WO2024253039A1 - 硬化性樹脂組成物およびその硬化物 - Google Patents
硬化性樹脂組成物およびその硬化物 Download PDFInfo
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- WO2024253039A1 WO2024253039A1 PCT/JP2024/020048 JP2024020048W WO2024253039A1 WO 2024253039 A1 WO2024253039 A1 WO 2024253039A1 JP 2024020048 W JP2024020048 W JP 2024020048W WO 2024253039 A1 WO2024253039 A1 WO 2024253039A1
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- 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
- C08F12/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring
- C08F12/34—Monomers containing two or more unsaturated aliphatic radicals
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- 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
- C08F2/00—Processes of polymerisation
- C08F2/38—Polymerisation using regulators, e.g. chain terminating agents, e.g. telomerisation
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- 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
- C08F2/00—Processes of polymerisation
- C08F2/44—Polymerisation in the presence of compounding ingredients, e.g. plasticisers, dyestuffs, fillers
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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
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/13—Phenols; Phenolates
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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
- C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
Definitions
- the present invention relates to a curable resin composition containing a compound having a specific structure and a cured product thereof, which is suitable for use in electrical and electronic components such as semiconductor encapsulants, printed wiring boards, and build-up laminates, lightweight, high-strength materials such as carbon fiber reinforced plastics and glass fiber reinforced plastics, and 3D printing applications.
- Low-dielectric materials include thermoplastic materials such as PTFE (polytetrafluoroethylene) and LCP (liquid crystal polymer), but they are poor in moldability compared to thermosetting resins. In light of this, the development of thermosetting resins and curable resin compositions that exhibit low dielectric tangent is desired.
- Patent Document 1 discloses a curable resin composition containing bisvinylphenylethane (BVPE) and a thermosetting polyphenylene ether (Patent Document 1).
- BVPE bisvinylphenylethane
- Patent Document 1 a thermosetting polyphenylene ether
- a polymerization inhibitor is used to improve the storage stability of the resin composition, and 2,5-bis(1,1-dimethylbutyl)hydroquinone is used.
- a polymerization inhibitor having a polar group a substituent containing a hetero atom
- the optimal polymerization inhibitor also changes, making its selection difficult and an important issue.
- the present invention was made in consideration of these circumstances, and aims to provide a curable resin composition that has excellent storage stability and exhibits a low dielectric tangent, and a cured product thereof.
- a curable resin composition comprising a compound represented by the following formula (1) and a compound represented by the following formula (2):
- A is a hydrocarbon group having 1 to 20 carbon atoms, and each of the multiple R's independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms, or a halogenated alkyl group having 1 to 10 carbon atoms.
- p is an integer from 0 to 4
- q is an integer from 0 to 3
- n is the average number of repetitions, with 1 ⁇ n ⁇ 20.
- R 1 and R 2 each independently represent a hydrocarbon group having 1 to 20 carbon atoms, and n represents an integer of 0 to 3.
- each of the multiple R's independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms, or a halogenated alkyl group having 1 to 10 carbon atoms; p and r each represent an integer of 0 to 4; q represents an integer of 0 to 3; n represents the average number of repetitions, and 1 ⁇ n ⁇ 20.
- R 1 and R 2 each independently represent a hydrocarbon group having 1 to 20 carbon atoms, and n represents an integer of 0 to 3.
- n represents an integer of 0 to 3.
- the curable resin composition of the present invention and its cured product exhibit a low dielectric tangent.
- the present embodiment an embodiment of the present invention (hereinafter, also referred to as “the present embodiment”) will be described in further detail.
- the curable resin composition of this embodiment contains a compound represented by the following formula (1) as an essential component.
- A is a hydrocarbon group having 1 to 20 carbon atoms, preferably a hydrocarbon group having 2 to 20 carbon atoms, more preferably a hydrocarbon group having 6 to 20 carbon atoms, and particularly preferably a hydrocarbon group having 8 to 20 carbon atoms.
- the hydrocarbon preferably contains a methylene chain, an alicyclic structure, or an aromatic ring, more preferably a methylene chain or an aromatic ring, and even more preferably contains at least one aromatic ring.
- the inclusion of an aromatic ring suppresses molecular vibration, improving the dielectric properties and also contributing to improved heat resistance.
- Each of the multiple R's independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms, or a halogenated alkyl group having 1 to 10 carbon atoms, and is preferably a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms, and even more preferably a hydrogen atom or a hydrocarbon group having 1 to 3 carbon atoms. Hydrocarbons having 10 or fewer carbon atoms are less likely to undergo molecular vibration when exposed to high frequency waves, and therefore have particularly excellent electrical properties.
- n is the average number of repetitions, and is preferably 1 ⁇ n ⁇ 20, more preferably 1.1 ⁇ n ⁇ 20, particularly preferably 1.1 ⁇ n ⁇ 10, and most preferably 1.1 ⁇ n ⁇ 5.
- Mn number average molecular weight
- the number average molecular weight is preferably 200 or more and less than 5000, more preferably 300 or more and less than 3000, and particularly preferably 400 or more and less than 2000. If the weight average molecular weight is less than 5000, purification by washing with water becomes easy, and if it is 200 or more, the target compound does not volatilize in the solvent distillation step.
- the compound represented by formula (1) is particularly preferably a compound represented by formula (1-1) below.
- each of the multiple R's independently represents a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms, or a halogenated alkyl group having 1 to 10 carbon atoms, preferably a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms, and more preferably a hydrogen atom or a hydrocarbon group having 1 to 3 carbon atoms.
- Hydrocarbons having 10 or fewer carbon atoms are less likely to undergo molecular vibration when exposed to high frequency waves, and therefore have particularly excellent electrical properties.
- p and r are integers of 0 to 4, preferably 0 to 2.
- q is an integer of 0 to 3, preferably 0 to 2.
- n is the average number of repetitions, and is preferably 1 ⁇ n ⁇ 20, more preferably 1.1 ⁇ n ⁇ 20, particularly preferably 1.1 ⁇ n ⁇ 10, and most preferably 1.1 ⁇ n ⁇ 5.
- Mn number average molecular weight
- the number average molecular weight is preferably 200 or more and less than 5000, more preferably 300 or more and less than 3000, and particularly preferably 400 or more and less than 2000. If the weight average molecular weight is less than 5000, purification by washing with water becomes easy, and if it is 200 or more, the target compound does not volatilize in the solvent distillation step.
- the compound represented by the formula (1-1) is derived from the compound represented by the following formula (1-2).
- R represents a halogen atom, and from the viewpoints of reactivity and stability of the raw materials, a bromine atom or a chlorine atom is preferable, and a bromine atom is particularly preferable.
- the compound represented by the formula (1-1) can be obtained, for example, by a method of subjecting the compound represented by the formula (1-2) to a dehydrohalogenation reaction in a solvent in the presence of a basic catalyst.
- the solvent to be used include, but are not limited to, water-insoluble solvents such as aromatic solvents such as toluene and xylene, aliphatic solvents such as cyclohexane and n-hexane, ethers such as diethyl ether and diisopropyl ether, ester solvents such as ethyl acetate and butyl acetate, and ketone solvents such as methyl isobutyl ketone and cyclopentanone.
- water-insoluble solvents such as aromatic solvents such as toluene and xylene, aliphatic solvents such as cyclohexane and n-hexane, ethers such as diethyl ether and diisopropy
- aprotic polar solvents can also be used in combination. Examples include dimethyl sulfone, dimethyl sulfoxide, dimethylformamide, dimethylacetamide, 1,3-dimethyl-2-imidazolidinone, and N-methylpyrrolidone, and two or more of these may be used in combination.
- an aprotic polar solvent it is preferable to use one having a higher boiling point than the water-insoluble solvent to be used in combination.
- the catalyst is not particularly limited, but examples include basic catalysts such as sodium hydroxide, potassium hydroxide, and potassium carbonate.
- the aprotic polar solvent may be used in large excess relative to the substrate, and the dehydrohalogenation reaction may be repeated two or more times.
- the dehydrohalogenation reaction of the compound represented by the formula (1-2) may be carried out in an organic solvent in the presence of a base catalyst, and the resulting solution may be washed with water and then returned to the reaction vessel, and the base catalyst may be added to cause the reaction again. In this way, the progress of the dehydrohalogenation reaction can be increased. That is, it is possible to reduce the amount of residual halogen contained in the target compound.
- the amount of residual halogen is preferably 1 to 10,000 ppm in the target product, more preferably 1 to 1,000 ppm, and even more preferably 1 to 750 ppm. If the amount of residual halogen contained in the compound represented by the formula (1-1) is large, molecular vibration occurs when exposed to high frequency, which has a negative effect on electrical properties, particularly dielectric loss tangent. Furthermore, if the amount of residual halogen is large, the risk of problems such as metal corrosion and ion migration increases in environmental tests such as HAST tests (High Accelerated Stress Tests), so the above halogen content is preferable.
- the method for producing the compound represented by the formula (1-2) is not particularly limited, but for example, a compound having a (2-bromoethyl)benzene structure may be reacted with a bishalogenated methylaryl compound (or a bishydroxymethylaryl compound, etc.) under an acid catalyst such as hydrochloric acid, sulfonic acid, or activated clay, or a compound having a (2-bromoethyl)benzene structure may be reacted with a bishydroxymethylaryl compound under an acid catalyst such as hydrochloric acid, sulfonic acid, or activated clay.
- an acid catalyst such as hydrochloric acid, sulfonic acid, or activated clay
- neutralization with an alkali metal such as sodium hydroxide or potassium hydroxide may be performed before proceeding to the extraction step.
- an aromatic hydrocarbon solvent such as toluene or xylene may be used alone, or a non-aromatic hydrocarbon such as cyclohexane or toluene may be used in combination.
- the organic layer is washed with water until the wastewater becomes neutral, and the solvent and excess compounds having a (2-bromoethyl)benzene structure are distilled off using an evaporator or the like to obtain a compound having at least two or more (2-bromoethyl)benzene structures in the target molecule.
- Examples of compounds having a (2-bromoethyl)benzene structure include (2-bromoethyl)benzene, 1-(2-bromoethyl)-2-methylbenzene, 1-(2-bromoethyl)-3-methylbenzene, 1-(2-bromoethyl)-4-methylbenzene, 1-(2-bromoethyl)-2,3-dimethylbenzene, 1-(2-bromoethyl)-2,4-dimethylbenzene, 1-(2-bromoethyl)-2,5-dimethylbenzene, and 1-(2-bromoethyl)-2,6-dimethylbenzene, but are not limited to these.
- a larger carbon number improves solvent solubility but reduces heat resistance, so it is preferably unsubstituted or substituted with an alkyl group having 1 to 3 carbon atoms, more preferably unsubstituted or substituted with an alkyl group having 1 to 2 carbon atoms, and most preferably unsubstituted or substituted with a methyl group.
- bishalogenated methylaryl compounds include, but are not limited to, o-xylylene difluoride, m-xylylene difluoride, p-xylylene difluoride, o-xylylene dichloride, m-xylylene dichloride, p-xylylene dichloride, o-xylylene dibromide, m-xylylene dibromide, p-xylylene dibromide, o-xylylene diiodide, m-xylylene diiodide, p-xylylene diiodide, and the like. These may be used alone or in combination of two or more. From the viewpoint of the reactivity of the raw materials during synthesis, chloride-based compounds, bromide-based compounds, and iodide-based compounds are preferred, and chloride-based compounds and bromide-based compounds are more preferred.
- Bishydroxymethylaryl compounds include, but are not limited to, o-benzenedimethanol, m-benzenedimethanol, p-benzenedimethanol, and the like. These may be used alone or in combination of two or more.
- the amount of these compounds used is preferably 0.05 to 0.8 parts by mass, and more preferably 0.1 to 0.6 parts by mass, per part by mass of the compound having a (2-bromoethyl)benzene structure.
- a catalyst may be used as needed, such as hydrochloric acid, phosphoric acid, sulfuric acid, formic acid, p-toluenesulfonic acid, methanesulfonic acid, Lewis acids such as aluminum chloride and zinc chloride, activated clay, acidic clay, white carbon, zeolite, solid acids such as silica alumina, acidic ion exchange resins, etc. These may be used alone or in combination of two or more.
- the amount of catalyst used is 0.05 to 0.8 moles, preferably 0.1 to 0.7 moles, per mole of the compound having a (2-bromoethyl)benzene structure used. If the amount of catalyst used is too large, the viscosity of the reaction solution may be too high, making stirring difficult, and if the amount is too small, the reaction may proceed slowly.
- the reaction may be carried out using an organic solvent such as hexane, cyclohexane, octane, toluene, or xylene, as necessary, or may be carried out without a solvent.
- the water is removed from the system by azeotropy. Then, the reaction is carried out at 40 to 180°C, preferably 50 to 170°C, for 0.5 to 20 hours.
- the acidic catalyst may be neutralized with an alkaline aqueous solution, but it is also possible to proceed to the water washing step without neutralization.
- a water-insoluble organic solvent is added to the oil layer and water washing is repeated until the wastewater becomes neutral.
- the softening point of the compound represented by formula (1-2) is preferably 80°C or lower, more preferably 70°C or lower. If the softening point is 80°C or lower, the viscosity will be low when it is induced into the compound represented by formula (1-1). This makes it easier to ensure fluidity, does not impair the impregnation into glass cloth or carbon fiber, and makes it easier to make it into a B-stage, such as prepreg. If the viscosity is lowered by increasing the dilution solvent, there is a possibility that the resin will not adhere sufficiently to the fibrous material during the impregnation process.
- the curable resin composition of this embodiment further contains a compound represented by the following formula (2):
- R 1 and R 2 each independently represent a hydrocarbon group having 1 to 20 carbon atoms, preferably a hydrocarbon group having 1 to 15 carbon atoms, more preferably a hydrocarbon group having 1 to 10 carbon atoms, and even more preferably a hydrocarbon group having 1 to 5 carbon atoms.
