WO2022259981A1 - 組成物、並びに、金属張積層体及びその製造方法 - Google Patents
組成物、並びに、金属張積層体及びその製造方法 Download PDFInfo
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- WO2022259981A1 WO2022259981A1 PCT/JP2022/022650 JP2022022650W WO2022259981A1 WO 2022259981 A1 WO2022259981 A1 WO 2022259981A1 JP 2022022650 W JP2022022650 W JP 2022022650W WO 2022259981 A1 WO2022259981 A1 WO 2022259981A1
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- metal
- layer
- inorganic filler
- clad laminate
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- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2202/00—Metallic substrate
- B05D2202/40—Metallic substrate based on other transition elements
- B05D2202/45—Metallic substrate based on other transition elements based on Cu
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2506/00—Halogenated polymers
- B05D2506/10—Fluorinated polymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2227—Oxides; Hydroxides of metals of aluminium
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2237—Oxides; Hydroxides of metals of titanium
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2237—Oxides; Hydroxides of metals of titanium
- C08K2003/2241—Titanium dioxide
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/005—Additives being defined by their particle size in general
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/006—Additives being defined by their surface area
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/16—Solid spheres
- C08K7/18—Solid spheres inorganic
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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
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
Definitions
- the present invention relates to a composition, a metal-clad laminate, and a method for producing the same.
- a substrate material for forming a substrate of a printed wiring board used in various electronic devices is required to have a low dielectric constant and a low dielectric loss tangent in order to reduce dielectric loss.
- a composition containing a fluororesin which has excellent dielectric properties among resin materials (that is, has a low dielectric constant and a low dielectric loss tangent), is used in the core portion of a copper clad laminate (CCL).
- a fluororesin is used in the core portion of a copper-clad laminate, although the dielectric properties are good, there is a problem that the adhesiveness to the copper foil is low.
- the composition containing these fluororesins increases the surface roughness of the copper foil to obtain an anchor effect (for example, Patent Document 1 See), providing an adhesive layer (primer layer) between a composition layer made of a composition containing a fluororesin and a copper foil (see, for example, Patent Document 2), a composition layer made of a composition containing a fluororesin are plasma-treated to activate the composition layer surface (see, for example, Patent Document 3).
- Patent Document 1 the transmission loss of the metal-clad laminate may increase. Further, in Patent Document 2, since the dielectric loss of the adhesive layer is large, it may not be possible to obtain a metal-clad laminate with a reduced dielectric loss tangent. Furthermore, in Patent Document 3, since the resin layer is plasma-treated, the composition layer material may become brittle. As described above, there is a strong demand for the development of a composition capable of forming a metal-clad laminate having a low dielectric constant and a low dielectric loss tangent and having improved adhesiveness of the resin layer to the metal foil.
- the present invention provides a composition capable of obtaining a metal-clad laminate having a low dielectric constant and dielectric loss tangent and improved adhesion of the composition layer to the metal layer, and a composition comprising the composition.
- An object of the present invention is to provide a metal-clad laminate having a material layer and a method for manufacturing the same.
- the inventors of the present invention have made intensive studies to solve the above problems, and found that when the fluorine-containing polymer A1, which is an adhesive fluororesin, and an inorganic filler having specific properties are mixed in a specific ratio, the above-described The inventors have found that the problem can be solved and completed the present invention.
- the reason why the adhesion of the composition layer to the metal layer is improved when the fluoropolymer A1, which is an adhesive fluororesin, and the inorganic filler having a specific property are mixed in a specific ratio is It is presumed that this is because the composition has a suitable viscosity when applied and voids are less likely to occur in the metal layer/fluoropolymer A1/inorganic filler.
- a composition comprising a fluoropolymer A1 containing units based on a fluoroolefin and units based on a monomer having an adhesive functional group, and an inorganic filler having a specific surface area of less than 5.5 m 2 /g ,
- the composition wherein the content of the inorganic filler in the solid content of the composition is 55% by volume or more with respect to the total volume of the solid content of the composition.
- the composition of [1] further comprising a fluoropolymer A2 containing units based on a fluoroolefin and not containing units based on a monomer having an adhesive functional group.
- the content of the inorganic filler in the solid content of the composition is 85% by volume or less with respect to the total solid content of the composition.
- composition [9] The composition according to any one of [1] to [8], wherein the inorganic filler has a surface adsorbed water content of 500 mass ppm or less.
- a metal-clad laminate comprising a composition layer made of the composition according to any one of [1] to [9] and a metal layer.
- the metal-clad laminate according to [10] further comprising an adhesive layer containing the fluorine-containing polymer A1 and having a specific surface area of less than 5.5 m 2 /g and containing no inorganic filler.
- the adhesive layer further includes an inorganic filler having a specific surface area of 5.5 m 2 /g or more, and the content of the inorganic filler relative to the total volume of the adhesive layer is The metal-clad laminate according to [11], which is 85% by volume or less.
- a composition that provides a metal-clad laminate having a low dielectric constant and a low dielectric loss tangent and having improved adhesion of the composition layer to the metal layer, and a composition layer comprising the composition. It is possible to provide a metal-clad laminate and a method for manufacturing the same.
- FIG. 1 is a schematic cross-sectional view showing an example of the metal-clad laminate of the present invention.
- FIG. 2 is a schematic cross-sectional view showing another example of the metal-clad laminate of the present invention.
- FIG. 3 is a schematic cross-sectional view showing still another example of the metal-clad laminate of the present invention.
- FIG. 4 is a schematic cross-sectional view showing an example of the resin-coated metal foil used when manufacturing the metal-clad laminate of the present invention.
- FIG. 5 is a schematic cross-sectional view showing an example of a wiring board manufactured using the metal-clad laminate of the present invention.
- any definition of preferable can be adopted, and it can be said that a combination of preferable ones is more preferable.
- the description "XX to YY” means “XX or more and YY or less”.
- the lower and upper limits described stepwise can be independently combined. For example, from the statement “preferably 10 to 90, more preferably 30 to 60", combining "preferred lower limit (10)” and “more preferred upper limit (60)” to “10 to 60” can also Moreover, in the numerical ranges described in this specification, the upper and lower limits of the numerical ranges may be replaced with the values shown in the examples.
- a unit based on a monomer is a general term for an atomic group directly formed by polymerization of one molecule of a monomer and an atomic group obtained by chemically converting a part of this atomic group.
- units based on monomer A are also referred to as monomer A units.
- not containing units based on a monomer having an adhesive functional group means that "the content of monomer units having an adhesive functional group is 0.05 based on the total units contained in the polymer.
- the term "solid content of the composition” means components constituting the composition layer other than the solvent, if the composition is a slurry containing a solvent.
- the content of the polymer A1 (% by volume), the content of the polymer A2 (% by volume), and the content of the inorganic filler with respect to the total volume of the "composition layer, adhesive layer, or intermediate layer” (% by volume) is obtained by measuring the mass of each of the polymer A1, the polymer A2, and the inorganic filler before mixing (preparing) them, and converting the respective specific gravities into volume.
- composition contains a fluoropolymer A1 and an inorganic filler, and if necessary, further contains a fluoropolymer A2, a thermoplastic elastomer, a solvent and other components.
- fluoropolymer A1 a fluoropolymer A1 and an inorganic filler, and if necessary, further contains a fluoropolymer A2, a thermoplastic elastomer, a solvent and other components.
- the fluoropolymer A1 contains units based on a fluoroolefin and units having an adhesive functional group, and if necessary, units based on other monomers other than the fluoroolefin and the monomer having an adhesive functional group.
- tetrafluoroethylene and perfluoroalkyl vinyl ether are preferable because of their low dielectric loss tangent.
- CF 2 CFOCF 2 CF 2 CF 3 is preferred.
- the content of the fluoroolefin-based units in the fluoropolymer A1 is not particularly limited, but is preferably 90.0 to 99.9 mol% relative to the total molar amount of all units in the fluoropolymer A1. , more preferably 95.0 to 99.8 mol%, particularly preferably 97.0 to 99.7 mol%.
- a composition layer having a low dielectric constant and low dielectric loss tangent can be obtained.
- the "adhesive functional group" in the "monomer having an adhesive functional group” includes, for example, a carbonyl group, a hydroxy group, an epoxy group, an amide group, an amino group, an isocyanate group, and the like. These may be used individually by 1 type, and may be used 2 or more types. Among these, a carbonyl group is preferable from the viewpoint of excellent adhesiveness of the composition layer to the metal layer.
- Examples of the "monomer having an adhesive functional group” include, for example, a cyclic hydrocarbon monomer having a dicarboxylic anhydride group and a polymerizable unsaturated group in the ring (hereinafter simply referred to as “cyclic hydrocarbon monomer” abbreviated) are preferably mentioned.
- the above-mentioned "cyclic hydrocarbon monomer” is a cyclic hydrocarbon consisting of one or more five-membered or six-membered rings, and a polymerizable compound having a dicarboxylic anhydride group and an intracyclic polymerizable unsaturated group.
- cyclic hydrocarbons cyclic hydrocarbons having one or more bridged polycyclic hydrocarbons are preferred.
