WO2012131971A1 - 予備硬化物、粗化予備硬化物及び積層体 - Google Patents
予備硬化物、粗化予備硬化物及び積層体 Download PDFInfo
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- WO2012131971A1 WO2012131971A1 PCT/JP2011/058198 JP2011058198W WO2012131971A1 WO 2012131971 A1 WO2012131971 A1 WO 2012131971A1 JP 2011058198 W JP2011058198 W JP 2011058198W WO 2012131971 A1 WO2012131971 A1 WO 2012131971A1
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- cured product
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/092—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising epoxy resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/26—Layered products comprising a layer of synthetic resin characterised by the use of special additives using curing agents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/4007—Curing agents not provided for by the groups C08G59/42 - C08G59/66
- C08G59/4014—Nitrogen containing compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/42—Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/62—Alcohols or phenols
- C08G59/621—Phenols
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/68—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the catalysts used
- C08G59/686—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the catalysts used containing nitrogen
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
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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
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/102—Oxide or hydroxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/538—Roughness
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
- C08K3/36—Silica
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/259—Silicic material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T428/268—Monolayer with structurally defined element
Definitions
- the present invention relates to a precured product obtained by advancing curing of an epoxy resin material using an epoxy resin material containing an epoxy resin, a curing agent, and silica, and a roughened preliminary material using the precured material.
- the present invention relates to a cured product and a laminate.
- a resin composition is used in order to form an insulating layer for insulating inner layers or to form an insulating layer located in a surface layer portion.
- Patent Document 1 discloses a resin composition containing an epoxy resin, a curing agent, a phenoxy resin, and an inorganic filler having an average particle diameter of 0.01 to 2 ⁇ m. Has been. Further, Patent Document 1 discloses a resin composition containing an epoxy resin, a curing agent, and an inorganic filler having an average particle diameter of 0.1 to 10 ⁇ m.
- each layer of a multilayer film having a two-layer laminated structure is formed using two different types of resin compositions described above. It is described that this multilayer film is satisfactorily embedded in a gap or the like provided on the substrate.
- Patent Document 2 discloses a resin composition containing an epoxy resin, a curing agent, at least one of a phenoxy resin and a polyvinyl acetal resin, and a phosphorus-containing benzoxazine compound.
- Patent Document 2 when a cured product obtained by curing a resin composition is roughened, the roughened surface exhibits high adhesion to the plated conductor even though the roughness of the roughened surface is relatively small.
- an insulating layer excellent in flame retardancy can be obtained.
- Patent Document 1 since two types of resin compositions are prepared and a multilayer film is produced, there is a problem that it takes time to produce the multilayer film and the cost is high.
- Patent Document 2 describes that the roughness of the roughened surface is not sufficiently reduced although the resin composition has the above composition to reduce the roughness.
- the object of the present invention is to reduce the surface roughness of the roughened surface of the roughened preliminary-cured product and to increase the adhesive strength between the cured product obtained by curing the roughened preliminary-cured product and the metal layer. It is to provide a precured material that can be prepared, and a roughened precured material and a laminate using the precured material.
- a pre-cured product obtained by advancing curing of an epoxy resin material, which has a first main surface and a second main surface, the first main surface
- the surface is a surface to be roughened
- the epoxy resin material includes an epoxy resin, a curing agent, and silica
- the silica has a first small particle diameter of 0.01 ⁇ m or more and less than 0.5 ⁇ m. It contains a particle size silica and a second large particle size silica having a particle size of 0.5 ⁇ m or more and 20 ⁇ m or less, and the first small particle size silica is roughened in the precured product.
- the surface is unevenly distributed so as to be present on the first main surface side, and the second large particle size silica is unevenly distributed so as to be present on the second main surface side.
- a pre-cured product is provided.
- the minimum melt viscosity of the pre-cured epoxy resin material in the temperature range of 60 to 120 ° C. is 50 Pa ⁇ s or more and 150 Pa ⁇ s or less.
- the epoxy resin material further includes a phenoxy resin.
- the roughened preliminary-cured material according to the present invention is a roughened preliminary-cured material obtained by roughening the first main surface of the preliminary-cured material configured according to the present invention.
- the precured material is swelled before the roughening treatment.
- the laminate according to the present invention includes a cured product obtained by curing a roughened preliminary cured product obtained by roughening the first main surface of the preliminary cured product configured according to the present invention, and the cured product. And a metal layer laminated on the roughened surface.
- the adhesive strength between the cured product and the metal layer is preferably 0.39 N / mm or more.
- the precured material according to the present invention is a precured material obtained by advancing curing of an epoxy resin material containing an epoxy resin, a curing agent, and silica, and the silica has a particle diameter of 0.01 ⁇ m or more, A first small particle size silica having a particle size of less than 0.5 ⁇ m and a second large particle size silica having a particle size of 0.5 ⁇ m or more and 20 ⁇ m or less; The particle size silica is unevenly distributed so as to be present on the first main surface side, which is the surface to be roughened, and the second large particle size silica is present on the second main surface side.
- the surface roughness of the roughened surface of the roughened preliminary-cured product can be reduced. Furthermore, when the metal layer is formed on the surface of the cured product obtained by curing the roughened preliminary-cured product, the adhesive strength between the cured product and the metal layer can be increased.
- FIG. 1 is a partially cutaway front sectional view schematically showing a precured product according to an embodiment of the present invention.
- FIG. 2 is a partially cutaway front sectional view schematically showing a laminate using a precured product according to an embodiment of the present invention.
- the pre-cured product according to the present invention is a pre-cured product obtained by allowing the epoxy resin material to cure.
- FIG. 1 is a front sectional view schematically showing a precured product according to an embodiment of the present invention.
- Pre-cured product 1 is laminated on the upper surface 6a of the lamination target member 6.
- Pre-cured product 1 has a first main surface 1a and a second main surface 1b.
- the first main surface 1a is a surface to be roughened.
- the second main surface 1 b is in contact with the upper surface 6 a of the stacking target member 6.
- the epoxy resin material for obtaining the precured material 1 includes an epoxy resin, a curing agent, and silica 2.
- Silica 2 includes a first small particle size silica 2A having a particle size of 0.01 ⁇ m or more and less than 0.5 ⁇ m, and a second large particle size silica 2B having a particle size of 0.5 ⁇ m or more and 20 ⁇ m or less. contains.
- the first small particle size silica 2A is unevenly distributed so as to be present on the first main surface 1a side which is a surface to be roughened.
- the second large particle size silica 2B is unevenly distributed so as to be present on the second main surface 1b side.
- the first main surface 1a is roughened in the precured product 1
- the first small particle size silica 2A and the second large particle size silica 2B are unevenly distributed as described above.
- fine holes from which the first small particle size silica 2A is detached are formed.
- the surface roughness of the roughened surface can be reduced.
- the adhesive strength between the cured product and the metal layer can be increased.
- the pre-cured product 1 and the first main surface 1a of the pre-cured material 1 are provided.
- the strength of the roughened preliminary-cured material that has been subjected to the roughening treatment can be further increased.
- the second large particle size silica 2B the interface between the silica and the resin is reduced, the melt viscosity can be lowered, the embedding processability is improved, and the precured material 1 and the roughened precured material. , And the electrical insulation, water absorption and chemical resistance of the cured product are improved.
- the precured material and the roughened precured material are further cured.
- the first region R1 (the region above the broken line in FIG. 1) having a thickness of 0.3 ⁇ m on the surface portion on the first main surface 1a side, which is the surface to be roughened. )
- the content of the second large particle size silica is preferably 5% by volume or less, more preferably 4% by volume or less, and 3% by volume or less. More preferably, it is particularly preferably 0% by volume.
- the first region R1 may not contain any second large particle size silica.
- the second region continuous with the first region R1 is used.
