WO2022131151A1 - 熱硬化性樹脂組成物の相容性評価方法、熱硬化性樹脂組成物、プリプレグ、樹脂フィルム、積層板、多層プリント配線板及び半導体パッケージ - Google Patents
熱硬化性樹脂組成物の相容性評価方法、熱硬化性樹脂組成物、プリプレグ、樹脂フィルム、積層板、多層プリント配線板及び半導体パッケージ Download PDFInfo
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- WO2022131151A1 WO2022131151A1 PCT/JP2021/045494 JP2021045494W WO2022131151A1 WO 2022131151 A1 WO2022131151 A1 WO 2022131151A1 JP 2021045494 W JP2021045494 W JP 2021045494W WO 2022131151 A1 WO2022131151 A1 WO 2022131151A1
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Images
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- G01N23/2251—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by measuring secondary emission from the material using electron or ion using incident electron beams, e.g. scanning electron microscopy [SEM]
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
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Definitions
- the present embodiment relates to a method for evaluating compatibility of a thermosetting resin composition, a thermosetting resin composition, a prepreg, a resin film, a laminated board, a multilayer printed wiring board, and a semiconductor package.
- the speed and capacity of signals used are increasing year by year.
- the substrate material of the printed wiring board mounted on these electronic devices has a dielectric characteristic that can reduce the transmission loss of a high frequency signal [hereinafter, may be referred to as "high frequency characteristic”. ], That is, a low relative permittivity and a low dielectric loss tangent are required.
- high frequency characteristic a dielectric characteristic that can reduce the transmission loss of a high frequency signal
- practical application or practical planning of a new system handling high-frequency radio signals is in progress. Therefore, it is expected that the need for substrate materials having excellent high-frequency characteristics will increase for printed wiring boards used in these fields in the future.
- thermoplastic polymer having excellent high frequency characteristics has been used for a printed wiring board that requires low transmission loss.
- a thermoplastic polymer for example, a polymer having no polar group in the molecule such as polyphenylene ether and polybutadiene is effective for low dielectric loss tangent.
- these thermoplastic polymers have low compatibility with other resins having a polar group, and when they are made into a resin composition, there are problems such as separation from other resins. Separation of the resins may lead to a decrease in workability, a decrease in the homogeneity of the product, and a resulting decrease in physical properties, and is therefore desirable to be suppressed.
- Patent Document 1 discloses a curable resin composition containing a specific polyphenylene ether and a polyfunctional vinyl aromatic copolymer.
- the compatibility of the polyfunctional vinyl aromatic copolymer with the epoxy resin is determined by dissolving the polyfunctional vinyl aromatic copolymer, the epoxy resin and the phenol resin in a solvent, and the sample after dissolution. It is evaluated by visually confirming the transparency.
- the present embodiment uses a method for evaluating compatibility of a thermosetting resin composition, a thermosetting resin composition having improved compatibility, and the thermosetting resin composition.
- An object of the present invention is to provide a prepreg, a resin film, a laminated board, a multilayer printed wiring board, and a semiconductor package.
- thermosetting resin composition containing two or more kinds of resins and an inorganic filler, which comprises the following steps 1A and 2A, and is a phase of the thermosetting resin composition.
- Capacity evaluation method Acquiring a backscattered electron image of a scanning electron microscope with respect to a cross section of a cured product of the thermosetting resin composition at an observation magnification of 50 to 250 times
- Step 2A A phase-separated resin region in the backscattered electron image.
- Step [2] A method for evaluating compatibility of a thermosetting resin composition containing two or more kinds of resins and an inorganic filler, which comprises the following steps 1B and 2B. Compatibility evaluation method.
- Step 1B Acquiring a backscattered electron image of the cured product of the thermosetting resin composition with respect to the cross section of the cured product. Step of acquiring the average domain size DL of the part [3]
- the reflected electron image of the scanning electron microscope is acquired with respect to the cross section of the cured product of the thermosetting resin composition at an observation magnification of 50 to 200 times.
- the area ratio R w of the non-separable portion acquired under the condition that the observation magnification of the scanning electron microscope is 100 times or 200 times is 50% or more.
- the domain size of the separation portion observed in at least three fields of view is large under the condition that the observation magnification of the scanning electron microscope is 65 times.
- [6] A resin film containing the thermosetting resin composition according to the above [4].
- thermosetting resin composition a thermosetting resin composition having improved compatibility
- prepreg and a resin film using the thermosetting resin composition a method for evaluating compatibility of a thermosetting resin composition, a thermosetting resin composition having improved compatibility, and a prepreg and a resin film using the thermosetting resin composition.
- Laminated boards, multilayer printed wiring boards and semiconductor packages can be provided.
- the numerical range indicated by using "-" indicates a range including the numerical values before and after "-" as the minimum value and the maximum value, respectively.
- the lower and upper limits of the numerical range described herein are optionally combined with the lower or upper limit of the other numerical ranges, respectively.
- the upper limit value or the lower limit value of the numerical range may be replaced with the value shown in the examples.
- each component and material exemplified in the present specification may be used alone or in combination of two or more.
- the content of each component in the thermosetting resin composition is the thermosetting resin composition unless otherwise specified, when a plurality of substances corresponding to each component are present in the thermosetting resin composition.
- thermosetting resin composition it means the total amount of the plurality of substances present in the object.
- An embodiment in which the items described in the present specification are arbitrarily combined is also included in the present embodiment.
- the mechanism of action described herein is speculative and does not limit the mechanism by which the thermosetting resin composition according to this embodiment is effective.
- phase in the present specification means that the resins are miscible in nano, micro units, or in appearance, even if they are not necessarily compatible in molecular units.
- the number average molecular weight in the present specification means a value measured in terms of polystyrene by gel permeation chromatography (GPC), and can be specifically measured by the method described in Examples.
- thermosetting resin composition may be simply abbreviated as "resin composition”.
- the compatibility evaluation method of the first aspect of the present embodiment is a method of evaluating the compatibility of a thermosetting resin composition containing two or more kinds of resins and an inorganic filler, and is described in the following steps 1A and It is a compatibility evaluation method of a thermosetting resin composition containing 2A.
- Step 1A A step of acquiring a reflected electron image of a scanning electron microscope with respect to a cross section of a cured product of the thermosetting resin composition at an observation magnification of 50 to 250 times.
- Step 2A A phase-separated resin region in the reflected electron image.
- the area ratio of the region of the non-separable portion of the binarized image (the area of the region of the non-separable portion ⁇ 100 / the area of the entire region of the binarized image) is calculated as the area ratio R w of the non-separable portion.
- step 1A a backscattered electron image of a thermosetting resin composition containing two or more kinds of resins and an inorganic filler is acquired by a scanning electron microscope (SEM) at an observation magnification of 50 to 250 times. It is a process.
- the resin composition to be measured by the compatibility evaluation method of the present embodiment is not particularly limited as long as it is a resin composition containing two or more kinds of resins and an inorganic filler.
- the resin composition may be a measurement target.
- the curing conditions of the resin composition are not particularly limited, and the resin composition may be cured under conditions suitable for the resin composition to be measured.
- the conditions described in the examples can be used. Specifically, the resin composition is heated and dried at 170 ° C. for 5 minutes to be in a B stage state, and then cured by heat and pressure molding at a temperature of 230 ° C., a pressure of 2.0 MPa, and a time of 120 minutes. You can get things.
- the method for forming the cross section of the cured product of the resin composition is not particularly limited, and a conventionally known method can be adopted.
- a precision cutting machine, an ion milling device, an ultrasonic cutting machine or the like can be used to form the cured product.
- a method of forming a cross section of the above can be mentioned.
- the cured product of the resin composition may be embedded in the embedding resin from the viewpoint of processability.
- polishing treatment or the like may be performed as necessary.
- After forming the cross section of the cured product it is preferable to carry out a vapor deposition treatment of platinum or the like on the cross section in order to perform SEM observation satisfactorily.
- the object of SEM observation obtained by the above steps is referred to as a "test piece".
- the SEM observation in the compatibility evaluation method of the present embodiment is performed in the backscattered electron mode in order to enhance the contrast between the inorganic filler and the resin component.
- the acceleration voltage during SEM observation may be appropriately adjusted according to the measurement target, but may be adjusted in the range of 0.5 to 20 kV, for example.
- the observation magnification of the SEM in step 1A is in the range of 50 to 250 times, preferably 60 to 230 times, and more preferably 80 to 210 times.
- the observation magnification within the above range, measurement variation due to the visual field can be suppressed, and the reproducibility of the calculated area ratio R w of the non-separable portion can be improved.
- the phase-separated resin region and the other regions are each in the form of a domain having a uniform color. Since it can be observed in the above, it becomes easy to carry out the step 2A described later.
- the reflected electron image of the test piece can be acquired by the step 1A.
- step 2A in the backscattered electron image, the phase-separated resin region is set as a separation portion and the other region is set as a non-separation portion, so that the separation portion has one value and the non-separation portion has the other value.
- Area ratio of the area of the non-separable part of the binarized image to the whole area of the binarized image obtained by quantifying (area of the non-separable part ⁇ 100 / area of the whole area of the binarized image) ) Is a step of calculating the area ratio R w of the non-separable portion.
- FIG. 1 shows an example of a reflected electron image obtained in step 1A.
- the reflected electron image obtained in step 1A includes a region 1 that looks relatively bright and a region 2 that looks relatively dark.
- the region that looks relatively dark is a phase rich in the resin having a low electron density, and corresponds to a phase-separated resin region.
- the region that looks relatively bright is the phase in which the compatible resin and the inorganic filler having a high electron density are contained.
- the phase-separated resin region is designated as a “separated portion”, and the other regions are designated as a “non-separated portion”.
- the separated portion can be clearly and easily identified by visual inspection.
- the reflected electron image is binarized so that the separated portion has one value and the non-separated portion has the other value, and then the binarized value is obtained for the entire region of the obtained binarized image.
- the area ratio of the region of the non-separable portion of the image (area of the region of the non-separable portion ⁇ 100 / the area of the entire region of the binarized image) is calculated as the area ratio R w of the non-separable portion.
- the binarization in this step is, for example, a process of giving a pixel value "1 (white)" to a pixel having a pixel value equal to or higher than a predetermined threshold value and giving a pixel value "0 (black)" to other pixels.
- the binarization may be performed by a known method, and can be performed, for example, by using commercially available image processing software.
- the binarization condition may be appropriately adjusted according to the reflected electron image obtained in the step 1A, and the binarization may be performed under the condition that the separated portion has one value and the non-separated portion has the other value.
- the RGB threshold is appropriately adjusted to the range of 40 to 100 as a processing condition. It can be binarized by this.
- the area ratio of the region of the non-separated portion of the binarized image to the entire region of the obtained binarized image (area of the region of the non-separated portion ⁇ 100 / area of the entire region of the binarized image) is calculated. , Calculated as the area ratio R w of the non-separable part.
- the area ratio R w may be calculated, for example, by counting the number of pixels in the entire region of the binarized image and the number of pixels having a value representing the non-separable portion.
- the area ratio R w of the non-separable portion may be calculated for one visual field, but from the viewpoint of reproducibility, the area ratio R w of the non-separable portion is calculated for a plurality of visual fields. Then, it is preferable to average this.
- the number of visual fields to be averaged is not particularly limited, and may be, for example, 2, 3, 4, or 5 or more visual fields, and may be appropriately selected depending on the required accuracy.
- the area ratio R w of the non-separable portion obtained by the above method can be used as an index of compatibility. That is, it can be seen that the larger the area ratio R w of the non-separated portion, the smaller the amount of the phase-separated resin, and the better the compatibility of the resin composition.
- the compatibility evaluation method of the second aspect of the present embodiment is a method of evaluating the compatibility of a thermosetting resin composition containing two or more kinds of resins and an inorganic filler, and is described in the following steps 1B and It is a compatibility evaluation method of a thermosetting resin composition containing 2B.
- Step 1B Acquiring a backscattered electron image of the cured product of the thermosetting resin composition
- Step 2B In the backscattered electron image, the phase-separated resin region is used as a separation portion, and the separation is performed.
- Step 1B is a step of acquiring a reflected electron image of a scanning electron microscope for a cross section of a cured product of a thermosetting resin composition containing two or more kinds of resins and an inorganic filler.
- the observation magnification of the scanning electron microscope in the step 1B is not particularly limited, but is preferably 30 to 500 times, more preferably 40 to 200 times, still more preferably 50 to 200 times, particularly, from the viewpoint of workability and reproducibility. It is preferably 50 to 100 times.
- the description of step 1B other than the observation magnification is the same as the description of step 1A.
- Step 2B is a step of acquiring the average domain size DL of the separated portion by using the phase-separated resin region as the separating portion in the backscattered electron image.
- the domain size in this step is defined as the diameter of the maximum perfect circle that can be drawn in the domain of the separation portion.
- 2 and 3 show a schematic diagram showing a method of measuring the domain size of the separated portion. For example, as shown in FIG. 2A, when a domain is regarded as a perfect circle, its diameter corresponds to the domain size. Further, for example, when the domain is regarded as an ellipse or an amorphous shape as shown in FIG. 2B or FIG. 2C, the diameter of the maximum perfect circle that can be drawn in the ellipse or the amorphous shape corresponds to the domain size. ..
- the domain of the separation portion may have a shape in which two or more domains are connected.
- the diameter t is 1/3 or less of the diameter s.
- the domain is divided by the above-mentioned concatenated part. That is, it is assumed that the domain shown in FIG. 3A has two domains, a domain having a diameter s and a domain having a diameter u.
- the domain shown in FIG. 3B since the diameter t exceeds 1/3 of the diameter s, it is assumed that the domain is not divided at the connecting portion and has a domain size of the diameter s.
- the average domain size DL of the separation part in step 2B is obtained by averaging the domain sizes of the domains having the second and subsequent sizes, counting from the domain of the separation part having the largest domain size. Is preferable. As a result, it is possible to eliminate the influence of a large separation portion that is unintentionally generated due to factors other than compatibility during the production of the resin composition, and it is possible to improve the reproducibility.
- the number of the second and subsequent domains for obtaining the average value is not particularly limited, and may be appropriately determined according to the measurement target. From the viewpoint of workability and reproducibility, the average domain size DL of the separation part is the domain having the size within the 100th, preferably the domain having the size within the 50th, in order from the second and the largest. , More preferably, it is obtained by averaging the domain sizes of domains having a size within the 10th, and more preferably domains having a size of 2nd to 6th.
- the average domain size DL may be obtained by performing the above step for only one visual field, but from the viewpoint of reproducibility, after observing a plurality of visual fields, the said. It is preferable to obtain the average domain size DL from all the domains included in the plurality of fields of view.
- the number is preferably 3 visual fields or more, more preferably 5 visual fields or more, and further preferably 6 visual fields or more.
- the upper limit of the number of visual fields to be observed is not particularly limited, but may be, for example, 20 visual fields or less, 15 visual fields or less, or 10 visual fields or less.
- the average domain size DL of the separated portion obtained by the above method can be used as an index of compatibility. That is, it can be seen that the smaller the average domain size DL of the separated portion, the more excellent the compatibility of the resin composition.
- thermosetting resin composition is a thermosetting resin composition containing two or more kinds of resins and an inorganic filler.
- the area ratio R w of the non-separable portion acquired under the condition that the observation magnification of the scanning electron microscope is 100 times or 200 times is 50% or more
- the observation magnification of the scanning electron microscope is 65 times, and the domain of the separation part observed in at least three fields of view is counted from the one having the largest domain size.
- thermosetting resin composition obtained by averaging the domain sizes of the domains having the second to sixth sizes and having an average domain size DL of 120 ⁇ m or less in the separated portion.
- the area ratio R w and the average domain size DL of the non-separable portion with respect to the thermosetting resin composition of the present embodiment are based on the compatibility evaluation method of the first aspect and the compatibility evaluation method of the second aspect. More specifically, it is a value measured by the method described in Examples.
- the area ratio R w of the non-separable portion of the resin composition of the present embodiment is not particularly limited, but is preferably 52% or more, more preferably 54% or more, still more preferably 56% or more.
- the upper limit of the area ratio R w of the non-separable portion is not particularly limited and may be 100%, but from the viewpoint of ease of manufacture and the like, it may be 98% or less, or 95% or less. May be good.
- the average domain size DL of the separated portion of the resin composition of the present embodiment is not particularly limited, but is preferably 100 ⁇ m or less, more preferably 90 ⁇ m or less, still more preferably 85 ⁇ m or less.
- the lower limit of the average domain size DL of the separated portion is not particularly limited and may be 0 ⁇ m, but from the viewpoint of ease of manufacture and the like, it may be 10 ⁇ m or more, or 30 ⁇ m or more.
- the average domain size DL of the separated portion is 0 ⁇ m, which means that the separated portion cannot be substantially observed and the domain size cannot be measured.
- the area ratio R w of the non-separable portion and the average domain size DL of the separated portion can be appropriately adjusted within the above ranges by, for example, selecting the type of resin contained in the resin composition.
- the resin composition of the present embodiment contains two or more kinds of resins and an inorganic filler.
- the resin component is not particularly limited as long as it satisfies the above-mentioned area ratio R w of the non-separable portion and the average domain size DL of the separated portion, but contains at least two types of elastomer and thermosetting resin. Is preferable.
- the elastomer examples include polyether elastomers, styrene elastomers, conjugated diene elastomers, urethane elastomers, polyester elastomers, polyamide elastomers, acrylic elastomers, silicone elastomers and the like.
- the elastomer one type may be used alone, or two or more types may be used in combination.
- a polyether elastomer, a styrene elastomer, and a conjugated diene elastomer are preferable from the viewpoint of dielectric properties.
- thermosetting resin examples include epoxy resins, cyanate ester compounds, maleimide compounds, bisallyl nadiimide resins, benzoxazine compounds, and derivatives thereof.
- the thermosetting resin one type may be used alone, or two or more types may be used in combination.
- the thermosetting resin is preferably a maleimide compound or a derivative thereof from the viewpoint of heat resistance, low thermal expansion property and mechanical properties.
- the resin composition of the present embodiment preferably contains a polyether elastomer as an elastomer and a maleimide compound or a derivative thereof as a thermosetting resin.
- the resin composition of the present embodiment may be referred to as a polyphenylene ether derivative having an ethylenically unsaturated bond-containing group [hereinafter, "polyphenylene ether derivative (A)” or “component (A)” as an elastomer.
- thermosetting resin one or more selected from the group consisting of a maleimide compound having two or more N-substituted maleimide groups and a derivative thereof [hereinafter, "maleimide compound or its derivative (B)” or It may be referred to as "(B) component”. ] Is more preferable.
- thermoplastic elastomer (D) styrene-based thermoplastic elastomer (D)" or “component (D)".
- styrene-based thermoplastic elastomer (D) or “component (D)”.
- the resin composition of the present embodiment may be referred to as (E) an imidazole compound or a modified imidazole compound [hereinafter, "imidazole compound or its modified product (E)" or “(E) component” as a curing accelerator. be. ] Is particularly preferable.
- the component (A) has an ethylenically unsaturated bond-containing group. That is, it can be said that the component (A) is a polyphenylene ether introduced with an ethylenically unsaturated bond-containing group.
- the "ethylenically unsaturated bond” means a carbon-carbon double bond capable of an addition reaction, and does not include a double bond of an aromatic ring.
- the "ethylenically unsaturated bond-containing group” means a substituent containing the ethylenically unsaturated bond.
- one type may be used alone, or two or more types may be used in combination.
- the position of the ethylenically unsaturated bond-containing group in the component (A) is not particularly limited, and may be a terminal or a position other than the terminal.
