 4,000 or less, an increase in the viscosity of the thermosetting composition can be suppressed, and good resin fluidity during heat molding can be obtained.
• the number average molecular weight may be a value measured by a general molecular weight measurement method, and specifically a value measured using GPC.
• the cross-linking agent preferably has an average of two or more carbon-carbon unsaturated double bonds per molecule from the viewpoint of cross-linking reaction.
• the cross-linking agent may be composed of one type of compound, or may be composed of two or more types of compounds.
• the term "carbon-carbon unsaturated double bond" as used herein refers to a double bond located at the terminal branched from the main chain when the cross-linking agent is a polymer or oligomer. Carbon-carbon unsaturated double bonds include, for example, 1,2-vinyl bonds in polybutadiene.
• the number (average value) of carbon-carbon unsaturated double bonds per molecule of the cross-linking agent is preferably 2-4.
• the number (average value) of carbon-carbon unsaturated double bonds per molecule of the cross-linking agent is preferably 4-26.
• the number average molecular weight of the cross-linking agent is 1,500 or more and 4,000 or less, the number (average value) of carbon-carbon unsaturated double bonds per molecule of the cross-linking agent is 26-60. preferable.
• the number average molecular weight of the cross-linking agent is within the above range, the number of carbon-carbon unsaturated double bonds is equal to or greater than the above specific value, so that the thermosetting composition of the present embodiment exhibits the reactivity of the cross-linking agent is further increased, the crosslink density of the cured product of the thermosetting composition is further improved, and as a result, further excellent heat resistance can be imparted.
• the number average molecular weight of the cross-linking agent is within the above range, the number of carbon-carbon unsaturated double bonds is not more than the above specific value, thereby imparting even better resin fluidity during thermoforming. can.
• cross-linking agents examples include triallyl isocyanurate compounds such as triallyl isocyanurate (TAIC), triallyl cyanurate compounds such as triallyl cyanurate (TAC), and polyfunctional methacrylates having two or more methacrylic groups in the molecule.
• TAIC triallyl isocyanurate
• TAC triallyl cyanurate
• polyfunctional methacrylates having two or more methacrylic groups in the molecule.
• compounds polyfunctional acrylate compounds having two or more acrylic groups in the molecule, polyfunctional vinyl compounds having two or more vinyl groups in the molecule such as polybutadiene, vinylbenzyl compounds such as divinylbenzene having a vinylbenzyl group in the molecule , 4,4′-bismaleimidediphenylmethane, and other polyfunctional maleimide compounds having two or more maleimide groups in the molecule.
• cross-linking agents are used singly or in combination of two or more.
• the cross-linking agent preferably contains at least one compound selected from the group consisting of triallyl cyanurate, triallyl isocyanurate, and polybutadiene. Since the cross-linking agent contains at least one or more compounds described above, the thermosetting composition is more excellent in compatibility and coatability between the cross-linking agent and the polyphenylene ether, and is mounted on an electronic circuit board. The substrate properties tend to be more excellent.
• the mass ratio of the polyphenylene ether and the cross-linking agent is said to further improve the compatibility between the cross-linking agent and the polyphenylene ether, the coatability of the thermosetting composition, and the characteristics of the mounted electronic circuit board. From the point of view, it is preferably 25:75 to 95:5, more preferably 32:68 to 85:15.
• organic peroxide Any organic peroxide capable of accelerating the polymerization reaction of the thermoset composition comprising the polyphenylene ether and the crosslinker can be used in this embodiment.
• organic peroxides include benzoyl peroxide, cumene hydroperoxide, 2,5-dimethylhexane-2,5-dihydroperoxide, 2,5-dimethyl-2,5-di(t-butyl peroxide), oxy)hexyne-3, di-t-butyl peroxide, t-butylcumyl peroxide, di(2-t-butylperoxyisopropyl)benzene, 2,5-dimethyl-2,5-di(t-butylperoxy ) Hexane, dicumyl peroxide, di-t-butylperoxyisophthalate, t-butylperoxybenzoate, 2,2-bis(t-butylperoxy)butane, 2,2-bis(t-butylperoxy
• Radical generators such as 2,3-dimethyl-2,3-diphenylbutane can also be used as reaction initiators for thermosetting compositions. Among them, 2,5-dimethyl-2,5-di(t-butylperoxy ) hexyne-3, di(2-t-butylperoxyisopropyl)benzene, and 2,5-dimethyl-2,5-di(t-butylperoxy)hexane are preferred.