- the content of the second large particle size silica 2B is 95 volume%. As mentioned above, it is preferable that it is 100 volume% or less, It is more preferable that it is 96 volume% or more, It is still more preferable that it is 97 volume% or more.
- the second region R2 is continuous with the first region R1.
- the first region R1 and the second region R2 are in contact with each other.
- the second region R2 is the remaining region excluding the first region R1.
- the minimum melt viscosity of the pre-cured epoxy resin material in the temperature range of 60 to 120 ° C. is preferably 300 Pa ⁇ s or less.
- the melt viscosity is preferably 10 Pa ⁇ s or more, more preferably 50 MPa ⁇ s or more, further preferably more than 50 MPa ⁇ s, more preferably 150 MPa ⁇ s or less, still more preferably 120 Pa ⁇ s or less, and particularly preferably 100 Pa ⁇ s. s or less.
- the melt viscosity of the epoxy resin material is not less than the above lower limit and not more than the above upper limit, the surface roughness of the roughened surface of the roughened preliminary-cured product is further reduced, and the cured product and the metal layer are bonded. The strength is further increased.
- melt viscosity is a value measured using a rheometer under conditions in which the epoxy resin material before preliminary curing is heated from 50 ° C. to 150 ° C.
- examples of the rheometer include “AR-2000” manufactured by TA Instruments.
- first small particle size silica 2A and the second large particle size silica 2B are not unevenly distributed as described above by simply using the first small particle size silica 2A and the second large particle size silica 2B together.
- the surface of the resin is controlled by the temperature and pressure during lamination. And a method of unevenly distributing the resin on the surface at the time of flattening press, a method of unevenly distributing the resin at the time of curing, and the like.
- the softening points or melting points of the epoxy resin and the curing agent are set to the lamination temperature. It is preferable to make them close to each other, and it is preferable to perform the lamination process and the flattening process in separate steps. Hereinafter, the detail of each component contained in the said epoxy resin material is demonstrated.
- Epoxy resin material [Epoxy resin]
- Epoxy resin material The epoxy resin contained in the epoxy resin material is not particularly limited. A conventionally well-known epoxy resin can be used as this epoxy resin.
- the epoxy resin refers to an organic compound having at least one epoxy group. As for an epoxy resin, only 1 type may be used and 2 or more types may be used together.
- epoxy resin examples include bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, phenol novolac type epoxy resin, biphenyl novolac type epoxy resin, biphenol type epoxy resin, naphthalene type epoxy resin, and fluorene type epoxy resin.
- examples thereof include resins.
- the above epoxy resin is a biphenyl novolac type epoxy.
- a resin or a dicyclopentadiene type epoxy resin is preferred.
- the epoxy resin is preferably a bifunctional or higher functional epoxy resin, and more preferably a polyfunctional epoxy resin.
- the polyfunctional epoxy resin include a trifunctional alicyclic epoxy monomer (“Epolide GT301” manufactured by Union Carbide) and a trivalent epoxy resin having a triazine nucleus as a skeleton (“Denacol EX-” manufactured by Nagase ChemteX Corporation).
- the melting point or softening point of the epoxy resin is preferably 50 ° C. or higher, more preferably 65 ° C. or higher, preferably 90 ° C. or lower, more preferably 85 ° C. or lower.
- the melting point or softening point of the epoxy resin is not less than the above lower limit and not more than the above upper limit, in the precured product obtained by precuring the epoxy resin material on the lamination target member, the first small particle size silica and the second large particle The particle size silica is present in the preferred uneven distribution state described above. For this reason, when the surface of the preliminary-cured material is roughened, the surface roughness of the roughened surface of the roughened preliminary-cured material is further reduced. Furthermore, when the melting point or softening point of the epoxy resin is not less than the above lower limit and not more than the above upper limit, the adhesive strength between the cured product obtained by curing the roughened preliminary cured product and the metal layer is also increased.
- the epoxy equivalent of the epoxy resin is preferably Is 90 or more, more preferably 100 or more, preferably 1000 or less, more preferably 800 or less.
- the weight average molecular weight of the epoxy resin is preferably 5000 or less.
- the content of silica in the epoxy resin material can be increased.
- liquidity can be obtained.
- the combined use of an epoxy resin having a weight average molecular weight of 5000 or less and a phenoxy resin can suppress a decrease in melt viscosity of the B stage film that is an epoxy resin material. For this reason, when a B stage film is laminated on a board
- the curing agent contained in the epoxy resin material is not particularly limited.
- a conventionally known curing agent can be used as the curing agent.
- curing agent only 1 type may be used and 2 or more types may be used together.
- the curing agent examples include cyanate ester resin (cyanate ester curing agent), phenol compound (phenol curing agent), amine compound (amine curing agent), thiol compound (thiol curing agent), imidazole compound, phosphine compound, acid anhydride, Examples include active ester compounds and dicyandiamide.
- curing agent is cyanate ester resin or a phenol compound.
- the curing agent is preferably a cyanate ester resin, and is preferably a phenol compound.
- the curing agent preferably has a functional group capable of reacting with the epoxy group of the epoxy resin.
- the curing agent is a cyanate ester resin, A phenol compound or an active ester compound is preferred. Furthermore, from the viewpoint of imparting good insulation reliability with a curing agent, the curing agent is more preferably a cyanate ester resin.
- the cyanate ester resin is not particularly limited.
- a conventionally known cyanate ester resin can be used as the cyanate ester resin.
- As for the said cyanate ester resin only 1 type may be used and 2 or more types may be used together.
- Examples of the cyanate ester resin include novolak type cyanate resin and bisphenol type cyanate resin.
- Examples of the bisphenol type cyanate resin include bisphenol A type cyanate resin, bisphenol F type cyanate resin, and tetramethylbisphenol F type cyanate resin.
- cyanate ester resins include phenol novolac type cyanate resins (“PT-30” and “PT-60” manufactured by Lonza Japan), and prepolymers obtained by triazation of bisphenol A dicyanate into trimers. (Lonza Japan “BA230”, “BA200” and “BA3000”).
- the use of the above phenolic compound can further increase the adhesive strength between the cured product and the metal layer. Moreover, by using the phenol compound, for example, the adhesion between the cured product and copper can be further enhanced by blackening or Cz treatment of the surface of copper provided on the surface of the cured product.
- the phenol compound is not particularly limited.
- a conventionally well-known phenol compound can be used as this phenol compound.
- As for the said phenol compound only 1 type may be used and 2 or more types may be used together.
- phenol compound examples include novolak type phenol, biphenol type phenol, naphthalene type phenol, dicyclopentadiene type phenol, and aralkyl type phenol.
- phenol compounds include novolak type phenol (“TD-2091” manufactured by DIC), biphenyl novolac type phenol (“MEH-7851” manufactured by Meiwa Kasei Co., Ltd.) and aralkyl type phenol compound (“MEH manufactured by Meiwa Kasei Co., Ltd.). -7800 ").
- the phenol compound is a biphenyl novolac type phenol. Or an aralkyl-type phenol compound.
- the active ester compound is not particularly limited.
- Examples of commercially available active ester compounds include “EXB-9460S-65T” manufactured by DIC.
- the surface roughness of the roughened surface of the roughened preliminary-cured product is further reduced, the adhesive strength between the cured product and the metal layer is further increased, and good insulation reliability is imparted by the curing agent.
- curing agent contains the hardening
- the equivalent of the curing agent indicates a cyanate ester group equivalent
- the curing agent is a phenol compound
- the curing agent is an active ester compound. Is the active ester group equivalent.
- a decrease in the melt viscosity of the B-stage film, which is an epoxy resin material, can be suppressed by using a curing agent having a weight average molecular weight of 1000 or less and a phenoxy resin. For this reason, when a B stage film is laminated on a board
- total content of the epoxy resin and the curing agent in 100% by weight of the total solid content excluding the silica contained in the epoxy resin material is: Preferably it is 75 weight% or more, More preferably, it is 80 weight% or more, 100 weight% or less, Preferably it is 99 weight% or less, More preferably, it is 97 weight% or less.