- the position of the ethylenically unsaturated bond-containing group may be one end or both ends.
- the "terminal" of the component (A) means not only the atom at the end of the molecule but also the entire organic group bonded to the ether bond existing at the end of the polyphenylene ether chain from the end side.
- the component (A) having an ethylenically unsaturated bond-containing group at the end means that the organic group bonded to the ether bond existing at the most end of the polyphenylene ether chain from the end side is an ethylenically unsaturated bond-containing group. It is synonymous with having.
- the component (A) may be a mixture of a polyphenylene ether derivative having an ethylenically unsaturated bond-containing group at one end and a polyphenylene ether derivative having an ethylenically unsaturated bond-containing group at both ends, but at least, It is preferable to contain a polyphenylene ether derivative having an ethylenically unsaturated bond-containing group at one end, and more preferably the polyphenylene ether derivative itself having an ethylenically unsaturated bond-containing group at one end.
- the content of the polyphenylene ether derivative having an ethylenically unsaturated bond-containing group at one end in the component (A). is preferably 30% by mass or more, more preferably 45% by mass or more, further preferably 55% by mass or more, still more preferably 70% by mass or more, particularly preferably 90% by mass or more, and most preferably substantially 100% by mass. %.
- Examples of the ethylenically unsaturated bond-containing group contained in the component (A) include unsaturated aliphatic hydrocarbon groups such as vinyl group, isopropenyl group, allyl group, 1-methylallyl group and 3-butenyl group; maleimide group, Examples thereof include a substituent containing a hetero atom such as a (meth) acryloyl group.
- unsaturated aliphatic hydrocarbon group and a maleimide group are preferable, an allyl group and a maleimide group are more preferable, and an allyl group is further preferable, from the viewpoint of dielectric properties.
- the unsaturated aliphatic hydrocarbon group described as the ethylenically unsaturated bond-containing group does not contain a hetero atom.
- the number of unsaturated aliphatic hydrocarbon groups contained in one molecule of the component (A) is not particularly limited, but is preferably 2 or more, more preferably 3 or more, still more preferably 4 from the viewpoint of dielectric properties. That is all.
- the upper limit of the number of unsaturated aliphatic hydrocarbon groups contained in one molecule of the component (A) is not particularly limited, and may be 8 or less, 7 or less, or 6 It may be less than one.
- the number of unsaturated aliphatic hydrocarbon groups (A) contained in one end is not particularly limited, but from the viewpoint of dielectric properties, it is preferably 2 or more, more preferably 3 or more, still more preferably 4 or more. Is.
- (A) There is no particular limitation on the upper limit of the number of unsaturated aliphatic hydrocarbon groups that the component has at one end, and it may be 8 or less, 7 or less, or 6 or less. May be. It is most preferable that the number of unsaturated aliphatic hydrocarbon groups contained in the component (A) and the number of unsaturated aliphatic hydrocarbon groups contained in the component (A) at one end are both four.
- the component (A) preferably contains a structure represented by the following general formula (a-1) from the viewpoint of dielectric properties.
- Ra1 is an unsaturated aliphatic hydrocarbon group having 2 to 10 carbon atoms.
- N1 is 1 or 2
- n2 is 0 or 1. * Is a bond position to another structure. Shows.
- unsaturated fats having 2 to 5 carbon atoms from the viewpoint of dielectric properties.
- Group hydrocarbon groups are preferred, vinyl groups, isopropenyl groups, allyl groups, 1-methylallyl groups and 3-butenyl groups are more preferred, and allyl groups are even more preferred.
- n1 is 2, the plurality of Ra1s may be the same or different from each other.
- the component (A) preferably includes a structure represented by the following general formula (a-2).
- R a2 and R a3 are each independently unsaturated aliphatic hydrocarbon group having 2 to 10 carbon atoms. * Indicates the bond position to another structure.
- Examples of the unsaturated aliphatic hydrocarbon group having 2 to 10 carbon atoms represented by Ra 2 and Ra 3 in the general formula (a-2) are the same as those in Ra 1 in the general formula (a-1). , The same is preferred.
- the component (A) more preferably contains a structure represented by any of the following general formulas (a-3) to (a-5), and the following general formula (a-5) is used. It is more preferred to include the structure represented.
- Ra4 is an unsaturated aliphatic hydrocarbon group having 2 to 10 carbon atoms. * Indicates a bond position to another structure.
- R a5 and R a6 are each independently unsaturated aliphatic hydrocarbon group having 2 to 10 carbon atoms.
- X a1 is a divalent aliphatic hydrocarbon group having 1 to 6 carbon atoms. * Indicates the position of connection to other structures.
- R a7 to R a10 are independently unsaturated aliphatic hydrocarbon groups having 2 to 10 carbon atoms.
- X a2 is a divalent organic group. * Is a divalent organic group. Indicates the bonding position.
- the unsaturated aliphatic hydrocarbon group having 2 to 10 carbon atoms represented by R a4 to R a10 in the general formulas (a-3) to (a-5) is R in the general formula (a-1).
- the same as in the case of a1 can be mentioned, and the preferred one is also the same.
- Examples of the divalent aliphatic hydrocarbon group having 1 to 6 carbon atoms represented by Xa1 in the general formula (a-4) include an alkylene having 1 to 6 carbon atoms such as a methylene group, an ethylene group and a trimethylene group.
- An alkylidene group having 2 to 6 carbon atoms such as an isopropyridene group can be mentioned. Among these, a methylene group and an isopropyridene group are preferable, and an isopropyridene group is more preferable.
- Examples of the divalent organic group represented by Xa2 in the above general formula (a-5) include an aliphatic hydrocarbon group which may contain a hetero atom in a part and a hetero atom in a part. Examples thereof include an alicyclic hydrocarbon group which may be present, an aromatic hydrocarbon group which may partially contain a hetero atom, a group consisting of any combination of these groups, and the like. Examples of the hetero atom include an oxygen atom, a nitrogen atom, a sulfur atom and the like.
- the divalent organic group represented by X a2 is preferably a group that does not contain a hetero atom, an aliphatic hydrocarbon group that does not contain a hetero atom, and an alicyclic hydrocarbon that does not contain a hetero atom.
- a hydrogen group is more preferable, and a group consisting of a combination of an aliphatic hydrocarbon group that does not contain a hetero atom and an alicyclic hydrocarbon group that does not contain a hetero atom is further preferable
- the structures represented by the general formula (a-3), the general formula (a-4), or the general formula (a-5) are described in the following formula (a-3') and the following, respectively, from the viewpoint of dielectric properties. It is preferable that the structure is represented by the formula (a-4') or the following general formula (a-5'). Among these, from the viewpoint of dielectric properties, the structure represented by the following formula (a-4') or the following general formula (a-5') is more preferable, and is represented by the following general formula (a-5'). The structure is more preferred.
- component (A) is a polyphenylene ether derivative, it also has a phenylene ether bond, and preferably has a structural unit represented by the following general formula (a-10).
- Ra11 is an aliphatic hydrocarbon group or a halogen atom having 1 to 5 carbon atoms.
- N3 is an integer of 0 to 4.
- Examples of the aliphatic hydrocarbon group represented by Ra11 in the general formula (a-10) include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group and a t-butyl group. , N-pentyl group and the like.
- an aliphatic hydrocarbon group having 1 to 3 carbon atoms is preferable, an alkyl group having 1 to 3 carbon atoms is more preferable, and a methyl group is further preferable.
- halogen atom represented by R a11 examples include a fluorine atom, a chlorine atom, a bromine atom, an iodine atom and the like.
- Ra11 an aliphatic hydrocarbon group having 1 to 5 carbon atoms is preferable.
- N3 in the general formula (a-10) is an integer of 0 to 4, preferably an integer of 1 or 2, and more preferably 2.
- the substitution position of Ra 11 is preferably the ortho position with respect to the substitution position of the oxygen atom.
- the plurality of Ra 11s may be the same or different from each other.
- the structural unit represented by the general formula (a-10) specifically, the structural unit represented by the following general formula (a-10') is preferable.
- the component (A) preferably contains a polyphenylene ether derivative represented by any of the following general formulas (a-6) to (a-8), and preferably contains the following general formula (a-7) or (a-8). ), It is more preferable to contain the polyphenylene ether derivative represented by the following general formula (a-8), and it is further preferable to contain the polyphenylene ether derivative represented by the following general formula (a-8).
- X a2 is the same as X a2 in the above general formula (a-5).
- N4 to n6 are independently integers of 1 to 200.
- n4 to n6 are independently integers of 1 to 200, and are preferably 1 from the viewpoint of dielectric properties and compatibility with other resins. It is an integer of up to 150, more preferably an integer of 1 to 120, and even more preferably an integer of 1 to 100.
- a mixture of polyphenylene ether derivatives having different values of n4 to n6 may be used.
- the number average molecular weight of the component (A) is not particularly limited, but is preferably 1,000 to 25,000, more preferably 2,000 to 20,000, still more preferably 3,000 to 10,000, and particularly preferably. It is 4,000 to 6,000.
- (A) When the number average molecular weight of the component is at least the above lower limit value, the dielectric property tends to be better. Further, when the number average molecular weight of the component (A) is not more than the above upper limit value, the compatibility of the resin composition becomes good, and it tends to be difficult to separate even if it is left for a long period of time.
- a phenol compound having a structure represented by any of the above general formulas (a-1) to (a-5) and a polyphenylene ether are redistributed in an organic solvent.
- the phenolic compound containing the structure represented by any of the above general formulas (a-1) to (a-5) is referred to as "unsaturated aliphatic hydrocarbon group-containing phenolic compound (1)".
- unsaturated aliphatic hydrocarbon group-containing phenolic compound (1) is sometimes referred to.
- the polyphenylene ether used as a raw material for the redistribution reaction may be referred to as "raw material polyphenylene ether".
- the number average molecular weight of the raw material polyphenylene ether is not particularly limited, but is preferably 3,000 to 30,000.
- the oxy radical of the unsaturated aliphatic hydrocarbon group-containing phenol compound (1) attacks the carbon atom to which the oxygen atom in the raw material polyphenylene ether is bonded, so that the OC bond is formed there. It is a reaction that cuts and reduces the molecular weight. At that time, the oxyradical of the attacked unsaturated aliphatic hydrocarbon group-containing phenol compound (1) is bonded to the broken carbon atom and incorporated into the structure of the polyphenylene ether.
- known methods can be used and applied.
- the molecular weight of the component (A) can be controlled by the amount of the unsaturated aliphatic hydrocarbon group-containing phenol compound (1) used, and the larger the amount of the unsaturated aliphatic hydrocarbon group-containing phenol compound (1) used, the more (A).
- the components are reduced in molecular weight. That is, the amount of the unsaturated aliphatic hydrocarbon group-containing phenol compound (1) used may be appropriately adjusted so that the number average molecular weight of the component (A) finally produced is in a suitable range.
- the amount of the unsaturated aliphatic hydrocarbon group-containing phenol compound (1) to be used is not particularly limited, but for example, the raw material polyphenylene ether to be reacted with the unsaturated aliphatic hydrocarbon group-containing phenol compound (1). It may be determined according to the number average molecular weight. For example, when the number average molecular weight of the raw material polyphenylene ether is 3,000 to 30,000, the amount of hydroxyl groups of the unsaturated aliphatic hydrocarbon group-containing phenol compound (1) with respect to 1 mol of the raw material polyphenylene ether is preferably 1. It is ⁇ 10 mol, more preferably 1-8 mol, still more preferably 2-6 mol. When the amount of the unsaturated aliphatic hydrocarbon group-containing phenol compound (1) used is within the above range, the component (A) having a number average molecular weight within the above-mentioned preferable range can be obtained.
- Examples of the organic solvent used in the process for producing the component (A) include alcohol solvents such as methanol, ethanol, butanol, butyl cellosolve, ethylene glycol monomethyl ether and propylene glycol monomethyl ether; acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone.
- alcohol solvents such as methanol, ethanol, butanol, butyl cellosolve, ethylene glycol monomethyl ether and propylene glycol monomethyl ether
- acetone methyl ethyl ketone
- methyl isobutyl ketone cyclohexanone
- Ketone-based solvents such as; aromatic hydrocarbon-based solvents such as toluene, xylene, mesityrene; ester-based solvents such as methoxyethyl acetate, ethoxyethyl acetate, butoxyethyl acetate, ethyl acetate; N, N-dimethylformamide, N, N Examples thereof include nitrogen atom-containing solvents such as -dimethylacetamide and N-methyl-2-pyrrolidone.
- the organic solvent one kind may be used alone, or two or more kinds may be used in combination.
- a reaction catalyst can be used as needed, as described above.
- the reaction catalyst for example, from the viewpoint of obtaining the component (A) having a stable number average molecular weight with good reproducibility, an organic peroxide such as t-butylperoxyisopropyl monocarbonate and a carboxylic acid such as manganese naphthenate and manganese octylate are used. It is preferable to use it in combination with an acid metal salt.
- the organic peroxide and the carboxylic acid metal salt are used in combination, the amount of both used is not particularly limited, but the amount of the organic peroxide used is 0.5 to 5 with respect to 100 parts by mass of the raw material polyphenylene ether.
- the amount of the carboxylic acid metal salt used is preferably 0.05 to 0.5 parts by mass.
- the reaction rate and the suppression of gelation in the production of the component (A) tend to be better.
- An unsaturated aliphatic hydrocarbon group-containing phenol compound (1), a raw material polyphenylene ether, an organic solvent and, if necessary, a reaction catalyst are charged in a reactor, and if necessary, the reaction is carried out while heating, keeping warm and stirring (A). Ingredients are obtained.
- the reaction temperature of the redistribution reaction is preferably 70 to 110 ° C.
- the reaction time of the redistribution reaction is preferably 1 to 8 hours. When the reaction temperature and the reaction time are within the above ranges, the workability and the suppression of gelation are excellent, and the component (A) having the above-mentioned number average molecular weight tends to be easily produced.
- the reaction conditions are not limited to the above conditions, and can be appropriately adjusted according to the type of raw material and the like. Further, as the reaction conditions, known reaction conditions for the redistribution reaction can also be applied.
- reaction concentration Solid content concentration during the reaction in the manufacturing process of the component
- reaction concentration Is not particularly limited, but is preferably 10 to 60% by mass, more preferably 15 to 55% by mass, and even more preferably 20 to 50% by mass.
- reaction concentration is at least the above lower limit value, a good reaction rate is obtained, and the productivity tends to be better.
- reaction concentration is not more than the above upper limit value, better solubility is obtained, stirring efficiency is improved, and gelation tends to be further suppressed.
- the solution of the polyphenylene ether derivative (A) produced by the above method may be concentrated to remove a part of the organic solvent, or may be diluted by adding an organic solvent. ..
- the resin composition of the present embodiment tends to have better dielectric properties than the resin composition containing the above-mentioned raw material polyphenylene ether instead of the component (A).
- the content thereof is not particularly limited, but is preferable with respect to 100 parts by mass of the total resin components in the resin composition from the viewpoint of dielectric properties. Is 0.1 to 20 parts by mass, more preferably 0.5 to 10 parts by mass, still more preferably 0.7 to 5 parts by mass, and particularly preferably 1 to 3 parts by mass.
- the "resin component” refers to, for example, a component (A), a component (B), a component (C), a component (D), and the like, and when other resins are contained. , The other resin is also included in the resin component.
- the component (B) is one or more selected from the group consisting of maleimide compounds having two or more N-substituted maleimide groups and derivatives thereof.
- the above-mentioned "derivative of a maleimide compound having two or more N-substituted maleimide groups” includes, for example, an addition reaction product of the above-mentioned maleimide compound having two or more N-substituted maleimide groups and the diamine compound (b2). And so on.
- the component (B) one type may be used alone, or two or more types may be used in combination.
- the component (B) is one or more compounds selected from the group consisting of the following (i) and (ii) from the viewpoint of compatibility with other resins, adhesiveness with conductors, and dielectric properties. Is preferable.
- Maleimide compound (b1) having two or more N-substituted maleimide groups [hereinafter, may be referred to as “maleimide compound (b1)” or “component (b1)”.
- the component (b1) is not particularly limited as long as it is a maleimide compound having two or more N-substituted maleimide groups.
- the component (b1) one type may be used alone, or two or more types may be used in combination.
- component (b1) examples include bis (4-maleimidephenyl) methane, bis (4-maleimidephenyl) ether, bis (4-maleimidephenyl) sulfone, and 3,3'-dimethyl-5,5'-diethyl-. 2 in molecules such as 4,4'-diphenylmethanebismaleimide, 4-methyl-1,3-phenylenebismaleimide, m-phenylenebismaleimide, 2,2-bis [4- (4-maleimidephenoxy) phenyl] propane, etc.
- Aromatic maleimide compound having two N-substituted maleimide groups Aromatic polymaleimide compound having three or more N-substituted maleimide groups in the molecule such as polyphenylmethane maleimide and biphenyl aralkyl type maleimide; 1,6-bismaleimide -(2,2,4-trimethyl) hexane, aliphatic maleimide compounds such as pyrophosphate binder type long chain alkyl bismaleimide and the like can be mentioned.
- aromatic maleimide compounds and molecules having two N-substituted maleimide groups in the molecule from the viewpoints of compatibility with other resins, adhesion to conductors, heat resistance, low thermal expansion, and mechanical properties.
- Aromatic polymaleimide compounds having three or more N-substituted maleimide groups within are preferred, with 3,3'-dimethyl-5,5'-diethyl-4,4'-diphenylmethanebismaleimide, and biphenylaralkyl-type maleimide being more. preferable.
- component (b1) a compound represented by the following general formula (b1-1) is preferable.
- X b1 is a divalent organic group.
- X b1 in the above general formula (b1-1) is a divalent organic group, and corresponds to a divalent group obtained by removing two N-substituted maleimide groups from the component (b1).
- Examples of the divalent organic group represented by X b1 include a group represented by the following general formula (b1-2), a group represented by the following general formula (b1-3), and the following general formula (b1-4). Examples thereof include a group represented by the following general formula (b1-5), a group represented by the following general formula (b1-6), and the like.
- R b1 is an aliphatic hydrocarbon group or a halogen atom having 1 to 5 carbon atoms.
- P1 is an integer of 0 to 4. * Indicates a bond position to another structure.
- Examples of the aliphatic hydrocarbon group having 1 to 5 carbon atoms represented by R b1 include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a t-butyl group and an n-pentyl group. Group etc. can be mentioned.
- an aliphatic hydrocarbon group having 1 to 3 carbon atoms is preferable, an alkyl group having 1 to 3 carbon atoms is more preferable, and a methyl group is further preferable.
- halogen atom examples include a fluorine atom, a chlorine atom, a bromine atom, an iodine atom and the like.
- p1 is an integer of 0 to 4, preferably an integer of 0 to 2, more preferably 0 or 1, and even more preferably 0, from the viewpoint of availability.
- p1 is an integer of 2 or more, the plurality of R b1s may be the same or different.
- R b2 and R b3 are independently aliphatic hydrocarbon groups or halogen atoms having 1 to 5 carbon atoms.
- X b2 is an alkylene group having 1 to 5 carbon atoms and 2 to 5 carbon atoms.
- P2 and p3 are, respectively. Independently, it is an integer from 0 to 4. * indicates the position of connection to other structures.
- Examples of the aliphatic hydrocarbon group having 1 to 5 carbon atoms and the halogen atom represented by R b2 and R b3 are the same as in the case of R b1 .
- As the aliphatic hydrocarbon group an aliphatic hydrocarbon group having 1 to 3 carbon atoms is preferable, a methyl group and an ethyl group are more preferable, and an ethyl group is further preferable.