• the 1-minute half-life temperature of the organic peroxide is preferably 155 to 185°C, more preferably 160 to 180°C, still more preferably 165 to 175°C. Since the one-minute half-life temperature of the organic peroxide is in the range of 155 to 185 ° C., the compatibility between the organic peroxide and the polyphenylene ether, the coatability of the thermosetting composition, and the mounted electronic circuit The properties of the substrate tend to be even more excellent.
• the 1-minute half-life temperature is the temperature at which the organic peroxide decomposes and the amount of active oxygen halves in 1 minute.
• organic peroxides having a 1-minute half-life temperature in the range of 155 to 185° C. include t-hexylperoxyisopropyl monocarbonate (155.0° C.), t-butylperoxy-3,5,5- trimethylhexanoate (166.0°C), t-butyl peroxylaurate (159.4°C), t-butylperoxyisopropyl monocarbonate (158.8°C), t-butylperoxy 2-ethylhexyl monocarbonate ( 161.4°C), t-hexylperoxybenzoate (160.3°C), 2,5-dimethyl-2,5-di(benzoylperoxy)hexane (158.2°C), t-butylperoxyacetate ( 159.9°C), 2,2-di-(t-butylperoxy)butane (159.9°C), t-butyl peroxybenzoate (166.8°C), n-he
• the content of the organic peroxide is based on the total of 100 parts by mass of the polyphenylene ether and the cross-linking agent, and the compatibility between the organic peroxide and the polyphenylene ether and the coatability of the thermosetting composition are further improved. , preferably 0.05 parts by mass or more, more preferably 0.5 parts by mass or more, still more preferably 1 part by mass or more, and even more preferably 1.5 parts by mass or more, and the thermosetting composition is applied to the electronic circuit board From the viewpoint of excellent board characteristics when mounted, the amount is preferably 5 parts by mass or less, more preferably 4.5 parts by mass or less.
• thermoplastic resin is a block copolymer of a vinyl aromatic compound and an olefinic alkene compound and its hydrogenated product (a hydrogenated block copolymer obtained by hydrogenating a block copolymer of a vinyl aromatic compound and an olefinic alkene compound). block copolymers) and homopolymers of vinyl aromatic compounds.
• the weight-average molecular weight of the thermoplastic resin is preferably more than 50,000 to 780 from the viewpoint of being more excellent in compatibility with polyphenylene ether, resin fluidity, coatability of the thermosetting composition, heat resistance during curing, and the like. ,000 or less, more preferably 60,000 to 750,000, still more preferably 70,000 to 700,000.
• the vinyl aromatic compound may have an aromatic ring and a vinyl group in the molecule, and examples thereof include styrene.
• the olefinic alkene compound may be any alkene having a linear or branched structure in the molecule, and examples thereof include ethylene, propylene, butylene, isobutylene, butadiene, and isoprene.
• the hydrogenation rate in the above hydrogenated product is not particularly limited, and a portion of the carbon-carbon unsaturated double bonds derived from the olefinic alkene compound may remain.
• the content of the thermoplastic resin is preferably 2 to 20 parts by mass, more preferably 3 to 19 parts by mass, based on a total of 100 parts by mass of the polyphenylene ether and the cross-linking agent, and 4 to 18 parts by mass. Parts by weight is more preferred, and 5 to 17 parts by weight is particularly preferred.
• the thermosetting composition of the present embodiment is more excellent in compatibility and coatability between the thermoplastic resin and the polyphenylene ether, and when mounted on an electronic circuit board It tends to be more excellent in substrate properties.
• the flame retardant is preferably decabromodiphenylethane from the viewpoint of better compatibility between the flame retardant and the polyphenylene ether, the coatability of the thermosetting composition, and the characteristics of the mounted electronic circuit board. .
