CN100402605C - 含反应性阻燃剂膦酸酯低聚物和填料的环氧树脂组合物 - Google Patents

含反应性阻燃剂膦酸酯低聚物和填料的环氧树脂组合物 Download PDF

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CN100402605C
CN100402605C CNB2003801053608A CN200380105360A CN100402605C CN 100402605 C CN100402605 C CN 100402605C CN B2003801053608 A CNB2003801053608 A CN B2003801053608A CN 200380105360 A CN200380105360 A CN 200380105360A CN 100402605 C CN100402605 C CN 100402605C
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谢尔盖·列夫奇克
马克·布切克
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Abstract

本发明公开了环氧树脂组合物，所述的组合物包括环氧树脂、反应性膦酸酯固化剂、无机填料、任选的聚苯并恶嗪树脂和任选的共固化剂，与不含填料的组合物相比，无机填料的存在可降低膦酸酯的量。

Description

含反应性阻燃剂膦酸酯低聚物和填料的环氧树脂组合物
本发明涉及涉及一种环氧树脂组合物，所述的组合物例如能被使用在电子学应用场合的印刷布线板中，例如而且本发明的组合物相对于描述在Shin Kobe Electric Manufacturing Co.Ltd./Hitachi Chemical Co.Ltd.的日本专利出版物No.2001/302,879中的组合物类型具有新颖的改进。
本发明的组合物包含作为主要成分的环氧树脂。该组份的含量为组合物总重量的约20wt％～约50wt％。优选，该组份是不含卤素的环氧树脂，比如双酚A类型环氧树脂，或者该一般类型的用于制造印刷线路板或者其他电子学的基底材料的类型的其他树脂(双酚F环氧基、苯酚酚醛清漆环氧基、甲酚酚醛清漆环氧基和/或双酚A酚醛清漆环氧树脂)。可以使用这些树脂任何的相容的混合物。
另外任选的，但是优选的用于本发明组合物的组份是聚苯并噁恶嗪树脂，含量为组合物总重量的直至约50wt％，优选为约5wt％～约20wt％。该组合物是热固性树脂，包含通过以下描述反应形成的二氢苯并恶嗪：
Figure C20038010536000031
该组份和它的制造过程进一步描述在US 5,945,222中(栏2、行59～栏3、行62)，其在此引入作为参考。
然后另外任选的本发明组合物的组份是上述树脂组份的共固化剂。相容的共固化剂的混合物能被使用。共固化剂含量为组合物总重量的约0wt％～约20wt％，优选为约5wt％～约15wt％。代表性的共固化剂包括苯酚甲醛、甲酚甲醛、酚醛清漆、酚醛清漆/三聚氰胺、磷酰化的酚醛清漆、三嗪改性的酚醛清漆树脂、双氰胺等。
本发明组合物同样包含一种或多种无机填料材料，含量为约10wt％～约50wt％。填充材料或者材料可选自这样已知的填料，例如滑石、二氧化硅、氧化铝、氢氧化铝、氢氧化镁、硼酸锌等。优选的用于本发明的材料是三水合氧化铝。
尽管PCT出版的专利申请No.WO03/029258教导那些环氧树脂可包含羟基封端的低聚膦酸酯作为阻燃剂，但PCT申请一般地说明这样的膦酸酯含量需要在环氧树脂约20wt％～约30wt％附近，或者对于可接受的结果含量更高。在这样的组合物中没有提到使用填料。根据本发明，另外存在的填料可允许使用较低含量的膦酸酯添加剂。在如下表1中，实施例7说明仅需要10％的膦酸酯。不管是否使用较低含量的膦酸酯阻燃剂，使用填料可生产阻燃足够的环氧树脂组合物，同时仍然可生产具有良好物理性质(比如较高Tg、更好的水解稳定性等等)的产品。
本发明组合物每一上述的组分单独而言，本领域普通技术人员熟知有可能作为本发明类型环氧树脂组合物的组分，在此以前它们已经用于不同的组合物，上述日本专利出版物No.2001/302,879作为举例说明。
与现有技术依靠前面描述组分不同组合的方法相比，形成本发明新颖和重要添加剂的反应性膦酸酯固化剂的含量为组合物总重量的约3wt％约40wt％，优选为约5wt％～约20wt％。如更充分地描述在PCT出版物No.WO03/029258中的阻燃剂固化剂是低聚膦酸酯，含有-OP(O)(R)-O-亚芳基-重复单元，而且磷含量大于约12wt％。组合物中的膦酸酯物种包括那些含OH端基，也可能不含OH端基的那些。优选的R基团是甲基，但是可以是任何低级烷基。
就“亚芳基”来说，意思是任何的二羟酚基团。该二羟酚优选在不相邻位置具有两个羟基。例子包括间苯二酚、对苯二酚；和双酚比如双酚A、双酚F、4，4′-双苯酚、酚酞、4，4′-硫代双酚或者4，4′-磺酰基双酚。亚芳基基团是1，3-亚苯基、1，4-亚苯基，或者双酚双自由基单元，但是优选是1，3-亚苯基。
本发明的环氧树脂组合物的组份可以如描述于PCT专利申请03/029258中的几种路线的任一种制备：RPOCl2与HO-芳基-OH或者其盐反应，其中R是低级烷基优选甲基；(2)联苯磷酸烷基酯优选膦酸甲酯与HO-亚芳基-OH在酯交换条件下反应；(3)具有结构-OP(OR′)-O-亚芳基-重复单元的低聚亚磷酸酯在阿尔布佐夫重排催化剂存在下进行重排反应，其中R′是低级烷基优选甲基；或者(4)具有结构-OP(O-Ph)-O-亚芳基-重复单元的低聚亚磷酸酯与亚磷酸三甲基酯和阿尔布佐夫催化剂进行反应，或者与二甲基膦酸甲酯及任选阿尔布佐夫催化剂进行反应。-OH端基，如果连接到亚芳基，可以通过在反应介质中控制HO-亚芳基-OH摩尔过量而产生。-OH端基，如果是酸类型(P-OH)，可以通过水解反应形成。优选低聚物的端基主要是-亚芳基-OH类型。
本发明的环氧树脂组合物也可包含任选的添加剂，包括以下类型的材料：纤维和/或布增强添加剂；脱模制；着色剂等。
实施例
材料
环氧化合物-双酚A类型环氧树脂
酚醛清漆-苯酚-甲醛树脂(酚醛清漆类型)(助固化剂)
三聚氰胺-酚醛清漆-苯酚、三聚氰胺和甲醛的共聚物(助固化剂)
含磷-酚醛清漆-磷酰化的苯酚-甲醛树脂(助固化剂)
ATH-三水合铝
膦酸酯-反应性膦酸酯固化剂，其中“亚芳基”是间苯二酚
DICY-双氰胺(助固化剂)
AMI-2-2-甲基咪唑(催化剂)
BDP-双酚A双(磷酸二苯酯)Akzo Nobel商标，FYROLFLEXBDP
BDP(OH)-双酚A磷酸二苯酯
如描述于US 3,090,799中的方法制造。
RDP(OH)2间苯二酚双(磷酸苯基间羟苯基酯)
如描述于US 5,508,462中的方法制造。
试验
Tg-玻璃化转变温度，如IPC-TM-650规程中描述的TMA试验测量。
UL 94-易燃性评价，根据UL 94垂直规程评价(V-0、V-1、V-2)
PCT-根据IPC-TM-650规程接触加压蒸煮器试验中蒸汽的时间。吸水率在除去高压釜样品以后测定。
脱层-如IPC-TM-650规程描述的在260或者288℃下TMA试验中测定。
CTE-热膨胀系数，在玻璃转化温度以下和超出玻璃转化温度下(分别＜Tg和＞Tg)在TMA试验中测定。遵循IPC-TM-650规程。
以下描述的表I和II列出许多代表本发明实施方式的制剂。表III列出一套比较制剂。
表1
Figure C20038010536000071
表2
表3(对比)
Figure C20038010536000081