- Examples of the alkylene group having 1 to 5 carbon atoms represented by X b2 include a methylene group, a 1,2-dimethylene group, a 1,3-trimethylene group, a 1,4-tetramethylene group, a 1,5-pentamethylene group and the like. Can be mentioned.
- an alkylene group having 1 to 3 carbon atoms is preferable, and an alkylene group having 1 or 2 carbon atoms is preferable from the viewpoints of compatibility with other resins, adhesion to conductors, heat resistance, low thermal expansion, and mechanical properties.
- the alkylene group of the above is more preferable, and the methylene group is further preferable.
- Examples of the alkylidene group having 2 to 5 carbon atoms represented by X b2 include an ethylidene group, a propyridene group, an isopropylidene group, a butylidene group, an isobutylidene group, a pentylidene group and an isopentylidene group.
- an isopropylidene group is preferable from the viewpoint of compatibility with other resins, adhesiveness with a conductor, heat resistance, low thermal expansion property, and mechanical properties.
- p2 and p3 are each independently an integer of 0 to 4, and from the viewpoint of availability, both are preferably an integer of 0 to 3, more preferably an integer of 0 to 2, and even more preferably 0 or 2. Is.
- p2 or p3 is an integer of 2 or more, the plurality of R b2s or R b3s may be the same or different from each other.
- the divalent group represented by the general formula (b1-3-1) represented by X b2 is as follows.
- R b4 and R b5 are independently aliphatic hydrocarbon groups or halogen atoms having 1 to 5 carbon atoms.
- X b3 is an alkylene group having 1 to 5 carbon atoms and 2 to 5 carbon atoms. It is an alkylidene group, an ether group, a sulfide group, a sulfonyl group, a carbonyloxy group, a keto group or a single bond.
- P4 and p5 are independently integers of 0 to 4, respectively. * Is a bond position to another structure. Shows.)
- the aliphatic hydrocarbon group having 1 to 5 carbon atoms and the halogen atom represented by R b4 and R b5 will be described in the same manner as in the case of R b1 .
- Examples of the alkylene group having 1 to 5 carbon atoms and the alkylidene group having 2 to 5 carbon atoms represented by X b3 are the same as the alkylene group having 1 to 5 carbon atoms and the alkylidene group having 2 to 5 carbon atoms represented by X b2 . Be done.
- an alkylidene group having 2 to 5 carbon atoms is preferable, an alkylidene group having 2 to 4 carbon atoms is more preferable, and an isopropylidene group is further preferable.
- p4 and p5 are each independently an integer of 0 to 4, and from the viewpoint of availability, both are preferably an integer of 0 to 2, more preferably 0 or 1, and even more preferably 0.
- p4 or p5 is an integer of 2 or more
- the plurality of R b4s or R b5s may be the same or different from each other.
- p6 is an integer from 0 to 10. * Indicates the bonding position to other structures.
- p6 is preferably an integer of 0 to 5, more preferably an integer of 0 to 4, and even more preferably an integer of 0 to 3.
- R b6 and R b7 are each independently a hydrogen atom or an aliphatic hydrocarbon group having 1 to 5 carbon atoms.
- P8 is an integer of 1 to 8; * is a bond to another structure. Indicates the position.
- R b6 and R b7 The aliphatic hydrocarbon group having 1 to 5 carbon atoms represented by R b6 and R b7 will be described in the same manner as in the case of R b1 .
- p8 is an integer of 1 to 8, preferably an integer of 1 to 5, more preferably an integer of 1 to 3, and even more preferably 1.
- the plurality of R b6s or R b7s may be the same or different from each other.
- the component (B1) is an aminomaleimide compound having a structural unit derived from the maleimide compound (b1) and a structural unit derived from the diamine compound (b2).
- the component (B1) one type may be used alone, or two or more types may be used in combination.
- the structural unit derived from the component (b1) for example, at least one N-substituted maleimide group among the N-substituted maleimide groups of the component (b1) has a Michael addition reaction with the amino group of the diamine compound (b2).
- the structural unit derived from the component (b1) contained in the component (B1) may be one type alone or two or more types.
- Examples of the structural unit derived from the component (b1) include a group represented by the following general formula (b1-7), a group represented by the following general formula (b1-8), and the like.
- X b1 is a divalent organic group, and * indicates the bond position to another structure.
- the content of the structural unit derived from the component (b1) in the aminomaleimide compound (B1) is not particularly limited, but is preferably 5 to 95% by mass, more preferably 30 to 93% by mass, and further preferably 60 to 90% by mass. %, Especially preferably 75 to 90% by mass. (B1) When the content of the structural unit derived from the component is within the above range, the dielectric property and the film handleability tend to be better.
- the structural unit derived from the component (b2) for example, of the two amino groups possessed by the component (b2), one or both amino groups are added with the N-substituted maleimide group possessed by the maleimide compound (b1) and Michael addition. Examples thereof include structural units formed by reaction.
- the structural unit derived from the component (b2) contained in the component (B1) may be one type alone or two or more types.
- the amino group contained in the component (b2) is preferably a primary amino group.
- Examples of the structural unit derived from the component (b2) include a group represented by the following general formula (b2-1), a group represented by the following general formula (b2-2), and the like.
- X b4 is a divalent organic group, and * indicates the bond position to another structure.
- X b4 in the general formula (b2-1) and the general formula (b2-2) is a divalent organic group, and corresponds to a divalent group obtained by removing two amino groups from the component (b2). ..
- X b4 in the general formula (b2-1) and the general formula (b2-2) is a divalent group represented by the following general formula (b2-3).
- R b11 and R b12 are independently aliphatic hydrocarbon groups having 1 to 5 carbon atoms, alkoxy groups having 1 to 5 carbon atoms, hydroxyl groups or halogen atoms.
- X b5 has 1 carbon atom.
- P9 and p10 are independently integers of 0 to 4. * Indicates a binding position to another structure.
- R b13 and R b14 are independently aliphatic hydrocarbon groups or halogen atoms having 1 to 5 carbon atoms.
- X b6 is an alkylene group having 1 to 5 carbon atoms and 2 to 5 carbon atoms. Alkylidene group, m-phenylenediisopropyridene group, p-phenylenediisopropyridene group, ether group, sulfide group, sulfonyl group, carbonyloxy group, keto group or single bond.
- P11 and p12 are 0 independently. It is an integer of ⁇ 4. * indicates the position of connection to other structures.
- R b15 is an aliphatic hydrocarbon group or a halogen atom having 1 to 5 carbon atoms.
- X b7 and X b8 are independently alkylene groups having 1 to 5 carbon atoms and 2 to 5 carbon atoms, respectively. Alkylidene group, ether group, sulfide group, sulfonyl group, carbonyloxy group, keto group or single bond.
- P13 is an integer of 0 to 4. * Indicates the bond position to other structures.
- Examples of the aliphatic hydrocarbon group or halogen atom of 1 to 5 include the same as R b1 in the above general formula (b1-2).
- As the aliphatic hydrocarbon group an aliphatic hydrocarbon group having 1 to 3 carbon atoms is preferable, an alkyl group having 1 to 3 carbon atoms is more preferable, and a methyl group and an ethyl group are further preferable.
- the number of carbon atoms represented by X b5 in the general formula (b2-3), X b6 in the general formula (b2-3-1), and X b7 and X b8 in the general formula (b2-3-2) is 1.
- the alkylene group to 5 and the alkylidene group having 2 to 5 carbon atoms will be described in the same manner as in the case of X b2 in the above general formula (b1-3).
- P9 and p10 in the above general formula (b2-3) are independently integers of 0 to 4, and from the viewpoint of availability, both are preferably integers of 0 to 3, more preferably 0 to 3. An integer of 2, more preferably 0 or 2.
- P11 and p12 in the above general formula (b2-3-1) are independently integers of 0 to 4, and from the viewpoint of availability, both are preferably integers of 0 to 2, more preferably. It is 0 or 1, more preferably 0.
- R b13s or R b14s may be the same or different from each other.
- P13 in the above general formula (b2-3-2) is an integer of 0 to 4, preferably an integer of 0 to 2, more preferably 0 or 1, and even more preferably 0 from the viewpoint of availability. be.
- component (b2) examples include 4,4'-diaminodiphenylmethane, 4,4'-diamino-3,3'-dimethyldiphenylmethane, 4,4'-diamino-3,3'-diethyldiphenylmethane, 4,4.
- the component (b2) includes 4,4'-diaminodiphenylmethane and 4,4'-diamino from the viewpoint of excellent solubility in an organic solvent, reactivity with the maleimide compound (b1), and heat resistance.
- the component (b2) is preferably 3,3'-dimethyl-5,5'-diethyl-4,4'-diaminodiphenylmethane from the viewpoint of excellent dielectric properties and low water absorption.
- the component (b2) is preferably 2,2-bis [4- (4-aminophenoxy) phenyl] propane from the viewpoint of excellent mechanical properties such as high adhesiveness to a conductor, elongation, and breaking strength.
- the component (b2) is excellent in solubility in an organic solvent, reactivity at the time of synthesis, heat resistance, high adhesion to a conductor, and also excellent in dielectric properties and low hygroscopicity.
- 4,4'-[1,3-phenylenebis (1-methylethylidene)] bisaniline and 4,4'-[1,4-phenylenebis (1-methylethylidene)] bisaniline are preferable.
- the content of the structural unit derived from the component (b2) in the aminomaleimide compound (B1) is not particularly limited, but is preferably 5 to 95% by mass, more preferably 7 to 70% by mass, and further preferably 10 to 40% by mass. %, Especially preferably 10 to 25% by mass. (B2)
- the content of the structural unit derived from the component is within the above range, the dielectric properties, heat resistance, flame retardancy and glass transition temperature tend to be better.
- the equivalent ratio (Tb2 / Tb1) of the group (including the N-substituted maleimide group) to the total equivalent (Tb1) is not particularly limited, but is preferably 0.05 to 10, more preferably 0.5 to 7, and further. It is preferably 1 to 5. When the equivalent ratio (Tb2 / Tb1) is within the above range, the dielectric properties, heat resistance, flame retardancy and glass transition temperature tend to be better.
- the number average molecular weight of the aminomaleimide compound (B1) is not particularly limited, but is preferably 400 to 10,000, more preferably 500 to 5,000, still more preferably 600 to 2,000, and particularly preferably 700 to 1, It is 500.
- the aminomaleimide compound (B1) is an aminomaleimide compound represented by the following general formula (b2-4) from the viewpoints of dielectric properties, solubility in an organic solvent, high adhesiveness to a conductor, moldability of a resin film, and the like. Is preferably contained.
- the component (B1) can be produced, for example, by reacting a maleimide compound (b1) with a diamine compound (b2) in an organic solvent. By reacting the maleimide compound (b1) with the diamine compound (b2), the aminomaleimide compound (B1) obtained by the Michael addition reaction between the maleimide compound (b1) and the diamine compound (b2) is obtained.
- reaction catalyst When the maleimide compound (b1) and the diamine compound (b2) are reacted, a reaction catalyst may be used if necessary.
- the reaction catalyst include acidic catalysts such as p-toluenesulfonic acid; amines such as triethylamine, pyridine and tributylamine; imidazoles such as methylimidazole and phenylimidazole; and phosphorus catalysts such as triphenylphosphine. ..
- One type of reaction catalyst may be used alone, or two or more types may be used in combination.
- the amount of the reaction catalyst to be blended is not particularly limited, but for example, 0.01 to 5 parts by mass may be used with respect to 100 parts by mass of the total amount of the maleimide compound (b1) and the diamine compound (b2).
- the reaction temperature of the above reaction is preferably 50 to 160 ° C. from the viewpoint of workability such as reaction rate and suppression of gelation during the reaction. Further, the reaction time of the above reaction is preferably 1 to 10 hours from the same viewpoint. Further, in this step, the solid content concentration and the solution viscosity of the reaction raw material may be adjusted by adding or concentrating the organic solvent.
- the solid content concentration of the reaction raw material is not particularly limited, but is preferably 10 to 90% by mass, more preferably 15 to 85% by mass, and further preferably 20 to 80% by mass. When the solid content concentration of the reaction raw material is at least the above lower limit value, a good reaction rate is obtained, and the productivity tends to be better. Further, when the solid content concentration of the reaction raw material is not more than the above upper limit value, better solubility is obtained, stirring efficiency is improved, and gelation tends to be further suppressed.
- the content thereof is not particularly limited, but from the viewpoint of heat resistance and dielectric properties, the total amount of the resin components in the resin composition is 100 parts by mass. It is preferably 10 to 90 parts by mass, more preferably 20 to 80 parts by mass, still more preferably 30 to 70 parts by mass, and particularly preferably 40 to 60 parts by mass.
- the component (C) is not particularly limited, but is not particularly limited.
- (C1) Conjugated diene polymer having a vinyl group in the side chain [hereinafter, may be referred to as "(c1) component”. ]
- the conjugated diene polymer having (c1) a vinyl group in the side chain may be referred to as (c2) a maleimide compound having two or more N-substituted maleimide groups [hereinafter, “component (c2)”.
- Modified conjugated diene polymer (C1) [hereinafter, may be referred to as "modified conjugated diene polymer (C1)” or "(C1) component”. ] Is preferable.
- the component (C) one type may be used alone, or two or more types may be used in combination.
- the component (c1) is not particularly limited as long as it is a conjugated diene polymer having a vinyl group in the side chain.
- the component (c1) one type may be used alone, or two or more types may be used in combination.
- the component (c1) is preferably a conjugated diene polymer having a plurality of vinyl groups in the side chain.
- the number of vinyl groups contained in one molecule of the component (c1) is not particularly limited, but is preferably 3 or more, more preferably 5 or more, still more preferably 10 or more from the viewpoint of dielectric properties and heat resistance. be.
- the conjugated diene polymer means a polymer of a conjugated diene compound.
- the conjugated diene compound include 1,3-butadiene, isoprene, 1,3-pentadiene, 2,3-dimethyl-1,3-butadiene, 2-phenyl-1,3-butadiene, 1,3-hexadiene and the like.
- the conjugated diene polymer may be a polymer of one kind of conjugated diene compound or a copolymer of two or more kinds of conjugated diene compounds.
- the conjugated diene polymer may be a copolymer of one or more kinds of conjugated diene compounds and one or more kinds of monomers other than the conjugated diene compounds.
- the polymerization mode in that case is not particularly limited, and may be any of random polymerization, block polymerization and graft polymerization.
- component (c1) examples include polybutadiene having a 1,2-vinyl group, a butadiene-styrene copolymer having a 1,2-vinyl group, polyisoprene having a 1,2-vinyl group, and the like. Be done. Among these, polybutadiene having a 1,2-vinyl group and a butadiene-styrene copolymer having a 1,2-vinyl group are preferable, and polybutadiene having a 1,2-vinyl group is preferable from the viewpoint of dielectric properties and heat resistance. More preferred.
- the butadiene-derived 1,2-vinyl group contained in the component (c1) is a vinyl group contained in the butadiene-derived structural unit represented by the following formula (c1-1).
- the component (c1) is polybutadiene having a 1,2-vinyl group
- the content of the structural unit having a 1,2-vinyl group with respect to all the structural units derived from butadiene constituting the polybutadiene [hereinafter, "vinyl”. It may be referred to as "group content”. ] Is not particularly limited, but is preferably 50 mol% or more, more preferably 60 mol% or more, still more preferably 70 mol, from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance. % Or more, particularly preferably 80 mol% or more, and most preferably 85 mol% or more.
- the upper limit of the vinyl group content is not particularly limited, and may be 100 mol% or less, 95 mol% or less, or 90 mol% or less.
- the structural unit having a 1,2-vinyl group a structural unit derived from butadiene represented by the above formula (c1-1) is preferable. From the same viewpoint, the polybutadiene having a 1,2-vinyl group is preferably a 1,2-polybutadiene homopolymer.
- the number average molecular weight of the component (c1) is not particularly limited, but is preferably 400 to 2,500, more preferably 500 to 500, from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance. It is 2,000, more preferably 600 to 1,800, and particularly preferably 700 to 1,500.
- the component (C1) is a modified conjugated diene polymer obtained by modifying (c1) a conjugated diene polymer having a vinyl group in the side chain with (c2) a maleimide compound having two or more N-substituted maleimide groups.
- the component (c2) may be any maleimide compound having two or more N-substituted maleimide groups, and the above-mentioned maleimide compound or the derivative (B) thereof can be used.
- the component (c2) one type may be used alone, or two or more types may be used in combination.
- the components (c2) include solubility in an organic solvent, suppression of gelation during the reaction, compatibility of the component (C1) with other resins, dielectric properties, low thermal expansion, and heat resistance. Therefore, an aromatic bismaleimide compound substituted with an aliphatic hydrocarbon group is preferable, and a compound represented by the following general formula (c2-1) is more preferable.
- R c1 and R c2 are independently aliphatic hydrocarbon groups having 1 to 5 carbon atoms.
- X c1 is an alkylene group having 1 to 5 carbon atoms and an alkylidene group having 2 to 5 carbon atoms.
- Q1 and q2 are independently, respectively. It is an integer of 0 to 4, and q1 + q2 is an integer of 1 or more.
- Examples of the aliphatic hydrocarbon group having 1 to 5 carbon atoms represented by R c1 and R c2 include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group and a t-butyl group. Examples thereof include an n-pentyl group.
- an aliphatic hydrocarbon group having 1 to 3 carbon atoms is preferable, and an alkyl group having 1 to 3 carbon atoms is preferable from the viewpoint of compatibility with other resins and suppression of gelation during the reaction. Is more preferable, and a methyl group and an ethyl group are further preferable.
- Examples of the alkylene group having 1 to 5 carbon atoms represented by X c1 include a methylene group, a 1,2-dimethylene group, a 1,3-trimethylene group, a 1,4-tetramethylene group, a 1,5-pentamethylene group and the like. Can be mentioned.
- an alkylene group having 1 to 3 carbon atoms is preferable, an alkylene group having 1 or 2 carbon atoms is more preferable, and a methylene group is further preferable.
- Examples of the alkylidene group having 2 to 5 carbon atoms represented by X c1 include an ethylidene group, a propyridene group, an isopropylidene group, a butylidene group, an isobutylidene group, a pentylidene group and an isopentylidene group.
- q1 and q2 are independently integers of 0 to 4, and are preferably integers of 1 to 3 from the viewpoints of availability, compatibility with other resins, and suppression of gelation during the reaction. , More preferably 1 or 2, still more preferably 2. From the same viewpoint, q1 + q2 is preferably an integer of 1 to 8, more preferably an integer of 2 to 6, and even more preferably 4. When q1 or q2 is an integer of 2 or more, the plurality of R c1s or R c2s may be the same or different from each other.
- the divalent group represented by the general formula (c2-1-1) represented by X c1 is as follows.
- R c3 and R c4 are independently aliphatic hydrocarbon groups or halogen atoms having 1 to 5 carbon atoms.
- X c2 is an alkylene group having 1 to 5 carbon atoms and 2 to 5 carbon atoms. It is an alkylidene group, an ether group, a sulfide group, a sulfonyl group, a carbonyloxy group, a keto group or a single bond.
- Q3 and q4 are independently integers of 0 to 4).
- the aliphatic hydrocarbon group having 1 to 5 carbon atoms and the halogen atom represented by R c3 and R c4 will be described in the same manner as in the case of R c1 .
- Examples of the alkylene group having 1 to 5 carbon atoms and the alkylidene group having 2 to 5 carbon atoms represented by X c2 are the same as the alkylene group having 1 to 5 carbon atoms and the alkylidene group having 2 to 5 carbon atoms represented by X c1 .