• thermosetting composition of the present embodiment may further contain additives such as heat stabilizers, antioxidants, UV absorbers, surfactants, lubricants, solvents, etc., in addition to the flame retardant and silica filler.
• additives such as heat stabilizers, antioxidants, UV absorbers, surfactants, lubricants, solvents, etc.
• the thermosetting composition of the present embodiment contains a solvent, it can be in the form of a varnish in which the solid components in the thermosetting composition are dissolved or dispersed in the solvent.
• a resin film can be formed from the cured composition.
• the prepreg of the present embodiment is a composite comprising a base material and the thermosetting composition of the present embodiment described above, and a base material and the thermosetting composition of the present embodiment impregnated or applied to the base material.
• the prepreg can be obtained, for example, by impregnating a base material such as a glass cloth with the varnish of the thermosetting composition, and then removing the solvent by drying with a hot air dryer or the like.
• glass cloths such as roving cloth, cloth, chopped mat, surfacing mat, etc.; asbestos cloth, metal fiber cloth, and other synthetic or natural inorganic fiber cloth; wholly aromatic polyamide fiber, wholly aromatic polyester Woven or non-woven fabric obtained from liquid crystal fiber such as fiber, polybenzoxazole fiber; Natural fiber cloth such as cotton cloth, hemp cloth, felt; Cloth obtained from carbon fiber cloth, kraft paper, cotton paper, paper-glass mixed yarn, etc. natural cellulosic substrates; polytetrafluoroethylene porous films; Among them, glass cloth is preferable. You may use these base materials individually by 1 type or in combination of 2 or more types.
• a method for producing a metal-clad laminate for example, a composite (for example, the above-mentioned prepreg) composed of a thermosetting composition and a base material is formed, and after stacking this with a metal foil, the thermosetting composition
• a method of obtaining a laminate in which a cured composite and a metal foil are laminated by curing is a printed wiring board. At least part of the metal foil is preferably removed from the metal-clad laminate of the printed wiring board.
• the printed wiring board of the present embodiment can typically be formed by using the prepreg of the present embodiment described above and performing pressurization and heat molding. Substrates include those described above with respect to prepregs.
• the printed wiring board of the present embodiment has excellent heat resistance and electrical properties (low dielectric constant and low dielectric loss tangent), and furthermore, electrical properties associated with environmental changes can be suppressed, and has excellent insulation reliability and mechanical properties.
• the repeating unit derived from the phenol of the formula (1) that is, the 2,6-dimethylphenol-derived structure (2,6-dimethylphenylene unit) and a repeating unit derived from the phenol of formula (2), i.e., a signal derived from a 2-tert-butyl-5-methylphenol-derived structure (2-tert-butyl-5-methylphenylene unit)
• Structural units derived from phenol of formula (3) ie, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane-derived structure (2,2-bis(3,5-dimethyl-4- Hydroxyphenyl)propane unit) was analyzed as follows for assigning signals.
• Mn number average molecular weight
• Shimadzu Corporation gel permeation chromatography product name: LC2030S
• LC2030S gel permeation chromatography
• a calibration curve is created with standard polystyrene and ethylbenzene, and the number average of the obtained polyphenylene ether is calculated using this calibration curve.
• Molecular weight (Mn) measurements were made.
• standard polystyrene molecular weights of 1,300 and 550 were used.
• As the column two K-805L columns manufactured by Showa Denko KK were connected in series. Chloroform was used as the solvent, the solvent flow rate was 1.0 mL/min, and the column temperature was 40°C.
• Example 1 A 1.5 liter jacketed reactor equipped with a sparger, stirring turbine blades and baffles for the introduction of oxygen-containing gas at the bottom of the reactor and a reflux condenser in the vent gas line at the top of the reactor was equipped with a preconditioned zero point.
• the organic phase was concentrated by a rotary evaporator to a polymer concentration of 25% by weight.
• the above solution was mixed with methanol at a ratio of 6 to the polymer solution to precipitate the polymer.