- R 1 and R 2 are hydrocarbon groups having more than 20 carbon atoms, the molecule is likely to vibrate when exposed to high frequency waves, and the dielectric properties may deteriorate.
- the number of carbon atoms is 20 or less, the equivalent weight of the phenolic hydroxyl group per weight is large, and a sufficient polymerization inhibition effect is obtained.
- n is an integer of 0 to 3, preferably 0 to 2, more preferably 0 to 1, and particularly preferably 0. When n is small, the equivalent weight of the phenolic hydroxyl group per weight is large, and a sufficient polymerization inhibition effect is obtained, which is more preferable.
- the compound represented by formula (2) has a hydrocarbon group at the ortho position of the phenolic hydroxyl group located at the top of formula (2), and a phenolic hydroxyl group at the para position.
- the hydrocarbon group regenerates the phenolic hydroxyl group by donating hydrogen to the phenoxy radical, and therefore has the effect of enhancing the polymerization inhibition effect.
- the phenolic hydroxyl group at the para position increases the electron density of the compound represented by formula (2), and therefore has the effect of improving the radical scavenging performance.
- the polar groups of the compound represented by formula (2) are symmetrically positioned, the dipole moment is small, and deterioration of the dielectric properties can be suppressed.
- the compound represented by formula (2) is preferably 0.0001 to 1 part by mass, more preferably 0.001 to 0.75 parts by mass, even more preferably 0.002 to 0.5 parts by mass, and particularly preferably 0.004 to 0.5 parts by mass, relative to 100 parts by mass of the compound represented by formula (1). If it is less than 0.0001 part by mass, there is a risk that a sufficient polymerization inhibition effect will not be obtained, and if it is more than 1 part by mass, there is a risk that the dielectric properties will be significantly impaired.
- the reaction initiation temperature of the curable resin composition be a temperature of 120°C or higher.
- the reaction initiation temperature obtained by DSC differs from the actual temperature because the device is a non-insulating system (Reference: Chemical Explosion Safety Information Database, http://www.explosion-safety.jp/INFOMATION/how_to_test_1-3.htm)
- the heat generation initiation temperature of the DSC be at least 170°C or higher. If it is less than 170°C, the reaction will proceed during drying of the prepreg, which may result in a lack of fluidity during molding and make it difficult to create a laminate.
- the curable resin composition of the present embodiment may contain other polymerization inhibitors in addition to the compound represented by formula (2). However, when a polymerization inhibitor is used, the amount of the polymerization inhibitor is limited to a range that does not significantly affect the dielectric properties and curing properties of the curable resin composition of the present embodiment.
- polymerization inhibitors examples include phenol-based, sulfur-based, phosphorus-based, hindered amine-based, nitroso-based, and nitroxyl radical-based.
- phenol-based polymerization inhibitors include, for example, monophenols such as 2,6-di-t-butyl-p-cresol, butylated hydroxyanisole, 2,6-di-t-butyl-p-ethylphenol, stearyl- ⁇ -(3,5-di-t-butyl-4-hydroxyphenyl)propionate, isooctyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 2,4-bis-(n-octylthio)-6-(4-hydroxy-3,5-di-t-butylanilino)-1,3,5-triazine, and 2,4-bis[(octylthio)methyl]-o-cresol; -t-butylphenol), 2,2'-methylenebis(4-ethyl-6-t-butylphenol), 4,4'-thiobis(3-methyl-6-t-butyl
- sulfur-based polymerization inhibitors examples include, but are not limited to, dilauryl-3,3'-thiodipropionate, dimyristyl-3,3'-thiodipropionate, and distearyl-3,3'-thiodipropionate.
- Examples of the phosphorus-based polymerization inhibitors include triphenyl phosphite, diphenyl isodecyl phosphite, phenyl diisodecyl phosphite, tris(nonylphenyl) phosphite, diisodecyl pentaerythritol phosphite, tris(2,4-di-t-butylphenyl) phosphite, cyclic neopentane tetrayl bis(octadecyl) phosphite, cyclic neopentane tetrayl bi(2,4-di-t-butylphenyl) phosphite, cyclic neopentane tetrayl bi(2,4-di-t-butyl-4-methylphenyl) phosphite, bis[2-t -butyl-6-
- Examples of the above hindered amine polymerization inhibitors include ADK STAB LA-40MP, ADK STAB LA-40Si, ADK STAB LA-402AF, ADK STAB LA-87, ADK STAB LA-82, ADK STAB LA-81, ADK STAB LA-77Y, ADK STAB LA-77G, ADK STAB LA-72, ADK STAB LA-68, ADK STAB LA-63P, ADK STAB LA-57, ADK STAB Examples include, but are not limited to, LA-52, Chimassorb 2020FDL, Chimassorb 944FDL, Chimassorb 944LD, Tinuvin 622SF, Tinuvin PA144, Tinuvin 765, Tinuvin 770DF, Tinuvin XT55FB, Tinuvin 111FDL, Tinuvin 783FDL, Tinuvin 791FB, etc.
- nitroso-based polymerization inhibitor examples include, but are not limited to, p-nitrosophenol, N-nitrosodiphenylamine, ammonium salt of N-nitrosophenylhydroxyamine, (cupferron), etc. Among these, the ammonium salt of N-nitrosophenylhydroxyamine (cupferron) is preferred.
- nitroxyl radical polymerization inhibitor examples include, but are not limited to, di-tert-butyl nitroxide, 2,2,6,6-tetramethylpiperidine-1-oxyl, 4-hydroxy-2,2,6,6-tetramethylpiperidine-1-oxyl, 4-oxo-2,2,6,6-tetramethylpiperidine-1-oxyl, 4-amino-2,2,6,6-tetramethylpiperidine-1-oxyl, 4-methoxy-2,2,6,6-tetramethylpiperidine-1-oxyl, 4-acetoxy-2,2,6,6-tetramethylpiperidine-1-oxyl, and 4-benzoyloxy-2,2,6,6-tetramethylpiperidine-1-oxyl.
- the curable resin composition of the present embodiment can also have improved curability by adding a curing accelerator.
- a curing accelerator an anionic curing accelerator that accelerates the curing reaction by generating anions upon irradiation with ultraviolet light or visible light or heating, or a cationic curing accelerator that accelerates the curing reaction by generating cations upon irradiation with ultraviolet light or visible light or heating, is preferred.
- anionic curing accelerators examples include imidazoles such as 2-methylimidazole, 2-ethylimidazole, and 2-ethyl-4-methylimidazole; trialkylamines such as triethylamine and tributylamine; 4-dimethylaminopyridine, benzyldimethylamine, 2,4,6-tris(dimethylaminomethyl)phenol, and 1,8-diazabicyclo(5,4,0)-undecene; of which 4-dimethylaminopyridine and 1,8-diazabicyclo(5,4,0)-undecene are preferred.
- imidazoles such as 2-methylimidazole, 2-ethylimidazole, and 2-ethyl-4-methylimidazole
- trialkylamines such as triethylamine and tributylamine
- 4-dimethylaminopyridine benzyldimethylamine, 2,4,6-tris(dimethylaminomethyl)
- phosphines such as triphenylphosphine
- quaternary ammonium salts such as tetrabutylammonium salts, triisopropylmethylammonium salts, trimethyldecanylammonium salts, cetyltrimethylammonium salts, and hexadecyltrimethylammonium hydroxide, but are not limited to these. These may be used alone or in combination.
- cationic curing accelerators include quaternary phosphonium salts such as triphenylbenzylphosphonium salt, triphenylethylphosphonium salt, and tetrabutylphosphonium salt (the counter ion of the quaternary salt may be a halogen, an organic acid ion, a hydroxide ion, or the like, but is not limited to organic acid ions and hydroxide ions); transition metal compounds (transition metal salts) such as tin octylate, zinc carboxylate (zinc 2-ethylhexanoate, zinc stearate, zinc behenate, zinc myristate), and zinc phosphate ester (zinc octylphosphate, zinc stearylphosphate); but are not limited to these. These may be used alone or in combination.
- quaternary phosphonium salts such as triphenylbenzylphosphonium salt, triphenylethylphosphonium salt, and t
- the amount of the curing accelerator used is 0.01 to 5.0 parts by mass per 100 parts by mass of the curable resin composition, as needed.
- the curable resin composition of the present embodiment may contain an inorganic filler.
- inorganic fillers include powders such as fused silica, crystalline silica, porous silica, alumina, zircon, calcium silicate, calcium carbonate, quartz powder, silicon carbide, silicon nitride, boron nitride, zirconia, aluminum nitride, graphite, forsterite, steatite, spinel, mullite, titania, talc, clay, iron oxide, asbestos, and glass powder, and inorganic fillers obtained by making these into a spherical or crushed shape, but are not limited thereto. In addition, these may be used alone or in combination.
- the inorganic filler When obtaining a curable resin composition for semiconductor encapsulation, the inorganic filler is used in an amount of preferably 80 to 92 parts by mass, and more preferably 83 to 90 parts by mass, per 100 parts by mass of the curable resin composition.
- the inorganic filler When obtaining a curable resin composition for use as an interlayer insulating layer forming material, or as a substrate material such as a copper-clad laminate, prepreg, or RCC, the inorganic filler is used in an amount of preferably 5 to 80 parts by mass, and more preferably 10 to 60 parts by mass, per 100 parts by mass of the curable resin composition.
- the curable resin composition of the present embodiment can also improve the curability by adding a polymerization initiator.
- the polymerization initiator is a compound capable of polymerizing an olefin functional group such as an ethylenically unsaturated bond, and examples of such a polymerization initiator include an olefin metathesis polymerization initiator, an anionic polymerization initiator, a cationic polymerization initiator, and a radical polymerization initiator. Among these, it is preferable to use a radical polymerization initiator having curability and moderate stability.
- the radical polymerization initiator is a compound that generates radicals by irradiation with ultraviolet light or visible light or by heating, and initiates a chain polymerization reaction.
- radical polymerization initiators examples include organic peroxides, azo compounds, and benzopinacoles, and it is preferable to use an organic peroxide because it has little effect on curing temperature control, outgassing suppression, and electrical properties of decomposition products.
- organic peroxides include, for example, ketone peroxides such as methyl ethyl ketone peroxide and acetylacetone peroxide, diacyl peroxides such as benzoyl peroxide, dialkyl peroxides such as dicumyl peroxide and 1,3-bis-(t-butylperoxyisopropyl)-benzene, peroxyketals such as t-butyl peroxybenzoate and 1,1-di-t-butylperoxycyclohexane, ⁇ -cumyl peroxyneodecanoate, t-butyl peroxyneodecanoate, t-butyl peroxypivalate, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate, t-amyl peroxy-2-ethylhexanoate, t-butyl
- the peroxycarbonate include, but are not limited to, alkyl
- ketone peroxides diacyl peroxides, hydroperoxides, dialkyl peroxides, peroxyketals, alkyl peresters, peroxycarbonates, etc. are preferred, with dialkyl peroxides being more preferred.
- azo compounds examples include, but are not limited to, azobisisobutyronitrile, 4,4'-azobis(4-cyanovaleric acid), 2,2'-azobis(2,4-dimethylvaleronitrile), etc. Furthermore, these may be used alone or in combination.
- the amount of polymerization initiator added is preferably 0.01 to 5 parts by mass, and particularly preferably 0.01 to 3 parts by mass, per 100 parts by mass of the curable resin composition. If the amount of polymerization initiator used is less than 0.01 parts by mass, there is a risk that the molecular weight will not be sufficiently extended during the polymerization reaction, and if it is more than 5 parts by mass, there is a risk that the dielectric properties such as the dielectric constant and dielectric tangent will be impaired.
- the curable resin composition of the present embodiment may contain a flame retardant.
- the flame retardant include halogen-based flame retardants, inorganic flame retardants (antimony compounds, metal hydroxides, nitrogen compounds, boron compounds, etc.), and phosphorus-based flame retardants. From the viewpoint of achieving halogen-free flame retardancy, phosphorus-based flame retardants are preferred.
- the phosphorus-based flame retardant may be of a reactive type or an additive type.
- phosphoric acid esters such as trimethyl phosphate, triethyl phosphate, tricresyl phosphate, trixylyleneyl phosphate, cresyl diphenyl phosphate, cresyl-2,6-dixylyleneyl phosphate, 1,3-phenylene bis(dixylyleneyl phosphate), 1,4-phenylene bis(dixylyleneyl phosphate), and 4,4'-biphenyl(dixylyleneyl phosphate), phosphanes such as 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide and 10-(2,5-dihydroxyphenyl)-10H-9-oxa-10-phosphaphenanthrene-10-oxide, phosphorus-containing epoxy compounds obtained by reacting epoxy resins with active hydrogen of the phosphanes, red phosphorus, and the like, but are not limited thereto.
- phosphoric acid esters such as
- phosphates, phosphanes, or phosphorus-containing epoxy compounds are preferred, with 1,3-phenylenebis(dixylilenyl phosphate), 1,4-phenylenebis(dixylilenyl phosphate), 4,4'-biphenyl(dixylilenyl phosphate) or phosphorus-containing epoxy compounds being particularly preferred.
- the content of the flame retardant is preferably in the range of 0.1 to 0.6 parts by mass per 100 parts by mass of the curable resin composition. If it is less than 0.1 part by mass, there is a risk that the flame retardancy will be insufficient, and if it is more than 0.6 parts by mass, there is a risk that it will have a negative effect on the moisture absorption and dielectric properties of the cured product.
- the curable resin composition of the present embodiment may contain a light stabilizer.
- a light stabilizer a hindered amine light stabilizer, in particular HALS, etc.