- the total content of the epoxy resin and the curing agent is not less than the above lower limit and not more than the above upper limit, a better cured product can be obtained and the melt viscosity can be adjusted, so that the presence state of silica is changed.
- the B stage film can be prevented from spreading in an unintended region during the curing process. Furthermore, the dimensional change by the heat
- Total solid content B refers to the total of the epoxy resin, the curing agent, and other solid content blended as necessary. The total solid content B does not contain silica. “Solid content” refers to a non-volatile component that does not volatilize during molding or heating.
- the compounding ratio of the epoxy resin and the curing agent is not particularly limited.
- the compounding ratio of the epoxy resin and the curing agent is appropriately determined depending on the kind of the epoxy resin and the curing agent.
- the epoxy resin material contains silica.
- the average particle diameter of all silica contained in the epoxy resin material is preferably 0.1 ⁇ m or more, and preferably 0.8 ⁇ m or less.
- the median diameter (d50) value of 50% is adopted as the average particle diameter of the silica.
- the average particle size can be measured using a laser diffraction / scattering particle size distribution measuring apparatus.
- the silica contained in the epoxy resin material includes a first small particle size silica having a particle size of 0.01 ⁇ m or more and less than 0.5 ⁇ m, and a second particle size of 0.5 ⁇ m or more and 20 ⁇ m or less.
- Contains large particle size silica Said 1st small particle size silica is a silica whose particle diameter is 0.01 micrometer or more and less than 0.5 micrometer among all the silica contained in the said epoxy resin material.
- the second large particle size silica is a silica having a particle size of 0.5 ⁇ m or more and 20 ⁇ m or less among all silicas contained in the epoxy resin material.
- the particle diameter in the first small particle diameter silica and the second large particle diameter silica means a diameter when the silica is a true sphere, and means a maximum diameter when the silica is other than a true sphere. To do.
- silica is satisfactorily present in the pre-cured product before the roughening treatment in which the epoxy resin material is pre-cured.
- the surface of the preliminary-cured product is roughened, the surface roughness of the roughened pre-cured product can be reduced, and the roughened preliminary-cured product is further cured.
- the adhesive strength between the object and the metal layer can be increased.
- the silica is more preferably fused silica. By using fused silica, the surface roughness of the roughened surface of the roughened preliminary-cured product can be effectively reduced.
- the shape of silica is preferably substantially spherical.
- the silica contained in the epoxy resin material, the first small particle size silica, and the second large particle size silica are each preferably surface-treated, and surface-treated with a coupling agent. It is more preferable. As a result, the surface roughness of the roughened surface of the roughened precured material is further reduced, the adhesive strength between the hardened material and the metal layer is further increased, and the inter-wiring insulation reliability is further improved. And interlayer insulation reliability can be imparted.
- the coupling agent examples include silane coupling agents, titanate coupling agents, and aluminum coupling agents.
- the coupling agent used for the surface treatment is epoxy silane, amino silane, vinyl silane, mercapto silane, sulfur silane, N-phenyl-3-aminopropyl silane, (meth) acrylic acid silane, isocyanate silane, ureido silane, or the like. preferable.
- the epoxy resin material preferably includes the first small particle size silica and the second large particle size silica in a weight ratio of 5:95 to 50:50, preferably 10:90 to 30:70. More preferably.
- the epoxy resin material contains the first small particle size silica and the second large particle size silica in the weight ratio, the surface roughness of the roughened surface of the roughened preliminary-cured product is further increased. Further, the adhesive strength between the cured product and the metal layer is further increased.
- the content of silica is not particularly limited. All of the above silica (first small particle size silica and second large particle size) in 100% by weight of the total solid content (hereinafter sometimes abbreviated as total solid content A) contained in the epoxy resin material.
- the content of (including silica) is preferably 30% by weight or more, more preferably 40% by weight or more, still more preferably 50% by weight or more, preferably 85% by weight or less, and more preferably 80% by weight or less.
- the content of the silica is not less than the above lower limit and not more than the above upper limit, the linear thermal expansion coefficient of the resin is suppressed, the difference in expansion coefficient from copper and silicon is alleviated, the thermal shock reliability is improved, and the warpage is suppressed.
- Total solid content A refers to the sum of the epoxy resin, the curing agent, silica, and the solid content blended as necessary.
- Solid content refers to a non-volatile component that does not volatilize during molding or heating.
- the total content of the first small particle size silica and the second large particle size silica is preferably 60% by weight or more, more preferably 80% by weight, out of all the silica content of 100% by weight. More preferably, it is 90% by weight or more, particularly preferably 95% by weight or more and 100% by weight or less. All the silicas may be the first small particle size silica and the second large particle size silica.
- the said epoxy resin material may contain the hardening accelerator as needed.
- the curing rate can be further increased.
- the crosslinked structure of the cured product can be made uniform, the number of unreacted functional groups can be reduced, and as a result, the crosslinking density can be increased.
- the curing accelerator is not particularly limited.
- As the curing accelerator a conventionally known curing accelerator can be used.
- As for the said hardening accelerator only 1 type may be used and 2 or more types may be used together.
- curing accelerator examples include imidazole compounds, phosphorus compounds, amine compounds, and organometallic compounds.
- imidazole compound examples include 2-undecylimidazole, 2-heptadecylimidazole, 2-methylimidazole, 2-ethyl-4-methylimidazole, 2-phenylimidazole, 2-phenyl-4-methylimidazole, 1-benzyl- 2-methylimidazole, 1-benzyl-2-phenylimidazole, 1,2-dimethylimidazole, 1-cyanoethyl-2-methylimidazole, 1-cyanoethyl-2-ethyl-4-methylimidazole, 1-cyanoethyl-2-un Decylimidazole, 1-cyanoethyl-2-phenylimidazole, 1-cyanoethyl-2-undecylimidazolium trimellitate, 1-cyanoethyl-2-phenylimidazolium trimellitate, 2,4-diamino-6- [2 ' -Mechi Imidazolyl- (1 ′)]-
- Examples of the phosphorus compound include triphenylphosphine.
- Examples of the amine compound include diethylamine, triethylamine, diethylenetetramine, triethylenetetramine and 4,4-dimethylaminopyridine.
- organometallic compound examples include zinc naphthenate, cobalt naphthenate, tin octylate, cobalt octylate, bisacetylacetonate cobalt (II), and trisacetylacetonate cobalt (III).
- the curing accelerator is particularly preferably an imidazole compound.
- the content of the curing accelerator is not particularly limited. From the viewpoint of efficiently curing the epoxy resin material, the content of the curing accelerator in the total solid content B of 100% by weight is preferably 0.01% by weight or more, and preferably 3% by weight or less.
- the total solid content B includes the curing accelerator.
- the epoxy resin material preferably contains a thermoplastic resin.
- thermoplastic resin By using the thermoplastic resin, the followability to the unevenness of the circuit of the epoxy resin material is increased, the surface roughness of the roughened surface of the roughened preliminary-cured material is further reduced, and further roughened. The surface roughness can be made even more uniform.
- thermoplastic resin examples include phenoxy resin and polyvinyl acetal resin. From the viewpoint of unevenly distributing the silica, further reducing the surface roughness of the roughened surface of the roughened preliminary-cured product, and further increasing the adhesive strength between the cured product and the metal layer,
- the plastic resin is preferably a phenoxy resin.
- phenoxy resins examples include phenoxy resins having a skeleton such as a bisphenol A skeleton, a bisphenol F skeleton, a bisphenol S skeleton, a biphenyl skeleton, a novolac skeleton, and a naphthalene skeleton.
