JP7472839B2 - 樹脂組成物 - Google Patents
樹脂組成物 Download PDFInfo
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- JP7472839B2 JP7472839B2 JP2021053572A JP2021053572A JP7472839B2 JP 7472839 B2 JP7472839 B2 JP 7472839B2 JP 2021053572 A JP2021053572 A JP 2021053572A JP 2021053572 A JP2021053572 A JP 2021053572A JP 7472839 B2 JP7472839 B2 JP 7472839B2
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- IDXDWPWXHTXJMZ-UHFFFAOYSA-N tris(2,4,6-trimethylphenyl)phosphane Chemical compound CC1=CC(C)=CC(C)=C1P(C=1C(=CC(C)=CC=1C)C)C1=C(C)C=C(C)C=C1C IDXDWPWXHTXJMZ-UHFFFAOYSA-N 0.000 description 1
- XDHRVAHAGMMFMC-UHFFFAOYSA-N tris(2,4-dimethylphenyl)phosphane Chemical compound CC1=CC(C)=CC=C1P(C=1C(=CC(C)=CC=1)C)C1=CC=C(C)C=C1C XDHRVAHAGMMFMC-UHFFFAOYSA-N 0.000 description 1
- KAAYGTMPJQOOGY-UHFFFAOYSA-N tris(2,5-dimethylphenyl)phosphane Chemical compound CC1=CC=C(C)C(P(C=2C(=CC=C(C)C=2)C)C=2C(=CC=C(C)C=2)C)=C1 KAAYGTMPJQOOGY-UHFFFAOYSA-N 0.000 description 1
- RERMPCBBVZEPBS-UHFFFAOYSA-N tris(2,6-dimethylphenyl)phosphane Chemical compound CC1=CC=CC(C)=C1P(C=1C(=CC=CC=1C)C)C1=C(C)C=CC=C1C RERMPCBBVZEPBS-UHFFFAOYSA-N 0.000 description 1
- IIOSDXGZLBPOHD-UHFFFAOYSA-N tris(2-methoxyphenyl)phosphane Chemical compound COC1=CC=CC=C1P(C=1C(=CC=CC=1)OC)C1=CC=CC=C1OC IIOSDXGZLBPOHD-UHFFFAOYSA-N 0.000 description 1
- COIOYMYWGDAQPM-UHFFFAOYSA-N tris(2-methylphenyl)phosphane Chemical compound CC1=CC=CC=C1P(C=1C(=CC=CC=1)C)C1=CC=CC=C1C COIOYMYWGDAQPM-UHFFFAOYSA-N 0.000 description 1
- XRALRSQLQXKXKP-UHFFFAOYSA-N tris(3,5-dimethylphenyl)phosphane Chemical compound CC1=CC(C)=CC(P(C=2C=C(C)C=C(C)C=2)C=2C=C(C)C=C(C)C=2)=C1 XRALRSQLQXKXKP-UHFFFAOYSA-N 0.000 description 1
- LFNXCUNDYSYVJY-UHFFFAOYSA-N tris(3-methylphenyl)phosphane Chemical compound CC1=CC=CC(P(C=2C=C(C)C=CC=2)C=2C=C(C)C=CC=2)=C1 LFNXCUNDYSYVJY-UHFFFAOYSA-N 0.000 description 1
- RYXYUARTMQUYKV-UHFFFAOYSA-N tris(4-butylphenyl)phosphane Chemical compound C1=CC(CCCC)=CC=C1P(C=1C=CC(CCCC)=CC=1)C1=CC=C(CCCC)C=C1 RYXYUARTMQUYKV-UHFFFAOYSA-N 0.000 description 1
- SPNVODOGUAUMCA-UHFFFAOYSA-N tris(4-ethoxy-2,6-dimethylphenyl)phosphane Chemical compound CC1=CC(OCC)=CC(C)=C1P(C=1C(=CC(OCC)=CC=1C)C)C1=C(C)C=C(OCC)C=C1C SPNVODOGUAUMCA-UHFFFAOYSA-N 0.000 description 1
- LQEKTSMTEYLBLJ-UHFFFAOYSA-N tris(4-ethoxyphenyl)phosphane Chemical compound C1=CC(OCC)=CC=C1P(C=1C=CC(OCC)=CC=1)C1=CC=C(OCC)C=C1 LQEKTSMTEYLBLJ-UHFFFAOYSA-N 0.000 description 1
- PCCAGZSOGFNURV-UHFFFAOYSA-N tris(4-ethylphenyl)phosphane Chemical compound C1=CC(CC)=CC=C1P(C=1C=CC(CC)=CC=1)C1=CC=C(CC)C=C1 PCCAGZSOGFNURV-UHFFFAOYSA-N 0.000 description 1
- UYUUAUOYLFIRJG-UHFFFAOYSA-N tris(4-methoxyphenyl)phosphane Chemical compound C1=CC(OC)=CC=C1P(C=1C=CC(OC)=CC=1)C1=CC=C(OC)C=C1 UYUUAUOYLFIRJG-UHFFFAOYSA-N 0.000 description 1