- a cyclic hydrocarbon consisting of a bridged polycyclic hydrocarbon, a cyclic hydrocarbon in which two or more bridged polycyclic hydrocarbons are condensed, or a cyclic hydrocarbon in which a bridged polycyclic hydrocarbon and another cyclic hydrocarbon are condensed
- a cyclic hydrocarbon consisting of a bridged polycyclic hydrocarbon, a cyclic hydrocarbon in which two or more bridged polycyclic hydrocarbons are condensed, or a cyclic hydrocarbon in which a bridged polycyclic hydrocarbon and another cyclic hydrocarbon are condensed
- the cyclic hydrocarbon monomer has one or more endocyclic polymerizable unsaturated groups, that is, one or more polymerizable unsaturated groups present between carbon atoms constituting the hydrocarbon ring.
- This cyclic hydrocarbon monomer further has a dicarboxylic anhydride group (--CO--O--CO--), and the dicarboxylic anhydride group may be bonded to two carbon atoms constituting a hydrocarbon ring, It may be bonded to two outer carbon atoms.
- the dicarboxylic anhydride group is a carbon atom that constitutes the ring of the cyclic hydrocarbon and is bonded to two adjacent carbon atoms.
- hydrogen atoms instead of hydrogen atoms, halogen atoms, alkyl groups, halogenated alkyl groups, and other substituents may be bonded to the carbon atoms that constitute the ring of the cyclic hydrocarbon.
- R in formulas (2), (5) to (8) is a lower alkyl group having 1 to 6 carbon atoms; a halogen atom selected from a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom; or A halogenated alkyl group in which a hydrogen atom in the lower alkyl group is substituted with a halogen atom;
- the cyclic hydrocarbon monomer is preferably 5-norbornene-2,3-dicarboxylic anhydride (hereinafter referred to as “NAH”) represented by formula (1); a cyclic hydrocarbon monomer that is an acid anhydride represented; a cyclic hydrocarbon monomer in which the substituent R is a methyl group in the formulas (2) and (5) to (8); and more preferably NAH .
- NAH 5-norbornene-2,3-dicarboxylic anhydride
- the content of units based on a monomer having an adhesive functional group in the fluoropolymer A1 is not particularly limited, but is preferably 0.01 to 0.01 based on the total molar amount of all units in the fluoropolymer A1. 5 mol %, more preferably 0.03 to 3 mol %, particularly preferably 0.05 to 2 mol %.
- a composition layer having excellent adhesiveness to a metal layer can be obtained.
- Other monomers include, for example, olefins having 2 to 4 carbon atoms such as ethylene, propylene and isobutene; vinyl esters such as vinyl acetate; vinyl ethers such as ethyl vinyl ether and cyclohexyl vinyl ether; These may be used individually by 1 type, and may be used 2 or more types.
- the content of the units derived from other monomers in the fluoropolymer A1 is not particularly limited, but is preferably 0.1 to 10 mol% relative to the total molar amount of all units in the fluoropolymer A1. More preferably 0.5 to 5 mol %, particularly preferably 1 to 3 mol %.
- the adhesiveness of the composition layer to the metal layer can be improved.
- the melting point of the fluoropolymer A1 is not particularly limited, and is preferably 150°C or higher and 320°C or lower, more preferably 200°C or higher and 310°C or lower.
- the melting point can be adjusted by appropriately selecting the content ratios of units based on fluoroolefin, units based on a monomer having an adhesive functional group, and units based on other monomers.
- the volumetric flow rate (hereinafter referred to as Q value) of the fluoropolymer A is not particularly limited, and is preferably 5 to 500 mm 3 /sec, more preferably 10 to 200 mm 3 /sec.
- the Q value is an index representing the melt fluidity of the fluoropolymer A1 and serves as a measure of the molecular weight. A large Q value indicates a low molecular weight, and a small Q value indicates a high molecular weight.
- the Q value is obtained by using a flow tester manufactured by Shimadzu Corporation and extruding the fluoropolymer A1 through an orifice having a diameter of 2.1 mm and a length of 8 mm under a load of 7 kg at a temperature 50°C higher than the melting point of the fluoropolymer A1. is the extrusion speed. If the Q value is too small, molding becomes difficult, and if it is too large, the mechanical strength of the fluoropolymer A1 decreases.
- the method for producing the fluoropolymer A1 is not particularly limited, and it can be produced by a known method.
- the fluoropolymer A1 obtained by a known production method can be obtained in the form of pellets, powder, and other forms according to standard methods. Since the fluoropolymer A1 has excellent moldability, it can be molded into a desired shape by injection molding, extrusion molding, press molding, or the like.
- the fluoropolymer A1 can be produced as described above, but a commercially available product can also be used. Commercial products of the fluoropolymer A1 are not particularly limited, and examples thereof include EA-2000 manufactured by AGC Corporation.
- the content of the fluoropolymer A1 in the solid content of the composition of the present invention is not particularly limited as long as it is 45% by volume or less with respect to the total solid content of the composition. From the viewpoint of mechanical strength, it is preferably 15 to 45% by volume, more preferably 20 to 40% by volume, and particularly preferably 30 to 40% by volume. When the content of the fluoropolymer A1 in the solid content of the composition of the present invention is within the above preferable range, the adhesiveness of the composition layer to the metal layer can be improved without impairing the strength of the substrate. .
- inorganic fillers include silicon oxides such as spherical silica; metal oxides such as titanium oxide, alumina and mica; metal hydroxides such as aluminum hydroxide and magnesium hydroxide; talc; aluminum borate; barium sulfate; calcium; and the like.
- the inorganic filler may be hollow inorganic microspheres such as glass microspheres, ceramic microspheres and the like.
- the glass microspheres preferably comprise silica glass or borosilicate glass.
- the ceramic microspheres comprise barium titanate, particularly barium titanate doped with neodymium or zinc oxide.
- Hollow inorganic microspheres may be non-porous or porous, crystalline or non-crystalline.
- Hollow inorganic microspheres include phenyltrimethoxysilane, phenyltriethoxysilane, (3,3,3-trifluoropropyl)trimethoxysilane, (tridecafluoro-1,1,2,2-tetrahydrooctyl)-1 , 1-triethoxysilane, (heptadecafluoro-1,1,2,2-tetrahydrodecyl)-1-triethoxysilane and other silane coupling agents; neopentyl(diallyl)oxytri(dioctyl)pyrophosphate zirconate, zirconates such as neopentyl(diallyl)oxytri(N-ethylenediamino)ethylzirconate; neopentyl(diallyl)oxytri-neodecanoyl titanate, neopentyl(diallyl)oxytri(dodecyl)benzene-sul
- the specific surface area of the inorganic filler is not particularly limited as long as it is less than 5.5 m 2 /g, preferably less than 4.5 m 2 /g, more preferably less than 3.5 m 2 /g, particularly preferably 3 less than .0 m 2 /g.
- the composition layer has sufficient adhesiveness to the metal layer.
- the "specific surface area" here is measured by the same method as in the examples.
- the sphericity of the inorganic filler is not particularly limited, but is preferably 0.80 or more, more preferably 0.83 or more, and particularly preferably 0.85 or more. When the sphericity of the inorganic filler is within the above preferable range, through-hole plating quality can be improved.
- the "sphericity" here is measured by the same method as in the examples.
- the median diameter (average particle diameter D50) of the inorganic filler is not particularly limited, but is preferably less than 20 ⁇ m, more preferably less than 15 ⁇ m, and particularly preferably less than 10 ⁇ m.
- the composition layer is excellent in homogeneity and drillability.
- the “median diameter (average particle diameter D50)" here is measured by the same method as in the examples.
- the amount of water adsorbed on the surface of the inorganic filler is not particularly limited, but is preferably 500 mass ppm or less, more preferably 400 mass ppm or less, and particularly preferably 300 mass ppm or less. When the amount of water adsorbed on the surface of the inorganic filler is within the above preferred range, the dielectric loss tangent of the composition layer can be reduced.
- the "surface adsorbed water content" is measured in the same manner as in the examples.
- the content of the inorganic filler in the solid content of the composition is not particularly limited as long as it is 55% by volume or more with respect to the total solid content of the composition, but the thermal expansion coefficient of the composition layer is suppressed. From this point of view, the content is preferably 63% by volume or more, more preferably 65% by volume or more. By increasing the content of the inorganic filler, the rigidity of the composition layer and the coefficient of thermal expansion CTE, which will be described later, can be made smaller, which is preferable.
- the upper limit of the content of the inorganic filler in the solid content of the composition is not particularly limited, but from the viewpoint of suppressing the thermal expansion coefficient of the composition layer, it is preferably 85% by volume or less, more preferably 75% by volume. % by volume or less, particularly preferably 73% by volume or less.
- the optional fluoropolymer A2 contains units based on a fluoroolefin and does not contain units based on a monomer having an adhesive functional group, and contains other monomers other than the fluoroolefin and the monomer having an adhesive functional group. May contain units based on.
- the "fluoroolefin-based unit”, the “monomer-based unit having an adhesive functional group”, and the “other monomer-based unit” are as described in the "fluoropolymer A1" section.
- the content of the fluoroolefin-based units in the fluoropolymer A2 is not particularly limited, but is preferably 90 to 100 mol%, more preferably 90 to 100 mol%, based on the total molar amount of all units in the fluoropolymer A2. 95 to 100 mol %, particularly preferably 97 to 100 mol %.
- a composition layer having a low dielectric constant and low dielectric loss tangent can be obtained.