- the phenoxy resin Since the adhesive strength between the cured product and the metal layer can be increased when the surface of the precured product is roughened and then plated to form a metal layer, the phenoxy resin has a biphenyl skeleton. It is preferable to have a biphenol skeleton.
- phenoxy resin examples include, for example, “YP50”, “YP55” and “YP70” manufactured by Toto Kasei Co., Ltd., and “1256B40”, “4250”, “4256H40”, “4275” manufactured by Mitsubishi Chemical Corporation, “YX6954BH30”, “YX8100BH30”, “YL7600DMAcH25”, “YL7213BH30”, and the like.
- the weight average molecular weight of the phenoxy resin is preferably 5000 or more, and preferably 100,000 or less.
- the content of the thermoplastic resin is not particularly limited.
- the content of the thermoplastic resin in the total solid content B of 100% by weight is preferably 0.1% by weight or more, more preferably 0% 0.5% by weight or more, more preferably 1% by weight or more, preferably 40% by weight or less, more preferably 30% by weight or less, still more preferably 20% by weight or less, and particularly preferably 15% by weight or less.
- the content of the thermoplastic resin is not less than the above lower limit and not more than the above upper limit, the dimensional change due to heat of the cured product is further reduced.
- corrugation of the circuit board of an epoxy resin material becomes it favorable that content of the said thermoplastic resin is below the said upper limit.
- the total solid content B includes the thermoplastic resin.
- epoxy resin materials include coupling agents, colorants, antioxidants, UV degradation inhibitors, antifoaming agents, and thickeners.
- a thixotropic agent and other resins other than those mentioned above may be added.
- Examples of the coupling agent include silane coupling agents, titanium coupling agents, and aluminum coupling agents.
- Examples of the silane coupling agent include amino silane, imidazole silane, vinyl silane, phenylamino silane, and epoxy silane.
- the content of the coupling agent is not particularly limited.
- the content of the coupling agent is preferably 0.01% by weight or more and 5% by weight or less.
- the other resin examples include polyphenylene ether resin, divinyl benzyl ether resin, polyarylate resin, diallyl phthalate resin, polyimide resin, benzoxazine resin, benzoxazole resin, bismaleimide resin, and acrylate resin.
- the total solid content B includes the coupling agent.
- the epoxy resin material may contain a solvent.
- the solvent include acetone, methanol, ethanol, butanol, 2-propanol, 2-methoxyethanol, 2-ethoxyethanol, 1-methoxy-2-propanol, 2-acetoxy-1-methoxypropane, toluene, xylene, methyl ethyl ketone, Examples thereof include N, N-dimethylformamide, methyl isobutyl ketone, N-methyl-pyrrolidone, n-hexane, cyclohexane, cyclohexanone and naphtha which is a mixture.
- the said solvent only 1 type may be used and 2 or more types may be used together.
- a resin composition containing a solvent can be used as a varnish.
- the viscosity of the varnish can be adjusted by adjusting the solvent content according to the application.
- the content of the solvent is preferably 10 parts by weight or more and preferably 1000 parts by weight or less with respect to 100 parts by weight of the total solid content A.
- the epoxy resin material may be a resin composition or a B-stage film in which the resin composition is formed into a film.
- a B-stage film can be obtained by forming the resin composition into a film.
- an extrusion molding method is used in which the resin composition is melt-kneaded using an extruder, extruded, and then formed into a film using a T-die or a circular die.
- examples thereof include a casting molding method in which the resin composition is dissolved or dispersed in a solvent such as an organic solvent and then cast into a film, and other conventionally known film molding methods.
- the extrusion molding method or the casting molding method is preferable because the thickness can be reduced.
- the film includes a sheet.
- a B-stage film can be obtained by forming the resin composition into a film and drying it by heating at 90 to 200 ° C. for 10 to 180 minutes, for example, to such an extent that curing by heat does not proceed excessively.
- the film-like resin composition that can be obtained by the drying process as described above is referred to as a B-stage film.
- the B-stage film is a semi-cured product in a semi-cured state.
- the semi-cured product is not completely cured and curing can proceed further.
- the resin composition is suitably used for forming a laminated film including a base material and a B stage film laminated on one surface of the base material.
- a B-stage film of a laminated film is formed from the resin composition.
- Examples of the base material of the laminated film include polyester resin films such as polyethylene terephthalate film and polybutylene terephthalate film, olefin resin films such as polyethylene film and polypropylene film, polyimide resin film, metal foil such as copper foil and aluminum foil, and the like. Can be mentioned.
- the surface of the base material may be subjected to a release treatment as necessary.
- the thickness of the layer formed of the epoxy resin material is preferably equal to or greater than the thickness of the conductor layer that forms the circuit.
- the thickness of the layer formed of the epoxy resin material is preferably 5 ⁇ m or more, more preferably 6 ⁇ m or more, further preferably 10 ⁇ m or more, preferably 200 ⁇ m or less, more preferably 65 ⁇ m or less, and even more preferably 50 ⁇ m or less.
- the epoxy resin material is a B-stage film, and after the B-stage film is laminated on the lamination target member, the B-stage film is cured to obtain a precured product.
- the laminating temperature is preferably 55 ° C. or higher, more preferably 65 ° C. or higher, preferably 130 ° C. or lower, more preferably 120 ° C. or lower.
- the laminating pressure is preferably 0.5 MPa or more, more preferably 0.8 MPa or more, preferably 1.5 MPa or less, more preferably 1.2 MPa or less.
- the melt viscosity near the lamination temperature is low.
- the melt viscosity of a B stage film composed mainly of a phenoxy resin, a liquid epoxy resin, and a cyanate ester curing agent having a low melt viscosity is 150 Pa ⁇ s or less, and the fluidity of the resin component is increased.
- the first small particle size silica having a relatively small particle size is present in the upper layer portion of the precured product, and the second large particle size silica having a relatively large particle size is present in the lower layer portion.
- the surface of the precured product is roughened, the surface roughness of the roughened surface of the roughened precured product is reduced. Furthermore, the adhesive strength between the cured product and the metal layer is also increased.
- the method of laminating by laminating the B stage film may be a known method, and is not particularly limited.
- the B-stage film is laminated on a circuit board, preferably the laminated film is laminated from the B-stage film side, and pressurized using a pressure laminator. At this time, it may be heated or not heated.
- a parallel plate press type heat press the lamination target member and the B stage film or laminated film are heated and pressurized.
- the pre-cured product may be formed by pre-curing the B-stage film by heating and pressing. The heating temperature and the pressurizing pressure can be appropriately changed and are not particularly limited.
- the roll temperature is set to 20 to 120 ° C. under the conditions of a roll diameter of 60 mm and a roll peripheral speed of 0.1 to 10 m / min. While pressing with a pressure of 6 MPa, the B-stage film is laminated on the circuit board, or the laminated film is laminated on the lamination target member from the B-stage film side.
- the B stage film can be precured by heat treatment to obtain a precured product.
- the base material of the laminated film may be removed before forming the precured product, or may be removed after forming the precured product. After laminating under such conditions, by performing a roughening treatment, fine irregularities can be formed on the surface of the roughened preliminary-cured product.
- the precured product is preferably cured at a temperature 10 to 60 ° C. lower than the glass transition temperature of the final cured product.
- the surface smoothness of the precured product may be increased by performing a parallel plate heating press after roll lamination.
- a laminate of a circuit board and a B stage film or a laminated film may be heated and pressurized with a stainless steel plate having a thickness of 1 mm using a parallel plate heating press.
- a commercially available apparatus can be used as a pressurizing laminator such as a hot pressurizing roll laminator and a press machine such as a parallel plate heating press.
- Lamination with a roll laminator is preferably performed in a vacuum state.
- the material of the roll of the roll laminator can be appropriately selected from a rubber roll having a soft surface and a metal roll having a hard surface.