Claims (9)

1.一种环氧树脂组合物，含有环氧树脂、反应性膦酸酯固化剂、无机填料、聚苯并噁嗪树脂和任选的共固化剂。
2.如权利要求1的组合物，其中环氧树脂占组合物总重量的10wt％～50wt％。
3.如权利要求1的组合物，其中反应性膦酸酯固化剂占组合物总重量的5wt％～30wt％。
4.如权利要求1的组合物，其中聚苯并噁嗪树脂占组合物总重量的直至50wt％。
5.如权利要求1的组合物，其中共固化剂占组合物总重量的5wt％～20wt％。
6.如权利要求1的组合物，其中无机填料占组合物总重量的10wt％～50wt％。
7.如权利要求1的组合物，其中环氧树脂占组合物总重量的10wt％～50wt％，反应性膦酸酯固化剂占组合物总重量的5wt％～30wt％，无机填料占组合物总重量的10wt％～50wt％，和苯并噁嗪树脂占组合物总重量的直至50wt％。
8.如权利要求7的组合物，进一步含有占组合物总重量的5wt％～20wt％的共固化剂。
9.如权利要求1～6和8任一项的组合物，其中共固化剂选自酚醛清漆、三聚氰胺酚醛清漆和含磷酚醛清漆组合物。
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