- q3 and q4 are each independently an integer of 0 to 4, and from the viewpoint of availability, both are preferably an integer of 0 to 2, more preferably 0 or 1, and even more preferably 0.
- the plurality of R c3s or R c4s may be the same or different from each other.
- Examples of the compound represented by the general formula (c2-1) include solubility in an organic solvent and suppression of gelation during the reaction, compatibility with the obtained component (C1) with other resins, and dielectric. From the viewpoint of properties, low thermal expansion and heat resistance, 3,3'-dimethyl-5,5'-diethyl-4,4'-diphenylmethanebismaleimide is preferable.
- the modified conjugated diene polymer (C1) is a substituent formed by reacting a vinyl group of the conjugated diene polymer (c1) with an N-substituted maleimide group of the maleimide compound (c2) in the side chain [hereinafter, "" It may be referred to as "substituent (x)". ] It is preferable to have.
- the substituent (x) has the following general formula (C-11) or (C) as a structure derived from the maleimide compound (c2) from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance. It is preferable that the group contains the structure represented by -12).
- X C1 is a divalent organic group
- * C1 is a site where the conjugated diene polymer (c1) is bonded to a carbon atom derived from a vinyl group in the side chain.
- * C2 is another It is a part that binds to an atom.
- the substituent (x) is represented by the following general formula (C-21) as a structure derived from the maleimide compound (c2) from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance. It is more preferable to include at least one selected from the group consisting of the above-mentioned structure and the structure represented by the following general formula (C-22).
- the modified conjugated diene polymer (C1) preferably has a substituent (x) and a vinyl group (y) in the side chain.
- the extent to which the substituent (x) is present in the modified conjugated diene polymer (C1) is the degree to which the vinyl group of the component (c1) is modified by the component (c2) [hereinafter, "vinyl group modification rate”. May be called. ] Can be used as an index.
- the vinyl group modification rate is not particularly limited, but is preferably 20 to 70%, more preferably 30 to 60%, still more preferably, from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance. Is 35 to 50%.
- the vinyl group modification rate is a value obtained by the method described in Examples.
- the vinyl group (y) is preferably a 1,2-vinyl group having a structural unit derived from butadiene.
- the component (C1) can be produced by reacting a conjugated diene polymer (c1) with a maleimide compound (c2).
- the method for reacting the conjugated diene polymer (c1) with the maleimide compound (c2) is not particularly limited.
- the component (C1) is obtained by charging a conjugated diene polymer (c1), a maleimide compound (c2), a reaction catalyst and an organic solvent into a reaction vessel and reacting them with heating, heat retention, stirring, etc., if necessary. Can be done.
- the reaction temperature of the above reaction is preferably 70 to 120 ° C., more preferably 80 to 110 ° C., still more preferably 85 to 105 ° C. from the viewpoint of workability and suppression of gelation during the reaction.
- the reaction time of the above reaction is preferably 0.5 to 15 hours, more preferably 1 to 10 hours, still more preferably 3 to 7 hours.
- these reaction conditions can be appropriately adjusted according to the type of raw material used and the like, and are not particularly limited.
- organic solvent used in the above reaction examples include alcohol solvents such as methanol, ethanol, butanol, butyl cellosolve, ethylene glycol monomethyl ether and propylene glycol monomethyl ether; and ketone solvents such as acetone, methyl ethyl acetate, methyl isobutyl ketone and cyclohexanone.
- alcohol solvents such as methanol, ethanol, butanol, butyl cellosolve, ethylene glycol monomethyl ether and propylene glycol monomethyl ether
- ketone solvents such as acetone, methyl ethyl acetate, methyl isobutyl ketone and cyclohexanone.
- Aromatic hydrocarbon solvents such as toluene, xylene, mesitylen; ester solvents such as methoxyethyl acetate, ethoxyethyl acetate, butoxyethyl acetate, ethyl acetate; N, N-dimethylformamide, N, N-dimethylacetamide, N Examples thereof include a nitrogen atom-containing solvent such as methyl-2-pyrrolidone.
- the organic solvent one kind may be used alone, or two or more kinds may be used in combination. Among these, toluene is preferable from the viewpoint of resin solubility.
- the total content of the conjugated diene polymer (c1) and the maleimide compound (c2) in the reaction solution is not particularly limited, but is preferably 10 to 70% by mass, more preferably 15 to. It is 60% by mass, more preferably 20 to 50% by mass.
- the total content of the conjugated diene polymer (c1) and the maleimide compound (c2) is at least the above lower limit, a good reaction rate is obtained and the productivity tends to be better.
- the total content of the conjugated diene polymer (c1) and the maleimide compound (c2) is not more than the above upper limit value, better solubility is obtained, stirring efficiency is improved, and gelation tends to be further suppressed. be.
- reaction catalyst organic peroxide is preferable from the viewpoint of obtaining sufficient reactivity while suppressing gelation during the reaction, and ⁇ , ⁇ '-bis (t-butylperoxy) diisopropylbenzene is more preferable. preferable.
- One type of reaction catalyst may be used alone, or two or more types may be used in combination.
- the amount of the reaction catalyst used is not particularly limited, but is preferably 0.01 to 1.2 parts by mass, more preferably 0, with respect to 100 parts by mass of the total amount of the conjugated diene polymer (c1) and the maleimide compound (c2). It is 03 to 1.0 part by mass, more preferably 0.05 to 0.8 part by mass.
- the ratio of the number of moles (M m ) of the N-substituted maleimide group of the maleimide compound (c2) to the number of moles (M v ) of the side chain vinyl group of the conjugated diene polymer (c1) in carrying out the above reaction is not particularly limited, but is preferably 0.001 to 0.5, from the viewpoint of compatibility with other resins of the obtained (C1) component and suppression of gelation during the reaction. It is preferably 0.005 to 0.1, more preferably 0.008 to 0.05.
- the number average molecular weight of the component (C) is not particularly limited, but is preferably 700 to 6,000, more preferably 800 to 6,000, from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance. It is 5,000, more preferably 900 to 4,500, and particularly preferably 1,000 to 4,000.
- the content thereof is not particularly limited, but from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance, the resin.
- the content thereof is not particularly limited, but from the viewpoint of compatibility with other resins, dielectric properties, low thermal expansion and heat resistance, the resin.
- 100 parts by mass of the total resin components in the composition preferably 1 to 50 parts by mass, more preferably 5 to 40 parts by mass, still more preferably 10 to 30 parts by mass, and particularly preferably 15 to 25 parts by mass. be.
- the component (D) is not particularly limited as long as it is a thermoplastic elastomer having a structural unit derived from a styrene compound.
- the component (D) one type may be used alone, or two or more types may be used in combination.
- the component (D) preferably has a structural unit represented by the following general formula (d-1).
- R d1 is a hydrogen atom or an alkyl group having 1 to 5 carbon atoms
- R d2 is an alkyl group having 1 to 5 carbon atoms
- K is an integer of 0 to 5).
- Examples of the alkyl group having 1 to 5 carbon atoms represented by R d1 and R d2 include a methyl group, an ethyl group, an n-propyl group and the like. Among these, an alkyl group having 1 to 3 carbon atoms is preferable, an alkyl group having 1 or 2 carbon atoms is more preferable, and a methyl group is further preferable.
- k is preferably an integer of 0 to 2, more preferably 0 or 1, and even more preferably 0.
- Examples of the structural unit other than the structural unit derived from the styrene compound contained in the component (D) include a structural unit derived from butadiene, a structural unit derived from isoprene, a structural unit derived from maleic acid, a structural unit derived from maleic anhydride, and the like. Can be mentioned.
- the structural unit derived from butadiene and the structural unit derived from isoprene may be hydrogenated.
- the structural unit derived from butadiene is a structural unit in which ethylene units and butylene units are mixed
- the structural unit derived from isoprene is a structural unit in which ethylene units and propylene units are mixed.
- the components (D) include hydrogenated additives (SEBS, SBBS) of a styrene-butadiene-styrene block copolymer and styrene from the viewpoints of dielectric properties, adhesion to conductors, heat resistance, glass transition temperature and low thermal expansion.
- SEBS hydrogenated additives
- SBBS hydrogenated additives
- SEPS hydrogenated additive
- SMA styrene-maleic anhydride copolymer
- SEBS hydrogen additive
- SEPS hydrogen additive
- styrene content the content of structural units derived from styrene
- styrene content Is not particularly limited, but is preferably 5 to 80% by mass, more preferably 10 to 75% by mass, still more preferably, from the viewpoints of dielectric properties, adhesiveness to conductors, heat resistance, glass transition temperature and low thermal expansion. Is 15 to 70% by mass, particularly preferably 20 to 50% by mass.
- the melt flow rate (MFR) of SEBS is not particularly limited, but is preferably 0.1 to 20 g / 10 min, more preferably 0.3 to 17 g under the measurement conditions of 230 ° C. and a load of 2.16 kgf (21.2 N). / 10 min, more preferably 0.5 to 15 g / 10 min.
- the weight average molecular weight (Mw) of the component (D) is not particularly limited, but is preferably 12,000 to 1,000,000, more preferably 30,000 to 500,000, still more preferably 50,000 to 120, 000, particularly preferably 70,000 to 100,000.
- the weight average molecular weight (Mw) means a value measured by gel permeation chromatography (GPC) in terms of polystyrene.
- the content thereof is not particularly limited, but from the viewpoint of dielectric properties, heat resistance, moldability and compatibility, the resin component in the resin composition It is preferably 10 to 60 parts by mass, more preferably 15 to 50 parts by mass, still more preferably 20 to 40 parts by mass, and particularly preferably 25 to 30 parts by mass with respect to 100 parts by mass of the total.
- the resin composition of the present embodiment tends to exhibit excellent dielectric properties while having even better heat resistance.
- the component (E) one type may be used alone, or two or more types may be used in combination.
- component (E) examples include 2-methylimidazole, 2-ethylimidazole, 2-undecylimidazole, 2-heptadecylimidazole, 2-phenylimidazole, 1,2-dimethylimidazole, and 2-ethyl-1-methyl.
- Imidazole 1,2-diethylimidazole, 1-ethyl-2-methylimidazole, 2-ethyl-4-methylimidazole, 4-ethyl-2-methylimidazole, 1-isobutyl-2-methylimidazole, 2-phenyl-4 -Methylimidazole, 1-benzyl-2-phenylimidazole, 1-cyanoethyl-2-methylimidazole, 1-cyanoethyl-2-ethylimidazole, 1-cyanoethyl-2-phenylimidazole, 1-cyanoethyl-2-ethyl-4- Methylimidazole, 2-phenyl-4,5-dihydroxymethylimidazole, 2-phenyl-4-methyl-5-hydroxymethylimidazole, 2,3-dihydro-1H-pyrrolo [1,2-a] benzimidazole, 2, 4-Diamino-6- [2'-methylimidazolyl- (1')] eth
- Examples thereof include a salt of the above-mentioned imidazole compound and a salt of isocyanuric acid, and a modified imidazole compound such as a salt of the above-mentioned imidazole compound and hydrobromic acid.
- the modified imidazole compound represented by the following general formula (e-1) or the following general formula (e-2) is preferable.
- R e1 , R e2 , R e3 and R e4 are each independently a hydrogen atom, an aliphatic hydrocarbon group or a phenyl group having 1 to 20 carbon atoms, and X e1 is an alkylene group or a divalent group. It is an aromatic hydrocarbon group of.
- R e5 , R e6 , R e7 and R e8 are independently hydrogen atoms, an aliphatic hydrocarbon group having 1 to 20 carbon atoms or a phenyl group, and X e2 is an alkylene group and an alkylidene group. , Ether group or sulfonyl group.
- the resin composition of the present embodiment is further excellent in compatibility of the resin component by containing the modified imidazole compound represented by the general formula (e-1) or the general formula (e-2). It will be.
- the cause is not clear, but it is presumed as follows.
- the modified imidazole compound has an imidazolyl group as a highly polar group, and "-CH 2 -X e1 -CH 2- " in the general formula (e-1) and the general formula (e-2) as a group having a low polarity. It has a hydrocarbon group represented by "-Ph-X e2 -Ph-" in it. Therefore, it is presumed that the modified imidazole compound functions as a compatibilizer between the highly polar component (B) and the less polar elastomer.
- the resin composition containing the modified imidazole compound represented by the above general formula (e-1) tends to have particularly excellent dielectric properties while having good heat resistance. Further, the resin composition containing the modified imidazole compound represented by the general formula (e-2) tends to have particularly excellent heat resistance as well as improved dielectric properties.
- the aliphatic hydrocarbon group represented by R e1 , R e2 , R e3 and R e4 in the above general formula (e-1) has 1 to 20 carbon atoms, preferably 1 to 10 and more preferably 1 to 5 carbon atoms. , More preferably 1 or 2.
- Examples of the aliphatic hydrocarbon group represented by R e1 , R e2 , R e3 and R e4 include a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group and a decyl group.
- Alkyl groups such as dodecyl group, tridecyl group, tetradecyl group, pentadecyl group, hexadecyl group, heptadecyl group and stearyl group; alkenyl group; alkynyl group and the like can be mentioned.
- These aliphatic hydrocarbon groups may be linear or branched chain. Among these, a methyl group and an ethyl group are preferable.
- the carbon number of the alkylene group represented by Xe1 in the general formula (e-1) is preferably 1 to 10, more preferably 2 to 8, and even more preferably 3 to 5.
- Examples of the alkylene group represented by X e1 include a methylene group, an ethylene group, a 1,3-trimethylene group, a 1,4-tetramethylene group, a 1,5-pentamethylene group, a 1,6-hexamethylene group and the like. Be done. Among these, a 1,4-tetramethylene group is preferable.
- the number of carbon atoms of the divalent aromatic hydrocarbon group represented by X e1 is preferably 6 to 20, more preferably 6 to 15, and even more preferably 6 to 12.
- Examples of the divalent aromatic hydrocarbon group represented by X e1 include a phenylene group, a biphenylene group, a terphenylene group, a naphthylene group, an anthrylene group and the like.
- the aliphatic hydrocarbon group represented by R e5 , R e6 , R e7 and R e8 in the above general formula (e-2) has 1 to 20 carbon atoms, preferably 1 to 10 and more preferably 1 to 5 carbon atoms. , More preferably 1 or 2.
- Examples of the aliphatic hydrocarbon group represented by R e5 , R e6 , R e7 and R e8 include a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group and a decyl group.
- Alkyl groups such as dodecyl group, tridecyl group, tetradecyl group, pentadecyl group, hexadecyl group, heptadecyl group and stearyl group; alkenyl group; alkynyl group and the like can be mentioned.
- These aliphatic hydrocarbon groups may be linear or branched chain.
- R e5 , R e6 , R e7 and R e8 , R e5 and R e6 are preferably hydrogen atoms, and R e7 and R e8 are preferably phenyl groups.
- the carbon number of the alkylene group represented by Xe2 in the general formula ( e -2) is preferably 1 to 10, more preferably 2 to 8, and even more preferably 3 to 5.
- Examples of the alkylene group represented by X e2 include a methylene group, an ethylene group, a 1,3-trimethylene group, a 1,4-tetramethylene group, a 1,5-pentamethylene group, a 1,6-hexamethylene group and the like. Be done.
- the carbon number of the alkylidene group represented by X- e2 is preferably 3 to 10, more preferably 3 to 8, and even more preferably 3 to 5.
- Examples of the alkylidene group represented by X- e2 include an ethylidene group, a propyridene group, an isopropylidene group, a butylidene group, an isobutylidene group, a pentylidene group, and an isopentylidene group.
- the propylidene group is preferable.
- the content thereof is not particularly limited, but the total of the resin components in the resin composition is 100 from the viewpoint of compatibility, dielectric properties and heat resistance. It is preferably 0.01 to 10 parts by mass, more preferably 0.1 to 6 parts by mass, still more preferably 0.5 to 4 parts by mass, and particularly preferably 0.8 to 2 parts by mass with respect to parts by mass. ..
- the resin composition of the present embodiment may be referred to as an inorganic filler (F) [hereinafter, "(F) component”. ],
- the coefficient of thermal expansion, elastic modulus, heat resistance and flame retardancy tend to be further improved.
- the inorganic filler (F) one type may be used alone, or two or more types may be used in combination.
- the component (F) is not particularly limited, but is, for example, silica, alumina, titanium oxide, mica, beryllia, barium titanate, potassium titanate, strontium titanate, calcium titanate, aluminum carbonate, magnesium hydroxide, and hydroxide.
- examples thereof include aluminum, aluminum silicate, calcium carbonate, calcium silicate, magnesium silicate, silicon nitride, boron nitride, clay, talc, aluminum borate, silicon carbide and the like.
- silica, alumina, mica, and talc are preferable, silica and alumina are more preferable, and silica is further preferable, from the viewpoints of thermal expansion coefficient, elastic modulus, heat resistance, and flame retardancy.
- silica examples include precipitated silica produced by a wet method and having a high water content, and dry silica produced by a dry method and containing almost no bound water or the like. Further, as the dry method silica, for example, crushed silica, fumed silica, molten silica and the like can be mentioned depending on the difference in the manufacturing method.
- the particle size of the inorganic filler (F) is not particularly limited, but is preferably 0.01 to 20 ⁇ m, more preferably 0.1 to 10 ⁇ m, still more preferably 0.2 to 1 ⁇ m, and particularly preferably 0.3 to 0. It is 0.8 ⁇ m.
- the particle size of the inorganic filler (F) refers to the average particle size, and when the cumulative frequency distribution curve by the particle size is obtained with the total volume of the particles as 100%, the particles having a volume corresponding to 50%. It is the diameter.
- the particle size of the inorganic filler (F) can be measured by a particle size distribution measuring device or the like using a laser diffraction / scattering method.
- Examples of the shape of the inorganic filler (F) include a spherical shape and a crushed shape, and the shape is preferably spherical.
- the content of the inorganic filler (F) in the resin composition is not particularly limited, but has low thermal expansion property, elastic modulus, heat resistance and heat resistance. From the viewpoint of flame retardancy, it is preferably 10 to 70% by mass, more preferably 20 to 65% by mass, still more preferably 30 to 60% by mass, particularly, with respect to the total solid content (100% by mass) of the resin composition. It is preferably 40 to 55% by mass.
- the resin composition of the present embodiment contains the inorganic filler (F)
- a coupling agent is used in combination as necessary for the purpose of improving the dispersibility of the inorganic filler (F) and the adhesion with the organic component. You may.
- the resin composition of the present embodiment tends to further improve the flame retardancy of the resin composition by containing the flame retardant (G).
- the flame retardant (G) may be used alone or in combination of two or more. Further, a flame retardant aid may be contained if necessary.
- Examples of the flame retardant (G) include phosphorus-based flame retardants, metal hydrates, halogen-based flame retardants, and the like. Among these, phosphorus-based flame retardants and metal hydrates are preferable from the viewpoint of environmental problems.
- -Phosphorus flame retardant- Phosphorus-based flame retardants which are generally used as flame retardants, can be used without particular limitation as long as they contain phosphorus atoms, but from the viewpoint of environmental problems, they do not contain halogen atoms. Is preferable.
- the phosphorus-based flame retardant may be an inorganic phosphorus-based flame retardant, but is organic from the viewpoints of dielectric properties, adhesion to conductors, heat resistance, glass transition temperature, low thermal expansion and flame retardancy. Phosphorus flame retardants are preferred.