- the content of units derived from other monomers in the fluoropolymer A2 is not particularly limited, but is preferably 0 to 10 mol%, more preferably 0 to 10 mol%, based on the total molar amount of all units in the fluoropolymer A2. is 0 to 5 mol %, particularly preferably 0 to 3 mol %.
- the fluoropolymer A2 contains units based on fluoroolefin and does not contain units based on a monomer having an adhesive functional group, the dielectric loss tangent of the composition layer can be lowered.
- a commercially available product can also be used as the fluoropolymer A2.
- Commercially available products of the fluoropolymer A2 are not particularly limited, but examples thereof include Fluon FL1710 manufactured by AGC Corporation.
- the content of the fluoropolymer A2 is not particularly limited. More preferably 20 to 80% by volume, particularly preferably 40 to 70% by volume. When the content of the fluoropolymer A2 is within the above preferred range, the fluorine units are increased, so that the dielectric loss tangent can be further improved.
- solvents examples include toluene, xylene, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, ethyl acetate, butyl acetate, dimethylformamide, dimethylacetamide, and N-methylpyrrolidone. These may be used individually by 1 type, and may be used 2 or more types. Among these, toluene, methyl ethyl ketone, N-methylpyrrolidone, and cyclohexanone are preferred from the viewpoint of the solubility and handleability of the composition.
- the content of the solvent in the composition of the present invention is not particularly limited. 400 parts by mass, more preferably 100 to 300 parts by mass, particularly preferably 150 to 250 parts by mass.
- the content of the solvent is at least the above lower limit value, the composition is easy to handle, and when it is at most the above upper limit value, a composition layer having a predetermined thickness can be obtained.
- ⁇ Other ingredients> include, for example, surfactants; antifoaming agents such as silicone antifoaming agents and acrylate ester antifoaming agents; heat stabilizers; antistatic agents; ultraviolet absorbers; dyes; a lubricant; a dispersant such as a wetting and dispersing agent; These may be used individually by 1 type, and may be used 2 or more types. Among these, surfactants are preferable from the viewpoint of mechanical properties.
- surfactants include nonionic fluorine-based surfactants, silicone-based surfactants, and hydrocarbon-based surfactants. These may be used individually by 1 type, and may be used 2 or more types. Among these, nonionic fluorine-based surfactants are preferred from the viewpoint of dispersibility of the fluoropolymer A1.
- the content of the surfactant is not particularly limited. More preferably 10 to 20 parts by mass.
- composition of the present invention is cured, for example, by heating the composition at 330 to 380° C. for 5 to 60 minutes to form a composition layer to be described later.
- the metal-clad laminate of the present invention comprises a composition layer made of the composition of the present invention, a metal layer, and, if necessary, an adhesive layer and an intermediate layer.
- FIG. 1 is a schematic cross-sectional view showing an example of the metal-clad laminate of the present invention.
- the metal-clad laminate 11 comprises a composition layer (insulating layer) 12 made of the composition of the present invention and metal layers 13 disposed on both sides of the composition layer (insulating layer) 12.
- the metal-clad laminate of the present invention may be a double-sided metal foil-clad laminate in which metal layers 13 are arranged on both sides of a composition layer 12.
- a single-sided metal foil-clad laminated plate having a metal layer 13 disposed on one side of 12 may also be used (see FIG. 4 described later).
- the metal-clad laminate of the present invention may have a structure in which a number of laminated structures composed of the metal layers 13 and the composition layers 12 are laminated.
- a single-sided metal-foiled laminate using copper foil as the metal layer 13 is called a resin-coated copper foil (RCC), and a double-sided metal-foiled laminate using copper foil as the metal layer 13. is called a copper clad laminate (CCL).
- the thermal expansion coefficient CTE of the composition layer is preferably 10-25 ppm/°C.
- the coefficient of thermal expansion CTE (ppm/° C.) is obtained by measuring the coefficient of thermal expansion CTE below the glass transition temperature of the evaluation sample (composition layer) using a thermomechanical analyzer (TMA402FA Hyperion manufactured by NETZSCH). did.
- the coefficient of thermal expansion CTE below the glass transition temperature was measured at a heating rate of 5°C/min in the range of -20°C to 240°C.
- a metal-clad laminate is obtained that allows a substrate with sufficiently reduced dielectric loss to be produced.
- FIG. 2 is a schematic cross-sectional view showing another example of the metal-clad laminate of the present invention.
- the metal clad laminate 21 includes a composition layer 12 made of the composition of the present invention, a metal layer 13 disposed on both outer surfaces of the composition layer 12, a composition layer 12 and a metal layer. and an adhesive layer (primer layer) 14 disposed between the layers 13 . That is, the metal-clad laminate 21 has a metal layer 13, an adhesive layer 14, and a composition layer 12 in this order, the adhesive layer 14 being provided on the surface of the metal layer 13, and the composition layer 12 being , is provided on the surface of the adhesive layer 14 .
- FIG. 3 is a schematic cross-sectional view showing still another example of the metal-clad laminate of the present invention.
- the metal-clad laminate 31 is similar to the metal-clad laminate 21 of FIG. 2 except that it further includes an intermediate layer 15 that divides the composition layer 12 into two.
- a composition layer is a layer which consists of the composition of this invention.
- the thickness of the composition layer is not particularly limited, but is preferably 50 ⁇ m or more, more preferably 70 ⁇ m or more, and particularly preferably 100 ⁇ m or more from the viewpoint of preventing disconnection of circuit wiring due to deformation or bending.
- the thickness of the composition layer is not particularly limited, but is preferably 300 ⁇ m or less, more preferably 200 ⁇ m or less, and particularly preferably 150 ⁇ m or less from the viewpoint of flexibility, size reduction, and weight reduction of the wiring board to be produced. .
- the dielectric loss tangent Df of the composition layer at a frequency of 10 GHz is preferably 0.0020 or less, more preferably 0.0015 or less, and particularly preferably 0.0010 or less.
- the "dielectric loss tangent Df" here is measured by the same method as in the examples.
- the dielectric constant Dk of the composition layer at a frequency of 10 GHz is preferably 2.0 or higher, more preferably 2.2 or higher, and particularly preferably 2.4 or higher, from the viewpoint of ease of production and widening options. Further, the dielectric constant Dk of the composition layer at a frequency of 10 GHz is preferably 4.0 or less, more preferably 3.5 or less, particularly preferably 3.2 or less, from the viewpoint of suppressing transmission loss.
- the "relative permittivity Dk" here is measured by the same method as in the examples.
- a conductive metal foil such as a copper foil, a silver foil, a gold foil and an aluminum foil having a low electric resistance can be used, and a copper foil is preferably used.
- the metal layer may be composed of one kind of metal by using one kind of metal alone, or may be composed of two or more kinds of metals by using two or more kinds of metals together.
- a method for using a plurality of kinds of metals in combination a method of plating a metal foil with a metal can be used.
- a gold-plated copper foil can be used as the metal foil.
- a carrier-attached metal foil having a peeling layer and a carrier may be used to improve handling.
- the metal layer may be a metal foil (raw foil) as it has been electrolytically manufactured or rolled, or may be surface-treated on one side or both sides. Examples of the surface treatment include rust prevention treatment, silane treatment, surface roughening treatment, and barrier formation treatment.
- TQ-M4-VSP (trade name, manufactured by Mitsui Kinzoku Mining Co., Ltd., copper foil, Rzjis: 0.6 ⁇ m, thickness: 18 ⁇ m) can be used.
- the thickness of the metal layer is not particularly limited, it is preferably 0.1 to 100 ⁇ m, more preferably 0.2 to 50 ⁇ m, and particularly preferably 1.0 to 30 ⁇ m. As long as the thickness of the metal layer is within the above preferable range, it is possible to easily adopt a normal wiring pattern forming method for wiring substrates, such as the MSAP (modified semi-additive) method and the subtractive method.
- MSAP modified semi-additive
- the ten-point average roughness (Rzjis) of the surface of the metal layer on the composition layer side is not particularly limited, but is preferably 2.0 ⁇ m or less, more preferably 1.0 ⁇ m or less, and particularly preferably 0.8 ⁇ m or less. be. These upper limits are preferable from the viewpoint of reducing transmission loss by reducing conductor loss caused by the metal layer, which may increase due to the skin effect of the metal foil during use in a high frequency region.
- the skin effect means a phenomenon in which a high-frequency electric signal flows only near the surface of a metal layer. Due to the skin effect, electrical signals flow following the irregularities on the surface of the metal layer. Therefore, the more rough the metal layer, the longer the electrical signal transmission distance, and the worse the conductor loss.
- the ten-point average roughness (Rzjis) of the surface of the metal foil on the composition layer side is not particularly limited, but is preferably 0.10 ⁇ m or more, more preferably 0.15 ⁇ m or more, and particularly preferably 0.20 ⁇ m or more. be. These lower limits are preferable from the viewpoint of improving the adhesion between the metal layer and the composition layer or the adhesive layer described below.
- the "ten-point average roughness (Rzjis)" here is measured by the same method as in the examples.
- the peel strength (adhesion) at the interface between the metal layer and the composition layer or adhesive layer is preferably 8.1 N/cm or more, more preferably 9 N/cm or more, and particularly preferably 10 N/cm or more. Generally, the higher the peel strength, the better, but from the viewpoint of mass production of products, it is preferably 30 N/cm or less, more preferably 20 N/cm or less.