- WXAZIUYTQHYBFW-UHFFFAOYSA-N tris(4-methylphenyl)phosphane Chemical compound C1=CC(C)=CC=C1P(C=1C=CC(C)=CC=1)C1=CC=C(C)C=C1 WXAZIUYTQHYBFW-UHFFFAOYSA-N 0.000 description 1
- NTUMNRFLAZXNBW-UHFFFAOYSA-N tris(4-propan-2-ylphenyl)phosphane Chemical compound C1=CC(C(C)C)=CC=C1P(C=1C=CC(=CC=1)C(C)C)C1=CC=C(C(C)C)C=C1 NTUMNRFLAZXNBW-UHFFFAOYSA-N 0.000 description 1
- JTOQWGJGVSYTTN-UHFFFAOYSA-N tris(4-propylphenyl)phosphane Chemical compound C1=CC(CCC)=CC=C1P(C=1C=CC(CCC)=CC=1)C1=CC=C(CCC)C=C1 JTOQWGJGVSYTTN-UHFFFAOYSA-N 0.000 description 1
- UQHFPPSBVOIUFM-UHFFFAOYSA-N tris(4-tert-butylphenyl)phosphane Chemical compound C1=CC(C(C)(C)C)=CC=C1P(C=1C=CC(=CC=1)C(C)(C)C)C1=CC=C(C(C)(C)C)C=C1 UQHFPPSBVOIUFM-UHFFFAOYSA-N 0.000 description 1
- UGNAOCDIZFIEQK-UHFFFAOYSA-N tris[4-[(2-methylpropan-2-yl)oxy]phenyl]phosphane Chemical compound C1=CC(OC(C)(C)C)=CC=C1P(C=1C=CC(OC(C)(C)C)=CC=1)C1=CC=C(OC(C)(C)C)C=C1 UGNAOCDIZFIEQK-UHFFFAOYSA-N 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 238000004506 ultrasonic cleaning Methods 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 229920001866 very low density polyethylene Polymers 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
- CHJMFFKHPHCQIJ-UHFFFAOYSA-L zinc;octanoate Chemical compound [Zn+2].CCCCCCCC([O-])=O.CCCCCCCC([O-])=O CHJMFFKHPHCQIJ-UHFFFAOYSA-L 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
- 229910000166 zirconium phosphate Inorganic materials 0.000 description 1
- LEHFSLREWWMLPU-UHFFFAOYSA-B zirconium(4+);tetraphosphate Chemical compound [Zr+4].[Zr+4].[Zr+4].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LEHFSLREWWMLPU-UHFFFAOYSA-B 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/42—Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/62—Alcohols or phenols
- C08G59/621—Phenols
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- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/013—Fillers, pigments or reinforcing additives
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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- C—CHEMISTRY; METALLURGY
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
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- C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
- C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
- C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
- C08L71/12—Polyphenylene oxides
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/29—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the material, e.g. carbon
- H01L23/293—Organic, e.g. plastic
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0313—Organic insulating material
- H05K1/0353—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
- H05K1/0373—Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement containing additives, e.g. fillers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2379/00—Other polymers having nitrogen, with or without oxygen or carbon only, in the main chain