- inorganic phosphorus-based flame retardant examples include red phosphorus; ammonium phosphate such as monoammonium phosphate, diammonium phosphate, triammonium phosphate, and ammonium polyphosphate; and inorganic nitrogen-containing phosphorus compounds such as phosphate amide. Phosphoric acid; phosphine oxide and the like.
- organic phosphorus-based flame retardant examples include aromatic phosphoric acid esters, mono-substituted phosphonic acid diesters, 2-substituted phosphinic acid esters, metal salts of 2-substituted phosphinic acid, organic nitrogen-containing phosphorus compounds, and cyclic organic phosphorus compounds.
- examples thereof include phosphine oxide compounds.
- aromatic phosphate esters, metal salts of disubstituted phosphinic acid, and phosphine oxide compounds are preferable.
- the metal salt of the disubstituted phosphinic acid include lithium salt, sodium salt, potassium salt, calcium salt, magnesium salt, aluminum salt, titanium salt, zinc salt and the like. Among these, aluminum salts are preferable.
- aromatic phosphate ester examples include triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyldiphenyl phosphate, cresyldi-2,6-xylenyl phosphate, resorcinolbis (diphenyl phosphate), 1,3. -Phenylene bis (di-2,6-xylenyl phosphate), bisphenol A-bis (diphenyl phosphate), 1,3-phenylene bis (diphenyl phosphate) and the like can be mentioned.
- Examples of the mono-substituted phosphonic acid diester include divinyl phenylphosphonate, diallyl phenylphosphonate, and bis (1-butenyl) phenylphosphonate.
- Examples of the disubstituted phosphinic acid ester include phenyl diphenylphosphine acid and methyl diphenylphosphine acid.
- Examples of the metal salt of disubstituted phosphinic acid include a metal salt of dialkylphosphinic acid, a metal salt of diallylphosphinic acid, a metal salt of divinylphosphinic acid, a metal salt of diarylphosphinic acid and the like. As these metal salts, aluminum salts are preferable.
- organic nitrogen-containing phosphorus compound examples include phosphazene compounds such as bis (2-allylphenoxy) phosphazene and dicredylphosphazene; melamine phosphate; melamine pyrophosphate; melamine polyphosphate; and melam polyphosphate.
- phosphazene compounds such as bis (2-allylphenoxy) phosphazene and dicredylphosphazene; melamine phosphate; melamine pyrophosphate; melamine polyphosphate; and melam polyphosphate.
- cyclic organic phosphorus compound examples include 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, 10- (2,5-dihydroxyphenyl) -9,10-dihydro-9-oxa-. Examples thereof include 10-phosphaphenanthrene-10-oxide.
- Examples of the phosphine oxide compound include paraxylylene bisdiphenylphosphine oxide, paraphenylene bisdiphenylphosphine oxide, ethylene bisdiphenylphosphine oxide, biphenylene bisdiphenylphosphine oxide, and naphthylene bisdiphenylphosphine oxide.
- aromatic phosphoric acid esters aromatic phosphoric acid esters, metal salts of disubstituted phosphinic acid, and phosphinoxide compounds are preferable, and 1,3-phenylenebis (di-2,6-xylenyl phosphate).
- 1,3-phenylenebis di-2,6-xylenyl phosphate
- Aluminum salt of dialkylphosphinic acid, paraxylylene bisdiphenylphosphine oxide are more preferred.
- Metal hydrate examples include aluminum hydroxide hydrate and magnesium hydroxide hydrate.
- halogen-based flame retardant examples include chlorine-based flame retardants and brominated flame retardants.
- chlorine-based flame retardant examples include chlorinated paraffin and the like.
- the content of the phosphorus-based flame retardant in the resin composition is not particularly limited, but is flame-retardant, moldable and heat-resistant.
- the total amount of the resin components in the resin composition is 100 parts by mass, preferably 0.2 to 10 parts by mass, more preferably 0.3 to 7 parts by mass, still more preferably, in terms of phosphorus atoms. It is 0.5 to 5 parts by mass, particularly preferably 1 to 3 parts by mass.
- the resin composition of the present embodiment may be further referred to as a component (H) [hereinafter, "(H) component” other than the above. ] May be contained.
- the other component (H) include thermosetting resins, thermoplastic polymers, curing accelerators, flame retardants, additives, organic solvents, and the like, in addition to the above components.
- the component (H) one type may be used alone or two or more types may be used in combination for each.
- Examples of the curing accelerator as the component (H) include an acidic catalyst such as p-toluenesulfonic acid; an amine compound such as triethylamine, pyridine and tributylamine; a tertiary amine compound; a quaternary ammonium compound; triphenylphosphine.
- an acidic catalyst such as p-toluenesulfonic acid
- an amine compound such as triethylamine, pyridine and tributylamine
- a tertiary amine compound such as triethylamine, pyridine and tributylamine
- a tertiary amine compound such as triethylamine, pyridine and tributylamine
- a tertiary amine compound such as triethylamine, pyridine and tributylamine
- a tertiary amine compound such as triethylamine, pyridine and tribu
- Phosphorus compounds such as: Dicumyl peroxide, 2,5-dimethyl-2,5-bis (t-butylperoxy) hexin-3, 2,5-dimethyl-2,5-bis (t-butylperoxy) )
- Organic peroxides such as hexane, t-butylperoxyisopropyl monocarbonate, ⁇ , ⁇ '-bis (t-butylperoxy) diisopropylbenzene; carboxylates such as manganese, cobalt and zinc.
- the additive as the component (H) include antioxidants, heat stabilizers, antistatic agents, ultraviolet absorbers, pigments, colorants, lubricants and the like.
- the amount of the component (H) used is not particularly limited and may be used within a range that does not impair the effects of the present invention.
- the resin composition of the present embodiment may contain an organic solvent. Diluting with an organic solvent tends to improve the handleability of the resin composition of the present embodiment and the ease of producing a prepreg described later.
- the resin composition containing an organic solvent may be generally referred to as a resin varnish or a varnish.
- organic solvent examples include alcohol solvents such as ethanol, propanol, butanol, methyl cellosolve, butyl cellosolve, and propylene glycol monomethyl ether; ketone solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether solvents such as tetrahydrofuran; Aromatic hydrocarbon solvents such as toluene, xylene and mesitylen; nitrogen atom-containing solvents such as dimethylformamide, dimethylacetamide and N-methylpyrrolidone; sulfur atom-containing solvents such as dimethylsulfoxide; ester solvents such as ⁇ -butyrolactone Can be mentioned.
- alcohol solvents such as ethanol, propanol, butanol, methyl cellosolve, butyl cellosolve, and propylene glycol monomethyl ether
- ketone solvents such as acetone, methyl
- alcohol-based solvents ketone-based solvents, nitrogen atom-containing solvents, and aromatic hydrocarbon-based solvents are preferable, aromatic hydrocarbon-based solvents are more preferable, and toluene is even more preferable.
- the solid content concentration of the resin composition is not particularly limited, but is preferably 30 to 90% by mass, more preferably 35 to 80% by mass, and further preferably 40. It is about 60% by mass.
- the solid content concentration of the resin composition is within the above range, the handleability of the resin composition tends to be easy, the impregnation property into the base material and the appearance of the produced prepreg tend to be better. Further, the solid content concentration of the resin in the prepreg, which will be described later, tends to be easily adjusted, and the production of the prepreg having a desired thickness tends to be easier.
- the resin composition of the present embodiment can be produced by mixing each of the above components by a known method. At this time, each component may be dissolved or dispersed while stirring. Conditions such as mixing order, temperature, and time are not particularly limited, and may be arbitrarily set according to the type of raw material and the like.
- the dielectric constant (Dk) of the cured product of the present embodiment at 10 GHz is not particularly limited, but is preferably 3.0 or less, more preferably 2.9 or less, still more preferably 2.8 or less.
- the dielectric constant (Dk) is a value based on the cavity resonator perturbation method, and more specifically, a value measured by the method described in the examples. Further, in the present specification, the term "dielectric constant" simply means the relative permittivity.
- the dielectric loss tangent (Df) of the cured product of the resin composition of the present embodiment at 10 GHz is not particularly limited, but is preferably 0.0050 or less, more preferably 0.0040 or less, still more preferably 0.0030 or less, and particularly preferably 0.0030 or less. Is 0.0025 or less, most preferably 0.0022 or less.
- the dielectric loss tangent (Df) is a value based on the cavity resonator perturbation method, and more specifically, a value measured by the method described in Examples.
- the resin composition of the present embodiment is not particularly limited, but the glass transition temperature measured by the method described in Examples is preferably 190 ° C. or higher, more preferably 200 ° C. or higher, still more preferably 210 ° C. or higher. ..
- the prepreg of the present embodiment is a prepreg containing the resin composition of the present embodiment.
- a known sheet-shaped fiber reinforced base material used for various laminated plates for electrical insulating materials can be used as the sheet-shaped fiber reinforced base material contained in the prepreg of the present embodiment.
- the material of the sheet-shaped fiber reinforcing base material include inorganic fibers such as E glass, D glass, S glass, and Q glass; organic fibers such as polyimide, polyester, and tetrafluoroethylene; and a mixture thereof.
- These sheet-shaped fiber reinforced base materials have shapes such as woven fabrics, non-woven fabrics, robinks, chopped strand mats, and surfaced mats.
- the thickness of the sheet-shaped fiber reinforced base material is not particularly limited, but is, for example, 0.02 to 0.5 mm.
- the sheet-shaped fiber reinforced base material may be surface-treated with a coupling agent or the like from the viewpoints of impregnation property of the resin composition, heat resistance when formed into a laminated board, hygroscopicity and processability, and may be a machine. It may be the one which has been subjected to the fiber opening treatment.
- the prepreg of the present embodiment can be produced, for example, by impregnating or applying the resin composition of the present embodiment to a sheet-shaped fiber reinforced base material and then drying it, if necessary.
- a method of impregnating or applying the resin composition to the sheet-shaped fiber reinforced base material for example, a hot melt method, a solvent method, or the like can be adopted.
- the hot melt method is a method of impregnating or applying a resin composition containing no organic solvent to a sheet-shaped fiber reinforced base material.
- One aspect of the hot melt method is a method in which the resin composition is once coated on coated paper having good peelability, and then the coated resin composition is laminated on a sheet-shaped fiber reinforced base material.
- the solvent method is a method of impregnating or applying a resin composition containing an organic solvent to a sheet-shaped fiber reinforced base material. Specifically, for example, a method of immersing a sheet-shaped fiber reinforced base material in a resin composition containing an organic solvent and then drying it can be mentioned.
- the drying conditions of the solvent method can be, for example, a condition of heating at 80 to 200 ° C. for 1 to 30 minutes. By drying, the organic solvent is removed and the resin composition is semi-cured (B-staged) to obtain the prepreg of the present embodiment.
- the solid content concentration derived from the resin composition in the prepreg of the present embodiment is not particularly limited, but is preferably 30 to 90% by mass. When the solid content concentration derived from the resin composition in the prepreg is within the above range, better formability tends to be obtained when the laminated board is formed.
- the resin film of the present embodiment is a resin film containing the resin composition of the present embodiment.
- the resin film of the present embodiment can be produced, for example, by applying a resin composition containing an organic solvent, that is, a resin varnish, to a support and then heat-drying the support.
- a resin composition containing an organic solvent that is, a resin varnish
- the support for example, a film of a polyolefin such as polyethylene, polypropylene, or polyvinyl chloride; polyethylene terephthalate [hereinafter, may be referred to as "PET". ].
- Polyester film such as polyethylene naphthalate
- various plastic films such as polycarbonate film and polyimide film
- metal foil such as copper foil and aluminum foil
- release paper and the like for example, by applying a resin composition containing an organic solvent, that is, a resin varnish.
- the support may be surface-treated such as matte treatment and corona treatment. Further, the support may be one that has been subjected to a mold release treatment with a silicone resin-based mold release agent, an alkyd resin-based mold release agent, a fluororesin-based mold release agent, or the like.
- the thickness of the support is not particularly limited, but is preferably 10 to 150 ⁇ m, more preferably 20 to 100 ⁇ m, and even more preferably 25 to 50 ⁇ m.
- a coating device for coating the resin varnish for example, a coating device known to those skilled in the art such as a comma coater, a bar coater, a kiss coater, a roll coater, a gravure coater, and a die coater can be used. These coating devices may be appropriately selected according to the film thickness to be formed.
- the drying conditions after the resin composition is applied may be appropriately determined according to the content of the organic solvent, the boiling point, and the like, and are not particularly limited. For example, in the case of a resin varnish containing 40 to 60% by mass of an aromatic hydrocarbon solvent, a resin film can be suitably formed by drying at 50 to 200 ° C. for about 3 to 10 minutes.
- the laminated board of this embodiment is a laminated board containing the prepreg of this embodiment and a metal foil.
- the laminated board having a metal foil may be referred to as a metal-clad laminated board.
- the metal of the metal foil is not particularly limited as long as it is used for electrical insulating materials, but from the viewpoint of conductivity, copper, gold, silver, nickel, platinum, molybdenum, ruthenium, aluminum, tungsten, iron and titanium. , Chromium, alloys containing at least one of these metal elements are preferred, copper and aluminum are more preferred, and copper is even more preferred.
- the laminated board of the present embodiment can be manufactured, for example, by arranging a metal foil on one side or both sides of the prepreg of the present embodiment and then heat-pressing molding. At that time, only one prepreg may be used, or two or more prepregs may be laminated and used.
- the conditions for heat-press molding are not particularly limited, but for example, the temperature can be 100 to 300 ° C., the pressure can be 0.2 to 10 MPa, and the time can be 0.1 to 5 hours. Further, for the heat and pressure molding, a method of holding the vacuum state for 0.5 to 5 hours by using a vacuum press or the like may be adopted.
- the multilayer printed wiring board of the present embodiment contains one or more selected from the group consisting of the prepreg, the resin film, and the laminated board of the present embodiment. That is, the multilayer printed wiring board of the present embodiment includes at least a multilayer structure and a conductor circuit layer containing a cured product of the prepreg of the present embodiment, a cured product of the resin film of the present embodiment, or the laminated plate of the present embodiment. include.
- the multilayer printed wiring board of the present embodiment is subjected to conductor circuit formation and multi-layer adhesive processing by a known method for one or more selected from the group consisting of the prepreg, the resin film and the laminated board of the present embodiment. Can be manufactured by.
- the conductor circuit can be formed, for example, by appropriately performing drilling, metal plating, etching of a metal foil, or the like.
- the semiconductor package of this embodiment is a semiconductor package formed by using the multilayer printed wiring board of this embodiment.
- the semiconductor package of this embodiment is, for example, a semiconductor package mounted on a multilayer printed wiring board of this embodiment.
- the semiconductor package of the present embodiment can be manufactured, for example, by mounting a semiconductor chip, a memory, or the like on the multilayer printed wiring board of the present embodiment by a known method.
- the number average molecular weight was measured by the following procedure. (Measurement method of number average molecular weight) The number average molecular weight was converted from the calibration curve using standard polystyrene by gel permeation chromatography (GPC).
- the calibration curve is standard polystyrene: TSKstandard POLYSTYRENE (Type; A-2500, A-5000, F-1, F-2, F-4, F-10, F-20, F-40) [manufactured by Tosoh Corporation, Product name] was used for approximation by a cubic equation.
- the measurement conditions of GPC are shown below.
- HLC-8320GPC Detector Ultraviolet absorption detector UV-8320 [manufactured by Tosoh Corporation]
- Eluent Tetrahydrofuran ⁇ Sample concentration: 10 mg / 5 mL ⁇ Injection amount: 25 ⁇ L ⁇ Flow rate: 1.00 mL / min ⁇ Measurement temperature: 40 ° C
- X a2 is a divalent organic group and is described in the same manner as X a2 in the above general formula (a-5).
- the vinyl group modification rate of the component (c2) was 40%, and the number average molecular weight of the obtained modified conjugated diene polymer was 3,500.
- a low profile copper foil manufactured by Mitsui Mining & Smelting Co., Ltd., trade name: 3EC-VLP-18
- the low profile copper foil was arranged with the M side facing the resin powder side.
- the laminate was heat-press molded under the conditions of a temperature of 230 ° C., a pressure of 2.0 MPa, and a time of 120 minutes to form and cure the resin powder on the resin plate to obtain a resin plate with double-sided copper foil.
- the thickness of the resin plate portion of the obtained resin plate with double-sided copper foil was 1 mm.
- the image for calculating the average domain size DL of the separated portion was taken at an observation magnification of 65 times for any 6 visual fields.
- backscattered electron images were acquired even at the observation magnifications of 200 times and 1,000 times.
- phase-separated resin region that looks relatively dark was identified as the "separated portion”, and the other regions were identified as the "non-separated portion".
- the separated portion could be clearly identified, for example, as shown in FIG.
- Binarization processing of reflected electron image The reflected electron image obtained above is used as a condition for binarization processing by image analysis processing software (manufactured by Nippon Roper Co., Ltd., product name: Image-Pro Analyzer 7.0J).
- a binarized image is obtained by adjusting the RGB threshold in the range of 40 to 100 and binarizing under the condition that the separated portion specified in (3) above has one value and the non-separated portion has the other value. Obtained.
- the copper foil was removed by immersing the resin plate with double-sided copper foil obtained in each example in a 10% by mass solution of ammonium persulfate (manufactured by Mitsubishi Gas Chemical Company, Inc.), which is a copper etching solution, to prepare a 2 mm ⁇ 50 mm test piece. did.
- the relative permittivity (Dk) and the dielectric loss tangent (Df) of the test piece were measured in the 10 GHz band at an atmospheric temperature of 25 ° C. according to the cavity resonator perturbation method.
- thermomechanical measuring device (manufactured by TA Instruments Japan Co., Ltd., Q400 (model number)]
- IPC The Institute for Interconnecting and Packaging Electronic Circuits
- Compounds that are tetramethylene groups-Modified imidazole compounds represented by the general formula (e-2): R e5 and R e6 in the above general formula (e-2) are hydrogen atoms, R e7 and R e8 are phenyl groups, and X.
- -Metal phosphate salt aluminum dialkylphosphinic acid salt, metal salt of disubstituted phosphinic acid, phosphorus content 23.5% by mass (manufactured by Clariant, trade name "OP-935”)
- -Paraxylylene bisdiphenylphosphine oxide Phosphorus content 12.0% by mass
- the cured products obtained in Examples 1 to 5 of the present embodiment have an area ratio R w of the non- separable portion of 50% or more and an average domain size DL of the separated portion of 120 ⁇ m or less. It can be seen that it is excellent in dielectric properties and heat resistance. On the other hand, the cured product of Comparative Example 1 in which the average domain size DL of the separated portion exceeded 120 ⁇ m was inferior in dielectric properties.
- thermosetting resin composition of the present embodiment can evaluate the compatibility that affects the physical properties such as the dielectric properties and heat resistance of the thermosetting resin composition, it is possible to evaluate the compatibility. It is useful as a substrate material used for printed wiring boards.