- HALS include reaction products of dibutylamine, 1,3,5-triazine, N,N'-bis(2,2,6,6-tetramethyl-4-piperidyl-1,6-hexamethylenediamine and N-(2,2,6,6-tetramethyl-4-piperidyl)butylamine, reaction products of dimethyl succinate-1-(2-hydroxyethyl)-4-hydroxy-2,2,6,6-tetramethylpiperidine, poly[ ⁇ 6-(1,1,3,3-tetramethylbutyl)amino-1,3,5-triazine-2,4-diyl ⁇ (2,2,6,6-tetramethyl-4-piperidyl)imino ⁇ hexamethylene ⁇ (2,2,6,6-tetramethyl-4-piperidyl)imino ⁇ ],
- the content of the light stabilizer is preferably in the range of 0.001 to 0.1 parts by mass per 100 parts by mass of the curable resin composition. If it is less than 0.001 parts by mass, it may be insufficient to achieve the light stabilizing effect, and if it is more than 0.1 parts by mass, it may have a negative effect on the moisture absorption and dielectric properties of the cured product.
- the curable resin composition of the present embodiment may use a binder resin.
- the binder resin include, but are not limited to, butyral resins, acetal resins, acrylic resins, epoxy-nylon resins, NBR-phenol resins, epoxy-NBR resins, and silicone resins. These may be used alone or in combination.
- the amount of binder resin used is preferably within a range that does not impair the flame retardancy and heat resistance of the cured product, and is preferably 0.05 to 50 parts by mass, and more preferably 0.05 to 20 parts by mass, per 100 parts by mass of the curable resin composition, as needed.
- the curable resin composition of the present embodiment may contain additives, such as modified acrylonitrile copolymers, polyethylene, fluororesins, silicone gels, silicone oils, surface treatment agents for fillers such as silane coupling agents, release agents, and colorants such as carbon black, phthalocyanine blue, and phthalocyanine green.
- additives such as modified acrylonitrile copolymers, polyethylene, fluororesins, silicone gels, silicone oils, surface treatment agents for fillers such as silane coupling agents, release agents, and colorants such as carbon black, phthalocyanine blue, and phthalocyanine green.
- the amount of additive is preferably 1,000 parts by mass or less, and more preferably 700 parts by mass or less, per 100 parts by mass of the curable resin composition.
- the curable resin composition of this embodiment may further contain epoxy resins, active ester compounds, phenolic resins, polyphenylene ether compounds, amine resins, compounds having ethylenically unsaturated bonds, isocyanate resins, polyamide resins, maleimide compounds, cyanate ester resins, polyimide resins, polybutadiene and modified products thereof, polystyrene and modified products thereof, polyethylene and modified products thereof, etc., and these may be used alone or in combination.
- maleimide compounds polyphenylene ether compounds, compounds having ethylenically unsaturated bonds, cyanate ester resins, polybutadiene and modified products thereof, polystyrene and modified products thereof, and polyethylene and modified products thereof, in view of the balance of heat resistance, adhesion, and dielectric properties.
- the brittleness of the cured product and adhesion to metals can be improved, and cracks in the package during solder reflow and during reliability tests such as thermal cycles can be suppressed.
- the total amount of the above compounds used is preferably 10 parts by mass or less, more preferably 5 parts by mass or less, and particularly preferably 3 parts by mass or less, relative to the mixture of this embodiment, unless otherwise specified.
- the lower limit is preferably 0.1 parts by mass or more, more preferably 0.25 parts by mass or more, and even more preferably 0.5 parts by mass or more.
- epoxy resin Preferred examples of the epoxy resin include, but are not limited to, the following.
- the epoxy resin may be liquid or solid, and may be used alone or in combination.
- liquid epoxy resins examples include bisphenol A type epoxy resins, bisphenol F type epoxy resins, bisphenol AF type epoxy resins, naphthalene type epoxy resins, glycidyl ester type epoxy resins, glycidyl amine type epoxy resins, phenol novolac type epoxy resins, alicyclic epoxy resins having an ester skeleton, cyclohexane type epoxy resins, cyclohexane dimethanol type epoxy resins, glycidyl amine type epoxy resins, and epoxy resins having a butadiene structure.
- solid epoxy resins include bixylenol type epoxy resins, naphthalene type epoxy resins, naphthalene type tetrafunctional epoxy resins, cresol novolac type epoxy resins, dicyclopentadiene type epoxy resins, trisphenol type epoxy resins, naphthol type epoxy resins, biphenyl type epoxy resins, naphthylene ether type epoxy resins, anthracene type epoxy resins, bisphenol A type epoxy resins, bisphenol AF type epoxy resins, and tetraphenylethane type epoxy resins, and examples of such solid epoxy resins include naphthol type epoxy resins, bisphenol AF type epoxy resins, naphthalene type epoxy resins, and biphenyl type epoxy resins.
- HP4032H manufactured by DIC Corporation, naphthalene type epoxy resin
- HP-4700 manufactured by DIC Corporation, naphthalene type tetrafunctional epoxy resin
- HP-4710 all manufactured by DIC Corporation, naphthalene type tetrafunctional epoxy resin
- N-690 manufactured by DIC Corporation, cresol novolac type epoxy resin
- N-695" manufactured by DIC Corporation, cresol novolac type epoxy resin
- HP-7200 manufactured by DIC Corporation, dicyclopentadiene type epoxy resin
- HP-7200 manufactured by DIC Corporation, dicyclopentadiene type epoxy resin
- HP-7200 manufactured by DIC Corporation, dicyclopentadiene type epoxy resin
- HP-7200 manufactured by DIC Corporation, dicyclopentadiene type epoxy resin
- HP-7200 manufactured by DIC Corporation, dicyclopentadiene type epoxy resin
- HP-7200 manufactured by DIC Corporation, dicyclopentadiene type epoxy resin
- HP-7200HH manufactured by DIC Corporation, dicyclopentad
- the active ester compound refers to a compound that contains at least one ester bond in the structure and has an aliphatic chain, an aliphatic ring, or an aromatic ring bonded to both sides of the ester bond.
- the active ester compound include compounds having two or more highly reactive ester groups in one molecule, such as phenol esters, thiophenol esters, N-hydroxyamine esters, and esters of heterocyclic hydroxy compounds, and are obtained by a condensation reaction between at least one compound of a carboxylic acid compound, an acid chloride, or a thiocarboxylic acid compound and at least one compound of a hydroxy compound or a thiol compound.
- the hydroxy compound is preferably a phenol compound or a naphthol compound.
- the active ester compound may be used alone or in combination of two or more types.
- carboxylic acid compounds examples include benzoic acid, acetic acid, succinic acid, maleic acid, itaconic acid, phthalic acid, isophthalic acid, terephthalic acid, and pyromellitic acid.
- Examples of the acid chlorides include acetyl chloride, acrylic acid chloride, methacrylic acid chloride, malonyl chloride, succinic acid dichloride, diglycolyl chloride, glutaric acid dichloride, suberic acid dichloride, sebacic acid dichloride, adipic acid dichloride, dodecandioyl dichloride, azelaic acid chloride, 2,5-furandicarbonyl dichloride, phthaloyl chloride, isophthaloyl chloride, terephthaloyl chloride, trimesic acid chloride, bis(4-chlorocarbonylphenyl) ether, 4,4'-diphenyldicarbonyl chloride, and 4,4'-azodibenzoyl dichloride.
- phenol compounds and naphthol compounds include, for example, hydroquinone, resorcin, bisphenol A, bisphenol F, bisphenol S, phenolphthaline, methylated bisphenol A, methylated bisphenol F, methylated bisphenol S, phenol, o-cresol, m-cresol, p-cresol, catechol, ⁇ -naphthol, ⁇ -naphthol, 1,5-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, dihydroxybenzophenone, trihydroxybenzophenone, tetrahydroxybenzophenone, phloroglucin, benzenetriol, dicyclopentadiene-type diphenol compounds, phenol novolac, and phenol resins described below.
- dicyclopentadiene-type diphenol compounds refers to diphenol compounds obtained by condensing one molecule of dicyclopentadiene with two molecules of
- active ester compounds include active ester compounds containing a dicyclopentadiene-type diphenol structure, active ester compounds containing a naphthalene structure, active ester compounds containing an acetylated phenol novolac, active ester compounds containing a benzoylated phenol novolac, the compounds described in Example 2 of WO 2020/095829, and the compounds disclosed in WO 2020/059625.
- active ester compounds containing a naphthalene structure and active ester compounds containing a dicyclopentadiene-type diphenol structure are more preferred.
- the dicyclopentadiene-type diphenol structure refers to a divalent structural unit consisting of phenylene-dicyclopentylene-phenylene.
- active ester compounds include, for example, "EXB9451”, “EXB9460”, “EXB9460S”, “HPC-8000-65T”, “HPC-8000H-65TM”, “EXB-8000L-65TM”, and “EXB-8150-65T” (manufactured by DIC Corporation) as active ester compounds containing a dicyclopentadiene-type diphenol structure, “EXB9416-70BK” (manufactured by DIC Corporation) as an active ester compound containing a naphthalene structure, and "phenolnoxamine” (manufactured by DIC Corporation).
- active ester compounds containing acetylated volac examples include “DC808” (manufactured by Mitsubishi Chemical Corporation), active ester compounds containing benzoylated phenol novolac include “YLH1026", “YLH1030", and “YLH1048” (manufactured by Mitsubishi Chemical Corporation), active ester curing agent that is an acetylated phenol novolac, and "EXB-9050L-62M” (manufactured by DIC Corporation) as an active ester curing agent containing phosphorus atoms.
- the ratio ( ⁇ / ⁇ ) of the active ester equivalent ( ⁇ ) to the epoxy equivalent ( ⁇ ) is preferably 0.5 to 1.5, more preferably 0.8 to 1.2, and even more preferably 0.90 to 1.10. Outside the above range, there is a risk that excess epoxy groups or active ester groups will remain in the system, which may result in deterioration of characteristics in high-temperature storage tests (e.g., 150°C, 1000 hours) and long-term reliability tests under high-temperature and high-humidity conditions (e.g., temperature: 85°C, humidity: 85%).
- a phenolic resin is a compound having two or more phenolic hydroxyl groups in a molecule.
- the phenolic resin include, but are not limited to, a reaction product of a phenol with an aldehyde, a reaction product of a phenol with a diene compound, a reaction product of a phenol with a ketone, a reaction product of a phenol with a substituted biphenyl, a reaction product of a phenol with a substituted phenyl, a reaction product of a bisphenol with an aldehyde, and the like. These may be used alone or in combination. Specific examples of the above-mentioned raw materials are given below, but the raw materials are not limited thereto.
- Phenol alkyl-substituted phenol, aromatic-substituted phenol, hydroquinone, resorcin, naphthol, alkyl-substituted naphthol, dihydroxybenzene, alkyl-substituted dihydroxybenzene, dihydroxynaphthalene, etc.
- ⁇ Aldehydes > Formaldehyde, acetaldehyde, alkyl aldehyde, benzaldehyde, alkyl-substituted benzaldehyde, hydroxybenzaldehyde, naphthaldehyde, glutaraldehyde, phthalaldehyde, crotonaldehyde, cinnamaldehyde, furfural, and the like.
- ⁇ Diene Compound Dicyclopentadiene, terpenes, vinylcyclohexene, norbornadiene, vinylnorbornene, tetrahydroindene, divinylbenzene, divinylbiphenyl, diisopropenylbiphenyl, butadiene, isoprene, and the like.
- ⁇ Ketones Acetone, methyl ethyl ketone, methyl isobutyl ketone, acetophenone, benzophenone, fluorenone, etc.
- ⁇ Substituted biphenyls 4,4'-bis(chloromethyl)-1,1'-biphenyl, 4,4'-bis(methoxymethyl)-1,1'-biphenyl, 4,4'-bis(hydroxymethyl)-1,1'-biphenyl, and the like.
- ⁇ Substituted Phenyls 1,4-bis(chloromethyl)benzene, 1,4-bis(methoxymethyl)benzene, 1,4-bis(hydroxymethyl)benzene and the like.
- the polyphenylene ether compound is preferably a polyphenylene ether compound having an ethylenically unsaturated bond, and more preferably a polyphenylene ether compound having an acrylic group, a methacrylic group, or a styrene structure.
- Commercially available products include SA-9000 (manufactured by SABIC, a polyphenylene ether compound having a methacrylic group) and OPE-2St 1200 (manufactured by Mitsubishi Gas Chemical Company, a polyphenylene ether compound having a styrene structure).
- the number average molecular weight (Mn) of the polyphenylene ether compound is preferably 500 to 5000, more preferably 2000 to 5000, and more preferably 2000 to 4000. If the molecular weight is less than 500, the heat resistance of the cured product tends to be insufficient. If the molecular weight is more than 5000, the melt viscosity increases and sufficient fluidity cannot be obtained, which tends to lead to molding defects. In addition, the reactivity decreases, the curing reaction takes a long time, and the amount of unreacted material that is not incorporated into the curing system increases, which decreases the glass transition temperature of the cured product and tends to decrease the heat resistance of the cured product.
- the number average molecular weight of the polyphenylene ether compound is 500 to 5000, it is possible to exhibit excellent heat resistance, moldability, etc. while maintaining excellent dielectric properties.
- the number average molecular weight here can be specifically measured using gel permeation chromatography, etc.
- the polyphenylene ether compound may be one obtained by a polymerization reaction, or one obtained by a redistribution reaction of a high molecular weight polyphenylene ether compound having a number average molecular weight of about 10,000 to 30,000. These may also be used as raw materials and reacted with a compound having an ethylenically unsaturated bond, such as methacryl chloride, acrylic chloride, or chloromethylstyrene, to impart radical polymerizability.
- a compound having an ethylenically unsaturated bond such as methacryl chloride, acrylic chloride, or chloromethylstyrene
- the polyphenylene ether compound obtained by the redistribution reaction may be obtained, for example, by heating a high molecular weight polyphenylene ether compound in a solvent such as toluene in the presence of a phenolic compound and a radical initiator to cause a redistribution reaction.