- the "peel strength (adhesion)" here is measured by the same method as in the examples.
- the adhesive layer contains the fluoropolymer A1 described above, and if necessary, an inorganic filler and other components. It is preferable not to include an inorganic filler having a specific surface area of less than 5.5 m 2 /g.
- the adhesion layer is preferably a layer that functions as a primer layer for improving adhesion between the metal layer and the composition layer.
- the fluoropolymer A1 contained in the adhesive layer is the same as the fluoropolymer A1 contained in the composition forming the composition layer.
- Other components that can be contained in the adhesive layer are the same as other components that can be contained in the composition forming the composition layer.
- the specific surface area of the inorganic filler that can be contained in the adhesive layer is preferably 5.5 m 2 /g or more, more preferably 5.5 to 30 m 2 /g, still more preferably 5.5 to 25 m 2 /g, especially It is preferably 5.5 to 20 m 2 /g.
- the specific surface area of the inorganic filler in the adhesive layer is within the above preferred range, the thickness of the adhesive layer can be reduced and the amount of inorganic filler added can be increased.
- the "specific surface area" here is measured by the same method as in the examples.
- the median diameter (average particle diameter D50) of the inorganic filler that can be contained in the adhesive layer is not particularly limited. 0.1 to 2 ⁇ m. When the median diameter (average particle diameter D50) of the inorganic filler in the adhesive layer is within the preferred range, a thin and uniform adhesive layer can be obtained.
- the “median diameter (average particle diameter D50)" here is measured by the same method as in the examples.
- the inorganic filler that can be contained in the adhesive layer differs from the inorganic filler contained in the composition that constitutes the composition layer only in terms of specific surface area and median diameter (average particle diameter D50), and is otherwise the same. be.
- the content of the inorganic filler in the adhesive layer is not particularly limited, but is preferably 85% by volume or less, more preferably 40 to 85% by volume, and even more preferably 50 to 75% by volume, based on the total volume of the adhesive layer. %, particularly preferably 55 to 70% by volume.
- the relative dielectric constant Dk of the adhesive layer can be brought close to the Dk of the composition layer.
- the thickness of the adhesive layer is preferably 12 ⁇ m or less, more preferably 7 ⁇ m or less, and particularly preferably 4 ⁇ m or less, from the viewpoint of reducing transmission loss in a high frequency region and suppressing warping and peeling.
- the thickness of the adhesive layer is preferably 0.1 ⁇ m or more, more preferably 0.3 ⁇ m or more, and particularly preferably 1 ⁇ m or more, from the viewpoint of improving adhesion between the metal foil and the composition layer.
- the dielectric loss tangent Df of the adhesive layer at a frequency of 10 GHz is preferably 0.003 or less, more preferably 0.0025 or less, and particularly preferably 0.002 or less.
- the "dielectric loss tangent Df" here is measured by the same method as in the examples.
- the dielectric constant Dk of the adhesive layer at a frequency of 10 GHz is preferably 2.0 or higher, more preferably 2.2 or higher, and particularly preferably 2.4 or higher, from the viewpoint of ease of production and widening options. Also, the dielectric constant Dk of the adhesive layer at a frequency of 10 GHz is preferably 4.0 or less, more preferably 3.5 or less, and particularly preferably 3.2 or less, from the viewpoint of suppressing transmission loss.
- the "relative permittivity Dk" here is measured by the same method as in the examples.
- an intermediate layer containing the fluoropolymer A2 described above but not the fluoropolymer A1 described above and containing other components as necessary may be provided.
- an intermediate layer it is preferably provided between composition layers. That is, it is preferably a layer that functions as a layer that divides the composition layer to improve the adhesiveness.
- the method for producing the metal-clad laminate of the present invention is not particularly limited, and conventionally known methods can be used as appropriate.
- a method of press hardening to obtain a metal-clad laminate can also be used.
- a laminate molding method or the like can also be used.
- the coating device used for coating can be appropriately selected according to the film thickness of the metal foil to be formed. be done. These may be used individually by 1 type, and may be used 2 or more types.
- the metal-clad laminate of the present invention using a resin-coated metal foil, which will be described later, for example, two resin-coated metal foils are laminated so that the resin sides face each other, and then heat-pressed to form a laminated body.
- the heating and pressing conditions can be appropriately set according to the thickness of the laminate to be produced, the type of composition, etc.
- the temperature can be 300 to 400° C.
- the pressure can be 5 to 10 MPa
- the time can be 30 to 100 minutes.
- the viscosity of the composition used in the method for producing the metal-clad laminate of the present invention at a temperature of 23° C. is not particularly limited, and is preferably 10 to 200 mPa ⁇ s, more preferably 20 to 160 mPa ⁇ s, particularly preferably 30 to 30 mPa ⁇ s. It is 120 mPa ⁇ s.
- the viscosity of the composition at a temperature of 23° C. is within the above preferred range, the adhesion between the metal layer and the composition layer can be strengthened.
- FIG. 4 is a schematic cross-sectional view showing an example of the resin-coated metal foil used when manufacturing the metal-clad laminate of the present invention.
- the resin-coated metal foil 41 has a structure in which a composition layer 12 made of the composition of the present invention and a metal layer 13 are laminated.
- the resin-coated metal foil 41 may include the composition layer 12 made of the composition before curing and the metal layer 13, and the composition layer 12 made of the semi-cured composition and the metal layer 13 may be provided. may be provided. According to the configuration as described above, it is possible to obtain a resin-coated metal foil from which a metal-clad laminate with sufficiently reduced dielectric loss can be produced.
- Examples of the method of manufacturing the resin-coated metal foil 41 include a method of applying a composition to the surface of the metal foil 13 such as a copper foil and then drying the composition.
- the coating device used for coating can be appropriately selected according to the film thickness of the metal foil to be formed. be done. These may be used individually by 1 type, and may be used 2 or more types.
- the composition or the semi-cured composition may be obtained by drying or heat-drying the composition.
- the conditions for drying or heat drying in the manufacturing method of the resin-coated metal foil 41 are not particularly limited, and it is preferable that the heating temperature is 300 to 400° C. and the heating time is about 5 to 60 minutes.
- the solvent is volatilized, the solvent is reduced or removed, and the resin-coated metal foil 41 in a pre-cured or semi-cured state is obtained.
- a wiring board is manufactured by arranging a wiring circuit on the surface of the metal-clad laminate of the present invention.
- Conventionally known methods can be used as appropriate for the method of forming a wiring circuit on the surface of the metal-clad laminate of the present invention to manufacture a wiring board. can be used, such as a subtractive method of etching the surface or an MSAP method of plating the surface.
- FIG. 5 is a schematic cross-sectional view showing an example of a wiring board manufactured using the metal-clad laminate of the present invention.
- a wiring circuit 16 is formed by etching (partially removed).
- Examples 1 to 9, 11, and 14 to 21 are examples, and Examples 10, 12, and 13 are comparative examples.
- Fluoropolymer A1 EA-2000 (product of AGC Co., Ltd., fluoropolymer containing units based on fluoroolefin and units based on a monomer having an adhesive functional group, melting point 300 ° C. by DSC measurement)
- Fluorine-containing polymer A2 Fluon FL1710 (product of AGC Co., Ltd., polytetrafluoroethylene, a fluoropolymer containing units based on fluoroolefin and not containing units based on a monomer having an adhesive functional group)
- Inorganic filler B1 FB-950XFC (Denka Co., Ltd.
- Inorganic filler B2 FB-25SX (Denka Co., Ltd. product, spherical silica particles, median diameter (average particle diameter D50): 17.3 ⁇ m, specific surface area 3.9 m 2 /g, surface adsorbed water content 483 mass ppm)
- Inorganic filler B3 FB-7SDC (Denka Co., Ltd.
- Inorganic filler B4 FB-304 (Denka Co., Ltd.
- Inorganic filler B5 FB-950FD (product of Denka Co., Ltd., spherical silica particles, median diameter (average particle diameter D50): 24.2 ⁇ m, specific surface area 1.4 m 2 /g, sphericity 0.85 or more, surface adsorbed moisture Amount 173 mass ppm)
- Inorganic filler B6 FB-8C (product of Denka Co., Ltd., spherical silica particles, median diameter (average particle diameter D50): 8.3 ⁇ m, specific surface area 1.6 m 2 /g, sphericity 0.85 or more, surface adsorbed moisture Amount 198 mass ppm)
- Inorganic filler B7 FB-7SDX (Denka Co., Ltd.
- Inorganic filler B8 FB-302X (Denka Co., Ltd. product, spherical silica particles, median diameter (average particle diameter D50): 5.9 ⁇ m, specific surface area 3.5 m 2 /g, surface adsorbed water content 433 mass ppm)
- Inorganic filler B9 FB-105X (Denka Co., Ltd.
- Inorganic filler B10 FB-100XFD (Denka Co., Ltd.
- Inorganic filler B11 FB-950XFD (product of Denka Co., Ltd., spherical silica particles, median diameter (average particle diameter D50): 13.0 ⁇ m, specific surface area 2.0 m 2 /g, surface adsorbed water content 247 mass ppm)
- Examples 1-21 A total of 200 g of each component and 137 g of cyclohexanone described in the component column of the composition in Tables 1 and 2 below were put into a pot, and the mixture was stirred for 20 minutes while applying an acceleration of about 80 G with a low-frequency resonance acoustic mixer (LabMAS II) manufactured by Resodyne. Vibration mixing was carried out to obtain a slurry composition.