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Abstract
Description
近年、上述した電子機器の他に、自動車、交通システム関連等のITS分野及び室内の近距離通信分野でも、高周波無線信号を扱う新規システムの実用化又は実用計画が進んでいる。そのため、今後、これらの分野で使用するプリント配線板に対しても、高周波特性に優れる基板材料の必要性が高まると予想される。
すなわち、本実施形態は、下記[1]~[9]に関する。
[1]2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の相容性を評価する方法であって、以下の工程1A及び2Aを含む、熱硬化性樹脂組成物の相容性評価方法。
工程1A:前記熱硬化性樹脂組成物の硬化物の断面について、観察倍率50~250倍で走査型電子顕微鏡の反射電子画像を取得する工程
工程2A:前記反射電子画像において、相分離した樹脂領域を分離部、それ以外の領域を非分離部として、前記分離部が一方の値、前記非分離部が他方の値になるように二値化し、得られた二値化画像の全領域に対する、前記二値化画像の前記非分離部の領域の面積比率(非分離部の領域の面積×100/二値化画像の全領域の面積)を、前記非分離部の面積比率Rwとして算出する工程
[2]2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の相容性を評価する方法であって、以下の工程1B及び2Bを含む、熱硬化性樹脂組成物の相容性評価方法。
工程1B:前記熱硬化性樹脂組成物の硬化物の断面について、走査型電子顕微鏡の反射電子画像を取得する工程
工程2B:前記反射電子画像において、相分離した樹脂領域を分離部として、前記分離部の平均ドメインサイズDLを取得する工程
[3]前記工程1Bが、前記熱硬化性樹脂組成物の硬化物の断面について、観察倍率50~200倍で走査型電子顕微鏡の反射電子画像を取得する工程である、上記[2]に記載の熱硬化性樹脂組成物の相容性評価方法。
[4]2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物であって、
上記[1]に記載の相容性評価方法において、前記走査型電子顕微鏡の観察倍率が100倍又は200倍の条件で取得される前記非分離部の面積比率Rwが50%以上であり、かつ、
上記[2]に記載の相容性評価方法において、前記走査型電子顕微鏡の観察倍率が65倍の条件であって、少なくとも3視野で観測される前記分離部のドメインのうち、ドメインサイズが大きいものから数えて、2番目から6番目までの大きさを有するドメインのドメインサイズを平均して取得される前記分離部の平均ドメインサイズDLが120μm以下である、熱硬化性樹脂組成物。
[5]上記[4]に記載の熱硬化性樹脂組成物を含有してなるプリプレグ。
[6]上記[4]に記載の熱硬化性樹脂組成物を含有してなる樹脂フィルム。
[7]上記[5]に記載のプリプレグと金属箔を含有してなる積層板。
[8]上記[5]に記載のプリプレグ、上記[6]に記載の樹脂フィルム及び上記[7]に記載の積層板からなる群から選択される1種以上を含有してなる多層プリント配線板。
[9]上記[8]に記載のプリント配線板を用いて形成される半導体パッケージ。
本明細書中に記載されている数値範囲の下限値及び上限値は、それぞれ他の数値範囲の下限値又は上限値と任意に組み合わせられる。
本明細書中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
本明細書に例示する各成分及び材料は、特に断らない限り、1種を単独で使用してもよいし、2種以上を併用してもよい。
本明細書において、熱硬化性樹脂組成物中の各成分の含有量は、熱硬化性樹脂組成物中に各成分に該当する物質が複数存在する場合、特に断らない限り、熱硬化性樹脂組成物中に存在する当該複数の物質の合計量を意味する。
本明細書における記載事項を任意に組み合わせた態様も本実施形態に含まれる。
本明細書に記載されている作用機序は推測であって、本実施形態に係る熱硬化性樹脂組成物の効果を奏する機序を限定するものではない。
本実施形態の第1態様の相容性評価方法は、2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の相容性を評価する方法であって、以下の工程1A及び2Aを含む、熱硬化性樹脂組成物の相容性評価方法である。
工程1A:前記熱硬化性樹脂組成物の硬化物の断面について、観察倍率50~250倍で走査型電子顕微鏡の反射電子画像を取得する工程
工程2A:前記反射電子画像において、相分離した樹脂領域を分離部、それ以外の領域を非分離部として、前記分離部が一方の値、前記非分離部が他方の値になるように二値化し、得られた二値化画像の全領域に対する、前記二値化画像の前記非分離部の領域の面積比率(非分離部の領域の面積×100/二値化画像の全領域の面積)を、前記非分離部の面積比率Rwとして算出する工程
本実施形態の第1態様の相容性評価方法によると、樹脂組成物の相容性を数値化することが可能であり、従来の相容性評価方法よりも厳密に相容性を評価することが可能である。
以下、本実施形態の第1態様の相容性評価方法の各工程について、詳細に説明する。
工程1Aは、2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の硬化物の断面について、観察倍率50~250倍で走査型電子顕微鏡(SEM)の反射電子画像を取得する工程である。
本実施形態の相容性評価方法の測定対象である樹脂組成物は、2種以上の樹脂及び無機充填材を含有する樹脂組成物であれば特に限定されず、例えば、後述する本実施形態の樹脂組成物を測定対象としてもよい。
硬化物の断面を形成した後、SEM観察を良好に行うため、上記断面に対して白金等の蒸着処理を行うことが好ましい。
以上の工程によって得られたSEM観察の対象物を「試験片」と称する。
本実施形態の相容性評価方法におけるSEM観察は、特に無機充填材と樹脂成分とのコントラストを高めるために反射電子モードで行う。
SEM観察時の加速電圧は、測定対象に応じて適宜調整すればよいが、例えば、0.5~20kVの範囲で調整してもよい。
工程1Aによって試験片の反射電子画像を取得することができる。
工程2Aは、前記反射電子画像において、相分離した樹脂領域を分離部、それ以外の領域を非分離部として、前記分離部が一方の値、前記非分離部が他方の値になるように二値化し、得られた二値化画像の全領域に対する、前記二値化画像の前記非分離部の領域の面積比率(非分離部の領域の面積×100/二値化画像の全領域の面積)を、前記非分離部の面積比率Rwとして算出する工程である。
本工程では、相分離した樹脂領域を「分離部」、それ以外の領域を「非分離部」として特定する。図1から明らかな通り、反射電子画像においては、目視でも分離部を明確且つ容易に特定することが可能である。
二値化は、公知の方法で行えばよく、例えば、市販されている画像処理ソフトを用いて実施することができる。
二値化の条件は、工程1Aで得られた反射電子画像に応じて適宜調整すればよく、分離部が一方の値、非分離部が他方の値になる条件で二値化すればよい。具体的には、例えば、日本ローパー株式会社製の画像分析処理ソフト(Image-Pro Analyzer 7.0J)を用いて二値化する場合、処理条件としてRGBの閾値を40~100の範囲に適宜調整することによって二値化することができる。
次に、得られた二値化画像の全領域に対する、二値化画像の非分離部の領域の面積比率(非分離部の領域の面積×100/二値化画像の全領域の面積)を、非分離部の面積比率Rwとして算出する。上記面積比率Rwは、例えば、二値化画像の全領域の画素数と、非分離部を表す値の画素数をそれぞれカウントすることによって算出すればよい。
本実施形態の第2態様の相容性評価方法は、2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の相容性を評価する方法であって、以下の工程1B及び2Bを含む、熱硬化性樹脂組成物の相容性評価方法である。
工程1B:前記熱硬化性樹脂組成物の硬化物の断面について、走査型電子顕微鏡の反射電子画像を取得する工程
工程2B:前記反射電子画像において、相分離した樹脂領域を分離部として、前記分離部の平均ドメインサイズDLを取得する工程
本実施形態の第2態様の相容性評価方法によると、樹脂組成物の相容性を数値化することが可能であり、従来の相容性評価方法よりも厳密に相容性を評価することが可能である。
以下、本実施形態の第2態様の相容性評価方法の各工程について、詳細に説明する。
工程1Bは、2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の硬化物の断面について走査型電子顕微鏡の反射電子画像を取得する工程である。
工程1Bにおける走査型電子顕微鏡の観察倍率は、特に限定されないが、作業性及び再現性の観点から、好ましくは30~500倍、より好ましくは40~200倍、さらに好ましくは50~200倍、特に好ましくは50~100倍である。
観察倍率以外の工程1Bについての説明は、工程1Aの説明と同じである。
工程2Bは、前記反射電子画像において、相分離した樹脂領域を分離部として、前記分離部の平均ドメインサイズDLを取得する工程である。
図2及び図3に、分離部のドメインサイズの測長方法を示す模式図を示す。
例えば、図2(a)に示すようにドメインが真円とみなされる場合はその直径がドメインサイズに相当する。また、例えば、図2(b)又は(c)に示すようにドメインが楕円又は不定形とみなされる場合は、当該楕円又は不定形内に描き得る最大の真円の直径がドメインサイズに相当する。
平均値を求めるための2番目以降のドメインの数は、特に限定されず、測定対象に応じて適宜決定すればよい。作業性及び再現性の観点からは、分離部の平均ドメインサイズDLは、2番目以降、大きいものから順に、100番目以内の大きさを有するドメイン、好ましくは50番目以内の大きさを有するドメイン、より好ましくは10番目以内の大きさを有するドメイン、さらに好ましくは2番目から6番目までの大きさを有するドメインのドメインサイズを平均することによって得られるものである。
次に、本実施形態の熱硬化性樹脂組成物について説明する。
本実施形態の熱硬化性樹脂組成物は、2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物であって、
上記した第1態様の相容性評価方法において、走査型電子顕微鏡の観察倍率が100倍又は200倍の条件で取得される非分離部の面積比率Rwが50%以上であり、かつ、
上記した第2態様の相容性評価方法において、走査型電子顕微鏡の観察倍率が65倍の条件であり、少なくとも3視野において観測される分離部のドメインのうち、ドメインサイズが大きいものから数えて、2番目から6番目までの大きさを有するドメインのドメインサイズを平均して得られた、分離部の平均ドメインサイズDLが120μm以下である、熱硬化性樹脂組成物である。
本実施形態の熱硬化性樹脂組成物に関する非分離部の面積比率Rw及び平均ドメインサイズDLは、上記第1態様の相容性評価方法及び第2態様の相容性評価方法に準拠して測定される値であり、より具体的には、実施例に記載の方法によって測定される値である。
非分離部の面積比率Rwの上限値は、特に限定されず、100%であってもよいが、製造容易性等の観点から、98%以下であってもよく、95%以下であってもよい。
分離部の平均ドメインサイズDLの下限値は、特に限定されず、0μmであってもよいが、製造容易性等の観点から、10μm以上であってもよく、30μm以上であってもよい。なお、分離部の平均ドメインサイズDLが0μmであるとは、分離部が実質的に観察されずに、ドメインサイズを測長できないことを意味する。
樹脂成分は、上記した非分離部の面積比率Rw及び分離部の平均ドメインサイズDLを充足するものであれば、特に限定されないが、少なくともエラストマーと熱硬化性樹脂の2種を含有することが好ましい。
熱硬化性樹脂としては、例えば、エポキシ樹脂、シアネートエステル化合物、マレイミド化合物、ビスアリルナジイミド樹脂、ベンゾオキサジン化合物、これらの誘導体等が挙げられる。熱硬化性樹脂は、1種を単独で用いてもよく、2種以上を併用してもよい。これらの中でも、熱硬化性樹脂は、耐熱性、低熱膨張性及び機械特性の観点から、マレイミド化合物又はその誘導体が好ましい。
さらに、本実施形態の樹脂組成物は、エラストマーとして、エチレン性不飽和結合含有基を有するポリフェニレンエーテル誘導体[以下、「ポリフェニレンエーテル誘導体(A)」又は「(A)成分」と称する場合がある。]を含有し、熱硬化性樹脂として、N-置換マレイミド基を2個以上有するマレイミド化合物及びその誘導体からなる群から選択される1種以上[以下、「マレイミド化合物又はその誘導体(B)」又は「(B)成分」と称する場合がある。]を含有することがより好ましい。
さらに、本実施形態の樹脂組成物は、(A)成分及び(B)成分に加えて、エラストマーとして、(C)共役ジエンポリマー又は変性共役ジエンポリマー[以下、「共役ジエンポリマー又はその変性物(C)」又は「(C)成分」と称する場合がある。]、及び(D)スチレン系熱可塑性エラストマー[以下、「スチレン系熱可塑性エラストマー(D)」又は「(D)成分」と称する場合がある。]からなる選択される2種以上を含有することがさらに好ましい。
さらに、本実施形態の樹脂組成物は、硬化促進剤として、(E)イミダゾール化合物又は変性イミダゾール化合物[以下、「イミダゾール化合物又はその変性物(E)」又は「(E)成分」と称する場合がある。]を含有することが特に好ましい。
(A)成分は、エチレン性不飽和結合含有基を有するものである。すなわち、(A)成分は、ポリフェニレンエーテルにエチレン性不飽和結合含有基を導入したものとも言える。
なお、本明細書において、「エチレン性不飽和結合」とは、付加反応が可能な炭素-炭素二重結合を意味し、芳香環の二重結合は含まないものとする。また、「エチレン性不飽和結合含有基」とは、上記エチレン性不飽和結合を含有する置換基を意味する。
(A)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
なお、本明細書において、エチレン性不飽和結合含有基として説明する不飽和脂肪族炭化水素基は、ヘテロ原子を含有しないものとする。
(A)成分が片末端に有する不飽和脂肪族炭化水素基の数は、特に限定されないが、誘電特性の観点から、好ましくは2個以上、より好ましくは3個以上、さらに好ましくは4個以上である。(A)成分が片末端に有する不飽和脂肪族炭化水素基の数の上限値に特に制限はなく、8個以下であってもよいし、7個以下であってもよいし、6個以下であってもよい。
(A)成分が有する不飽和脂肪族炭化水素基の数及び(A)成分が片末端に有する不飽和脂肪族炭化水素基の数は、いずれも4個であることが最も好ましい。
n1が2である場合、複数のRa1同士は、それぞれ同一であってもよいし、異なっていてもよい。
上記一般式(a-4)中のXa1が表す炭素数1~6の2価の脂肪族炭化水素基としては、例えば、メチレン基、エチレン基、トリメチレン基等の炭素数1~6のアルキレン基;イソプロピリデン基等の炭素数2~6のアルキリデン基などが挙げられる。これらの中でも、メチレン基、イソプロピリデン基が好ましく、イソプロピリデン基がより好ましい。
上記ヘテロ原子としては、例えば、酸素原子、窒素原子、硫黄原子等が挙げられる。
Xa2が表す2価の有機基としては、ヘテロ原子を含有していない基であることが好ましく、ヘテロ原子を含有していない脂肪族炭化水素基、ヘテロ原子を含有していない脂環式炭化水素基がより好ましく、ヘテロ原子を含有していない脂肪族炭化水素基とヘテロ原子を含有していない脂環式炭化水素基との組み合わせからなる基であることがさらに好ましい。
これらの中でも、誘電特性の観点から、下記式(a-4’)又は下記一般式(a-5’)で表される構造がより好ましく、下記一般式(a-5’)で表される構造がさらに好ましい。
Ra11が表すハロゲン原子としては、例えば、フッ素原子、塩素原子、臭素原子、ヨウ素原子等が挙げられる。
以上の中でも、Ra11としては、炭素数1~5の脂肪族炭化水素基が好ましい。
上記一般式(a-6)~(a-8)のいずれにおいても、n4~n6の値が異なるポリフェニレンエーテル誘導体の混合物であってもよい。
(A)成分の数平均分子量は、特に限定されないが、好ましくは1,000~25,000、より好ましくは2,000~20,000、さらに好ましくは3,000~10,000、特に好ましくは4,000~6,000である。
(A)成分の数平均分子量が上記下限値以上であると、誘電特性がより良好になる傾向にある。また、(A)成分の数平均分子量が上記上限値以下であると、樹脂組成物の相容性が良好となり、長期間放置しておいても分離し難くなる傾向にある。
以下、(A)成分の製造方法の一態様について説明するが、特に下記説明に限定されるものではない。
(A)成分は、例えば、上記一般式(a-1)~(a-5)のいずれかで表される構造を含むフェノール化合物と、ポリフェニレンエーテルを有機溶媒中で、再分配反応をさせることによって製造することができる。
なお、以下の説明で、上記一般式(a-1)~(a-5)のいずれかで表される構造を含むフェノール化合物を「不飽和脂肪族炭化水素基含有フェノール化合物(1)」と称する場合がある。また、再分配反応の原料として用いるポリフェニレンエーテルを「原料ポリフェニレンエーテル」と称する場合がある。原料ポリフェニレンエーテルの数平均分子量は、特に限定されないが、好ましくは3,000~30,000である。
不飽和脂肪族炭化水素基含有フェノール化合物(1)の使用量としては、特に制限されるものではないが、例えば、不飽和脂肪族炭化水素基含有フェノール化合物(1)と反応させる原料ポリフェニレンエーテルの数平均分子量に応じて決定してもよい。
例えば、原料ポリフェニレンエーテルの数平均分子量が3,000~30,000であれば、該原料ポリフェニレンエーテル1モルに対する不飽和脂肪族炭化水素基含有フェノール化合物(1)の水酸基の量は、好ましくは1~10モル、より好ましくは1~8モル、さらに好ましくは2~6モルである。不飽和脂肪族炭化水素基含有フェノール化合物(1)の使用量が上記範囲内であると、数平均分子量が上記した好ましい範囲内の(A)成分が得られる。
有機溶媒は、1種を単独で用いてもよく、2種以上を併用してもよい。
反応触媒としては、例えば、再現性良く安定した数平均分子量の(A)成分を得るという観点から、t-ブチルペルオキシイソプロピルモノカーボネート等の有機過酸化物とナフテン酸マンガン、オクチル酸マンガン等のカルボン酸金属塩とを併用することが好ましい。
有機過酸化物とカルボン酸金属塩とを併用する場合、両者の使用量としては、特に限定されないが、原料ポリフェニレンエーテル100質量部に対して、有機過酸化物の使用量が0.5~5質量部であり、カルボン酸金属塩の使用量が0.05~0.5質量部であることが好ましい。有機過酸化物とカルボン酸金属塩の含有量が上記範囲内であると、(A)成分を製造する際の反応速度及びゲル化抑制がより良好になる傾向にある。
上記再分配反応の反応温度は70~110℃が好ましい。また、上記再分配反応の反応時間は1~8時間が好ましい。反応温度及び反応時間が上記範囲内であると、作業性及びゲル化抑制に優れ、上記した数平均分子量を有する(A)成分を製造し易くなる傾向にある。但し、反応条件は、上記の条件に限定されず、原料の種類等に応じて適宜調整することができる。また、反応条件は、再分配反応についての公知の反応条件を適用することもできる。
ここで、本明細書において、「樹脂成分」とは、例えば、(A)成分、(B)成分、(C)成分、(D)成分等のことを指し、その他の樹脂を含有する場合は、当該その他の樹脂も樹脂成分に含まれる。
(B)成分は、N-置換マレイミド基を2個以上有するマレイミド化合物及びその誘導体からなる群から選択される1種以上である。
上記「N-置換マレイミド基を2個以上有するマレイミド化合物の誘導体」としては、例えば、後述する、上記N-置換マレイミド基を2個以上有するマレイミド化合物と、ジアミン化合物(b2)との付加反応物等が挙げられる。
(B)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
(i)N-置換マレイミド基を2個以上有するマレイミド化合物(b1)[以下、「マレイミド化合物(b1)」又は「(b1)成分」と称する場合がある。]