- the material of the flat plate of the parallel plate heating press is a hard metal.
- a release function is provided between a roll laminator roll and the above-described lamination target member, B-stage film or laminated film, or between a flat plate of a parallel plate heating press and the above-mentioned lamination target member, B-stage film or laminated film.
- a roll laminator roll and the above-described lamination target member, B-stage film or laminated film, or between a flat plate of a parallel plate heating press and the above-mentioned lamination target member, B-stage film or laminated film.
- an aluminum foil, a copper foil, a polyester resin film, a fluororesin film, or the like may be used.
- a flexible material such as a rubber sheet may be used.
- the pre-cured product is formed by laminating the laminated film on the circuit board from the B-stage film side, pressurizing it using a roll laminator, and then heating and heating using a parallel plate press type hot press machine. It is preferable to be a step of forming a precured product by pressing. In addition, the step of forming the precured product is performed by laminating the laminated film on the lamination target member from the B stage film side, pressurizing it using a roll laminator, and then using a parallel plate press type hot press machine. This is a process of heating and pressurizing to form a pre-cured product.
- the roughened preliminary-cured product according to the present invention is obtained by subjecting the first main surface of the preliminary-cured product to a roughening treatment.
- a roughening treatment In order to form fine irregularities on the surface of the preliminary-cured product, it is preferable that the rough-cured preliminary-cured product is subjected to a swelling treatment before the roughening treatment.
- the roughened precured product is preferably subjected to a swelling treatment after the precuring and before the roughening treatment.
- the pre-cured product may not necessarily be subjected to the swelling treatment.
- the laminate according to the present invention includes a cured product obtained by curing a roughened preliminary cured product obtained by roughening the first main surface of the preliminary cured product, and a roughened treatment of the cured product. And a metal layer laminated on the surface.
- the adhesive strength between the cured product and the metal layer is preferably 0.39 N / mm or more.
- the metal layer is preferably a copper layer, and more preferably a copper plating layer.
- the said epoxy resin material is used suitably in order to form an insulating layer in a printed wiring board.
- the printed wiring board can be obtained, for example, by heat-pressing the B stage film using a B stage film formed of the resin composition.
- a metal foil can be laminated on one side or both sides of the B-stage film.
- the method for laminating the B-stage film and the metal foil is not particularly limited, and a known method can be used.
- the B-stage film can be laminated on the metal foil using an apparatus such as a parallel plate press or a roll laminator while applying pressure while heating or without heating.
- the said epoxy resin material is used suitably in order to obtain a copper clad laminated board.
- An example of the copper-clad laminate is a copper-clad laminate comprising a copper foil and a B stage film laminated on one surface of the copper foil.
- the B-stage film of this copper-clad laminate is formed from the above epoxy resin material. By pre-curing the B-stage film, a copper-clad laminate having a pre-cured product can be obtained.
- the thickness of the copper foil of the copper-clad laminate is not particularly limited.
- the thickness of the copper foil is preferably in the range of 1 to 50 ⁇ m.
- the said copper foil has a fine unevenness
- the method for forming the unevenness is not particularly limited. Examples of the method for forming the unevenness include a formation method by treatment using a known chemical solution.
- the precured product is preferably used for obtaining a multilayer substrate.
- the multilayer substrate there is a circuit substrate including a circuit substrate and a cured product layer laminated on the surface of the circuit substrate.
- the cured product layer of the multilayer substrate is formed by roughening the precured product and then curing the roughened precured product. It is preferable that the said hardened
- the surface of the cured product layer opposite to the surface on which the circuit substrate is laminated is roughened.
- the roughening method can be any conventionally known roughening method and is not particularly limited.
- the surface of the cured product layer may be swelled before the roughening treatment.
- the multilayer substrate preferably further includes a copper plating layer laminated on the roughened surface of the cured product layer.
- a circuit board, a cured product layer laminated on the surface of the circuit board, and a surface of the cured product layer opposite to the surface on which the circuit board is laminated are provided.
- a circuit board provided with the laminated copper foil is mentioned.
- the copper stage and a B stage film laminated on one surface of the copper foil the B stage film is pre-cured, roughened, and It is preferably formed by a curing treatment.
- the copper foil is etched and is a copper circuit.
- the multilayer board is a circuit board including a circuit board and a plurality of cured product layers laminated on the surface of the circuit board. At least one of the plurality of cured product layers is formed of the preliminary-cured product. It is preferable that the multilayer substrate further includes a circuit laminated on at least one surface of the cured product layer formed by curing the epoxy resin material.
- FIG. 2 schematically shows a laminate using a pre-cured product according to an embodiment of the present invention in a partially cutaway front sectional view.
- a plurality of cured product layers 13 to 16 are laminated on the upper surface 12 a of the circuit board 12.
- the cured product layers 13 to 16 are insulating layers.
- a metal layer 17 is formed in a partial region of the upper surface 12 a of the circuit board 12.
- the cured product layers 13 to 15 other than the cured product layer 16 located on the outer surface opposite to the circuit board 12 side include a metal layer in a partial region of the upper surface. 17 is formed.
- the metal layer 17 is a circuit.
- Metal layers 17 are respectively disposed between the circuit board 12 and the cured product layer 13 and between the laminated cured product layers 13 to 16.
- the lower metal layer 17 and the upper metal layer 17 are connected to each other by at least one of via hole connection and through hole connection (not shown).
- the cured product layers 13 to 16 are formed by curing the epoxy resin material according to the present invention.
- FIG. 2 for convenience of illustration, silica and holes from which silica has been removed in the cured product layers 13 to 16 are not shown.
- the metal layer 17 reaches the inside of the fine hole.
- the width direction dimension (L) of the metal layer 17 and the width direction dimension (S) of the part in which the metal layer 17 is not formed can be made small.
- favorable insulation reliability is provided between the upper metal layer and lower metal layer which are not connected by the via-hole connection and through-hole connection which are not shown in figure.
- swelling treatment and roughening treatment As a method for the swelling treatment, for example, a method of treating a precured product with an aqueous solution or an organic solvent dispersion solution of a compound mainly composed of ethylene glycol or the like is used.
- the swelling liquid used for the swelling treatment generally contains an alkali as a pH adjuster or the like.
- the swelling liquid preferably contains sodium hydroxide.
- the swelling treatment is carried out by treating the precured material with a 40 wt% ethylene glycol aqueous solution at a treatment temperature of 30 to 85 ° C. for 1 to 30 minutes.
- the swelling treatment temperature is preferably in the range of 50 to 85 ° C. When the temperature of the swelling treatment is too low, it takes a long time for the swelling treatment, and the roughened adhesive strength between the cured product and the metal layer tends to be low.
- a chemical oxidant such as a manganese compound, a chromium compound, or a persulfate compound is used.
- chemical oxidizers are used as an aqueous solution or an organic solvent dispersion after water or an organic solvent is added.
- the roughening liquid used for the roughening treatment generally contains an alkali as a pH adjuster or the like.
- the roughening solution preferably contains sodium hydroxide.
- Examples of the manganese compound include potassium permanganate and sodium permanganate.
- Examples of the chromium compound include potassium dichromate and anhydrous potassium chromate.
- Examples of the persulfate compound include sodium persulfate, potassium persulfate, and ammonium persulfate.
- the method for the roughening treatment is not particularly limited.
- As the roughening treatment method for example, 30 to 90 g / L permanganic acid or permanganate solution and 30 to 90 g / L sodium hydroxide solution are used, and the treatment temperature is 30 to 85 ° C. and 1 to 30 minutes.
- a method of treating a precured product once or twice under conditions is preferable.
- the temperature of the roughening treatment is preferably in the range of 50 to 85 ° C.
- the arithmetic average roughness Ra of the roughened surface of the roughened preliminary cured product is preferably 50 nm or more, more preferably 350 nm or less, and further preferably 300 nm or less.