- a low-frequency resonance acoustic mixer (LabMAS II) manufactured by Resodyne. Vibration mixing was carried out to obtain a slurry composition.
- the slurry was applied to the surface of a 18 ⁇ m thick copper foil (TQ-M4-VSP, manufactured by Mitsui Mining & Smelting Co., Ltd.) by a doctor blade method to a thickness of 100 ⁇ m, dried for 12 hours in an atmospheric environment at room temperature, and then nitrogen.
- a composition layer was formed by heat drying at 350° C. for 20 minutes in an atmosphere.
- a single-sided metal-clad laminate having a composition layer and a metal layer made of copper foil was obtained. Two of the single-sided metal-clad laminates were stacked with the resin sides facing each other and pressed for 60 minutes at a temperature of 330° C.
- the ratio of the total volume of the polymer and the inorganic filler to the total volume of the composition layer was 100% by volume, and the thickness of the composition layer was 125 ⁇ m.
- the double-sided metal-clad laminate of each example was evaluated as described below. Results are shown in Tables 1 and 2.
- G-CPW grounded coplanar line
- the impedance is 50 ⁇ .
- ⁇ Ten point average roughness Rzjis> The roughened surface of the copper foil was measured using a surfcoder SE600 manufactured by Kosaka Laboratory according to the method specified in Annex JA of JIS B 0601:2013.
- ⁇ Relative permittivity Dk and dielectric loss tangent Df> The dielectric constant Dk and dielectric loss tangent Df of the composition layer (thickness 125 ⁇ m) were measured at 25° C. and 10 GHz according to the method specified in JIS R 1641:2007 using a cavity resonator and a vector network analyzer. In many cases, it is preferable that both the dielectric constant Dk and the dielectric loss tangent Df are small, but depending on the application, it may be better to adjust them to predetermined values.
- thermomechanical analyzer TMA402 FA Hyperion manufactured by NETZSCH
- CTE coefficient of thermal expansion
- the peel strengths of Examples 1-9, 11, 12, and 14-21 are 8.1-19.3 (N/cm), which are all higher than the peel strength of Example 10, 8.0 (N/cm). it was high. Among these, Example 1 (15.5 N/cm), Example 5 (19.3 N/cm), and Example 11 (17.7 N/cm) were particularly high and good.
- the transmission loss for Examples 1-11 and 14-21 was -0.4 dB/cm.
- the transmission loss of Example 12 could not be measured because the composition layer had a high CTE and a transmission line could not be formed.
- the transmission loss of Example 13 could not be measured because the copper foil peeling strength was weak and a transmission path could not be formed.
- the ten-point average roughness of the roughened surface of each of the copper foils of Examples 1 to 21 was 0.6 ⁇ m.
- the dielectric loss tangents Df of Examples 1-12, 15-17, 19 and 21 were all 0.001.
- the dielectric loss tangents Df of Examples 13 and 14 were both 0.0008.
- the dielectric loss tangents Df of Examples 18 and 20 were both 0.0009.
- the dielectric constants Dk of Examples 1 to 14 were all 2.75.
- the dielectric constants Dk of Examples 15-21 were 2.8-2.9.
- a solid By using a composition in which the content of the inorganic filler per minute is 55% by volume or more with respect to the total solid content of the composition, the dielectric constant and dielectric loss tangent are low, and the composition for the metal layer It was found that a metal-clad laminate with improved adhesiveness between layers can be obtained. Further, in the above composition, instead of the fluoropolymer A1 containing units based on fluoroolefin-based units and units based on a monomer having an adhesive functional group, It has been found that when a fluoropolymer containing no units is used, sufficient peel strength cannot be obtained, and transmission loss cannot be measured.
- the present invention has wide industrial applicability in technical fields related to electronic materials and various devices using them.
- Metal-clad laminate 12 Composition layer (insulating layer) 13: Metal layer 14: Adhesive layer (primer layer) 15: Intermediate layer 16: Wiring circuit 41: Metal foil with resin
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Abstract
Description
そこで、これらのフッ素樹脂を含む組成物は、銅箔に対する接着性(金属箔ピール強度)を向上させるために、銅箔の表面粗さを大きくしてアンカー効果を得ること(例えば、特許文献1参照)、フッ素樹脂を含む組成物からなる組成物層と銅箔との間に接着層(プライマー層)を設けること(例えば、特許文献2参照)、フッ素樹脂を含む組成物からなる組成物層をプラズマ処理して組成物層表面を活性化すること(例えば、特許文献3参照)、などが行われている。
以上より、比誘電率及び誘電正接が低く、且つ、金属箔に対する樹脂層の接着性が向上した金属張積層体を形成可能な組成物の開発が強く求められている。
なお、接着性フッ素樹脂である含フッ素重合体A1と、特定の性質を有する無機フィラーとを特定の割合で混合すると、組成物層の金属層に対する接着性が向上する理由としては、金属層に組成物を塗布する場合の粘度が好適となり、金属層/含フッ素重合体A1/無機フィラーにおいて空隙が発生しにくくなるためであると推認される。
すなわち、本発明は下記の通りである。
[1]フルオロオレフィンに基づく単位及び接着性官能基を有するモノマーに基づく単位を含む含フッ素重合体A1と、比表面積が5.5m2/g未満である無機フィラーとを含む組成物であって、
前記組成物の固形分における前記無機フィラーの含有量が、前記組成物の固形分の全体積に対して、55体積%以上である、組成物。