(ii)マレイミド化合物(b1)由来の構造単位とジアミン化合物(b2)由来の構造単位とを有するアミノマレイミド化合物[以下、「アミノマレイミド化合物(B1)」又は「(B1)成分」と称する場合がある。]
(b1)成分は、N-置換マレイミド基を2個以上有するマレイミド化合物であれば特に限定されない。
(b1)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
Xb1が表す2価の有機基としては、例えば、下記一般式(b1-2)で表される基、下記一般式(b1-3)で表される基、下記一般式(b1-4)で表される基、下記一般式(b1-5)で表される基、下記一般式(b1-6)で表される基等が挙げられる。
ハロゲン原子としては、フッ素原子、塩素原子、臭素原子、ヨウ素原子等が挙げられる。
p1は0~4の整数であり、入手容易性の観点から、好ましくは0~2の整数、より好ましくは0又は1、さらに好ましくは0である。p1が2以上の整数である場合、複数のRb1同士は同一であっても異なっていてもよい。
(式中、Rb2及びRb3は、各々独立に、炭素数1~5の脂肪族炭化水素基又はハロゲン原子である。Xb2は炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基、エーテル基、スルフィド基、スルホニル基、カルボニルオキシ基、ケト基、単結合、又は下記一般式(b1-3-1)で表される2価の基である。p2及びp3は、各々独立に、0~4の整数である。*は他の構造への結合位置を示す。)
(式中、Rb4及びRb5は、各々独立に、炭素数1~5の脂肪族炭化水素基又はハロゲン原子である。Xb3は炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基、エーテル基、スルフィド基、スルホニル基、カルボニルオキシ基、ケト基又は単結合である。p4及びp5は、各々独立に、0~4の整数である。*は他の構造への結合位置を示す。)
Xb3が表す炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基としては、Xb2が表す炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基と同じものが挙げられる。
Xb3としては、上記選択肢の中でも、炭素数2~5のアルキリデン基が好ましく、炭素数2~4のアルキリデン基がより好ましく、イソプロピリデン基がさらに好ましい。
p8は1~8の整数であり、好ましくは1~5の整数、より好ましくは1~3の整数、さらに好ましくは1である。
p8が2以上の整数である場合、複数のRb6同士又はRb7同士は、それぞれ同一であってもよいし、異なっていてもよい。
(B1)成分は、マレイミド化合物(b1)由来の構造単位とジアミン化合物(b2)由来の構造単位とを有するアミノマレイミド化合物である。
(B1)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
(b1)成分由来の構造単位としては、例えば、(b1)成分が有するN-置換マレイミド基のうち、少なくとも1つのN-置換マレイミド基が、ジアミン化合物(b2)が有するアミノ基とマイケル付加反応してなる構造単位が挙げられる。
(B1)成分中に含まれる(b1)成分由来の構造単位は、1種単独であってもよく、2種以上であってもよい。
(b2)成分由来の構造単位としては、例えば、(b2)成分が有する2個のアミノ基のうち、一方又は両方のアミノ基が、マレイミド化合物(b1)が有するN-置換マレイミド基とマイケル付加反応してなる構造単位が挙げられる。
(B1)成分中に含まれる(b2)成分由来の構造単位は、1種単独であってもよく、2種以上であってもよい。
(b2)成分由来の構造単位としては、例えば、下記一般式(b2-1)で表される基、下記一般式(b2-2)で表される基等が挙げられる。
(式中、Rb11及びRb12は、各々独立に、炭素数1~5の脂肪族炭化水素基、炭素数1~5のアルコキシ基、水酸基又はハロゲン原子である。Xb5は、炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基、エーテル基、スルフィド基、スルホニル基、カルボニルオキシ基、ケト基、フルオレニレン基、単結合、又は下記一般式(b2-3-1)もしくは(b2-3-2)で表される2価の基である。p9及びp10は、各々独立に、0~4の整数である。*は他の構造への結合位置を示す。)
(式中、Rb13及びRb14は、各々独立に、炭素数1~5の脂肪族炭化水素基又はハロゲン原子である。Xb6は炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基、m-フェニレンジイソプロピリデン基、p-フェニレンジイソプロピリデン基、エーテル基、スルフィド基、スルホニル基、カルボニルオキシ基、ケト基又は単結合である。p11及びp12は、各々独立に、0~4の整数である。*は他の構造への結合位置を示す。)
(式中、Rb15は、炭素数1~5の脂肪族炭化水素基又はハロゲン原子である。Xb7及びXb8は、各々独立に、炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基、エーテル基、スルフィド基、スルホニル基、カルボニルオキシ基、ケト基又は単結合である。p13は0~4の整数である。*は他の構造への結合位置を示す。)
上記一般式(b2-3)中のXb5、上記一般式(b2-3-1)中のXb6並びに上記一般式(b2-3-2)中のXb7及びXb8が表す炭素数1~5のアルキレン基及び炭素数2~5のアルキリデン基としては、上記一般式(b1-3)中のXb2の場合と同様に説明される。
p9及びp10が2以上の整数である場合、複数のRb11同士又はRb12同士は、それぞれ同一であってもよいし、異なっていてもよい。
上記一般式(b2-3-1)中のp11及びp12は、各々独立に、0~4の整数であり、入手容易性の観点から、いずれも、好ましくは0~2の整数、より好ましくは0又は1、さらに好ましくは0である。
p11及びp12が2以上の整数である場合、複数のRb13同士又はRb14同士は、それぞれ同一であってもよいし、異なっていてもよい。
上記一般式(b2-3-2)中のp13は、0~4の整数であり、入手容易性の観点から、好ましくは0~2の整数、より好ましくは0又は1、さらに好ましくは0である。
(B1)成分は、例えば、マレイミド化合物(b1)とジアミン化合物(b2)とを有機溶媒中で反応させることによって製造することができる。
マレイミド化合物(b1)とジアミン化合物(b2)とを反応させることによって、マレイミド化合物(b1)とジアミン化合物(b2)とがマイケル付加反応してなるアミノマレイミド化合物(B1)が得られる。
反応触媒としては、例えば、p-トルエンスルホン酸等の酸性触媒;トリエチルアミン、ピリジン、トリブチルアミン等のアミン類;メチルイミダゾール、フェニルイミダゾール等のイミダゾール類;トリフェニルホスフィン等のリン系触媒などが挙げられる。
反応触媒は、1種を単独で用いてもよく、2種以上を併用してもよい。
また、反応触媒の配合量は、特に限定されないが、例えば、マレイミド化合物(b1)及びジアミン化合物(b2)の合計量100質量部に対して、0.01~5質量部使用すればよい。
また、この工程では有機溶媒を追加又は濃縮することによって、反応原料の固形分濃度及び溶液粘度を調整してもよい。反応原料の固形分濃度は、特に限定されないが、好ましくは10~90質量%、より好ましくは15~85質量%、さらに好ましくは20~80質量%である。反応原料の固形分濃度が上記下限値以上であると、良好な反応速度が得られ、生産性がより良好になる傾向にある。また、反応原料の固形分濃度が上記上限値以下であると、より良好な溶解性が得られ、撹拌効率が向上し、ゲル化をより抑制できる傾向にある。
(C)成分としては、特に限定されないが、
(c1)側鎖にビニル基を有する共役ジエンポリマー[以下、「(c1)成分」と称する場合がある。]、又は、
(c1)側鎖にビニル基を有する共役ジエンポリマーを、(c2)N-置換マレイミド基を2個以上有するマレイミド化合物[以下、「(c2)成分」と称する場合がある。]で変性してなる変性共役ジエンポリマー(C1)[以下、「変性共役ジエンポリマー(C1)」又は「(C1)成分」と称する場合がある。]が好ましい。
(C)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
(c1)成分は側鎖にビニル基を有する共役ジエンポリマーであれば特に限定されない。
(c1)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
共役ジエン化合物としては、例えば、1,3-ブタジエン、イソプレン、1,3-ペンタジエン、2,3-ジメチル-1,3-ブタジエン、2-フェニル-1,3-ブタジエン、1,3-ヘキサジエン等が挙げられる。
共役ジエンポリマーは、1種の共役ジエン化合物の重合体であってもよく、2種以上の共役ジエン化合物の共重合体であってもよい。
また、共役ジエンポリマーは、1種以上の共役ジエン化合物と、1種以上の共役ジエン化合物以外のモノマーと、の共重合体であってもよい。その場合の重合様式は特に限定されず、ランダム重合、ブロック重合又はグラフト重合のいずれであってもよい。
(c1)成分が有するブタジエン由来の1,2-ビニル基とは、下記式(c1-1)で表されるブタジエン由来の構造単位に含まれるビニル基である。
同様の観点から、1,2-ビニル基を有するポリブタジエンは、1,2-ポリブタジエンホモポリマーであることが好ましい。
(C1)成分は、(c1)側鎖にビニル基を有する共役ジエンポリマーを、(c2)N-置換マレイミド基を2個以上有するマレイミド化合物で変性してなる変性共役ジエンポリマーである。
(c2)成分は、N-置換マレイミド基を2個以上有するマレイミド化合物であればよく、上記したマレイミド化合物又はその誘導体(B)として挙げられたものを使用することができる。
(c2)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
(式中、Rc1及びRc2は、各々独立に、炭素数1~5の脂肪族炭化水素基である。Xc1は炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基、エーテル基、スルフィド基、スルホニル基、カルボニルオキシ基、ケト基、単結合、又は下記一般式(c2-1-1)で表される2価の基である。q1及びq2は、各々独立に、0~4の整数であり、q1+q2は1以上の整数である。)
Xc1が表す炭素数2~5のアルキリデン基としては、例えば、エチリデン基、プロピリデン基、イソプロピリデン基、ブチリデン基、イソブチリデン基、ペンチリデン基、イソペンチリデン基等が挙げられる。
同様の観点から、q1+q2は、好ましくは1~8の整数、より好ましくは2~6の整数、さらに好ましくは4である。
q1又はq2が2以上の整数である場合、複数のRc1同士又はRc2同士は、それぞれ同一であってもよいし、異なっていてもよい。
(式中、Rc3及びRc4は、各々独立に、炭素数1~5の脂肪族炭化水素基又はハロゲン原子である。Xc2は炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基、エーテル基、スルフィド基、スルホニル基、カルボニルオキシ基、ケト基又は単結合である。q3及びq4は、各々独立に、0~4の整数である。)
Xc2が表す炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基としては、Xc1が表す炭素数1~5のアルキレン基、炭素数2~5のアルキリデン基と同じものが挙げられる。
q3及びq4は、各々独立に、0~4の整数であり、入手容易性の観点から、いずれも、好ましくは0~2の整数、より好ましくは0又は1、さらに好ましくは0である。q3又はq4が2以上の整数である場合、複数のRc3同士又はRc4同士は、それぞれ同一であってもよいし、異なっていてもよい。
置換基(x)は、他の樹脂との相容性、誘電特性、低熱膨張性及び耐熱性の観点から、マレイミド化合物(c2)由来の構造として、下記一般式(C-11)又は(C-12)で表される構造を含む基であることが好ましい。
(式中、Rc1、Rc2、Xc1、q1及びq2についての説明は、上記一般式(c2-1)における説明の通りである。*C1及び*C2についての説明は、上記一般式(C-11)及び(C-12)における説明の通りである。)
変性共役ジエンポリマー(C1)中に置換基(x)がどの程度存在するかは、(c1)成分のビニル基が(c2)成分によってどの程度変性されたのか[以下、「ビニル基変性率」と称する場合がある。]を指標とすることができる。
ビニル基変性率は、特に限定されないが、他の樹脂との相容性、誘電特性、低熱膨張性及び耐熱性の観点から、好ましくは20~70%、より好ましくは30~60%、さらに好ましくは35~50%である。ここで、ビニル基変性率は、実施例に記載の方法によって求めた値である。
ビニル基(y)は、ブタジエン由来の構造単位が有する1,2-ビニル基であることが好ましい。
(C1)成分は、共役ジエンポリマー(c1)とマレイミド化合物(c2)とを反応させることによって製造することができる。
共役ジエンポリマー(c1)とマレイミド化合物(c2)とを反応させる方法は特に限定されない。例えば、共役ジエンポリマー(c1)、マレイミド化合物(c2)、反応触媒及び有機溶媒を反応容器に仕込み、必要に応じて、加熱、保温、撹拌等しながら反応させることによって(C1)成分を得ることができる。
上記反応の反応温度は、作業性及び反応中のゲル化抑制の観点から、好ましくは70~120℃、より好ましくは80~110℃、さらに好ましくは85~105℃である。
上記反応の反応時間は、同様の観点から、好ましくは0.5~15時間、より好ましくは1~10時間、さらに好ましくは3~7時間である。
但し、これらの反応条件は、使用する原料の種類等に応じて適宜調整することができ、特に限定されない。
有機溶媒は、1種を単独で用いてもよく、2種以上を併用してもよい。これらの中でも、樹脂溶解性の観点から、トルエンが好ましい。
反応触媒は、1種を単独で用いてもよく、2種以上を併用してもよい。
反応触媒の使用量は、特に限定されないが、共役ジエンポリマー(c1)及びマレイミド化合物(c2)の総量100質量部に対して、好ましくは0.01~1.2質量部、より好ましくは0.03~1.0質量部、さらに好ましくは0.05~0.8質量部である。
(D)成分としては、スチレン系化合物由来の構造単位を有する熱可塑性エラストマーであれば特に制限はない。
(D)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
kは、好ましくは0~2の整数、より好ましくは0又は1、さらに好ましくは0である。
上記ブタジエン由来の構造単位及び上記イソプレン由来の構造単位は、水素添加されていてもよい。水素添加されている場合、ブタジエン由来の構造単位はエチレン単位とブチレン単位とが混合した構造単位となり、イソプレン由来の構造単位はエチレン単位とプロピレン単位とが混合した構造単位となる。
本実施形態の樹脂組成物は、(E)成分を含有することによって、より一層、良好な耐熱性を有しながらも、優れた誘電特性を発現し得る傾向にある。
(E)成分は、1種を単独で用いてもよく、2種以上を併用してもよい。
Re1、Re2、Re3及びRe4が表す脂肪族炭化水素基としては、例えば、メチル基、エチル基、プロピル基、ブチル基、ペンチル基、ヘキシル基、ヘプチル基、オクチル基、デシル基、ドデシル基、トリデシル基、テトラデシル基、ペンタデシル基、ヘキサデシル基、ヘプタデシル基、ステアリル基等のアルキル基;アルケニル基;アルキニル基などが挙げられる。これらの脂肪族炭化水素基は、直鎖状又は分岐鎖状のいずれであってもよい。これらの中でも、メチル基、エチル基が好ましい。
Xe1が表すアルキレン基としては、例えば、メチレン基、エチレン基、1,3-トリメチレン基、1,4-テトラメチレン基、1,5-ペンタメチレン基、1,6-ヘキサメチレン基等が挙げられる。これらの中でも、1,4-テトラメチレン基が好ましい。
Xe1が表す2価の芳香族炭化水素基の炭素数は、好ましくは6~20、より好ましくは6~15、さらに好ましくは6~12である。
Xe1が表す2価の芳香族炭化水素基としては、例えば、フェニレン基、ビフェニレン基、ターフェニレン基、ナフチレン基、アントリレン基等が挙げられる。
Re5、Re6、Re7及びRe8が表す脂肪族炭化水素基としては、例えば、メチル基、エチル基、プロピル基、ブチル基、ペンチル基、ヘキシル基、ヘプチル基、オクチル基、デシル基、ドデシル基、トリデシル基、テトラデシル基、ペンタデシル基、ヘキサデシル基、ヘプタデシル基、ステアリル基等のアルキル基;アルケニル基;アルキニル基などが挙げられる。これらの脂肪族炭化水素基は、直鎖状又は分岐鎖状のいずれであってもよい。
Re5、Re6、Re7及びRe8が表す原子又は基の中でも、Re5及びRe6は水素原子であることが好ましく、Re7及びRe8はフェニル基であることが好ましい。
Xe2が表すアルキレン基としては、例えば、メチレン基、エチレン基、1,3-トリメチレン基、1,4-テトラメチレン基、1,5-ペンタメチレン基、1,6-ヘキサメチレン基等が挙げられる。
Xe2が表すアルキリデン基の炭素数は、好ましくは3~10、より好ましくは3~8、さらに好ましくは3~5である。
Xe2が表すアルキリデン基としては、例えば、エチリデン基、プロピリデン基、イソプロピリデン基、ブチリデン基、イソブチリデン基、ペンチリデン基、イソペンチリデン基等が挙げられる。これらの中でも、プロピリデン基が好ましい。
本実施形態の樹脂組成物に無機充填材(F)[以下、「(F)成分」と称する場合がある。]を含有させることによって、熱膨張係数、弾性率性、耐熱性及び難燃性がより向上する傾向にある。
無機充填材(F)は、1種を単独で用いてもよく、2種以上を併用してもよい。
シリカとしては、例えば、湿式法で製造され含水率の高い沈降シリカと、乾式法で製造され結合水等をほとんど含まない乾式法シリカ等が挙げられる。また、乾式法シリカとしては、さらに、製造法の違いによって、例えば、破砕シリカ、フュームドシリカ、溶融シリカ等が挙げられる。
無機充填材(F)の形状としては、球状、破砕状等が挙げられ、球状であることが好ましい。
本実施形態の樹脂組成物は、難燃剤(G)を含有することによって、樹脂組成物の難燃性がより向上する傾向にある。
難燃剤(G)は、1種を単独で用いてもよく、2種以上を併用してもよい。さらに、必要に応じて難燃助剤を含有させてもよい。
リン系難燃剤は、一般的に難燃剤として使用されるもののうち、リン原子を含有するものであれば特に制限はなく使用することができるが、環境問題の観点から、ハロゲン原子を含有しないものが好ましい。
リン系難燃剤は、無機系のリン系難燃剤であってもよいが、誘電特性、導体との接着性、耐熱性、ガラス転移温度、低熱膨張性及び難燃性の観点から、有機系のリン系難燃剤が好ましい。
2置換ホスフィン酸エステルとしては、例えば、ジフェニルホスフィン酸フェニル、ジフェニルホスフィン酸メチル等が挙げられる。
2置換ホスフィン酸の金属塩としては、例えば、ジアルキルホスフィン酸の金属塩、ジアリルホスフィン酸の金属塩、ジビニルホスフィン酸の金属塩、ジアリールホスフィン酸の金属塩等が挙げられる。これらの金属塩としては、アルミニウム塩が好ましい。
環状有機リン化合物としては、例えば、9,10-ジヒドロ-9-オキサ-10-ホスファフェナントレン-10-オキシド、10-(2,5-ジヒドロキシフェニル)-9,10-ジヒドロ-9-オキサ-10-ホスファフェナントレン-10-オキシド等が挙げられる。
金属水和物としては、例えば、水酸化アルミニウムの水和物、水酸化マグネシウムの水和物等が挙げられる。
ハロゲン系難燃剤としては、例えば、塩素系難燃剤、臭素系難燃剤等が挙げられる。塩素系難燃剤としては、例えば、塩素化パラフィン等が挙げられる。
本実施形態の樹脂組成物は、さらに上記以外のその他の成分(H)[以下、「(H)成分」と称する場合がある。]を含有してなるものであってもよい。その他の成分(H)としては、例えば、上記各成分以外の、熱硬化性樹脂、熱可塑性ポリマー、硬化促進剤、難燃剤、添加剤、有機溶媒等が挙げられる。
(H)成分は、各々について、1種を単独で用いてもよく、2種以上を併用してもよい。