• Wet polyphenylene ether was obtained by vacuum filtration using a glass filter. The wet polyphenylene ether was then washed with an amount of methanol to give a ratio of 3 methanol to wet polyphenylene ether. The above washing operation was performed three times.
• the wet polyphenylene ether was then held at 140° C. and 1 mmHg for 120 minutes to obtain a dry polyphenylene ether. Each measurement was performed on the obtained polyphenylene ether by the method described above. Table 1 shows the results of each analysis.
• Example 2 The phenolic raw materials were 22.00 g of 2,6-dimethylphenol, 69.01 g of 2-tert-butyl-5-methylphenol, 8.98 g of 2,2-bis(3,5-dimethyl-4-hydroxyphenyl ) The procedure was carried out in the same manner as in Example 1 except that propane was used. Table 1 shows the results of each analysis.
• Example 3 The phenolic raw materials were 20.00 g of 2,6-dimethylphenol, 62.75 g of 2-tert-butyl-5-methylphenol, 17.25 g of 2,2-bis(3,5-dimethyl-4-hydroxyphenyl ) The procedure was carried out in the same manner as in Example 1 except that propane was used. Table 1 shows the results of each analysis.
• Example 4 The phenolic raw materials were 18.16 g of 2,6-dimethylphenol, 56.97 g of 2-tert-butyl-5-methylphenol, 24.87 g of 2,2-bis(3,5-dimethyl-4-hydroxyphenyl ) The procedure was carried out in the same manner as in Example 1 except that propane was used. Table 1 shows the results of each analysis.
• Example 5 The phenolic raw materials were 16.72 g of 2,6-dimethylphenol, 52.45 g of 2-tert-butyl-5-methylphenol, 30.83 g of 1,1-bis(2-methyl-4-hydroxy-5- The operation was carried out in the same manner as in Example 1, except that t-butylphenyl)butane (ADEKA: AO-40) was used. Table 1 shows the results of each analysis.
• Example 6 The phenol raw material was 60.99 g of 2,6-dimethylphenol, 9.11 g of 2-tert-butyl-5-methylphenol, 29.90 g of 1,1,3-tris(2-methyl-4-hydroxy- The procedure was carried out in the same manner as in Example 1, except that 5-t-butylphenyl)butane (ADEKA: AO-30) was used. Table 1 shows the results of each analysis.
• Example 7 The phenolic raw materials were 25.52 g of 2,6-dimethylphenol, 34.31 g of 2-tert-butyl-5-methylphenol, 40.18 g of 1,1,3-tris(2-methyl-4-hydroxy- The procedure was carried out in the same manner as in Example 1, except that 5-t-butylphenyl)butane (ADEKA: AO-30) was used. Table 1 shows the results of each analysis.
• Example 8 The phenolic raw materials were 14.79 g of 2,6-dimethylphenol, 46.40 g of 2-tert-butyl-5-methylphenol, 38.81 g of 1,1,3-tris(2-methyl-4-hydroxy- The procedure was carried out in the same manner as in Example 1, except that 5-t-butylphenyl)butane (ADEKA: AO-30) was used. Table 1 shows the results of each analysis.
• Example 9 Oxidative polymerization, copper extraction, liquid-liquid separation, and concentration by a rotary evaporator were carried out in the same manner as in Example 1, and a polymer solution having a polymer concentration of 25% by mass was used as the stock solution for the modification reaction. After replacing the inside of the reactor with nitrogen, 200 g of unmodified polyphenylene ether solution, 4-dimethyl 0.94 g of aminopyridine was charged. 43 mL of triethylamine was added using a syringe while stirring. After that, 14.9 mL of methacryloyl chloride was collected in a syringe and dropped into the system at room temperature.
• the flask was heated in an oil bath for 1 hour after the completion of the dropwise addition, and stirring was continued at 90°C. After that, the mixture was further heated in an oil bath to continue the reaction under reflux. After 4 hours from the start of reflux, the heating was stopped, and after returning to room temperature, 5 g of methanol was added to terminate the reaction. Then, the reaction solution was filtered using a glass filter to obtain a solution from which the by-produced triethylammonium salt was removed. The above solution was mixed with methanol having a ratio of methanol to polymer solution of 10 to precipitate the polymer. Wet polyphenylene ether was obtained by vacuum filtration using a glass filter.