- the polyphenylene ether compound obtained by the redistribution reaction in this way has hydroxyl groups derived from phenolic compounds that contribute to hardening at both ends of the molecular chain, and is therefore preferable in that it can maintain even higher heat resistance, and that functional groups can be introduced at both ends of the molecular chain even after modification with a compound having an ethylenically unsaturated bond.
- the polyphenylene ether compound obtained by the polymerization reaction is also preferable in that it exhibits excellent fluidity.
- the molecular weight of the polyphenylene ether compound can be adjusted by adjusting the polymerization conditions.
- the molecular weight of the obtained polyphenylene ether compound can be adjusted by adjusting the conditions of the redistribution reaction. More specifically, it is possible to adjust the amount of the phenolic compound used in the redistribution reaction. That is, the greater the amount of the phenolic compound, the lower the molecular weight of the obtained polyphenylene ether compound.
- poly(2,6-dimethyl-1,4-phenylene ether) or the like can be used as a high molecular weight polyphenylene ether compound that undergoes the redistribution reaction.
- the phenolic compound used in the redistribution reaction is not particularly limited, but for example, a multifunctional phenolic compound having two or more phenolic hydroxyl groups in the molecule, such as bisphenol A, phenol novolac, cresol novolac, etc., is preferably used. These may be used alone or in combination of two or more.
- the amine resin is a compound having two or more amino groups in the molecule.
- the amine resin include diaminodiphenylmethane, diaminodiphenylsulfone, isophoronediamine, naphthalenediamine, aniline novolak (a reaction product of aniline and formalin), N-methylaniline novolak (a reaction product of N-methylaniline and formalin), orthoethylaniline novolak (a reaction product of orthoethylaniline and formalin), a reaction product of 2-methylaniline and formalin, a reaction product of 2,6-diisopropylaniline and formalin, a reaction product of 2,6-diethylaniline and formalin, a reaction product of 2-ethyl-6-ethylaniline and formalin, a reaction product of 2,6-dimethylaniline and formalin, and a reaction product obtained by reacting aniline and xylylene chloride.
- aniline resin examples include, but are not limited to, the aniline resin disclosed in Japanese Patent No. 6429862, a reaction product of aniline and a substituted biphenyl (4,4'-bis(chloromethyl)-1,1'-biphenyl and 4,4'-bis(methoxymethyl)-1,1'-biphenyl, etc.), a reaction product of aniline and a substituted phenyl (1,4-bis(chloromethyl)benzene, 1,4-bis(methoxymethyl)benzene and 1,4-bis(hydroxymethyl)benzene, etc.), 4,4'-(1,3-phenylenediisopropylidene)bisaniline, 4,4'-(1,4-phenylenediisopropylidene)bisaniline, a reaction product of aniline and diisopropenylbenzene, dimer diamine, etc. Furthermore, these may be used alone or in combination.
- the compound containing an ethylenically unsaturated bond is a compound having an ethylenically unsaturated bond which can be polymerized by heat or light.
- Examples of the compound containing an ethylenically unsaturated bond include, but are not limited to, a reaction product of the phenol resin with an ethylenically unsaturated bond-containing halogen-based compound (chloromethylstyrene, allyl chloride, methallyl chloride, acrylic acid chloride, methacrylic acid chloride, etc.), a reaction product of an ethylenically unsaturated bond-containing phenol (2-allylphenol, 2-propenylphenol, 4-allylphenol, 4-propenylphenol, eugenol, isoeugenol, etc.) with a halogen-based compound (1,4-bis(chloromethyl)benzene, 4,4'-bis(chloro
- An isocyanate resin is a compound having two or more isocyanate groups in the molecule.
- the isocyanate resin include aromatic diisocyanates such as p-phenylene diisocyanate, m-phenylene diisocyanate, p-xylylene diisocyanate, m-xylylene diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 4,4'-diphenylmethane diisocyanate, and naphthalene diisocyanate; aliphatic or alicyclic diisocyanates such as isophorone diisocyanate, hexamethylene diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, hydrogenated xylene diisocyanate, norbornene diisocyanate, and lysine diisocyanate; polyisocyanates such as one or more biure
- polyamide resin examples include reaction products of one or more of diamines, diisocyanates, and oxazolines with dicarboxylic acids, reaction products of diamines with acid chlorides, and ring-opening polymers of lactam compounds. These may be used alone or in combination. Specific examples of the above-mentioned raw materials are given below, but the raw materials are not limited thereto.
- ⁇ Dicarboxylic acid> Oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, undecanedioic acid, dodecanedioic acid, terephthalic acid, isophthalic acid, 5-hydroxyisophthalic acid, 2-chloroterephthalic acid, 2-methylterephthalic acid, 5-methylisophthalic acid, 5-sodium sulfoisophthalic acid, hexahydroterephthalic acid, hexahydroisophthalic acid, cyclohexanedicarboxylic acid, biphenyldicarboxylic acid, naphthalenedicarboxylic acid, benzophenonedicarboxylic acid, furandicarboxylic acid, 4,4'-dicarboxydiphenyl ether, and 4,4'-dicarboxydiphenyl sulfide.
- ⁇ Acid chloride Acetyl chloride, acrylic acid chloride, methacrylic acid chloride, malonyl chloride, succinic acid dichloride, diglycolyl chloride, glutaric acid dichloride, suberic acid dichloride, sebacic acid dichloride, adipic acid dichloride, dodecandioyl dichloride, azelaic acid chloride, 2,5-furandicarbonyl dichloride, phthaloyl chloride, isophthaloyl chloride, terephthaloyl chloride, trimesic acid chloride, bis(4-chlorocarbonylphenyl) ether, 4,4'-diphenyldicarbonyl chloride, 4,4'-azodibenzoyl dichloride, and the like.
- ⁇ Lactam > ⁇ -caprolactam, ⁇ -undecanelactam, ⁇ -laurolactam, and the like.
- polyimide resin examples include, but are not limited to, reaction products of the diamines and the tetracarboxylic dianhydrides shown below. These may be used alone or in combination.
- the curable resin composition of the present embodiment may contain a maleimide compound, and examples of such a maleimide compound include 4,4'-diphenylmethane bismaleimide, polyphenylmethane maleimide, m-phenylene bismaleimide, 2,2'-bis[4-(4-maleimidophenoxy)phenyl]propane, 3,3'-dimethyl-5,5'-diethyl-4,4'-diphenylmethane bismaleimide, 4-methyl-1,3-phenylene bismaleimide, 4,4'-diphenylether bismaleimide, 4,4'-diphenylsulfone bismaleimide, 1,3-bis(3-maleimidophenoxy)benzene, 1,3-bis(4-maleimidophenoxy)benzene), and Xylox type maleimide compounds (anilix).
- a maleimide compound include 4,4'-diphenylmethane bismaleimide, polyphenylmethane male
- maleimide manufactured by Mitsui Chemicals Fine Co., Ltd.
- biphenylaralkyl-type maleimide compound solidified by distilling off the solvent under reduced pressure from a resin solution containing the maleimide compound (M2) described in Example 4 of JP 2009-001783 A), bisaminocumylbenzene-type maleimide (maleimide compound described in WO 2020/054601 A), maleimide compounds having an indane structure described in Japanese Patent No. 6629692 or WO 2020/217679, MATERIAL STAGE Vol. 18, No. 12 2019 ⁇ Continued Epoxy Resin CAS Number Story - Hardener CAS Number Memorandum No. 31 Bismaleimide (1)'' and MATERIAL STAGE Vol. 19, No.
- maleimide compounds include, but are not limited to, the maleimide compounds described in "Epoxy Resin CAS Number Story Continued - Hardener CAS Number Memorandum No. 32 Bismaleimide (2)" in 2019. These compounds may be used alone or in combination.
- the cyanate ester resin is a cyanate ester compound obtained by reacting a phenol resin with a cyanogen halide, and specific examples thereof include dicyanatobenzene, tricyanatobenzene, dicyanatonaphthalene, dicyanatobiphenyl, 2,2'-bis(4-cyanatophenyl)propane, bis(4-cyanatophenyl)methane, bis(3,5-dimethyl-4-cyanatophenyl)methane, 2,2'-bis(3,5-dimethyl-4-cyanatophenyl)propane, 2,2'-bis(4-cyanatophenyl)ethane, 2,2'-bis(4-cyanatophenyl)hexafluoropropane, bis(4-cyanatophenyl)sulfone, bis(4-cyanatophenyl)thioether, phenol novolac cyanate, and phenol-dicyclopent
- the cyanate ester compound is particularly preferred as the cyanate ester compound because it has low moisture absorption, excellent flame retardancy, and excellent dielectric properties.
- the cyanate ester resin may contain a catalyst such as zinc naphthenate, cobalt naphthenate, copper naphthenate, lead naphthenate, zinc octoate, tin octoate, lead acetylacetonate, or dibutyltin maleate, if necessary, to trimerize the cyanate group to form a sym-triazine ring.
- the catalyst is preferably used in an amount of 0.0001 to 0.10 parts by mass, and more preferably 0.00015 to 0.0015 parts by mass, per 100 parts by mass of the cyanate ester resin and curable resin composition.
- polybutadiene and its modified products are polybutadiene or compounds having a structure derived from polybutadiene in the molecule.
- the unsaturated bonds in the polybutadiene-derived structure may be partially or entirely converted to single bonds by hydrogenation.
- Examples of polybutadiene and modified products thereof include, but are not limited to, polybutadiene, hydroxyl-terminated polybutadiene, (meth)acrylated polybutadiene, carboxylic acid-terminated polybutadiene, amine-terminated polybutadiene, styrene-butadiene rubber, and the like. These may be used alone or in combination.
- polybutadiene or styrene-butadiene rubber is preferred from the viewpoint of dielectric properties.
- styrene-butadiene rubber examples include RICON-100, RICON-181, RICON-184 (all manufactured by Cray Valley Corporation), 1,2-SBS (manufactured by Nippon Soda Co., Ltd.), and examples of polybutadiene include B-1000, B-2000, B-3000 (all manufactured by Nippon Soda Co., Ltd.), and the like.
- the molecular weight of polybutadiene and styrene-butadiene rubber is preferably 500 to 10,000 in weight average molecular weight, more preferably 750 to 7,500, and even more preferably 1,000 to 5,000.
- the amount of volatilization is large, making it difficult to adjust the solid content during prepreg preparation, and above the upper limit of the above range, the compatibility with other curable resins is deteriorated.
- compounds containing heteroatoms such as oxygen and nitrogen such as bismaleimide and polymaleimide, it is difficult to ensure compatibility with low-polarity compounds such as compounds mainly composed of hydrocarbons or compounds composed only of hydrocarbons due to their polarity.
- the compound of the present embodiment is not a skeleton design in which heteroatoms such as oxygen and nitrogen are actively introduced, and therefore has excellent compatibility with materials exhibiting low polarity and low dielectric tangent, and compounds composed only of hydrocarbons.
- Polystyrene and its modified products are polystyrene or compounds having a structure derived from polystyrene in the molecule.
- examples of polystyrene and modified products thereof include polystyrene, styrene-2-isopropenyl-2-oxazoline copolymers (Epocross RPS-1005, RP-61, both manufactured by Nippon Shokubai Co., Ltd.), SEP (styrene-ethylene-propylene copolymer: Septon 1020, manufactured by Kuraray Co., Ltd.), SEPS (styrene-ethylene-propylene-styrene copolymer: Septon 2002, Septon 2004F, Septon 2005, Septon 2006, Septon 2063, Septon 2104, all manufactured by Kuraray Co., Ltd.), SEEPS (styrene-ethylene/ethylene-propylene-styrene block copolymer: Septon 4003,
- block copolymer examples include, but are not limited to, SEEPS-OH (a styrene-ethylene/ethylene propylene-styrene block copolymer having a hydroxyl group at the end: SEPTON HG252, manufactured by Kuraray Co., Ltd.), SIS (styrene-isoprene-styrene block copolymer: SEPTON 5125, SEPTON 5127, manufactured by Kuraray Co., Ltd.), hydrogenated SIS (hydrogenated styrene-isoprene-styrene block copolymer: HYBRAR 7125F, HYBRAR 7311F, manufactured by Kuraray Co., Ltd.), SIBS (styrene-isobutylene-styrene block copolymer: SIBSTAR073T, SIBSTAR102T, SIBSTAR103T (all manufactured by Kaneka Corporation), SEPTON V9827 (manufactured by Kuraray Co.
- Polystyrene and modified products thereof have higher heat resistance and are less susceptible to oxidative deterioration, so it is preferable that they do not have unsaturated bonds.
- the weight-average molecular weight of polystyrene and modified products thereof is not particularly limited as long as it is 10,000 or more, but if it is too large, the compatibility with not only polyphenylene ether compounds but also low molecular weight components with a weight-average molecular weight of about 50 to 1,000 and oligomer components with a weight-average molecular weight of about 1,000 to 5,000 deteriorates, making it difficult to ensure mixing and solvent stability, so it is preferably about 10,000 to 300,000.
- Polyethylene and its modified products are compounds having polyethylene or a structure derived from polyethylene in the molecule.
- Examples of polyethylene and modified products thereof include ethylene-propylene copolymers, ethylene-styrene copolymers, ethylene-propylene-ethylidene norbornene copolymers (EBT: K-8370EM, K-9330M, etc., manufactured by Mitsui Chemicals, Inc.), ethylene-propylene-vinyl norbornene copolymers (VNB-EPT: PX-006M, PX-008M, PX-009M, etc., manufactured by Mitsui Chemicals, Inc.), ethylene-vinyl alcohol copolymers, ethylene-vinyl acetate copolymers, etc., but are not limited thereto.
- ethylene-propylene-ethylidene norbornene copolymers and ethylene-propylene-vinyl norbornene copolymers containing a crosslinkable structure may be used alone or in combination.