[2]フルオロオレフィンに基づく単位を含み、且つ接着性官能基を有するモノマーに基づく単位を含まない含フッ素重合体A2をさらに含む、[1]に記載の組成物。
[3]前記含フッ素重合体A2の含有量が、前記含フッ素重合体A1と前記含フッ素重合体A2の合計に対して、10体積%以上である、[2]に記載の組成物。
[4]前記接着性官能基が、カルボニル基、ヒドロキシ基、エポキシ基、アミド基、アミノ基及びイソシアネート基からなる群から選ばれる少なくとも1種である、[1]~[3]のいずれかに記載の組成物。
[5]前記無機フィラーは、酸化ケイ素及び酸化チタンの少なくともいずれかである、[1]~[4]のいずれかに記載の組成物。
[6]前記無機フィラーは球形度が0.80以上である、[1]~[5]のいずれかに記載の組成物。
[7]前記無機フィラーのメディアン径(平均粒子径D50)が20μm未満である、[1]~[6]のいずれかに記載の組成物。
[8]前記組成物の固形分における前記無機フィラーの含有量が、前記組成物の固形分の全体積に対して、85体積%以下である、[1]~[7]のいずれかに記載の組成物。
[9]前記無機フィラーの表面吸着水分量が500質量ppm以下である、[1]~[8]のいずれかに記載の組成物。
[10][1]~[9]のいずれかに記載の組成物からなる組成物層と、金属層とを備える、金属張積層体。
[11]前記含フッ素重合体A1を含み、比表面積が5.5m2/g未満の無機フィラーを含まない接着層をさらに備える、[10]に記載の金属張積層体。
[12]前記接着層は、比表面積が5.5m2/g以上である無機フィラーをさらに含み、前記接着層の全体積に対する前記無機フィラーの含有量が、接着層の全体積に対して、85体積%以下である、[11]に記載の金属張積層体。
[13]前記金属層が銅箔からなる層である、[10]~[12]のいずれかに記載の金属張積層体。
[14]前記金属層の前記組成物層側の表面の十点平均粗さ(Rzjis)が2.0μm以下である、[10]~[13]のいずれかに記載の金属張積層体。
[15][1]~[9]のいずれかに記載の組成物を、金属層表面に塗布し、金属張積層体を得る、金属張積層体の製造方法。
本明細書において、好ましいとされている規定は任意に採用でき、好ましいもの同士の組み合わせはより好ましいといえる。
本明細書において、「XX~YY」との記載は、「XX以上YY以下」を意味する。
本明細書において、好ましい数値範囲(例えば、含有量等の範囲)について、段階的に記載された下限値及び上限値は、それぞれ独立して組み合わせ得る。例えば、「好ましくは10~90、より好ましくは30~60」という記載から、「好ましい下限値(10)」と「より好ましい上限値(60)」とを組み合わせて、「10~60」とすることもできる。また、本明細書中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
本明細書において、「モノマーに基づく単位」は、モノマー1分子が重合して直接形成される原子団と、この原子団の一部を化学変換して得られる原子団との総称である。以下、モノマーAに基づく単位をモノマーA単位とも記す。
本明細書において、「接着性官能基を有するモノマーに基づく単位を含まない」とは、「接着性官能基を有するモノマー単位の含有量が、重合体に含まれる全単位に対して0.05モル%未満、好ましくは0.03モル%以下、より好ましくは0.01モル%以下である」ことを意味する。
本明細書において、「組成物の固形分」とは、仮に、組成物が溶媒を含むスラリーである場合、溶媒以外の組成物層を構成する成分を意味する。
本明細書において、「組成物層、接着層、又は中間層」の全体積に対する、重合体A1の含有量(体積%)、重合体A2の含有量(体積%)、及び無機フィラーの含有量(体積%)は、それらを混合(調合)する前に、重合体A1、重合体A2、及び無機フィラーのそれぞれの質量を測定し、それぞれの比重から体積換算して求める。
本発明の組成物は、含フッ素重合体A1と、無機フィラーとを含み、必要に応じて、含フッ素重合体A2、熱可塑性エラストマー、溶媒、その他の成分をさらに含む。
以下、本発明の組成物の各成分について、具体的に説明する。
含フッ素重合体A1は、フルオロオレフィンに基づく単位及び接着性官能基を有する単位を含み、必要に応じて、フルオロオレフィン及び接着性官能基を有するモノマー以外のその他のモノマーに基づく単位を有していてもよい。
「フルオロオレフィンに基づく単位」における「フルオロオレフィン」としては、例えば、テトラフルオロエチレン(以下、「TFE」という)、クロロトリフルオロエチレン(以下、「CTFE」という)、トリフルオロエチレン、フッ化ビニル、ビニリデンフルオライド(フッ化ビニリデン(以下、「VdF」という))、ヘキサフルオロプロピレン(以下、HFPという)、CF2=CFORf1(ここで、Rf1は炭素数1~10で炭素原子間に酸素原子を含んでもよいペルフルオロアルキル基)で表されるパーフルオロアルキルビニルエーテル、CF2=CFORf2SO2X1(Rf2は炭素数1~10で炭素原子間に酸素原子を含んでもよいペルフルオロアルキレン基、X1はハロゲン原子又は水酸基)、CF2=CFORf2CO2X2(ここで、Rf2は上記と同様、X2は水素原子又は炭素数1~3のアルキル基)、CF2=CF(CF2)pOCF=CF2(ここで、pは1又は2)、CH2=CX3(CF2)qX4(ここで、X3及びX4は、互いに独立に水素原子又はフッ素原子、qは2~10の整数)、ペルフルオロ(2-メチレン-4-メチル-1,3-ジオキソラン)、などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。これらの中でも、誘電正接が低い点で、テトラフルオロエチレン、パーフルオロアルキルビニルエーテルが好ましい。
パーフルオロアルキルビニルエーテルの具体例としては、例えば、CF2=CFOCF2CF3、CF2=CFOCF2CF2CF3、CF2=CFOCF2CF2CF2CF3、CF2=CFO(CF2)8F、などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。これらの中でも、CF2=CFOCF2CF2CF3が好ましい。
CH2=CX3(CF2)qX4の具体例としては、例えば、CH2=CH(CF2)2F、CH2=CH(CF2)3F、CH2=CH(CF2)4F、CH2=CF(CF2)3H、CH2=CF(CF2)4H、などが挙げられる。
「接着性官能基を有するモノマー」における「接着性官能基」としては、例えば、カルボニル基、ヒドロキシ基、エポキシ基、アミド基、アミノ基、イソシアネート基、などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。これらの中でも、金属層に対する組成物層の接着性が優れる観点で、カルボニル基が好ましい。
上記「環状炭化水素モノマー」は、1つ以上の5員環又は6員環からなる環状炭化水素であって、しかも、ジカルボン酸無水物基と環内重合性不飽和基を有する重合性化合物をいう。環状炭化水素としては、1つ以上の有橋多環炭化水素を有する環状炭化水素が好ましい。すなわち、有橋多環炭化水素からなる環状炭化水素、有橋多環炭化水素の2以上が縮合した環状炭化水素、又は有橋多環炭化水素と他の環状炭化水素が縮合した環状炭化水素であることが好ましい。
その他のモノマーとしては、例えば、エチレン、プロピレン、イソブテン等の炭素数2~4のオレフィン;酢酸ビニル等のビニルエステル;エチルビニルエーテル、シクロヘキシルビニルエーテル等のビニルエーテル;などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。
本発明の組成物の固形分における含フッ素重合体A1の含有量が、上記好ましい範囲内であると、基板の強度を損なうことなく、金属層に対する組成物層の接着性を向上させることができる。
無機フィラーとしては、例えば、球状シリカ等の酸化ケイ素;酸化チタン、アルミナ、マイカ等の金属酸化物;水酸化アルミニウム、水酸化マグネシウム等の金属水酸化物;タルク;ホウ酸アルミニウム;硫酸バリウム;炭酸カルシウム;などが挙げられる。
ガラス微小球は、シリカガラス又はボロシリケートガラスを含むものが好ましい。
セラミック微小球は、チタン酸バリウムを含むものが好ましく、ネオジウム又は酸化亜鉛がドープされたチタン酸バリウムを含むものが特に好ましい。
中空無機微小球は、非多孔質であってもよく、多孔質であってもよく、また、結晶性であってもよく、非結晶性であってもよい。
中空無機微小球は、フエニルトリメトキシシラン、フェニルトリエトキシシラン、(3,3,3-トリフルオロプロピル)トリメトキシシラン、(トリデカフルオロ-1,1,2,2-テトラヒドロオクチル)-1,1-トリエトキシシラン、(ヘプタデカフルオロ-1,1,2,2-テトラヒドロデシル)-1-トリエトキシシラン等のシランカップリング剤;ネオペンチル(ジアリル)オキシトリ(ジオクチル)ピロフォスフェートジルコネート、ネオペンチル(ジアリル)オキシトリ(N-エチレンジアミノ)エチルジルコネート等のジルコネート;ネオペンチル(ジアリル)オキシトリネオデカノイルチタネート、ネオペンチル(ジアリル)オキシトリ(ドデシル)ベンゼン-スルホニルチタネート、ネオペンチル(ジアリル)オキシトリ(ジオクチル)ホスフェートチタネート等のチタネート類;などによって被覆処理されて疎水性であることが好ましい。
これらは、1種単独で用いてもよく、2種以上用いてもよい。これらの中でも、低熱膨張性の観点で、酸化ケイ素、酸化チタンが好ましく、球状シリカがより好ましい。
無機フィラーの比表面積が、上記好ましい範囲内であると、金属層に対する組成物層の接着性が十分となる。
なお、ここでの「比表面積」は、実施例と同様の方法で測定される。
無機フィラーの球形度が、上記好ましい範囲内であると、スルーホールめっき品質を向上させることができる。
なお、ここでの「球形度」は、実施例と同様の方法で測定される。
無機フィラーのメディアン径(平均粒子径D50)が、上記好ましい範囲内であると、組成物層の均質性やドリル加工性に優れる。
なお、ここでの「メディアン径(平均粒子径D50)」は、実施例と同様の方法で測定される。
無機フィラーの表面吸着水分量が、上記好ましい範囲内であると、組成物層の誘電正接を低くすることができる。
なお、ここでの「表面吸着水分量」は、実施例と同様の方法で測定される。
また、組成物の固形分における無機フィラーの含有量の上限値としては、特に制限はないが、組成物層の熱膨張係数を抑制するという観点から、好ましくは85体積%以下、より好ましくは75体積%以下、特に好ましくは73体積%以下である。
任意成分である含フッ素重合体A2は、フルオロオレフィンに基づく単位を含み、且つ接着性官能基を有するモノマーに基づく単位を含まず、フルオロオレフィン及び接着性官能基を有するモノマー以外のその他のモノマーに基づく単位を含んでいてもよい。
なお、「フルオロオレフィンに基づく単位」、「接着性官能基を有するモノマーに基づく単位」、及び「その他のモノマーに基づく単位」は、「含フッ素重合体A1」の欄で説明した通りである。