(H)成分である添加剤としては、例えば、酸化防止剤、熱安定剤、帯電防止剤、紫外線吸収剤、顔料、着色剤、滑剤等が挙げられる。
(H)成分の使用量は、特に限定されず、本発明の効果を阻害しない範囲で使用すればよい。
本実施形態の樹脂組成物は、有機溶媒を含有していてもよい。有機溶媒で希釈することによって、本実施形態の樹脂組成物の取り扱い性及び後述するプリプレグの製造のし易さが向上する傾向にある。有機溶媒を含有させた樹脂組成物は、一般的に、樹脂ワニス又はワニスと称されることがある。
有機溶媒としては、例えば、エタノール、プロパノール、ブタノール、メチルセロソルブ、ブチルセロソルブ、プロピレングリコールモノメチルエーテル等のアルコール系溶媒;アセトン、メチルエチルケトン、メチルイソブチルケトン、シクロヘキサノン等のケトン系溶媒;テトラヒドロフラン等のエーテル系溶媒;トルエン、キシレン、メシチレン等の芳香族炭化水素系溶媒;ジメチルホルムアミド、ジメチルアセトアミド、N-メチルピロリドン等の窒素原子含有溶媒;ジメチルスルホキシド等の硫黄原子含有溶媒;γ-ブチロラクトン等のエステル系溶媒などが挙げられる。
これらの中でも、溶解性の観点から、アルコール系溶媒、ケトン系溶媒、窒素原子含有溶媒、芳香族炭化水素系溶媒が好ましく、芳香族炭化水素系溶媒がより好ましく、トルエンがさらに好ましい。
本実施形態の樹脂組成物は、上記各成分を公知の方法で混合することによって製造することができる。この際、各成分は撹拌しながら溶解又は分散させてもよい。混合順序、温度、時間等の条件は、特に限定されず、原料の種類等に応じて任意に設定すればよい。
(誘電特性)
本実施形態の樹脂組成物の硬化物の10GHzにおける誘電率(Dk)は、特に限定されないが、好ましくは3.0以下、より好ましくは2.9以下、さらに好ましくは2.8以下である。上記誘電率(Dk)は小さい程好ましく、その下限値に特に制限はないが、他の物性とのバランスを考慮して、例えば、2.3以上であってもよく、2.4以上であってもよく、2.5以上であってもよい。誘電率(Dk)は、空洞共振器摂動法に準拠した値であり、より詳細には、実施例に記載する方法によって測定された値である。また、本明細書において、単に誘電率というとき、比誘電率を意味する。
本実施形態の樹脂組成物は、特に限定されないが、実施例に記載の方法で測定されたガラス転移温度が、好ましくは190℃以上、より好ましくは200℃以上、さらに好ましくは210℃以上である。ガラス転移温度は高いほど好ましいが、製造容易性の観点から、300℃以下であってもよく、270℃以下であってもよく、250℃以下であってもよい。
本実施形態のプリプレグは、本実施形態の樹脂組成物を含有してなるプリプレグである。
本実施形態のプリプレグが含有するシート状繊維補強基材としては、各種の電気絶縁材料用積層板に用いられている公知のシート状繊維補強基材を使用することができる。
シート状繊維補強基材の材質としては、例えば、Eガラス、Dガラス、Sガラス、Qガラス等の無機物繊維;ポリイミド、ポリエステル、テトラフルオロエチレン等の有機繊維;これらの混合物などが挙げられる。これらのシート状繊維補強基材は、例えば、織布、不織布、ロービンク、チョップドストランドマット、サーフェシングマット等の形状を有する。
シート状繊維補強基材の厚さは、特に限定されないが、例えば、0.02~0.5mmである。
シート状繊維補強基材は、樹脂組成物の含浸性、積層板とした際の耐熱性、耐吸湿性及び加工性の観点から、カップリング剤等で表面処理したものであってもよく、機械的に開繊処理を施したものであってもよい。
樹脂組成物をシート状繊維補強基材に含浸又は塗布する方法としては、例えば、ホットメルト法、ソルベント法等を採用できる。
ソルベント法の乾燥条件としては、例えば、80~200℃で、1~30分間加熱する条件とすることができる。乾燥によって、有機溶媒を除去すると共に、樹脂組成物を半硬化(Bステージ化)させて、本実施形態のプリプレグが得られる。
本実施形態の樹脂フィルムは、本実施形態の樹脂組成物を含有してなる樹脂フィルムである。
本実施形態の樹脂フィルムは、例えば、有機溶媒を含有する樹脂組成物、つまり樹脂ワニスを支持体へ塗布してから、加熱乾燥させることによって製造することができる。
支持体としては、例えば、ポリエチレン、ポリプロピレン、ポリ塩化ビニル等のポリオレフィンのフィルム;ポリエチレンテレフタレート[以下、「PET」と称する場合がある。]、ポリエチレンナフタレート等のポリエステルのフィルム;ポリカーボネートフィルム、ポリイミドフィルム等の各種プラスチックフィルム;銅箔、アルミニウム箔等の金属箔;離型紙などが挙げられる。
支持体は、マット処理、コロナ処理等の表面処理を施したものであってもよい。また、支持体は、シリコーン樹脂系離型剤、アルキッド樹脂系離型剤、フッ素樹脂系離型剤等による離型処理を施したものであってもよい。
支持体の厚さは、特に限定されないが、好ましくは10~150μm、より好ましくは20~100μm、さらに好ましくは25~50μmである。
樹脂組成物を塗布した後の乾燥条件は、有機溶媒の含有量、沸点等に応じて適宜決定すればよく、特に限定されない。例えば、40~60質量%の芳香族炭化水素系溶媒を含有する樹脂ワニスの場合、50~200℃で3~10分間程度乾燥させることによって、樹脂フィルムを好適に形成することができる。
本実施形態の積層板は、本実施形態のプリプレグと金属箔とを含有してなる積層板である。なお、金属箔を有する積層板は、金属張積層板と称されることもある。
金属箔の金属としては、電気絶縁材料用途で用いられるものであれば特に限定されないが、導電性の観点から、銅、金、銀、ニッケル、白金、モリブデン、ルテニウム、アルミニウム、タングステン、鉄、チタン、クロム、これらの金属元素を1種以上含有する合金が好ましく、銅、アルミニウムがより好ましく、銅がさらに好ましい。
加熱加圧成形の条件は、特に限定されないが、例えば、温度を100~300℃、圧力を0.2~10MPa、時間を0.1~5時間とすることができる。また、加熱加圧成形は、真空プレス等を用いて、真空状態を0.5~5時間保持する方法を採用してもよい。
本実施形態の多層プリント配線板は、本実施形態のプリプレグ、樹脂フィルム及び積層板からなる群から選択される1種以上を含有してなるものである。
すなわち、本実施形態の多層プリント配線板は、少なくとも、本実施形態のプリプレグの硬化物、本実施形態の樹脂フィルムの硬化物又は本実施形態の積層板を含有する多層構造と導体回路層とを含む。
本実施形態の多層プリント配線板は、本実施形態のプリプレグ、樹脂フィルム及び積層板からなる群から選択される1種以上に対して、公知の方法によって、導体回路形成及び多層化接着加工を施すことによって製造することができる。導体回路は、例えば、穴開け加工、金属めっき加工、金属箔のエッチング等を適宜施すことによって形成することができる。
本実施形態の半導体パッケージは、本実施形態の多層プリント配線板を用いて形成される、半導体パッケージである。
本実施形態の半導体パッケージは、例えば、本実施形態の多層プリント配線板に半導体を搭載してなるものである。本実施形態の半導体パッケージは、例えば、公知の方法によって、本実施形態の多層プリント配線板上に、半導体チップ、メモリ等を搭載することによって製造することができる。
(数平均分子量の測定方法)
数平均分子量はゲル浸透クロマトグラフィー(GPC)によって、標準ポリスチレンを用いた検量線から換算した。検量線は、標準ポリスチレン:TSKstandard POLYSTYRENE(Type;A-2500、A-5000、F-1、F-2、F-4、F-10、F-20、F-40)[東ソー株式会社製、商品名]を用いて3次式で近似した。GPCの測定条件を、以下に示す。
装置:高速GPC装置 HLC-8320GPC
検出器:紫外吸光検出器 UV-8320[東ソー株式会社製]
カラム:ガードカラム;TSK Guardcolumn SuperHZ-L+カラム;TSKgel SuperHZM-N+TSKgel SuperHZM-M+TSKgel SuperH-RC(すべて東ソー株式会社製、商品名)
カラムサイズ:4.6×20mm(ガードカラム)、4.6×150mm(カラム)、6.0×150mm(リファレンスカラム)
・溶離液:テトラヒドロフラン
・試料濃度:10mg/5mL
・注入量:25μL
・流量:1.00mL/分
・測定温度:40℃
後述する製造例2において、反応開始前の(c1)成分及び(c2)成分を含む溶液と、反応後の溶液について、上記方法によってGPCを測定することによって、反応前後における(c2)成分に由来するピーク面積を求めた。次いで、下記式によって(c2)成分のビニル基変性率を計算した。なお、ビニル基変性率は、反応による(c2)成分に由来するピーク面積の減少率に相当するものである。
ビニル基変性率=[(反応前の(c2)成分由来ピーク面積)-(反応後の(c2)成分由来ピーク面積)]×100/(反応前の(c2)成分由来ピーク面積)
温度計、還流冷却管及び撹拌装置を備えた加熱及び冷却可能な容積2Lのガラス製フラスコ容器に、トルエン、ポリフェニレンエーテル「ザイロン(登録商標)S203A」(商品名、旭化成株式会社製、数平均分子量=12,000、以下「原料PPE」ともいう。)を1mol、下記一般式(1)で表されるアリル基含有化合物を、原料PPEに対する水酸基当量が6になる量投入した。次いで、90~100℃で撹拌しながら、各成分を溶解させた。なお、トルエンの使用量は反応濃度が35質量%になる量とした。
温度計、還流冷却管及び撹拌装置を備えた加熱及び冷却可能な容積2Lのガラス製フラスコ容器に、(c1)成分として1,2-ポリブタジエンホモポリマー(数平均分子量=1,200、ビニル基含有率=85%以上)33.5質量部、(c2)成分として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1.47質量部、反応触媒及び有機溶媒を投入した。次いで、窒素雰囲気下、90~100℃で5時間、撹拌することによって、(c1)成分と(c2)成分とを反応させて、固形分濃度が35質量%である変性共役ジエンポリマーの溶液を得た。(c2)成分のビニル基変性率は40%であり、得られた変性共役ジエンポリマーの数平均分子量は3,500であった。
実施例1~5、比較例1
表1に記載の各成分を、表1に記載の配合量に従って配合してから、室温で又は50~80℃に加熱しながら撹拌及び混合することによって、固形分濃度が約50質量%の樹脂組成物を調製した。なお、表1中、各成分の配合量の単位は質量部であり、溶液の場合は、固形分換算の質量部を意味する。また、表1中、括弧内の数値は、樹脂組成物中における各成分由来のリン原子の含有量を意味する。
各例で得た樹脂組成物を、厚さ38μmのPETフィルム(帝人株式会社製、商品名:G2-38)に塗布した後、170℃で5分間加熱乾燥することによって、Bステージ状態の樹脂フィルムを作製した。この樹脂フィルムをPETフィルムから剥離した後、粉砕によってBステージ状態の樹脂粉末としてから、厚さ1mm×長さ50mm×幅35mmのサイズに型抜きしたテフロン(登録商標)シートに投入した。次いで、該樹脂粉末を投入したテフロン(登録商標)シートの上下に、厚さ18μmのロープロファイル銅箔(三井金属鉱業株式会社製、商品名:3EC-VLP-18)を配置することによって、加熱加圧成形前の積層物を得た。なおロープロファイル銅箔は、M面を樹脂粉末側にして配置した。続いて、該積層物を、温度230℃、圧力2.0MPa、時間120分間の条件で加熱加圧成形することによって、樹脂粉末を樹脂板に成形及び硬化させて、両面銅箔付き樹脂板を作製した。得られた両面銅箔付き樹脂板の樹脂板部分の厚さは1mmであった。
上記実施例及び比較例で得られた両面銅箔付き樹脂板を用いて、下記方法に従って各測定及び評価を行った。結果を表1に示す。
(1)試験片の作製
各例で得た両面銅箔付き樹脂板を銅エッチング液である過硫酸アンモニウム(三菱ガス化学株式会社製)10質量%溶液に浸漬することによって銅箔を除去して樹脂板を得た。
次に、該樹脂板を、注型樹脂で包埋し室温で12時間硬化させて、樹脂板の注型物を得た。得られた注型物を精密切断機(リファインテック株式会社製、商品名:リファイン・ソー・エクセル)を用いて切断することによって樹脂板の断面を形成した。次いで、該断面を白金蒸着処理したものを試験片とした。
上記で得た試験片の断面を、走査型電子顕微鏡(SEM)(日本電子株式会社製、商品名:JSM-6010PLUA/LA)を用いて、加速電圧15kV、傾斜無し、反射電子モードの条件で観察することによって、反射電子画像を取得した。
なお、非分離部の面積比率Rwを算出するための画像は、任意の3視野について、観察倍率100倍又は200倍(実施例1、3~5及び比較例1は100倍、実施例2は200倍)で撮影した。
また、分離部の平均ドメインサイズDLを算出するための画像は、任意の6視野について、観察倍率65倍で撮影した。
但し、実施例4については、観察倍率の影響を調査するため、観察倍率200倍及び1,000倍でも反射電子画像を取得した。
上記で得た反射電子画像において、相対的に暗く見える相分離した樹脂領域を「分離部」、それ以外の領域を「非分離部」として特定した。なお、分離部は、例えば、図1に示されるように明確に識別することが可能であった。
上記で取得した反射電子画像を、画像分析処理ソフト(日本ローパー株式会社製、商品名:Image-Pro Analyzer 7.0J)によって、二値化処理の条件としてRGBの閾値を40~100の範囲で調整し、上記(3)で特定した分離部が一方の値、非分離部が他方の値となる条件で二値化することによって、二値化画像を取得した。
上記の二値化画像の全領域に対する、二値化画像の非分離部の領域の面積比率(非分離部の領域の面積×100/二値化画像の全領域の面積)を計算し、3視野における面積比率を平均した値を非分離部の面積比率Rwとして算出した。算出されたRwの値が大きいもの程、相容性に優れていることを示す。
上記で得た6視野の反射電子画像における分離部のドメインのうち、ドメインサイズが最も大きいものから数えて、2番目から6番目までの大きさを有するドメインのドメインサイズを平均することによって分離部の平均ドメインサイズDLを算出した。算出された分離部の平均ドメインサイズDLの値が小さいもの程、相容性に優れていることを示す。なお、ドメインサイズの測長は上記した方法に準拠して行った。
各例で得た両面銅箔付き樹脂板を銅エッチング液である過硫酸アンモニウム(三菱ガス化学株式会社製)10質量%溶液に浸漬することによって銅箔を除去し、2mm×50mmの試験片を作製した。次いで、空洞共振器摂動法に準拠して、雰囲気温度25℃にて10GHz帯で、上記試験片の比誘電率(Dk)及び誘電正接(Df)を測定した。
各例で得た両面銅箔付き樹脂板の両面の銅箔をエッチング除去することによって、5mm角の試験片を作製した。次いで、熱機械測定装置(TMA)[ティー・エイ・インスツルメント・ジャパン株式会社製、Q400(型番)]を用いて、IPC(The Institute for Interconnecting and Packaging Electronic Circuits)規格に準拠して、上記試験片のガラス転移温度を測定した。
[(A)成分]
・ポリフェニレンエーテル誘導体:製造例1で製造したポリフェニレンエーテル誘導体
・マレイミド化合物(B-1):ビフェニルアラルキル型マレイミド(日本化薬株式会社製、商品名「MIR-3000」)
・マレイミド化合物(B-2):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
・未変性共役ジエンポリマー:1,2-ポリブタジエンホモポリマー(数平均分子量=1,200、ビニル基含有率=85%以上)
・変性共役ジエンポリマー:製造例2で製造した変性共役ジエンポリマー
・水添スチレン系熱可塑性エラストマー:スチレン-エチレン-ブチレン-スチレン(SEBS)共重合体(クレイトンポリマージャパン株式会社製、商品名「クレイトン(登録商標)MD1653」、メルトフローレート5.0g/10min、スチレン含有率30%、水素添加率100%)
・一般式(e-1)で表される変性イミダゾール化合物:上記一般式(e-1)におけるRe1、Re2がメチル基、Re3、Re4がエチル基、Xe1が1,4-テトラメチレン基である化合物
・一般式(e-2)で表される変性イミダゾール化合物:上記一般式(e-2)におけるRe5、Re6が水素原子、Re7及びRe8がフェニル基、Xe2がプロピリデン基である化合物
・2-エチル-4-メチルイミダゾール
・シリカ:球状溶融シリカ、平均粒子径=0.5μm
・1,3-フェニレンビス(ジ2,6-キシレニルホスフェート):リン含有量9.0質量%
・リン酸金属塩:ジアルキルホスフィン酸アルミニウム塩、2置換ホスフィン酸の金属塩、リン含有量23.5質量%(クラリアント社製、商品名「OP-935」)
・パラキシリレンビスジフェニルホスフィンオキサイド:リン含有量12.0質量%
・α,α’-ビス(t-ブチルパーオキシ)ジイソプロピルベンゼン
2 分離部
Claims (9)
- 2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の相容性を評価する方法であって、以下の工程1A及び2Aを含む、熱硬化性樹脂組成物の相容性評価方法。
工程1A:前記熱硬化性樹脂組成物の硬化物の断面について、観察倍率50~250倍で走査型電子顕微鏡の反射電子画像を取得する工程
工程2A:前記反射電子画像において、相分離した樹脂領域を分離部、それ以外の領域を非分離部として、前記分離部が一方の値、前記非分離部が他方の値になるように二値化し、得られた二値化画像の全領域に対する、前記二値化画像の前記非分離部の領域の面積比率(非分離部の領域の面積×100/二値化画像の全領域の面積)を、前記非分離部の面積比率Rwとして算出する工程 - 2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物の相容性を評価する方法であって、以下の工程1B及び2Bを含む、熱硬化性樹脂組成物の相容性評価方法。
工程1B:前記熱硬化性樹脂組成物の硬化物の断面について、走査型電子顕微鏡の反射電子画像を取得する工程
工程2B:前記反射電子画像において、相分離した樹脂領域を分離部として、前記分離部の平均ドメインサイズDLを取得する工程 - 前記工程1Bが、前記熱硬化性樹脂組成物の硬化物の断面について、観察倍率50~200倍で走査型電子顕微鏡の反射電子画像を取得する工程である、請求項2に記載の熱硬化性樹脂組成物の相容性評価方法。
- 2種以上の樹脂及び無機充填材を含有する熱硬化性樹脂組成物であって、
請求項1に記載の相容性評価方法において、前記走査型電子顕微鏡の観察倍率が100倍又は200倍の条件で取得される前記非分離部の面積比率Rwが50%以上であり、かつ、
請求項2に記載の相容性評価方法において、前記走査型電子顕微鏡の観察倍率が65倍の条件であって、少なくとも3視野において観測される前記分離部のドメインのうち、ドメインサイズが大きいものから数えて、2番目から6番目までの大きさを有するドメインのドメインサイズを平均して取得される前記分離部の平均ドメインサイズDLが120μm以下である、熱硬化性樹脂組成物。 - 請求項4に記載の熱硬化性樹脂組成物を含有してなるプリプレグ。
- 請求項4に記載の熱硬化性樹脂組成物を含有してなる樹脂フィルム。
- 請求項5に記載のプリプレグと金属箔を含有してなる積層板。
- 請求項5に記載のプリプレグ、請求項6に記載の樹脂フィルム及び請求項7に記載の積層板からなる群から選択される1種以上を含有してなる多層プリント配線板。
- 請求項8に記載の多層プリント配線板を用いて形成される、半導体パッケージ。
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JP2019184349A (ja) * | 2018-04-06 | 2019-10-24 | 日本製紙株式会社 | ゴム成分とセルロースナノファイバーの混合液の評価方法 |
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WO2024085028A1 (ja) * | 2022-10-19 | 2024-04-25 | 株式会社レゾナック | 樹脂組成物、プリプレグ、積層板、プリント配線板及び半導体パッケージ |
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