- the weight average molecular weight of the polyethylene and modified products thereof is not particularly limited as long as it is 10,000 or more. However, if it is too large, compatibility with not only the polyphenylene ether compound but also low molecular weight components having a weight average molecular weight of about 50 to 1,000 and oligomer components having a weight average molecular weight of about 1,000 to 5,000 deteriorates, making it difficult to ensure mixing and solvent stability. Therefore, it is preferably about 10,000 to 300,000.
- the curable resin composition of this embodiment is obtained by preparing the above components in a prescribed ratio, pre-curing at 130-180°C for 30-500 seconds, and then post-curing at 150-200°C for 2-15 hours, allowing the curing reaction to proceed sufficiently to obtain the cured product of this embodiment.
- the components of the curable resin composition can also be uniformly dispersed or dissolved in a solvent, etc., and cured after removing the solvent.
- the method for preparing the curable resin composition of this embodiment is not particularly limited, but the components may be mixed uniformly or may be prepolymerized.
- a mixture containing the compound of this embodiment is heated in the presence or absence of a curing accelerator or polymerization initiator, and in the presence or absence of a solvent, to form a prepolymer.
- amine compounds, compounds having ethylenically unsaturated bonds, maleimide compounds, cyanate ester compounds, polybutadiene and modified products thereof, polystyrene and modified products thereof, inorganic fillers, and other additives may be added to form a prepolymer.
- the components may be mixed or prepolymerized using, for example, an extruder, kneader, rolls, etc. in the absence of a solvent, and a reaction kettle with a stirrer, etc. in the presence of a solvent.
- the mixture is kneaded at a temperature in the range of 50 to 100°C using a device such as a kneader, roll, or planetary mixer to obtain a uniform resin composition.
- the obtained resin composition is crushed and then molded into a cylindrical tablet using a molding machine such as a tablet machine, or into a granular powder or powder molded body, or these compositions can be melted on a surface support and molded into a sheet having a thickness of 0.05 mm to 10 mm to obtain a molded curable resin composition.
- the obtained molded body is a non-sticky molded body at 0 to 20°C, and even if stored at -25 to 0°C for one week or more, the flowability and curability are hardly reduced.
- the obtained molded article can be molded into a cured product using a transfer molding machine or a compression molding machine.
- the curable resin composition of this embodiment can be made into a varnish-like composition (hereinafter, simply referred to as varnish) by adding an organic solvent.
- the curable resin composition of this embodiment can be dissolved in a solvent such as toluene, xylene, acetone, methyl ethyl ketone, methyl isobutyl ketone, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, etc.
- a varnish which can be impregnated into a substrate such as glass fiber, carbon fiber, polyester fiber, polyamide fiber, alumina fiber, paper, etc., and dried by heating to obtain a prepreg, which can be hot-press molded to obtain a cured product of the curable resin composition of this embodiment.
- the solvent used in this case is in an amount that occupies 10 to 70% by weight, preferably 15 to 70% by weight, of the mixture of the curable resin composition of this embodiment and the solvent. If the composition is in a liquid state, a curable resin composition containing carbon fiber can be obtained as it is, for example, by the RTM method.
- the curable resin composition of this embodiment can also be used as a modifier for a film-type composition. Specifically, it can be used to improve flexibility in the B-stage.
- a film-type resin composition can be obtained as a sheet-like adhesive by applying the curable resin composition of this embodiment as a curable resin composition varnish onto a release film, removing the solvent under heating, and then performing B-stage conversion.
- This sheet-like adhesive can be used as an interlayer insulating layer in a multilayer substrate, etc.
- the curable resin composition of the present embodiment can be heated and melted to reduce the viscosity, and impregnated into reinforcing fibers such as glass fibers, carbon fibers, polyester fibers, polyamide fibers, and alumina fibers to obtain a prepreg.
- reinforcing fibers such as glass fibers, carbon fibers, polyester fibers, polyamide fibers, and alumina fibers
- Specific examples include glass fibers such as E glass cloth, D glass cloth, S glass cloth, Q glass cloth, spherical glass cloth, NE glass cloth, and T glass cloth, as well as inorganic fibers other than glass, and organic fibers such as polyparaphenylene terephthalamide (Kevlar (registered trademark), manufactured by DuPont), fully aromatic polyamide, polyester, polyparaphenylene benzoxazole, polyimide, and carbon fibers, but are not limited to these.
- the shape of the substrate is not particularly limited, but examples include woven fabric, nonwoven fabric, roving, chopped strand mat, and the like.
- plain weave, sash weave, twill weave, and the like are known as ways of weaving woven fabric, and these known methods can be appropriately selected and used depending on the intended use and performance.
- woven fabrics that have been subjected to fiber opening treatment and glass woven fabrics that have been surface-treated with a silane coupling agent or the like are preferably used.
- the thickness of the substrate is not particularly limited, but is preferably about 0.01 to 0.4 mm. Prepregs can also be obtained by impregnating reinforcing fibers with the varnish and drying them by heating.
- a laminate can be manufactured using the prepreg.
- the laminate is not particularly limited as long as it has one or more prepregs, and may have any other layer.
- the manufacturing method of the laminate can be appropriately applied by a generally known method, and is not particularly limited. For example, when molding a metal foil-clad laminate, a multi-stage press machine, a multi-stage vacuum press machine, a continuous molding machine, an autoclave molding machine, etc. can be used, and the prepregs are laminated together and heated and pressurized to obtain a laminate. At this time, the heating temperature is not particularly limited, but is preferably 65 to 300 ° C, and more preferably 120 to 270 ° C.
- the pressure to be applied is not particularly limited, but if the pressure is too high, it is difficult to adjust the solid content of the resin of the laminate, and the quality is not stable, and if the pressure is too low, air bubbles and adhesion between the laminates are deteriorated, so that 2.0 to 5.0 MPa is preferable, and 2.5 to 4.0 MPa is more preferable.
- the laminate of this embodiment can be suitably used as a metal foil-clad laminate described later by providing a layer made of metal foil. The prepreg is cut into a desired shape and laminated with copper foil or the like as necessary. The laminate is then heated and cured while applying pressure thereto by press molding, autoclave molding, sheet winding molding or the like, to obtain an electrical and electronic laminate (printed wiring board) or a carbon fiber reinforced material.
- the curable resin composition of this embodiment can also be made into a resin sheet.
- a method for obtaining a resin sheet from the curable resin composition of this embodiment includes, for example, applying the curable resin composition onto a support film (support), drying the composition, and forming a resin composition layer on the support film.
- the curable resin composition of this embodiment is used for a resin sheet, it is essential that the film softens under the lamination temperature conditions (70°C to 140°C) in the vacuum lamination method, and exhibits fluidity (resin flow) that allows resin to fill via holes or through holes in the circuit board at the same time as laminating the circuit board, and it is preferable to mix the above-mentioned components so as to exhibit such characteristics.
- the obtained resin sheet or circuit board (copper-clad laminate, etc.) is required to have a uniform appearance in order to exhibit a certain performance at any part without causing a phenomenon in which characteristics values differ locally due to phase separation, etc.
- the through holes in the circuit board have a diameter of 0.1 to 0.5 mm and a depth of 0.1 to 1.2 mm, and it is preferable to make it possible to fill them with resin within this range. If both sides of the circuit board are to be laminated, it is desirable to fill about half of the through holes.
- a specific method for producing the resin sheet is to prepare a resin composition varnished by blending an organic solvent, and then coat the surface of the support film (Y) with the varnished resin composition, and then heat or blow hot air onto the resin composition to dry the organic solvent, thereby forming a resin composition layer (X).
- the organic solvents preferably used here include, for example, ketones such as acetone, methyl ethyl ketone, and cyclohexanone; acetate esters such as ethyl acetate, butyl acetate, cellosolve acetate, propylene glycol monomethyl ether acetate, and carbitol acetate; carbitols such as cellosolve and butyl carbitol; aromatic hydrocarbons such as toluene and xylene; dimethylformamide, dimethylacetamide, and N-methylpyrrolidone; and it is preferable to use them in a proportion that results in a non-volatile content of 30 to 60% by mass.
- ketones such as acetone, methyl ethyl ketone, and cyclohexanone
- acetate esters such as ethyl acetate, butyl acetate, cellosolve acetate, propylene glycol monomethyl ether
- the thickness of the resin composition layer (X) formed must be equal to or greater than the thickness of the conductor layer. Since the thickness of the conductor layer of the circuit board is in the range of 5 to 70 ⁇ m, the thickness of the resin composition layer (X) is preferably 10 to 100 ⁇ m.
- the resin composition layer (X) in this embodiment may be protected with a protective film, which will be described later. By protecting the resin composition layer with a protective film, it is possible to prevent the adhesion of dirt and the like to the surface of the resin composition layer and prevent scratches.
- the support film and protective film may be made of polyolefins such as polyethylene, polypropylene, and polyvinyl chloride; polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate; polycarbonate; polyimide; and even release paper and metal foils such as copper foil and aluminum foil.
- the support film and protective film may be subjected to a mud treatment, corona treatment, or release treatment. There are no particular limitations on the thickness of the support film, but it is generally in the range of 10 to 150 ⁇ m, and preferably 25 to 50 ⁇ m.
- the protective film is preferably made 1 to 40 ⁇ m thick.
- the support film (Y) is peeled off after laminating it onto the circuit board, or after forming an insulating layer by heat curing. If the support film (Y) is peeled off after the resin composition layer constituting the resin sheet has been heat cured, the adhesion of dirt and the like during the curing process can be prevented. If the support film is peeled off after curing, a release treatment is applied to the support film beforehand.
- a multilayer printed circuit board can be manufactured from the resin sheet obtained as described above.
- the resin composition layer (X) is protected by a protective film, the protective film is peeled off, and then the resin composition layer (X) is laminated on one or both sides of the circuit board so as to be in direct contact with the circuit board, for example, by a vacuum lamination method.
- the lamination method may be a batch type or a continuous type using a roll. If necessary, the resin sheet and the circuit board may be heated (preheated) before lamination.
- the lamination conditions are preferably a pressure bonding temperature (lamination temperature) of 70 to 140°C, a pressure bonding pressure of 1 to 11 kgf/cm 2 (9.8 ⁇ 10 4 to 107.9 ⁇ 10 4 N/m 2 ), and lamination is preferably performed under reduced pressure of 20 mmHg (26.7 hPa) or less air pressure.
- a semiconductor device can be manufactured using the curable resin composition of this embodiment.
- semiconductor devices include DIP (dual in-line package), QFP (quad flat package), BGA (ball grid array), CSP (chip size package), SOP (small outline package), TSOP (thin small outline package), TQFP (thin quad flat package), etc.
- the curable resin composition of this embodiment and its cured product can be used in a wide range of fields. Specifically, it can be used in various applications such as molding materials, adhesives, composite materials, and paints.
- the cured product of the curable resin composition described in this embodiment exhibits excellent heat resistance and dielectric properties, and is therefore suitable for use in electrical and electronic components such as encapsulants for semiconductor elements, encapsulants for liquid crystal display elements, encapsulants for organic EL elements, laminates (printed wiring boards, BGA substrates, build-up substrates, etc.), composite materials for lightweight and high-strength structural materials such as carbon fiber reinforced plastics and glass fiber reinforced plastics, 3D printing, etc.
- GPC gel permeation chromatography
- Example 1 Reference Example 1, Comparative Examples 1 to 7
- Each polymerization inhibitor and the compound (O-1) obtained in Synthesis Example 2 were mixed in the amounts shown in Table 1 to prepare a toluene solution with a solid content of 60 wt %.
- Each solution was stored in a 5 mL glass sample bottle at 40°C for 50 days, and gelation confirmed by visual observation was marked with an X, and no change in properties was noted with an ⁇ . The results are shown in Table 1.
- Example 2 Comparative Examples 8 and 9
- the compound (O-1) obtained in Synthesis Example 2 and the polymerization inhibitor were used in the amounts shown in Table 2, and the mixture was sandwiched between mirror-finished copper foil (T4X: manufactured by Fukuda Metal Copper Foil Co., Ltd.) and vacuum-press molded, followed by curing for 2 hours at 220°C.
- a test piece was cut out to the desired size using a laser cutter as necessary, and evaluation was performed.
- DSC Differential Scanning Calorimetry
- TBHQ tert-butyl hydroquinone (manufactured by TCI)
- DMHQ 2,6-dimethylhydroquinone (manufactured by TCI)
- o-Cresol manufactured by TCI
- the curable resin composition of the present invention is suitably used for electric and electronic parts such as semiconductor encapsulants, printed wiring boards, and build-up laminates.