• the wet polyphenylene ether was then washed with an amount of methanol to give a ratio of methanol to wet polyphenylene ether of 2.5. The above washing operation was performed three times. The wet polyphenylene ether was then held at 100° C. and 1 mmHg for 8 hours to obtain a dry polyphenylene ether. 1 H NMR measurement was performed to confirm the proton peak derived from the olefin of the methacrylic group, and it was determined that the hydroxyl group was modified with the methacrylic group.
• a prepreg was obtained by removing the This prepreg was cut into a predetermined size, and the solid content of the thermosetting composition in the prepreg was calculated by comparing the mass of the prepreg with the mass of glass cloth of the same size, and it was 52% by mass. .
• a predetermined number of these prepregs are stacked, and copper foil (manufactured by Furukawa Electric Co., Ltd., thickness 35 ⁇ m, GTS-MP foil) is superimposed on both sides of the prepreg, and vacuum press is performed to obtain copper clad.
• a laminate was obtained.
• the pressure is set to 40 kg/cm 2 while heating from room temperature at a temperature increase rate of 2°C/min, and then, after the temperature reaches 200°C, the temperature is maintained at 200°C.
• a pressure of 40 kg/cm 2 and a time of 60 minutes were adopted.
• a laminate (about 0.5 mm thick) was obtained by removing the copper foil from the copper-clad laminate by etching.
• the dielectric properties of the laminate obtained by the method described above were measured. Table 2 shows the results of each analysis.
• Example 12 Oxidative polymerization, copper extraction, liquid-liquid separation, and concentration by a rotary evaporator were carried out in the same manner as in Example 4, and the mixture was held at 100° C. and 1 mmHg for 2 hours to obtain a dry polyphenylene ether. After methacrylic modification was carried out in the same manner as in Example 9, except that the dry polyphenylene ether was used as the raw material for the modification reaction, a laminate was produced and the dielectric properties were measured. Table 2 shows the results of each analysis.
• Example 13 Oxidative polymerization, copper extraction, liquid-liquid separation and concentration by a rotary evaporator were carried out in the same manner as in Example 5, and the mixture was held at 100° C. and 1 mmHg for 2 hours to obtain a dry polyphenylene ether. After methacrylic modification was carried out in the same manner as in Example 9, except that the dry polyphenylene ether was used as the raw material for the modification reaction, a laminate was produced and the dielectric properties were measured. Table 2 shows the results of each analysis.
• Example 14 Oxidative polymerization, copper extraction, liquid-liquid separation, and concentration by a rotary evaporator were carried out in the same manner as in Example 6, and the mixture was held at 100° C. and 1 mmHg for 2 hours to obtain a dry polyphenylene ether. After methacrylic modification was carried out in the same manner as in Example 9, except that the dry polyphenylene ether was used as the raw material for the modification reaction, a laminate was produced and the dielectric properties were measured. Table 2 shows the results of each analysis.
• Example 15 Oxidative polymerization, copper extraction, liquid-liquid separation, and concentration by a rotary evaporator were carried out in the same manner as in Example 7, and the mixture was held at 100° C. and 1 mmHg for 2 hours to obtain a dry polyphenylene ether. After methacrylic modification was carried out in the same manner as in Example 9, except that the dry polyphenylene ether was used as the raw material for the modification reaction, a laminate was produced and the dielectric properties were measured. Table 2 shows the results of each analysis.
• Comparative Example 5 Oxidative polymerization, copper extraction, liquid-liquid separation, and concentration by a rotary evaporator were carried out in the same manner as in Comparative Example 2, and the mixture was held at 100° C. and 1 mmHg for 2 hours to obtain a dry polyphenylene ether. After methacrylic modification was carried out in the same manner as in Example 9, except that the dry polyphenylene ether was used as the raw material for the modification reaction, a laminate was produced and the dielectric properties were measured. Table 2 shows the results of each analysis.

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