- the adhesive strength between the cured product and the metal layer can be further increased, and further finer wiring can be formed on the surface of the cured product layer.
- a through-hole may be formed in the said precured material or the said hardened
- a via or a through hole is formed as a through hole.
- the via can be formed by irradiation with a laser such as a CO 2 laser.
- the diameter of the via is not particularly limited, but is about 60 to 80 ⁇ m. Due to the formation of the through hole, a smear that is a resin residue derived from the resin component contained in the cured product layer is often formed at the bottom of the via.
- the surface of the precured product is preferably desmeared.
- the desmear process may also serve as a roughening process.
- the desmear process is sometimes called a roughening process.
- a chemical oxidizing agent such as a manganese compound, a chromium compound, or a persulfate compound is used in the same manner as the roughening treatment.
- chemical oxidizers are used as an aqueous solution or an organic solvent dispersion after water or an organic solvent is added.
- the desmear treatment liquid used for the desmear treatment generally contains an alkali.
- the desmear treatment liquid preferably contains sodium hydroxide.
- the above desmear treatment method is not particularly limited.
- As the desmear treatment method for example, using a 30 to 90 g / L permanganate or permanganate solution and a 30 to 90 g / L sodium hydroxide solution, a treatment temperature of 30 to 85 ° C. and a condition of 1 to 30 minutes A method of treating a precured product or a cured product once or twice is preferable.
- the temperature of the desmear treatment is preferably in the range of 50 to 85 ° C.
- Epoxy resin Epoxy resin 1 (bisphenol F type epoxy resin, “830-S” manufactured by DIC, liquid at room temperature (23 ° C.))
- Epoxy resin 2 bisphenol F type epoxy resin, “830-S” manufactured by DIC, liquid at room temperature (23 ° C.)
- Epoxy resin 2 bisphenyl novolac type epoxy resin, “NC3000H” manufactured by Nippon Kayaku Co., Ltd., solid at normal temperature (23 ° C.), softening point 70 ° C.
- Epoxy resin 3 dicyclopentadiene type epoxy resin, DIC “HP-7200”, solid at normal temperature (23 ° C.), softening point 61 ° C.
- Active ester compound solution (“EXB-9460S-65T” manufactured by DIC, including active ester equivalent 223, active ester compound (solid content) 65 wt% and toluene 35 wt%)
- Cyanate ester resin solution (cyanate ester curing agent, prepolymer obtained by triazine conversion of bisphenol A dicyanate, Lonza Japan "BA230S-75", cyanate equivalent 230, cyanate ester resin (solid content) 75 weight And 25% by weight of methyl ethyl ketone)
- Phenol compound (phenol curing agent, “MEH7851-4H” manufactured by Meiwa Kasei Co., Ltd., phenolic hydroxyl group equivalent 242)
- Phenolic compound solution including phenolic curing agent having aminotriazine skeleton, “LA3018-50P” manufactured by DIC, phenolic hydroxyl group equivalent 151, phenolic compound (solid content) 50% by weight and propylene glycol monomethyl ether 50% by weight)
- Imidazole Compound 1 (2-ethyl-4-methylimidazole, “2E4MZ” manufactured by Shikoku Kasei Co., Ltd.)
- Imidazole Compound 2 (2-Phenyl-4-methyl-5-hydroxymethylimidazole, “2P4MHZ-PW” manufactured by Shikoku Kasei Co., Ltd.)
- First small particle size silica-containing slurry A The first small particle size silica a (silica (“YA050C-MMK” manufactured by Admatechs, average particle size 0.05 ⁇ m) is converted into phenylsilane (phenyltrimethoxysilane, “KBM-103” manufactured by Shin-Etsu Chemical Co., Ltd.)). 1st small particle size silica-containing slurry containing 65% by weight and 35% by weight methyl ethyl ketone
- First small particle size silica-containing slurry B First small particle size silica b (Silica (“UFP-30” manufactured by Denki Kagaku Kogyo Co., Ltd., average particle size 0.1 ⁇ m) surface-treated with imidazole silane (“IM-1000” manufactured by Nikko Metal Co., Ltd.)) ) And 30% by weight of N, N-dimethylformamide and a first small particle size silica-containing slurry
- Slurry X containing both the first small particle size silica and the second large particle size silica The first small particle size silica and the second large particle size silica x (silica (“SO-C2” manufactured by Admatechs Co., Ltd., average particle size: 0.5 ⁇ m) are combined with epoxysilane (3-glycidoxypropyltrimethoxy). Silane, surface treated with "KBM-403" manufactured by Shin-Etsu Chemical Co., Ltd.)) both first small particle size silica and second large particle size silica containing 70% by weight and 30% by weight methyl ethyl ketone Slurry containing
- Slurry X has a wide particle size distribution and contains silica having a particle size of 0.01 ⁇ m to 20 ⁇ m.
- the content of the first small particle size silica is 50% by volume in the total of 100% by volume of the first small particle size silica and the second large particle size silica, and the second large particle size silica x The content of is 50% by volume.
- Second large particle size silica-containing slurry Y Second large particle size silica y (Silica (“UF-320” manufactured by Tokuyama, average particle size 3.5 ⁇ m, coarse cut point 20 ⁇ m) is surface treated with imidazole silane (“IM-1000” manufactured by Nikko Metal Co., Ltd.)). The second large particle size silica-containing slurry containing 50% by weight and 50% by weight of N, N-dimethylformamide
- Phenoxy resin Mitsubishi Chemical "YX6954BH30"
- Example 1 Production of Resin Composition and Laminate Film
- resin 1 bisphenol F type epoxy resin, “830-S” manufactured by DIC
- epoxy resin 2 bisphenol F type epoxy resin, “830-S” manufactured by DIC
- epoxy resin 2 bisphenol F type epoxy resin, “830-S” manufactured by DIC
- epoxy resin 2 bisphenyl novolac type epoxy resin, “NC3000H” manufactured by Nippon Kayaku Co., Ltd.
- cyanate ester curing agent “BA230S-75” manufactured by Lonza Japan
- imidazole compound 1 (“2E4MZ” manufactured by Shikoku Kasei Co., Ltd.
- phenoxy resin Mitsubishi Chemical
- a release-treated transparent polyethylene terephthalate (PET) film (“PET5011 550” manufactured by Lintec Corporation, thickness 50 ⁇ m) was prepared.
- the obtained resin composition was applied onto the release-treated surface of this PET film using an applicator so that the thickness after drying was 50 ⁇ m.
- it was dried in a gear oven at 100 ° C. for 2 minutes to prepare a laminated film of an uncured resin sheet (B stage film) having a length of 200 mm ⁇ width of 200 mm ⁇ thickness of 50 ⁇ m and a polyethylene terephthalate film.
- B stage film the uncured resin sheet having a length of 200 mm ⁇ width of 200 mm ⁇ thickness of 50 ⁇ m and a polyethylene terephthalate film.
- the polyethylene terephthalate film was peeled from the laminated film, and the uncured product of the resin sheet was heated in a gear oven at 180 ° C. for 80 minutes to prepare a precured product of the resin sheet.
- Example 2 to 10 and Comparative Examples 1 to 2 Resin composition, laminated film of PET film and B stage film, and glass epoxy substrate and spare, in the same manner as in Example 1 except that the type and amount of materials used were changed as shown in Table 1 below. A laminate with a cured product was obtained.
- the first small particle size silica is not unevenly distributed so that a large amount exists on the first main surface side, or the second large particle size silica is on the second main surface side. Not ubiquitous as there are many
- the first small particle size silica is not unevenly distributed so that there are many on the first main surface side, and the second large particle size silica is on the second main surface side. Are not ubiquitous as there are many
- Adhesive strength peel strength
- arithmetic average roughness Ra Preparation of cured product B
- the pre-cured product in the laminate A was subjected to the following (a) swelling treatment, then the following (b) permanganate treatment, that is, roughening treatment, and further the following (c) copper plating treatment.