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Abstract
Description
[1]
下記式(1)で表される化合物と、下記式(2)で表される化合物とを含有する硬化性樹脂組成物。
[2]
下記式(1-1)で表される化合物と、下記式(2)で表される化合物とを含有する硬化性樹脂組成物。
[3]
さらに、重合開始剤を含有する、前項[1]または[2]に記載の硬化性樹脂組成物。
[4]
さらに、マレイミド化合物、ポリフェニレンエーテル化合物、エチレン性不飽和結合を有する化合物、シアネートエステル樹脂、ポリブタジエンおよびこの変性物、ポリスチレンおよびこの変性物、ポリエチレンおよびこの変性物、からなる群から選ばれる少なくとも1種以上を含有する、前項[1]から[3]のいずれか一項に記載の硬化性樹脂組成物。
[5]
前項[1]から[4]のいずれか一項に記載の硬化性樹脂組成物を硬化して得られる硬化物。
に説明する。
本実施形態の硬化性樹脂組成物は、前記式(2)で表される化合物に加えて、他の重合禁止剤を含有しても良い。ただし、重合禁止剤を使用する場合は、本実施形態の硬化性樹脂組成物の誘電特性や硬化特性に大きく影響しない範囲での添加量に限定される。
本実施形態の硬化性樹脂組成物は、硬化促進剤を添加することにより硬化性を向上させることもできる。硬化促進剤としては、紫外線や可視光の照射または加熱によりアニオンを発生することで硬化反応を促すアニオン系硬化促進剤、もしくは紫外線や可視光の照射または加熱によりカチオンを発生することで硬化反応を促すカチオン系硬化促進剤が好ましい。
本実施形態の硬化性樹脂組成物は、無機充填剤を含有しても良い。無機充填剤としては、例えば、溶融シリカ、結晶シリカ、多孔質シリカ、アルミナ、ジルコン、珪酸カルシウム、炭酸カルシウム、石英粉、炭化珪素、窒化珪素、窒化ホウ素、ジルコニア、窒化アルミニウム、グラファイト、フォルステライト、ステアタイト、スピネル、ムライト、チタニア、タルク、クレー、酸化鉄、アスベスト、ガラス粉末等の粉体、またはこれらを球形状あるいは破砕状にした無機充填剤等を挙げることができるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
本実施形態の硬化性樹脂組成物は、重合開始剤を添加することにより硬化性を向上させることもできる。重合開始剤とは、エチレン性不飽和結合等のオレフィン官能基を重合させることが可能な化合物であり、オレフィンメタセシス重合開始剤、アニオン重合開始剤、カチオン重合開始剤、ラジカル重合開始剤等が挙げられる。このなかでも硬化性および適度な安定性を有するラジカル重合開始剤を使用することが好ましい。ラジカル重合開始剤とは紫外線や可視光の照射または加熱によりラジカルを生じ、連鎖重合反応を開始させる化合物をいう。用い得るラジカル重合開始剤としては、有機過酸化物、アゾ系化合物、ベンゾピナコール類等が挙げられ、硬化温度制御やアウトガス抑制、分解物の電気特性への影響が少ないことから有機過酸化物を使用することが好ましい。
本実施形態の硬化性樹脂組成物は、難燃剤を用いてもよい。難燃剤としては、例えば、ハロゲン系難燃剤、無機系難燃剤(アンチモン化合物、金属水酸化物、窒素化合物、ホウ素化合物等)、リン系難燃剤等が挙げられるが、ハロゲンフリー難燃性を達成する観点からリン系難燃剤が好ましい。
上記リン系難燃剤としては反応型のものでも添加型のものでもよい。具体例としては、トリメチルホスフェート、トリエチルホスフェート、トリクレジルホスフェート、トリキシリレニルホスフェート、クレジルジフェニルホスフェート、クレジル-2,6-ジキシリレニルホスフェート、1,3-フェニレンビス(ジキシリレニルホスフェート)、1,4-フェニレンビス(ジキシリレニルホスフェート)、4,4’-ビフェニル(ジキシリレニルホスフェート)等のリン酸エステル類、9,10-ジヒドロ-9-オキサ-10-ホスファフェナントレン-10-オキサイド、10-(2,5-ジヒドロキシフェニル)-10H-9-オキサ-10-ホスファフェナントレン-10-オキサイド等のホスファン類のほか、エポキシ樹脂と前記ホスファン類の活性水素とを反応させて得られるリン含有エポキシ化合物、赤リン等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。上記例示物質のうち、リン酸エステル類、ホスファン類またはリン含有エポキシ化合物が好ましく、1,3-フェニレンビス(ジキシリレニルホスフェート)、1,4-フェニレンビス(ジキシリレニルホスフェート)、4,4’-ビフェニル(ジキシリレニルホスフェート)またはリン含有エポキシ化合物が特に好ましい。
本実施形態の硬化性樹脂組成物は、光安定剤を用いてもよい。光安定剤としては、ヒンダートアミン系の光安定剤、特にHALS等が好適である。HALSとしては、例えば、ジブチルアミン・1,3,5-トリアジン・N,N’-ビス(2,2,6,6-テトラメチル-4-ピペリジル-1,6-ヘキサメチレンジアミンとN-(2,2,6,6-テトラメチル-4-ピペリジル)ブチルアミンの反応物、コハク酸ジメチル-1-(2-ヒドロキシエチル)-4-ヒドロキシ-2,2,6,6-テトラメチルピペリジン反応物、ポリ〔{6-(1,1,3,3-テトラメチルブチル)アミノ-1,3,5-トリアジン-2,4-ジイル}{(2,2,6,6-テトラメチル-4-ピペリジル)イミノ}ヘキサメチレン{(2,2,6,6-テトラメチル-4-ピペリジル)イミノ}〕、ビス(1,2,2,6,6-ペンタメチル-4-ピペリジル)〔〔3,5-ビス(1,1-ジメチルエチル)-4-ヒドリキシフェニル〕メチル〕ブチルマロネート、ビス(2,2,6,6-テトラメチル-4-ピペリジル)セバケート、ビス(1,2,2,6,6-ペンタメチル-4-ピペリジル)セバケート、ビス(1-オクチロキシ-2,2,6,6-テトラメチル-4-ピペリジル)セバケート、2-(3,5-ジ-t-ブチル-4-ヒドロキシベンジル)-2-n-ブチルマロン酸ビス(1,2,2,6,6-ペンタメチル-4-ピペリジル)等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
本実施形態の硬化性樹脂組成物は、バインダー樹脂を用いてもよい。バインダー樹脂としては、例えば、ブチラール系樹脂、アセタール系樹脂、アクリル系樹脂、エポキシ-ナイロン系樹脂、NBR-フェノール系樹脂、エポキシ-NBR系樹脂、シリコーン系樹脂等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
本実施形態の硬化性樹脂組成物は、添加剤を用いてもよい。添加剤としては、例えば、アクリロニトリル共重合体の変性物、ポリエチレン、フッ素樹脂、シリコーンゲル、シリコーンオイル、シランカップリング剤のような充填材の表面処理剤、離型剤、カーボンブラック、フタロシアニンブルー、フタロシアニングリーン等の着色剤が挙げられる。
エポキシ樹脂として好ましいものを以下に例示するがこれらに限定されるものではない。なお、エポキシ樹脂の性状は液状であっても固形であってもよく、1種類で用いても、複数併用してもよい。
活性エステル化合物とは、構造体中にエステル結合を少なくとも1つ含み、かつ、エステル結合の両側に脂肪族鎖、脂肪族環又は芳香族環が結合している化合物をいう。活性エステル化合物としては、例えば、フェノールエステル類、チオフェノールエステル類、N-ヒドロキシアミンエステル類、複素環ヒドロキシ化合物のエステル類等の反応活性の高いエステル基を1分子中に2個以上有する化合物を挙げることができ、カルボン酸化合物、酸塩化物、またはチオカルボン酸化合物の少なくともいずれかの化合物と、ヒドロキシ化合物またはチオール化合物の少なくともいずれかの化合物との縮合反応によって得られる。特に、耐熱性向上の観点から、カルボン酸化合物または酸塩化物とヒドロキシ化合物から得られるときが好ましく、ヒドロキシ化合物としてはフェノール化合物またはナフトール化合物が好ましい。活性エステル化合物は1種単独で用いてもよく、2種以上を組み合わせて用いてもよい。
フェノール樹脂とは、分子内に2つ以上フェノール性水酸基を有する化合物である。フェノール樹脂としては、例えば、フェノール類とアルデヒド類との反応物、フェノール類とジエン化合物との反応物、フェノール類とケトン類との反応物、フェノール類と置換ビフェニル類との反応物、フェノール類と置換フェニル類との反応物、ビスフェノール類とアルデヒド類との反応物等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
上記各原料の具体例を以下に例示するが、これらに限定されるものではない。
<フェノール類>
フェノール、アルキル置換フェノール、芳香族置換フェノール、ハイドロキノン、レゾルシン、ナフトール、アルキル置換ナフトール、ジヒドロキシベンゼン、アルキル置換ジヒドロキシベンゼン、ジヒドロキシナフタレン等。
<アルデヒド類>
ホルムアルデヒド、アセトアルデヒド、アルキルアルデヒド、ベンズアルデヒド、アルキル置換ベンズアルデヒド、ヒドロキシベンズアルデヒド、ナフトアルデヒド、グルタルアルデヒド、フタルアルデヒド、クロトンアルデヒド、シンナムアルデヒド、フルフラール等。
<ジエン化合物>
ジシクロペンタジエン、テルペン類、ビニルシクロヘキセン、ノルボルナジエン、ビニルノルボルネン、テトラヒドロインデン、ジビニルベンゼン、ジビニルビフェニル、ジイソプロペニルビフェニル、ブタジエン、イソプレン等。
<ケトン類>
アセトン、メチルエチルケトン、メチルイソブチルケトン、アセトフェノン、ベンゾフェノン、フルオレノン等。
<置換ビフェニル類>
4,4’-ビス(クロルメチル)-1,1’-ビフェニル、4,4’-ビス(メトキシメチル)-1,1’-ビフェニル、4,4’-ビス(ヒドロキシメチル)-1,1’-ビフェニル等。
<置換フェニル類>
1,4-ビス(クロロメチル)ベンゼン、1,4-ビス(メトキシメチル)ベンゼン、1,4-ビス(ヒドロキシメチル)ベンゼン等。
ポリフェニレンエーテル化合物としては、耐熱性と電気特性の観点から、エチレン性不飽和結合を有するポリフェニレンエーテル化合物であることが好ましく、アクリル基、メタクリル基、又はスチレン構造を有するポリフェニレンエーテル化合物であることがさらに好ましい。市販品としては、SA-9000(SABIC社製、メタクリル基を有するポリフェニレンエーテル化合物)やOPE-2St 1200(三菱瓦斯化学社製、スチレン構造を有するポリフェニレンエーテル化合物)などが挙げられる。
ポリフェニレンエーテル化合物の数平均分子量(Mn)は、500~5000であることが好ましく、2000~5000であることがより好ましく、2000~4000であることがより好ましい。分子量が500未満であると、硬化物の耐熱性としては充分なものが得られない傾向がある。また、分子量が5000より大きいと、溶融粘度が高くなり、充分な流動性が得られないため、成形不良となりやすくなる傾向がある。また、反応性も低下して、硬化反応に長い時間を要し、硬化系に取り込まれずに未反応のものが増加して、硬化物のガラス転移温度が低下し、硬化物の耐熱性が低下する傾向がある。
ポリフェニレンエーテル化合物の数平均分子量が500~5000であれば、優れた誘電特性を維持したまま、優れた耐熱性及び成形性等を発現させることができる。なお、ここでの数平均分子量は、具体的には、ゲルパーミエーションクロマトグラフィー等を用いて測定することができる。
アミン樹脂とは、分子内に2つ以上アミノ基を有する化合物である。アミン樹脂としては、例えば、ジアミノジフェニルメタン、ジアミノジフェニルスルホン、イソホロンジアミン、ナフタレンジアミン、アニリンノボラック(アニリンとホルマリンの反応物)、N-メチルアニリンノボラック(N-メチルアニリンとホルマリンの反応物)、オルソエチルアニリンノボラック(オルソエチルアニリンとホルマリンの反応物)、2-メチルアニリンとホルマリンの反応物、2,6-ジイソプロピルアニリンとホルマリンの反応物、2,6-ジエチルアニリンとホルマリンの反応物、2-エチル-6-エチルアニリンとホルマリンの反応物、2,6-ジメチルアニリンとホルマリンの反応物、アニリンとキシリレンクロライドとの反応により得られるアニリン樹脂、日本国特許第6429862号公報に記載のアニリンと置換ビフェニル類(4,4’-ビス(クロルメチル)-1,1’-ビフェニル及び4,4’-ビス(メトキシメチル)-1,1’-ビフェニル等)の反応物、アニリンと置換フェニル類(1,4-ビス(クロロメチル)ベンゼン、1,4-ビス(メトキシメチル)ベンゼン及び1,4-ビス(ヒドロキシメチル)ベンゼン等)の反応物、4,4’-(1,3-フェニレンジイソプロピリデン)ビスアニリン、4,4’-(1,4-フェニレンジイソプロピリデン)ビスアニリン、アニリンとジイソプロペニルベンゼンの反応物、ダイマージアミン等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
エチレン性不飽和結合を含有する化合物とは、熱もしくは光により重合可能なエチレン性不飽和結合を有する化合物である。
エチレン性不飽和結合を含有する化合物としては、例えば、前記のフェノール樹脂とエチレン性不飽和結合含有のハロゲン系化合物(クロロメチルスチレン、アリルクロライド、メタリルクロライド、アクリル酸クロリド、メタクリル酸クロリド等)の反応物、エチレン性不飽和結合含有フェノール類(2-アリルフェノール、2-プロペニルフェノール、4-アリルフェノール、4-プロペニルフェノール、オイゲノール、イソオイゲノール等)とハロゲン系化合物(1,4-ビス(クロロメチル)ベンゼン、4,4’-ビス(クロロメチル)ビフェニル、4,4’-ジフルオロベンゾフェノン、4,4’-ジクロロベンゾフェノン、4,4’-ジブロモベンゾフェノン、塩化シアヌル等)の反応物、エポキシ樹脂若しくはアルコール類と(メタ)アクリル酸類(アクリル酸、メタクリル酸等)の反応物及びこれらの酸変性化物等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