含フッ素重合体A2におけるフルオロオレフィンに基づく単位の含有量としては、特に制限はないが、含フッ素重合体A2における全単位の合計モル量に対して、好ましくは90~100モル%、より好ましくは95~100モル%、特に好ましくは97~100モル%である。フルオロオレフィンに基づく単位の含有量が上記好ましい範囲にあると、比誘電率及び誘電正接が低い組成物層が得られる。
含フッ素重合体A2におけるその他のモノマーに基づく単位の含有量としては、特に制限はないが、含フッ素重合体A2における全単位の合計モル量に対して、好ましくは0~10モル%、より好ましくは0~5モル%、特に好ましくは0~3モル%である。
含フッ素重合体A2がフルオロオレフィンに基づく単位を含み、且つ接着性官能基を有するモノマーに基づく単位を含まないことによって、組成物層の誘電正接を低くすることができる。
含フッ素重合体A2の含有量が、上記好ましい範囲内であると、フッ素単位が多くなるので、誘電正接をさらに向上させることができる。
任意成分である溶媒としては、例えば、トルエン、キシレン、メチルエチルケトン、メチルイソブチルケトン、シクロヘキサノン、酢酸エチル、酢酸ブチル、ジメチルホルムアミド、ジメチルアセトアミド、N-メチルピロリドンなどが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。これらの中でも、組成物の溶解性及び取扱い性の観点で、トルエン、メチルエチルケトン、N-メチルピロリドン、シクロヘキサノンが好ましい。
溶媒の含有量が、上記下限値以上であると、組成物の取扱い性が良好になり、また、上記上限値以下であると、所定の厚みの組成物層が得られる。
任意成分であるその他の成分としては、例えば、界面活性剤;シリコーン系消泡剤、アクリル酸エステル系消泡剤等の消泡剤;熱安定剤;帯電防止剤;紫外線吸収剤;染料;顔料;滑剤;湿潤分散剤等の分散剤;などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。これらの中でも、機械特性の観点で、界面活性剤が好ましい。
界面活性剤としては、例えば、ノニオン性のフッ素系界面活性剤、シリコーン系界面活性剤、炭化水素系界面活性剤などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。これらの中でも、含フッ素重合体A1の分散性の観点で、ノニオン性のフッ素系界面活性剤が好ましい。
本発明の金属張積層体は、本発明の組成物からなる組成物層と、金属層とを備え、必要に応じて、接着層、中間層をさらに備える。
図1に示すように、金属張積層体11は、本発明の組成物からなる組成物層(絶縁層)12と、組成物層(絶縁層)12の両面に配置された金属層13とを有する。
なお、本発明の金属張積層体は、図1に示すように、組成物層12の両面に金属層13が配置された両面金属箔張りの積層板であってもよく、また、組成物層12の片面に金属層13が配置された片面金属箔張りの積層板であってもよい(後述する図4参照)。さらに、本発明の金属張積層体は、金属層13及び組成物層12で構成される積層構造を多数積層した構造を有していてもよい。なお、金属層13として銅箔を使用した片面金属箔張りの積層板を樹脂付き銅箔(Resin Coated Copper Foil:RCC)と呼び、金属層13として銅箔を使用した両面金属箔張りの積層板を銅張積層板(Copper Clad Laminate:CCL)と呼ぶ。
なお、熱膨張係数CTE(ppm/℃)は、評価用サンプル(組成物層)について、熱機械分析装置(NETZSCH社製のTMA402FA Hyperion)を用いて、ガラス転移温度未満における熱膨張係数CTEを測定した。なお、ガラス転移温度未満における熱膨張係数CTEは、昇温速度5℃/min、-20℃~240℃の範囲で行った。
図2に示すように、金属張積層体21は、本発明の組成物からなる組成物層12と、組成物層12の両表面外側に配置された金属層13と、組成物層12及び金属層13の間に配置された接着層(プライマー層)14とを有する。すなわち、金属張積層体21は、金属層13と、接着層14と、組成物層12とをこの順に有し、接着層14は、金属層13の表面上に設けられ、組成物層12は、接着層14の表面上に設けられる。
図3に示すように、金属張積層体31は、組成物層12を2つに分割する中間層15をさらに備えること以外は、図2の金属張積層体21と同様である。
組成物層は、本発明の組成物からなる層である。
組成物層の厚みは、特に制限はないが、変形や折れ曲がりによる回路配線の断線を予防する観点から、好ましくは50μm以上、より好ましくは70μm以上、特に好ましくは100μm以上である。
また、組成物層の厚みは、特に制限はないが、作製する配線基板の柔軟性、小型化及び軽量化の観点から、好ましくは300μm以下、より好ましくは200μm以下、特に好ましくは150μm以下である。
なお、ここでの「誘電正接Df」は、実施例と同様の方法で測定される。
また、周波数10GHzにおける組成物層の比誘電率Dkとしては、伝送損失を抑制する観点から、好ましくは4.0以下、より好ましくは3.5以下、特に好ましくは3.2以下である。
なお、ここでの「比誘電率Dk」は、実施例と同様の方法で測定される。
金属層としては、例えば、電気抵抗が低い、銅箔、銀箔、金箔及びアルミニウム箔等の導電性金属箔を用いることができ、銅箔を用いることが好ましい。
金属層は、1種の金属を単独で使用し、1種の金属から構成されてもよいし、複数種の金属を併用し、複数種の金属から構成されてもよい。複数種の金属の併用方法としては、金属箔に金属メッキを施す方法を用いることができ、例えば、金属箔として、金メッキを施した銅箔を用いることができる。
また、金属層の厚みに応じて、ハンドリング性向上のために、剥離層及びキャリアを備えたキャリア付き金属箔を用いてもよい。さらに、金属層は、電解製箔又は圧延製箔されたままの金属箔(生箔)であってもよいし、一方の面又は両面に表面処理が施されていてもよい。前記表面処理としては、例えば、防錆処理、シラン処理、粗面化処理、バリア形成処理を挙げることができる。
金属箔の組成物層側の面の十点平均粗さ(Rzjis)としては、特に制限はないが、好ましくは0.10μm以上、より好ましくは0.15μm以上、特に好ましくは0.20μm以上である。これらの下限値は、金属層と組成物層又は後述する接着層との密着性を向上させる観点から好ましい。
なお、ここでの「十点平均粗さ(Rzjis)」は、実施例と同様の方法で測定される。
なお、ここでの「剥離強度(密着度)」は、実施例と同様の方法で測定される。
接着層は、上述の含フッ素重合体A1を含み、必要に応じて、無機フィラー、その他の成分を含む。比表面積が5.5m2/g未満の無機フィラーは含まないことが好ましい。
接着層は、金属層と、組成物層との間の密着性を向上させるためのプライマー層として機能する層であることが好ましい。
なお、接着層に含まれる含フッ素重合体A1は、組成物層を構成する組成物に含まれる含フッ素重合体A1と同様である。また、接着層に含まれ得るその他の成分は、組成物層を構成する組成物に含まれ得るその他の成分と同様である。
接着層における無機フィラーの比表面積が、上記好ましい範囲内であると、接着層厚を薄くでき、無機フィラー添加量を多くできる。
なお、ここでの「比表面積」は、実施例と同様の方法で測定される。
接着層における無機フィラーのメディアン径(平均粒子径D50)が、上記好ましい範囲内であると、薄くて均質な接着層を得ることができる。
なお、ここでの「メディアン径(平均粒子径D50)」は、実施例と同様の方法で測定される。
接着層における無機フィラーの含有量が、上記好ましい範囲内であると、接着層の比誘電率Dkを組成物層のDkに近づけることができる。
また、接着層の厚みとしては、金属箔及び組成物層との密着性向上の観点から、好ましくは0.1μm以上、より好ましくは0.3μm以上、特に好ましくは1μm以上である。
なお、ここでの「誘電正接Df」は、実施例と同様の方法で測定される。
また、周波数10GHzにおける接着層の比誘電率Dkとしては、伝送損失を抑制する観点から、好ましくは4.0以下、より好ましくは3.5以下、特に好ましくは3.2以下である。
なお、ここでの「比誘電率Dk」は、実施例と同様の方法で測定される。
さらに、上述の含フッ素重合体A2を含み、上述の含フッ素重合体A1を含まず、必要に応じて、その他の成分を含む中間層を設けてもよい。
中間層を設ける場合は、組成物層と組成物層との間に配設されることが好ましい。即ち、組成物層を分割して接着性を向上させる層として機能する層であることが好ましい。
本発明の金属張積層体を製造する方法としては、特に制限はなく、従来公知の方法を適宜用いることができ、例えば、本発明の組成物を、金属層表面に塗布し、それらを加熱加圧し硬化して、金属張積層体を得る方法を用いることもできる。この他にもラミネート成形法なども使用できる。
ここで、塗布に使用される塗布装置としては、形成する金属箔の膜厚に応じて適宜選択することができ、例えば、バーコーター、コンマコーター、ダイコーター、ロールコーター、グラビアコーター、などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。
加熱加圧条件は、製造する積層板の厚みや組成物の種類等により適宜設定でき、例えば、温度を300~400℃、圧力を5~10MPa、時間を30~100分間にできる。
組成物の温度23℃における粘度が、上記好ましい範囲内であると、金属層と組成物層との密着力を強くすることができる。
図4は、本発明の金属張積層体を製造する際に用いる樹脂付き金属箔の一例を示す概略断面図である。
図4に示すように、樹脂付き金属箔41は、本発明の組成物からなる組成物層12と、金属層13と、が積層されている構成を有する。
樹脂付き金属箔41は、硬化前の組成物からなる組成物層12と、金属層13とを備えていてもよく、組成物の半硬化物からなる組成物層12と、金属層13とを備えていてもよい。
上述のような構成によれば、誘電損失が十分に低減された金属張積層体を作製可能な樹脂付き金属箔が得られる。
ここで、塗布に使用される塗布装置としては、形成する金属箔の膜厚に応じて適宜選択することができ、例えば、バーコーター、コンマコーター、ダイコーター、ロールコーター、グラビアコーター、などが挙げられる。これらは、1種単独で用いてもよく、2種以上用いてもよい。
図5は、本発明の金属張積層体を用いて製造した配線基板の一例を示す概略断面図であり、組成物層12の一方の面に接着層14を介して配された金属層13がエッチング(部分的に除去)され配線回路16が形成されている。
・含フッ素重合体A1:EA-2000(AGC株式会社製品、フルオロオレフィンに基づく単位及び接着性官能基を有するモノマーに基づく単位を含む含フッ素重合体、DSC測定による融点300℃)
・含フッ素重合体A2:Fluon FL1710(AGC株式会社製品、ポリテトラフルオロエチレン、フルオロオレフィンに基づく単位を含み接着性官能基を有するモノマーに基づく単位を含まない含フッ素重合体)