- (C) Copper plating treatment Next, electroless copper plating and electrolytic copper plating treatment were performed on the roughened preliminary-cured material subjected to the roughening treatment on the glass epoxy substrate by the following procedure.
- the surface of the roughened preliminary-cured material was treated with an alkaline cleaner (cleaner securigant 902) at 55 ° C. for 5 minutes and degreased and washed. After washing, the roughened precured product was treated with a 23 ° C. pre-dip solution (Pre-dip Neogant B) for 2 minutes. Thereafter, the roughened preliminary-cured product was treated with an activator solution (activator Neogant 834) at 40 ° C. for 5 minutes to attach a palladium catalyst. Next, the roughened preliminary-cured material was treated for 5 minutes with a reducing solution (reducer Neogant WA) at 30 ° C.
- an alkaline cleaner cleaning securigant 902
- Pre-dip Neogant B pre-dip solution
- activator Neogant 834 activator solution
- the roughened preliminary-cured material was treated for 5 minutes with a reducing solution (reducer Neogant WA) at 30 ° C.
- the above roughened preliminary-cured product is put in a chemical copper solution (basic print Gantt MSK-DK, copper print Gantt MSK, stabilizer print Gantt MSK), and electroless plating is performed until the plating thickness reaches about 0.5 ⁇ m. did.
- a chemical copper solution basic print Gantt MSK-DK, copper print Gantt MSK, stabilizer print Gantt MSK
- electroless plating is performed until the plating thickness reaches about 0.5 ⁇ m. did.
- annealing was performed at a temperature of 120 ° C. for 30 minutes in order to remove the remaining hydrogen gas. All the processes up to the electroless plating process were performed with a treatment liquid of 1 L on a beaker scale and while the cured product was rocked.
- total solid content A indicates the total solid content contained in the epoxy resin material
- ⁇ indicates that no evaluation was made.
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- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
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Abstract
Description
以下、上記エポキシ樹脂材料に含まれている各成分の詳細を説明する。
[エポキシ樹脂]
上記エポキシ樹脂材料に含まれているエポキシ樹脂は特に限定されない。該エポキシ樹脂として、従来公知のエポキシ樹脂を使用可能である。該エポキシ樹脂は、少なくとも1個のエポキシ基を有する有機化合物をいう。エポキシ樹脂は、1種のみが用いられてもよく、2種以上が併用されてもよい。
上記エポキシ樹脂材料に含まれている硬化剤は特に限定されない。該硬化剤として、従来公知の硬化剤を使用可能である。硬化剤は1種のみが用いられてもよく、2種以上が併用されてもよい。
上記エポキシ樹脂材料はシリカを含む。
上記エポキシ樹脂材料は、必要に応じて硬化促進剤を含んでいてもよい。硬化促進剤の使用により、硬化速度をより一層速くすることができる。エポキシ樹脂材料を速やかに硬化させることで、硬化物の架橋構造を均一にすることができると共に、未反応の官能基数を減らすことができ、結果的に架橋密度を高くすることができる。該硬化促進剤は特に限定されない。該硬化促進剤として、従来公知の硬化促進剤を使用可能である。上記硬化促進剤は、1種のみが用いられてもよく、2種以上が併用されてもよい。
上記エポキシ樹脂材料は、樹脂組成物であってもよく、該樹脂組成物がフィルム状に成形されたBステージフィルムであってもよい。上記樹脂組成物をフィルム状に成形することにより、Bステージフィルムを得ることができる。
上記エポキシ樹脂材料は、プリント配線板において絶縁層を形成するために好適に用いられる。
上記エポキシ樹脂材料は、銅張り積層板を得るために好適に用いられる。上記銅張り積層板の一例として、銅箔と、該銅箔の一方の表面に積層されたBステージフィルムとを備える銅張り積層板が挙げられる。この銅張り積層板のBステージフィルムが、上記エポキシ樹脂材料により形成される。該Bステージフィルムを予備硬化させることにより、予備硬化物を有する銅張り積層板を得ることができる。
上記膨潤処理の方法としては、例えば、エチレングリコールなどを主成分とする化合物の水溶液又は有機溶媒分散溶液などにより、予備硬化物を処理する方法が用いられる。膨潤処理に用いる膨潤液は、一般にpH調整剤などとして、アルカリを含む。膨潤液は、水酸化ナトリウムを含むことが好ましい。具体的には、例えば、上記膨潤処理は、40重量%エチレングリコール水溶液等を用いて、処理温度30~85℃で1~30分間、予備硬化物を処理することにより行なわれる。上記膨潤処理の温度は50~85℃の範囲内であることが好ましい。上記膨潤処理の温度が低すぎると、膨潤処理に長時間を要し、更に硬化物と金属層との粗化接着強度が低くなる傾向がある。
また、上記予備硬化物又は上記硬化物に、貫通孔が形成されることがある。上記多層基板などでは、貫通孔として、ビア又はスルーホール等が形成される。例えば、ビアは、CO2レーザー等のレーザーの照射により形成できる。ビアの直径は特に限定されないが、60~80μm程度である。上記貫通孔の形成により、ビア内の底部には、硬化物層に含まれている樹脂成分に由来する樹脂の残渣であるスミアが形成されることが多い。
エポキシ樹脂1(ビスフェノールF型エポキシ樹脂、DIC社製「830-S」、常温(23℃)で液状)
エポキシ樹脂2(ビフェニルノボラック型エポキシ樹脂、日本化薬社製「NC3000H」、常温(23℃)で固形、軟化点70℃)
エポキシ樹脂3(ジシクロペンタジエン型エポキシ樹脂、DIC製「HP-7200」、常温(23℃)で固形、軟化点61℃)
活性エステル化合物溶液(DIC社製「EXB-9460S-65T」、活性エステル当量223、活性エステル化合物(固形分)65重量%とトルエン35重量%とを含む)
イミダゾール化合物1(2-エチル-4-メチルイミダゾール、四国化成社製「2E4MZ」)
イミダゾール化合物2(2-フェニル-4-メチル-5-ヒドロキシメチルイミダゾール、四国化成社製「2P4MHZ-PW」)
第1の小粒径シリカ含有スラリーA:
第1の小粒径シリカa(シリカ(アドマテックス社製「YA050C-MMK」、平均粒子径0.05μm)が、フェニルシラン(フェニルトリメトキシシラン、信越化学工業社製「KBM-103」)により、表面処理されたもの)65重量%と、メチルエチルケトン35重量%とを含む第1の小粒径シリカ含有スラリー
第1の小粒径シリカb(シリカ(電気化学工業社製「UFP-30」、平均粒子径0.1μm)が、イミダゾールシラン(日鉱金属社製「IM-1000」)により表面処理されたもの)を30重量%と、N,N-ジメチルホルムアミドを70重量%とを含む第1の小粒径シリカ含有スラリー
第1の小粒径シリカと第2の大粒径シリカx(シリカ(アドマテックス社製「SO-C2」、平均粒子径0.5μm)とが、エポキシシラン(3-グリシドキシプロピルトリメトキシシラン、信越化学工業社製「KBM-403」)により表面処理されたもの)70重量%と、メチルエチルケトン30重量%とを含む第1の小粒径シリカと第2の大粒径シリカとの双方を含有するスラリー
第2の大粒径シリカy(シリカ(トクヤマ製「UF-320」、平均粒子径3.5μm、粗粒カットポイント20μm)が、イミダゾールシラン(日鉱金属社製「IM-1000」)により表面処理されたもの)50重量%と、N,N-ジメチルホルムアミド50重量%とを含む第2の大粒径シリカ含有スラリー
フェノキシ樹脂(三菱化学社製「YX6954BH30」)
(1)樹脂組成物及び積層フィルムの作製
第1の小粒径シリカ含有スラリーAを固形分で5重量部と、第2の大粒径シリカ含有スラリーYを固形分で55重量部と、エポキシ樹脂1(ビスフェノールF型エポキシ樹脂、DIC社製「830-S」)10重量部と、エポキシ樹脂2(ビフェニルノボラック型エポキシ樹脂、日本化薬社製「NC3000H」)10重量部と、シアネートエステル樹脂溶液(シアネートエステル硬化剤、ロンザジャパン社製「BA230S-75」)を固形分で10重量部と、イミダゾール化合物1(四国化成社製「2E4MZ」)0.5重量部と、フェノキシ樹脂(三菱化学社製「YX6954BH30」)9.5重量部とを配合し、撹拌機を用いて1200rpmで1時間撹拌し、樹脂組成物を得た。
離型処理された透明なポリエチレンテレフタレート(PET)フィルム(リンテック社製「PET5011 550」、厚み50μm)を用意した。このPETフィルムの離型処理面上にアプリケーターを用いて、乾燥後の厚みが50μmとなるように、得られた樹脂組成物を塗工した。次に、100℃のギアオーブン内で2分間乾燥して、縦200mm×横200mm×厚み50μmの樹脂シートの未硬化物(Bステージフィルム)とポリエチレンテレフタレートフィルムとの積層フィルムを作製した。次に、積層フィルムからポリエチレンテレフタレートフィルムを剥がし、樹脂シートの未硬化物を180℃のギアオーブン内で80分間加熱して、樹脂シートの予備硬化物を作製した。
得られた積層フィルムを、Bステージフィルムが、ガラスエポキシ基板(FR-4、品番「CS-3665」、利昌工業社製)側となるようにセットした。積層フィルムとガラスエポキシ基板とを、100℃に加熱した平行平板プレス機を用いて、減圧下で0.5MPaで60分間加圧加熱し、樹脂シートの予備硬化物を含む積層体を得た。その後、ポリエチレンテレフタレートフィルムを剥がし、ガラスエポキシ基板と予備硬化物との積層体Aを得た。得られた予備硬化物は、ガラスエポキシ基板側に第2の主面を有し、ガラスエポキシ基板とは反対側に粗化処理される面である第1の主面を有する。
使用した材料の種類及び配合量を下記の表1に示すように変更したこと以外は実施例1と同様にして、樹脂組成物、PETフィルムとBステージフィルムとの積層フィルム並びにガラスエポキシ基板と予備硬化物との積層体を得た。
(1)エポキシ樹脂材料の最低溶融粘度
Rheometer装置(TAインスツルメント社製「AR-2000」)を用いて、歪み21.6%及び周波数1Hzの条件で、得られた樹脂シートの未硬化物(Bステージフィルム)の50~150℃の温度領域での粘度を測定し、粘度が最も低くなる値を最低溶融粘度とした。
実施例及び比較例で得られた積層体Aにおける予備硬化物の断面観察を行った。予備硬化物中のシリカの存在状態1を下記の判定基準で判定した。
○:予備硬化物中で、上記第1の小粒径シリカが、上記第1の主面側に多く存在するように偏在しており、かつ上記第2の大粒径シリカが、上記第2の主面側に多く存在するように偏在している
上記シリカの存在状態1の判定結果が「○」である場合に、粗化処理される面である上記第1の主面側の表面部分の厚み0.3μmの第1の領域に含まれる全てのシリカ100重量%のうちの第2の大粒径シリカの含有量の割合(体積%)を評価した。また、第2の領域の厚みも評価した。
[硬化物Bの作製]
上記積層体Aにおける予備硬化物を、下記の(a)膨潤処理をした後、下記の(b)過マンガン酸塩処理すなわち粗化処理をし、さらに下記の(c)銅めっき処理をした。
60℃の膨潤液(スウェリングディップセキュリガントP、アトテックジャパン社製)に、上記積層体Aを入れて、20分間揺動させた。その後、純水で洗浄した。
75℃の過マンガン酸カリウム(コンセントレートコンパクトCP、アトテックジャパン社製)粗化水溶液に、上記積層体を入れて、20分間揺動させ、ガラスエポキシ基板上に粗化処理された粗化予備硬化物を得た。得られた粗化予備硬化物を、23℃の洗浄液(リダクションセキュリガントP、アトテックジャパン社製)により2分間洗浄した後、純水でさらに洗浄した。
120℃のギアオーブン中で2時間乾燥し、冷却した後、JIS B0601-1994に準拠して、粗化予備硬化物の粗化処理された表面の算術平均粗さRaを測定した。
次に、ガラスエポキシ基板上の粗化処理された粗化予備硬化物に、無電解銅めっき及び電解銅めっき処理を以下の手順で行った。
上記銅めっき層が形成された硬化物Bの銅めっき層の表面に10mm幅に切り欠きを入れた。その後、引張試験機(商品名「オートグラフ」、島津製作所社製)を用いて、クロスヘッド速度5mm/分の条件で、銅めっき層と硬化物との接着強度(ピール強度)を測定した。
1a…第1の主面
1b…第2の主面
2…シリカ
2A…第1の小粒径シリカ
2B…第2の大粒径シリカ
6…積層対象部材
6a…上面
11…積層体
12…回路基板
12a…上面
13~16…硬化物層
17…金属層
R1…第1の領域
R2…第2の領域
Claims (9)
- エポキシ樹脂材料の硬化を進行させることにより得られた予備硬化物であって、
第1の主面と第2の主面とを有し、前記第1の主面が粗化処理される面であり、
前記エポキシ樹脂材料が、エポキシ樹脂と硬化剤とシリカとを含み、
前記シリカが、粒子径が0.01μm以上、0.5μm未満である第1の小粒径シリカと、粒子径が0.5μm以上、20μm以下である第2の大粒径シリカとを含有し、
予備硬化物中で、前記第1の小粒径シリカが、粗化処理される面である前記第1の主面側に多く存在するように偏在しており、かつ前記第2の大粒径シリカが、前記第2の主面側に多く存在するように偏在している、予備硬化物。 - 粗化処理される面である前記第1の主面側の表面部分の厚み0.3μmの第1の領域に含まれる全てのシリカ100体積%のうち、前記第2の大粒径シリカの含有量は5体積%以下である、請求項1に記載の予備硬化物。
- 60~120℃の温度領域における予備硬化前のエポキシ樹脂材料の最低溶融粘度が50Pa・s以上、150Pa・s以下である、請求項1又は2に記載の予備硬化物。
- 前記エポキシ樹脂材料が、フェノキシ樹脂をさらに含む、請求項1又は2に記載の予備硬化物。
- 前記エポキシ樹脂材料が、フェノキシ樹脂をさらに含む、請求項3に記載の予備硬化物。
- 請求項1~5のいずれか1項に記載の予備硬化物の前記第1の主面を粗化処理することにより得られた粗化予備硬化物。
- 粗化処理される前に、前記予備硬化物が膨潤処理されている、請求項6に記載の粗化予備硬化物。
- 請求項1~5いずれか1項に記載の予備硬化物の前記第1の主面を粗化処理することにより得られた粗化予備硬化物を硬化させた硬化物と、該硬化物の粗化処理された表面に積層された金属層とを有する、積層体。
- 前記硬化物と前記金属層との接着強度が0.39N/mm以上である、請求項8に記載の積層体。
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KR20120121912A (ko) | 2012-11-06 |
US20130108861A1 (en) | 2013-05-02 |
CN102822272A (zh) | 2012-12-12 |
KR101298368B1 (ko) | 2013-08-20 |
JP4938910B1 (ja) | 2012-05-23 |
US9120293B2 (en) | 2015-09-01 |
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