イソシアネート樹脂とは、分子内に2つ以上イソシアネート基を有する化合物である。イソシアネート樹脂としては、例えば、p-フェニレンジイソシアネート、m-フェニレンジイソシアネート、p-キシレンジイソシアネート、m-キシレンジイソシアネート、2,4-トリレンジイソシアネート、2,6-トリレンジイソシアネート、4,4’-ジフェニルメタンジイソシアネート、ナフタレンジイソシアネート等の芳香族ジイソシアネート類、イソホロンジイソシアネート、ヘキサメチレンジイソシアネート、4,4’-ジシクロヘキシルメタンジイソシアネート、水添キシレンジイソシアネート、ノルボルネンジイソシアネート、リジンジイソシアネート等の脂肪族又は脂環構造のジイソシアネート類、イソシアネートモノマーの一種類以上のビュレット体、又は上記ジイソシアネート化合物を3量化したイソシアネート体等のポリイソシアネート、上記イソシアネート化合物とポリオール化合物とのウレタン化反応によって得られるポリイソシアネート等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
ポリアミド樹脂としては、例えば、ジアミン、ジイソシアネート、オキサゾリンのいずれか1種以上とジカルボン酸の反応物、ジアミンと酸塩化物の反応物、ラクタム化合物の開環重合物が挙げられる。また、これらは1種類で用いても、複数併用してもよい。
上記各原料の具体例を以下に例示するが、これらに限定されるものではない。
<ジアミン>
エチレンジアミン、トリメチレンジアミン、テトラメチレンジアミン、ペンタメチレンジアミン、ヘキサメチレンジアミン、ヘプタメチレンジアミン、オクタメチレンジアミン、ノナメチレンジアミン、デカンジアミン、ウンデカンジアミン、ドデカンジアミン、トリデカンジアミン、テトラデカンジアミン、ペンタデカンジアミン、ヘキサデカンジアミン、ヘプタデカンジアミン、オクタデカンジアミン、ノナデカンジアミン、エイコサンジアミン、2-メチル-1,5-ジアミノペンタン、2-メチル-1,8-ジアミノオクタン、ダイマージアミン、シクロヘキサンジアミン、ビス-(4-アミノシクロヘキシル)メタン、ビス(3-メチル-4-アミノシクロヘキシル)メタン、キシリレンジアミン、ノルボルナンジアミン、イソホロンジアミン、ビスアミノメチルトリシクロデカン、フェニレンジアミン、ジエチルトルエンジアミン、ナフタレンジアミン、ジアミノジフェニルメタン、ビス(4-アミノ-3,5-ジメチルフェニル)メタンビス(4-アミノ-3,5-ジエチルフェニル)メタン、4,4’-メチレンビス-о-トルイジン、4,4’-メチレンビス-о-エチルアニリン、4,4’-メチレンビス-2-エチル-6-メチルアニリン、4,4’-メチレンビス-2,6-ジイソプロピルアニリン、4,4-エチレンジアニリン、ジアミノジフェニルスルホン、ジアミノジフェニルエーテル、1,3-ビス(3-アミノフェノキシ)ベンゼン、1,3-ビス(4-アミノフェノキシ)ベンゼン、4,4-ビス(4-アミノフェノキシ)ビフェニル、2,2-ビス[4-(4-アミノフェノキシ)フェニル]プロパン、ビス[4-(4-アミノフェノキシ)フェニル]スルホン、2,2-ビス(3-アミノ-4-ヒドロキシフェニル)プロパン、2,2-ビス(4-アミノフェニル)ヘキサフルオロプロパン、4,4’-(1,3-フェニレンジイソプロピリデン)ビスアニリン、4,4’-(1,4-フェニレンジイソプロピリデン)ビスアニリン、9,9-ビス(4-アミノフェニル)フルオレン、2,7-ジアミノフルオレン、アミノベンジルアミン、ジアミノベンゾフェノン等。
<ジイソシアネート>
ベンゼンジイソシアネート、トルエンジイソシアネート、1,3-ビス(イソシアナトメチル)ベンゼン、1,3-ビス(イソシアナトメチル)シクロヘキサン、ビス(4-イソシアナトフェニル)メタン、イソホロンジイソシアネート、1,3-ビス(2-イソシアナト-2-プロピル)ベンゼン、2,2-ビス(4-イソシアナトフェニル)ヘキサフルオロプロパン、ジシクロヘキシルメタン-4,4’-ジイソシアナート等。
<ジカルボン酸>
シュウ酸、マロン酸、スクシン酸、グルタル酸、アジピン酸、スベリン酸、アゼライン酸、セバシン酸、ウンデカン二酸、ドデカン二酸、テレフタル酸、イソフタル酸、5-ヒドロキシイソフタル酸、2-クロロテレフタル酸、2-メチルテレフタル酸、5-メチルイソフタル酸、5-ナトリウムスルホイソフタル酸、ヘキサヒドロテレフタル酸、ヘキサヒドロイソフタル酸、シクロヘキサンジカルボン酸、ビフェニルジカルボン酸、ナフタレンジカルボン酸、ベンゾフェノンジカルボン酸、フランジカルボン酸、4,4’-ジカルボキシジフェニルエーテル、4,4’-ジカルボキシジフェニルスルフィド等。
<酸塩化物>
アセチルクロリド、アクリル酸クロリド、メタクリル酸クロリド、マロニルクロリド、こはく酸ジクロリド、ジグリコリルクロリド、グルタル酸ジクロリド、スベリン酸ジクロリド、セバシン酸ジクロリド、アジピン酸ジクロリド、ドデカンジオイルジクロリド、アゼラオイルクロリド、2,5-フランジカルボニルジクロリド、フタロイルクロリド、イソフタロイルクロリド、テレフタロイルクロリド、トリメシン酸クロリド、ビス(4-クロロカルボニルフェニル)エーテル、4,4’-ジフェニルジカルボニルクロリド、4,4’-アゾジベンゾイルジクロリド等。
<ラクタム>
ε-カプロラクタム、ω-ウンデカンラクタム、ω-ラウロラクタム等。
ポリイミド樹脂としては、例えば、前記ジアミンと以下に例示するテトラカルボン酸二無水物の反応物が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
<テトラカルボン酸二無水物>
4,4’-(ヘキサフルオロイソプロピリデン)ジフタル酸無水物、5-(2,5-ジオキソテトラヒドロ-3-フラニル)-3-メチル-シクロヘキセン-1,2ジカルボン酸無水物、ピロメリット酸二無水物、1,2,3,4-ベンゼンテトラカルボン酸二無水物、3,3’,4,4’-ベンゾフェノンテトラカルボン酸二無水物、2,2’,3,3’-ベンゾフェノンテトラカルボン酸二無水物、3,3’,4,4’-ビフェニルテトラカルボン酸二無水物、3,3’,4,4’-ジフェニルスルホンテトラカルボン酸二無水物、2,2’,3,3’-ビフェニルテトラカルボン酸二無水物、メチレン-4,4’-ジフタル酸二無水物、1,1-エチリデン-4,4’-ジフタル酸二無水物、2,2’-プロピリデン-4,4’-ジフタル酸二無水物、1,2-エチレン-4,4’-ジフタル酸二無水物、1,3-トリメチレン-4,4’-ジフタル酸二無水物、1,4-テトラメチレン-4,4’-ジフタル酸二無水物、1,5-ペンタメチレン-4,4’-ジフタル酸二無水物、4,4’-オキシジフタル酸二無水物、チオ-4,4’-ジフタル酸二無水物、スルホニル-4,4’-ジフタル酸二無水物、1,3-ビス(3,4-ジカルボキシフェニル)ベンゼン二無水物、1,3-ビス(3,4-ジカルボキシフェノキシ)ベンゼン二無水物、1,4-ビス(3,4-ジカルボキシフェノキシ)ベンゼン二無水物、1,3-ビス[2-(3,4-ジカルボキシフェニル)-2-プロピル]ベンゼン二無水物、1,4-ビス[2-(3,4-ジカルボキシフェニル)-2-プロピル]ベンゼン二無水物、ビス[3-(3,4-ジカルボキシフェノキシ)フェニル]メタン二無水物、ビス[4-(3,4-ジカルボキシフェノキシ)フェニル]メタン二無水物、2,2-ビス[3-(3,4-ジカルボキシフェノキシ)フェニル]プロパン二無水物、2,2-ビス[4-(3,4-ジカルボキシフェノキシ)フェニル]プロパン二無水物、ビス(3,4-ジカルボキシフェノキシ)ジメチルシラン二無水物、1,3-ビス(3,4-ジカルボキシフェニル)-1,1,3,3-テトラメチルジシロキサン二無水物、2,3,6,7-ナフタレンテトラカルボン酸二無水物、1,4,5,8-ナフタレンテトラカルボン酸二無水物、1,2,5,6-ナフタレンテトラカルボン酸二無水物、3,4,9,10-ペリレンテトラカルボン酸二無水物、2,3,6,7-アントラセンテトラカルボン酸二無水物、1,2,7,8-フェナントレンテトラカルボン酸二無水物、エチレンテトラカルボン酸二無水物、1,2,3,4-ブタンテトラカルボン酸二無水物、1,2,3,4-シクロブタンテトラカルボン酸二無水物)、シクロペンタンテトラカルボン酸二無水物、シクロヘキサン-1,2,3,4-テトラカルボン酸二無水物、シクロヘキサン-1,2,4,5-テトラカルボン酸二無水物、3,3’,4,4’-ビシクロヘキシルテトラカルボン酸二無水物、カルボニル-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、メチレン-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、1,2-エチレン-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、1,1-エチリデン-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、2,2-プロピリデン-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、オキシ-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、チオ-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、スルホニル-4,4’-ビス(シクロヘキサン-1,2-ジカルボン酸)二無水物、ビシクロ[2,2,2]オクト-7-エン-2,3,5,6-テトラカルボン酸二無水物、rel-[1S,5R,6R]-3-オキサビシクロ[3,2,1]オクタン-2,4-ジオン-6-スピロ-3’-(テトラヒドロフラン-2’,5’-ジオン)、4-(2,5-ジオキソテトラヒドロフラン-3-イル)-1,2,3,4-テトラヒドロナフタレン-1,2-ジカルボン酸無水物、エチレングリコール-ビス-(3,4-ジカルボン酸無水物フェニル)エーテル、4,4’-ビフェニルビス(トリメリット酸モノエステル酸無水物)、9,9’-ビス(3,4-ジカルボキシフェニル)フルオレン二無水物等。
本実施形態の硬化性樹脂組成物は、マレイミド化合物を含有しても良く、例えば、4,4’-ジフェニルメタンビスマレイミド、ポリフェニルメタンマレイミド、m-フェニレンビスマレイミド、2,2’-ビス〔4-(4-マレイミドフェノキシ)フェニル〕プロパン、3,3’-ジメチル-5,5’-ジエチル-4,4’-ジフェニルメタンビスマレイミド、4-メチル-1,3-フェニレンビスマレイミド、4,4’-ジフェニルエーテルビスマレイミド、4,4’-ジフェニルスルフォンビスマレイミド、1,3-ビス(3-マレイミドフェノキシ)ベンゼン、1,3-ビス(4-マレイミドフェノキシ)ベンゼン)、ザイロック型マレイミド化合物(アニリックス マレイミド、三井化学ファイン社製)、ビフェニルアラルキル型マレイミド化合物(特開2009-001783号公報の実施例4に記載のマレイミド化合物(M2)を含む樹脂溶液を減圧下溶剤留去することにより固形化したもの)、ビスアミノクミルベンゼン型マレイミド(国際公開第2020/054601号記載のマレイミド化合物)、特許6629692号または国際公開第2020/217679号記載のインダン構造を有するマレイミド化合物、MATERIAL STAGE Vоl.18,Nо.12 2019 『~続・エポキシ樹脂CAS番号物語~硬化剤CAS番号備忘録 第31回 ビスマレイミド(1)』やMATERIAL STAGE Vоl.19,Nо.2 2019 『~続・エポキシ樹脂CAS番号物語~硬化剤CAS番号備忘録 第32回 ビスマレイミド(2)』に記載されているマレイミド化合物等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
シアネートエステル樹脂は、フェノール樹脂をハロゲン化シアンと反応させることにより得られるシアネートエステル化合物であり、具体例としては、ジシアナートベンゼン、トリシアナートベンゼン、ジシアナートナフタレン、ジシアナートビフェニル、2、2’-ビス(4-シアナートフェニル)プロパン、ビス(4-シアナートフェニル)メタン、ビス(3,5-ジメチル-4-シアナートフェニル)メタン、2,2’-ビス(3,5-ジメチル-4-シアナートフェニル)プロパン、2,2’-ビス(4-シアナートフェニル)エタン、2,2’-ビス(4-シアナートフェニル)ヘキサフロロプロパン、ビス(4-シアナートフェニル)スルホン、ビス(4-シアナートフェニル)チオエーテル、フェノールノボラックシアナート、フェノール・ジシクロペンタジエン共縮合物の水酸基をシアネート基に変換したもの等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。
また、特開2005-264154号公報に合成方法が記載されているシアネートエステル化合物は、低吸湿性、難燃性、誘電特性に優れているためシアネートエステル化合物として特に好ましい。
シアネートエステル樹脂は、必要に応じてシアネート基を三量化させてsym-トリアジン環を形成するために、ナフテン酸亜鉛、ナフテン酸コバルト、ナフテン酸銅、ナフテン酸鉛、オクチル酸亜鉛、オクチル酸錫、鉛アセチルアセトナート、ジブチル錫マレエート等の触媒を含有させることもできる。
ポリブタジエンおよびこの変性物とは、ポリブタジエン、もしくはポリブタジエンに由来する構造を分子内に有する化合物である。ポリブタジエンに由来する構造は水素添加により、不飽和結合を一部、もしくは全て単結合に変換されていても良い。
ポリブタジエンおよびこの変性物としては、例えば、ポリブタジエン、水酸基末端ポリブタジエン、末端(メタ)アクリレート化ポリブタジエン、カルボン酸末端ポリブタジエン、アミン末端ポリブタジエン、スチレンブタジエンゴム等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。これらのうち、誘電特性の観点からポリブタジエンもしくはスチレンブタジエンゴムが好ましい。スチレンブタジエンゴム(SBR)としては例えば、RICON-100、RICON-181、RICON-184(いずれもクレイバレー社製)、1,2-SBS(日本曹達社製)などが挙げられ、ポリブタジエンとしては、B-1000、B-2000、B-3000(いずれも日本曹達社製)等が挙げられる。ポリブタジエンおよびスチレンブタジエンゴムの分子量としては重量平均分子量500~10000が好ましく、より好ましくは750~7500、さらに好ましくは1000~5000である。上記範囲の下限以下では揮発量が多く、プリプレグ作成時の固形分調整が困難となり、上記範囲の上限以上では、他の硬化性樹脂との相溶性が悪化する。一般に、ビスマレイミドやポリマレイミドのような酸素や窒素などのヘテロ原子を含む化合物の場合、その極性に起因し、主に炭化水素から構成される化合物もしくは炭化水素のみからなる化合物のような低極性化合物との相溶性の担保が困難である。一方、本実施形態の化合物は、それ自体が酸素や窒素などのヘテロ原子を積極的に導入した骨格設計ではないことに起因し、低極性かつ低誘電正接を示す材料や、炭化水素のみで構成される化合物との相溶性にも優れる。