・無機フィラーB1:FB-950XFC(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):15.5μm、比表面積1.7m2/g、表面吸着水分量210質量ppm)
・無機フィラーB2:FB-25SX(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):17.3μm、比表面積3.9m2/g、表面吸着水分量483質量ppm)
・無機フィラーB3:FB-7SDC(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):7.6μm、比表面積1.6m2/g、表面吸着水分量198質量ppm)
・無機フィラーB4:FB-304(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):4.0μm、比表面積4.0m2/g、表面吸着水分量495質量ppm)
・無機フィラーB5:FB-950FD(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):24.2μm、比表面積1.4m2/g、球形度0.85以上、表面吸着水分量173質量ppm)
・無機フィラーB6:FB-8C(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):8.3μm、比表面積1.6m2/g、球形度0.85以上、表面吸着水分量198質量ppm)
・無機フィラーB7:FB-7SDX(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):5.5μm、比表面積2.4m2/g、表面吸着水分量297質量ppm)
・無機フィラーB8:FB-302X(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):5.9μm、比表面積3.5m2/g、表面吸着水分量433質量ppm)
・無機フィラーB9:FB-105X(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):10.3μm、比表面積3.0m2/g、表面吸着水分量372質量ppm)
・無機フィラーB10:FB-100XFD(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):11.4μm、比表面積5.8m2/g、表面吸着水分量718質量ppm)
・無機フィラーB11:FB-950XFD(デンカ株式会社製品、球状シリカ粒子、メディアン径(平均粒子径D50):13.0μm、比表面積2.0m2/g、表面吸着水分量247質量ppm)
・無機フィラーB12:E-1(株式会社龍森製品、破砕シリカ粒子、メディアン径(平均粒子径D50):11.0μm、比表面積1.3m2/g、表面吸着水分量161質量ppm)
下記の表1および表2の組成物の成分欄に記載の各成分合計200g及びシクロヘキサノン137gをポットに投入し、レソダイン社製低周波共振音響ミキサー(LabMASII)で約80Gの加速度を与えながら20分間振動混合し、スラリー状の組成物状を得た。
前記片面金属張積層体の、樹脂側が向かいあうように2枚重ねたものを真空ホットプレス装置で、330℃の温度で8MPaの圧力をかけながら60分間プレスし、両面金属張積層体を得た。
得られた両面金属張積層体において、組成物層の全体積に対する重合体と無機フィラーとの合計体積の割合は100体積%であり、組成物層の厚みは125μmであった。
各例の両面金属張積層体について、後述の評価を行った。結果を表1および表2に示す。
レーザー回折・散乱式粒度分布測定装置(日機装株式会社製、MICROTRAC HRA DHSX100)を用い、無機フィラーを水に分散させて体積基準の粒度分布を測定し、メディアン径(平均粒子径D50)を求めた。
ガス吸着量測定装置(MICROTRAC MRB社製、BELSORP MAX)を用い、無機フィラーにN2ガスを吸着させ、その吸着挙動より比表面積を求めた。
Sysmex社製FPIA-3000を用い、下記計算式に基づいて、無機フィラーの球形度を測定した。
A:粒子像の面積
PM:粒子像の周囲長
B:周囲長がPMの真円の面積
HD:円相当径
とした場合、円相当径(HD)=(4/π×A)1/2であり、
球形度=A/B
三菱ケミカルアナリテック社製の微量水分測定装置CA-200を用いて電量滴定法により、無機フィラーの表面吸着水分量を測定した。
後述する金属張積層体から長さ100mm×幅10mmの矩形状の試験片を切り出した。試験片の長さ方向の一端から10mmの位置まで銅箔を組成物層から剥離した。剥がした銅箔の一端を引張り試験機(島津製作所製オートグラフAGS-X)を用いて、引張り速度50mm/分で90°剥離を行い、変位に対して荷重が一定となる荷重値を剥離強度(N/cm)とした。
なお、例13においては、組成物層に接着官能基が存在しないので銅箔の剥離が生じ、剥離強度を正確には測定できなかったが、測定結果(0.2N/cm)を記載した。
後述するコンポジットCCLに線路長12.5mmのグランド付きコプレナー線路(G-CPW)を作製し、80GHzにおける伝送損失を測定した。インピーダンスは50Ωである。
銅箔の粗化面を、JIS B 0601:2013の附属書JAに規定されている方法に従い、小坂研究所製のサーフコーダSE600を用いて測定した。
組成物層(厚み125μm)について、25℃、10GHzにおいて、JIS R 1641:2007に規定されている方法に従い、空洞共振器及びベクトルネットワークアナライザを用いて比誘電率Dk及び誘電正接Dfを測定した。
なお、比誘電率Dk及び誘電正接Dfは、いずれも、小さい方が好ましい場合が多いが用途によっては所定の値に調整した方が良い場合もある。
組成物層から10mm×10mmの試験片を切り出した。この試験片について、熱機械分析装置(NETZSCH社製、TMA402 FA Hyperion)を用いて厚さ方向の熱膨張係数CTE(z)を測定した。具体的には、測定温度が-20℃から240℃の温度範囲を5℃/分の速度でサンプルを昇温し、サンプルの厚さの変位量を測定した。測定終了後、-20℃から240℃までのサンプルの変位量から、-20℃から240℃での熱膨張係数(CTE)を求めた。
例1~11及び14~21の伝送損失は、-0.4dB/cmであった。
例12の伝送損失は、組成物層のCTEが高く伝送路形成ができなかったため、測定不可であった。
例13の伝送損失は、銅箔剥離強度が弱く伝送路形成ができなかったため、測定不可であった。
例1~21の銅箔の粗化面の十点平均粗さは、いずれも0.6μmであった。
例1~12、15~17、19、及び21の誘電正接Dfは、いずれも0.001であった。 例13及び14の誘電正接Dfは、いずれも0.0008であった。
例18及び20の誘電正接Dfは、いずれも0.0009であった。
例1~14の比誘電率Dkは、いずれも2.75であった。
例15~21の比誘電率Dkは、2.8~2.9であった。
以上より、フルオロオレフィンに基づく単位及び接着性官能基を有するモノマーに基づく単位を含む含フッ素重合体A1と、比表面積が5.5m2/g未満である無機フィラーとを含み、組成物の固形分における前記無機フィラーの含有量が、組成物の固形分の全体積に対して、55体積%以上である組成物を用いることによって、比誘電率及び誘電正接が低く、且つ、金属層に対する組成物層の接着性が向上した金属張積層体が得られることが分かった。
また、上記組成物において、フルオロオレフィンに基づく単位及び接着性官能基を有するモノマーに基づく単位を含む含フッ素重合体A1の代わりに、フルオロオレフィンに基づく単位を含み接着性官能基を有するモノマーに基づく単位を含まない含フッ素重合体を用いると、十分な剥離強度が得られず、伝送損失が測定不可となることが分かった。(例15と例13との比較を参照。)
さらに、上記組成物において、組成物の固形分における前記無機フィラーの含有量を63体積%以上にすることによって、誘電正接Dfの値を大きくすることなく比誘電率Dkの値が大きくなるように調整することが出来る。(例6と例16~18との比較、例3と例19~20との比較、および例7と例21とを比較を参照。)
12:組成物層(絶縁層)
13:金属層
14:接着層(プライマー層)
15:中間層
16:配線回路
41:樹脂付き金属箔
Claims (15)
- フルオロオレフィンに基づく単位及び接着性官能基を有するモノマーに基づく単位を含む含フッ素重合体A1と、比表面積が5.5m2/g未満である無機フィラーとを含む組成物であって、
前記組成物の固形分における前記無機フィラーの含有量が、前記組成物の固形分の全体積に対して、55体積%以上である、組成物。 - フルオロオレフィンに基づく単位を含み、且つ接着性官能基を有するモノマーに基づく単位を含まない含フッ素重合体A2をさらに含む、請求項1に記載の組成物。
- 前記含フッ素重合体A2の含有量が、前記含フッ素重合体A1と前記含フッ素重合体A2の合計に対して、10体積%以上である、請求項2に記載の組成物。
- 前記接着性官能基が、カルボニル基、ヒドロキシ基、エポキシ基、アミド基、アミノ基及びイソシアネート基からなる群から選ばれる少なくとも1種である、請求項1~3のいずれかに記載の組成物。
- 前記無機フィラーは、酸化ケイ素及び酸化チタンの少なくともいずれかである、請求項1~4のいずれかに記載の組成物。
- 前記無機フィラーは球形度が0.80以上である、請求項1~5のいずれかに記載の組成物。
- 前記無機フィラーのメディアン径(平均粒子径D50)が20μm未満である、請求項1~6のいずれかに記載の組成物。
- 前記組成物の固形分における前記無機フィラーの含有量が、前記組成物の固形分の全体積に対して、85体積%以下である、請求項1~7のいずれかに記載の組成物。
- 前記無機フィラーの表面吸着水分量が500質量ppm以下である、請求項1~8のいずれかに記載の組成物。
- 請求項1~9のいずれかに記載の組成物からなる組成物層と、金属層とを備える、金属張積層体。
- 前記含フッ素重合体A1を含み、比表面積が5.5m2/g未満の無機フィラーを含まない接着層をさらに備える、請求項10に記載の金属張積層体。
- 前記接着層は、比表面積が5.5m2/g以上である無機フィラーをさらに含み、前記接着層の全体積に対する前記無機フィラーの含有量が、接着層の全体積に対して、85体積%以下である、請求項11に記載の金属張積層体。
- 前記金属層が銅箔からなる層である、請求項10~12のいずれかに記載の金属張積層体。
- 前記金属層の前記組成物層側の表面の十点平均粗さ(Rzjis)が2.0μm以下である、請求項10~13のいずれかに記載の金属張積層体。
- 請求項1~9のいずれかに記載の組成物を、金属層表面に塗布し、金属張積層体を得る、金属張積層体の製造方法。
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