ポリスチレンおよびこの変性物とは、ポリスチレン、もしくはポリスチレンに由来する構造を分子内に有する化合物である。
ポリスチレンおよびこの変性物としては、例えば、ポリスチレン、スチレン・2-イソプロペニル-2-オキサゾリン共重合体(エポクロス RPS-1005、RP-61 いずれも日本触媒社製)、SEP(スチレン-エチレン・プロピレン共重合体:セプトン1020 クラレ社製)、SEPS(スチレン-エチレン・プロピレン-スチレン共重合体:セプトン2002、セプトン2004F、セプトン2005、セプトン2006、セプトン2063、セプトン2104 いずれもクラレ社製)、SEEPS(スチレン-エチレン/エチレン・プロピレン-スチレンブロック共重合体:セプトン4003、セプトン4044、セプトン4055、セプトン4077、セプトン4099 いずれもクラレ社製)、SEBS(スチレン-エチレン・ブチレン-スチレン ブロック共重合体:セプトン8004、セプトン8006、セプトン8007L いずれもクラレ社製)、SEEPS-ОH(スチレン-エチレン/エチレン・プロピレン-スチレンブロック共重合体の末端に水酸基を有する化合物:セプトンHG252 クラレ社製)、SIS(スチレン-イソプレン-スチレン ブロック共重合体:セプトン5125、セプトン5127 いずれもクラレ社製)、水添SIS(水添スチレン-イソプレン-スチレン ブロック共重合体:ハイブラー7125F、ハイブラー7311F いずれもクラレ社製)、SIBS(スチレン-イソブチレン-スチレンブロック共重合体:SIBSTAR073T、SIBSTAR102T、SIBSTAR103T(いずれもカネカ社製)、セプトンV9827(クラレ社製))等が挙げられるが、これらに限定されるものではない。また、これらは1種類で用いても、複数併用してもよい。ポリスチレンおよびこの変性物は、より高い耐熱性を有し、かつ酸化劣化しにくいため、不飽和結合を有さないものが好ましい。また、ポリスチレンおよびこの変性物の重量平均分子量は10000以上であれば特に制限はないが、大きすぎるとポリフェニレンエーテル化合物のほか、重量平均分子量50~1000程度の低分子量成分および、重量平均分子量1000~5000程度のオリゴマー成分との相溶性が悪化し、混合および溶剤安定性の担保が困難になることから、10000~300000程度であることが好ましい。
ポリエチレンおよびこの変性物とは、ポリエチレン、もしくはポリエチレンに由来する構造を分子内に有する化合物である。ポリエチレンおよびこの変性物としては、例えば、エチレン-プロピレン共重合体、エチレン-スチレン共重合体、エチレン-プロピレン-エチリデンノルボルネン共重合体(三井化学社製EBT:K-8370EM、K-9330M等)、エチレン-プロピレン-ビニルノルボルネン共重合体(三井化学社製VNB-EPT:PX-006M、PX-008M、PX-009M等)、エチレン-ビニルアルコール共重合体、エチレン-酢酸ビニル共重合体等が挙げられるが、これらに限定されるものではない。耐熱性向上の観点から、架橋可能な構造を含有するエチレン-プロピレン-エチリデンノルボルネン共重合体、エチレン-プロピレン-ビニルノルボルネン共重合体を用いることが好ましい。また、これらは1種類で用いても、複数併用してもよい。ポリエチレンおよびこの変性物の重量平均分子量は10000以上であれば特に制限はないが、大きすぎるとポリフェニレンエーテル化合物のほか、重量平均分子量50~1000程度の低分子量成分および、重量平均分子量1000~5000程度のオリゴマー成分との相溶性が悪化し、混合および溶剤安定性の担保が困難になることから、10000~300000程度であることが好ましい。
得られた成型体についてトランスファー成型機、コンプレッション成型機にて硬化物に成型することができる。
上記プリプレグを所望の形に裁断、必要により銅箔などと積層後、積層物にプレス成形法やオートクレーブ成形法、シートワインディング成形法などで圧力をかけながら硬化性樹脂組成物を加熱硬化させることにより電気電子用積層板(プリント配線板)や、炭素繊維強化材を得ることができる。
・GPC(ゲルパーミエーションクロマトグラフィー)分析
カラム:SHODEX GPC KF-601(2本)、KF-602、KF-602.5、KF-603
流速:1.5ml/min.
カラム温度:40℃
使用溶剤:THF(テトラヒドロフラン)
検出器:RI(示差屈折検出器)
温度計、冷却管、撹拌機を取り付けたフラスコに、アスピレータおよび塩基トラップを設置した。このフラスコに2-ブロモエチルベンゼン(東京化成社製)370.1部、α,α’-ジクロロ-p-キシレン(東京化成社製)175.1部、メタンスルホン酸(東京化成社製)27.3部を仕込み、発生する塩化水素を塩基トラップで捕集しながら130℃で6時間反応させた。トルエン100部、シクロヘキサン600部を加え抽出し、有機層を水100部で5回洗浄した。加熱減圧下、溶剤および過剰の2-ブロモエチルベンゼンを留去することにより下記式(3)で表される2-ブロモエチルベンゼン構造を有する化合物(BEB-1)380部を液状樹脂として得た(Mn:938、Mw:1290)。得られた化合物のGPCチャートを図1に示す。GPCチャートの面積%より計算した繰り返し単位の平均値nは2.2であった。
温度計、冷却管、撹拌機を取り付けたフラスコに合成例1で得られたBEB-1 300部、トルエン245部、ジメチルスルホキシド735部、4-ヒドロキシ-2,2,6,6-テトラメチルピペリジン-1-オキシル フリーラジカル0.15部、50wt%水酸化ナトリウム水溶液146.4部を加え、40℃で6時間反応を継続した。水100部を加え、有機層を洗浄後、有機層を反応容器に戻した。ジメチルスルホキシド735部、50wt%水酸化ナトリウム水溶液9.8部を加え、40℃で1時間再び反応させ、トルエン300部を加え、排水が中性になるまで有機層を水100部で繰り返し洗浄した。エバポレータにて減圧濃縮し、下記式(4)で表される分子内に2つ以上スチレン構造を有する化合物(O-1)を180部得た。得られた化合物のGPCチャートを図2に示す。また、得られた化合物の1H-NMRデータ(重クロロホルム)を図3に示す。1H-NMRチャートの5.10-5.30ppm、5.50-5.85ppm、および、6.60-6.80ppmにビニル基由来のシグナルが観測された。GPCチャートの面積%より計算した繰り返し単位の平均値nは2.2であった(樹脂成分の分子量は、Mn:797、Mw:1187であった)。
表1に示す配合量で各重合禁止剤と合成例2で得られた化合物(О-1)を配合し、固形分60wt%のトルエン溶液を調製した。各溶液を5mLガラスサンプル瓶中で40℃で50日保管し、目視にてゲル化が確認された場合を×、性状に変化がない場合を〇とした。結果を表1に示す。
TBC:4-tert-ブチルカテコール(TCI社製)
HQ:ハイドロキノン(TCI社製)
Chimassоrb944FDL:ヒンダードアミン系光安定剤(BASF社製)
TEMPОL Free Radical:4-ヒドロキシ-2,2,6,6-テトラメチルピペリジン1-オキシル フリーラジカル(TCI社製)
Q-1301:Ammоnium N-Nitrоsоphenylhydrоxylamine
AО-60:Pentaerythritоl tetrakis[3-(3,5-di-tert-butyl-4-hydrоxyphenyl)prоpiоnate](ADEKA社製)
Irganоx-1010:Pentaerythritоl tetrakis(3-(3,5-di-tert-butyl-4-hydrоxyphenyl)prоpiоnate)(BASF社製)
PEP-36:3,9-Bis(2,6-di-tert-butyl-4-methylphenоxy)-2,4,8,10-tetraоxa-3,9-diphоsphaspirо[5.5]undecane(ADEKA社製)
AО-412S:2,2-Bis{[3-(dоdecylthiо)-1-оxоprоpоxy]methyl}prоpane-1,3-diyl bis[3-(dоdecylthiо)prоpiоnate](ADEKA社製)
合成例2で得られた化合物(О-1)、および重合禁止剤を表2に示す量を用いて、鏡面銅箔(T4X:福田金属銅箔社製)で挟み込みながら真空プレス成型し、220℃で2時間硬化させた。この際、スペーサとして厚さ250μmのクッション紙の中央を縦横150mmにくり抜いたものを用いた。評価にあたっては、必要に応じてレーザーカッターを用いて所望のサイズに試験片を切り出し、評価を実施した。
(株)AET社製の10GHz空洞共振器を用いて、25℃において空洞共振器摂動法にてテストを行った。サンプルサイズは幅1.7mm×長さ100mmとし、厚さは0.1mmで試験を行った。評価結果を表2に示す。
合成例2で得られた化合物(О-1)、および重合禁止剤を表3に示す量用いて、示差走査熱量測定(DSC)を実施した。
LINSEIS社製のChip-DSC1を用いて、試験を行った。測定温度範囲は30℃-300℃とし、昇温速度は20℃/分、ガス流量は窒素ガスを150mL/分とした。発熱ピークの始点のオンセット温度(発熱開始温度)を表3に示す。
DMHQ:2,6-ジメチルハイドロキノン(TCI社製)
o-クレゾール:TCI社製
Claims (5)
- 下記式(1)で表される化合物と、下記式(2)で表される化合物とを含有する硬化性樹脂組成物。
(式(1)中、Aは炭素数1~20の炭化水素基であり、複数存在するRはそれぞれ独立して、水素原子、炭素数1~10の炭化水素基、または炭素数1~10のハロゲン化アルキル基を表す。pは0~4の整数、qは0~3の整数を表し、nは繰り返し数の平均値であり、1≦n≦20である。)
(式(2)中、R1およびR2はそれぞれ独立して炭素数1~20の炭化水素基を表し、nは0~3の整数を表す。) - 下記式(1-1)で表される化合物と、下記式(2)で表される化合物とを含有する硬化性樹脂組成物。
(式(1)中、複数存在するRはそれぞれ独立して、水素原子、炭素数1~10の炭化水素基、または炭素数1~10のハロゲン化アルキル基を表す。p、rは0~4の整数、qは0~3の整数を表し、nは繰り返し数の平均値であり、1≦n≦20である。)
(式(2)中、R1およびR2はそれぞれ独立して炭素数1~20の炭化水素基を表し、nは0~3の整数を表す。) - さらに、重合開始剤を含有する、請求項1に記載の硬化性樹脂組成物。
- さらに、マレイミド化合物、ポリフェニレンエーテル化合物、エチレン性不飽和結合を有する化合物、シアネートエステル樹脂、ポリブタジエンおよびこの変性物、ポリスチレンおよびこの変性物、ポリエチレンおよびこの変性物、からなる群から選ばれる少なくとも1種以上を含有する、請求項1に記載の硬化性樹脂組成物。
- 請求項1から請求項4のいずれか一項に記載の硬化性樹脂組成物を硬化して得られる硬化物。
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| JP2007191681A (ja) * | 2005-12-22 | 2007-08-02 | Mitsubishi Gas Chem Co Inc | 保存安定性に優れる硬化性樹脂組成物、硬化性フィルムおよびフィルム |
| WO2018012295A1 (ja) * | 2016-07-14 | 2018-01-18 | Dic株式会社 | 活性エネルギー線硬化型樹脂組成物及び金属薄膜用アンダーコート剤 |
| WO2021100658A1 (ja) * | 2019-11-19 | 2021-05-27 | 日本化薬株式会社 | 化合物、混合物、硬化性樹脂組成物およびその硬化物、並びに化合物の製造方法 |
| WO2022244725A1 (ja) * | 2021-05-17 | 2022-11-24 | パナソニックIpマネジメント株式会社 | 樹脂組成物、並びに、それを用いたプリプレグ、樹脂付きフィルム、樹脂付き金属箔、金属張積層板及び配線基板 |
| JP2023069669A (ja) * | 2021-11-08 | 2023-05-18 | 日本化薬株式会社 | 硬化性化合物を含む樹脂組成物 |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2007191681A (ja) * | 2005-12-22 | 2007-08-02 | Mitsubishi Gas Chem Co Inc | 保存安定性に優れる硬化性樹脂組成物、硬化性フィルムおよびフィルム |
| WO2018012295A1 (ja) * | 2016-07-14 | 2018-01-18 | Dic株式会社 | 活性エネルギー線硬化型樹脂組成物及び金属薄膜用アンダーコート剤 |
| WO2021100658A1 (ja) * | 2019-11-19 | 2021-05-27 | 日本化薬株式会社 | 化合物、混合物、硬化性樹脂組成物およびその硬化物、並びに化合物の製造方法 |
| WO2022244725A1 (ja) * | 2021-05-17 | 2022-11-24 | パナソニックIpマネジメント株式会社 | 樹脂組成物、並びに、それを用いたプリプレグ、樹脂付きフィルム、樹脂付き金属箔、金属張積層板及び配線基板 |
| JP2023069669A (ja) * | 2021-11-08 | 2023-05-18 | 日本化薬株式会社 | 硬化性化合物を含む樹脂組成物 |
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