- B32B2379/08—Polyimides
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- C08J2463/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2471/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
- C08J2471/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
- C08J2471/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
- C08J2471/12—Polyphenylene oxides
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- Epoxy Resins (AREA)
Description
[1] (A)有機粒子、(B)エポキシ樹脂、及び(C)無機充填材を含む樹脂組成物であって、
(A)成分が、コア粒子とコア粒子を覆うミドル層とミドル層を覆うシェル層からなる3層のポリマーで形成された有機粒子を含む、樹脂組成物。
[2] (A)成分において、コア粒子及びシェル層が、それぞれ、ガラス転移温度又は融点が40℃以上のポリマーで形成され、且つミドル層が、ガラス転移温度20℃以下のポリマーで形成された、上記[1]に記載の樹脂組成物。
[3] (A)成分において、ミドル層を形成するポリマーが、アルキル(メタ)アクリレート類及び共役ジエン類から選ばれる1種以上のモノマー由来の構造を構成単位として含む、上記[1]又は[2]に記載の樹脂組成物。
[4] (A)成分において、ミドル層を形成するポリマーが、式(1-1):
で表されるモノマー由来の構造を構成単位として含む、上記[3]に記載の樹脂組成物。
[5] (A)成分において、シェル層を形成するポリマーが、アルキル(メタ)アクリレート類及び芳香族ビニル類から選ばれる1種以上のモノマー由来の構造を構成単位として含む、上記[1]~[4]の何れかに記載の樹脂組成物。
[6] (A)成分において、コア粒子を形成するポリマーが、芳香族ビニル類由来の構造を構成単位として含む、上記[1]~[5]の何れかに記載の樹脂組成物。
[7] (A)成分において、コア粒子の平均半径とミドル層の平均厚みの比(コア粒子:ミドル層)が、1:200~1:0.02であり、コア粒子の平均半径とシェル層の平均厚みの比(コア粒子:シェル層)が、1:200~1:0.02である、上記[1]~[6]の何れかに記載の樹脂組成物。
[8] (C)成分の含有量が、樹脂組成物中の不揮発成分を100質量%とした場合、50質量%以上である、上記[1]~[7]の何れかに記載の樹脂組成物。
[9] (D)硬化剤をさらに含む、上記[1]~[8]の何れかに記載の樹脂組成物。
[10] (D)成分が、活性エステル系硬化剤を含む、上記[9]に記載の樹脂組成物。
[11] (D)成分が、フェノール系硬化剤を含む、上記[9]又は[10]に記載の樹脂組成物。
[12] (E)熱可塑性樹脂をさらに含む、上記[1]~[11]の何れかに記載の樹脂組成物。
[13] (E)成分が、フェノキシ樹脂を含む、上記[12]に記載の樹脂組成物。
[14] (E)成分の重量平均分子量(Mw)が、5,000以上である、上記[12]又は[13]に記載の樹脂組成物。
[15] (F)硬化促進剤をさらに含む、上記[1]~[14]の何れかに記載の樹脂組成物。
[16] 樹脂組成物の硬化物の誘電正接(Df)が、5.8GHz、23℃で測定した場合、0.0040以下である、上記[1]~[15]の何れかに記載の樹脂組成物。
[17] 樹脂組成物の硬化物の比誘電率(Dk)が、5.8GHz、23℃で測定した場合、3.5以下である、上記[1]~[16]の何れかに記載の樹脂組成物。
[18] 上記[1]~[17]の何れかに記載の樹脂組成物の硬化物。
[19] 上記[1]~[17]の何れかに記載の樹脂組成物を含有する、シート状積層材料。
[20] 支持体と、当該支持体上に設けられた上記[1]~[17]の何れかに記載の樹脂組成物から形成される樹脂組成物層と、を有する樹脂シート。
[21] 上記[1]~[17]の何れかに記載の樹脂組成物の硬化物からなる絶縁層を備えるプリント配線板。
[22] 上記[21]に記載のプリント配線板を含む、半導体装置。
本発明の樹脂組成物は、(A)有機粒子、(B)エポキシ樹脂、及び(C)無機充填材を含み、(A)有機粒子が、コア粒子とコア粒子を覆うミドル層とミドル層を覆うシェル層からなる3層のポリマーで形成された有機粒子を含む。このような樹脂組成物を用いることにより、誘電正接(Df)をより低く抑え且つデスミア処理(粗化処理)後のクラックの発生を抑えることができる硬化物を得ることができる。また、一実施形態において、得られる硬化物の銅箔密着性をより向上させることができる。
本発明の樹脂組成物は、(A)有機粒子を含有する。(A)有機粒子は、ポリマーで形成された粒子である。
で表されるモノマーである。このようなモノマー由来の構造は、ポリマー中に、1種類単独で含まれていてもよく、2種類以上含まれていてもよい。
で表されるモノマーである。このようなモノマー由来の構造は、ポリマー中に、1種類単独で含まれていてもよく、2種類以上含まれていてもよい。
で表されるモノマーである。このようなモノマー由来の構造は、ポリマー中に、1種類単独で含まれていてもよく、2種類以上含まれていてもよい。
で表されるモノマーである。このようなモノマー由来の構造は、ポリマー中に、1種類単独で含まれていてもよく、2種類以上含まれていてもよい。
本発明の樹脂組成物は、(B)エポキシ樹脂を含有する。(B)エポキシ樹脂とは、エポキシ当量5,000g/eq.以下のエポキシ基を有する硬化性樹脂である。
本発明の樹脂組成物は、(C)無機充填材を含有する。(C)無機充填材は、粒子の状態で樹脂組成物に含まれる。
本発明の樹脂組成物は、任意成分として(D)硬化剤を含有していてもよい。(D)硬化剤は、1種類単独で用いてもよく、2種類以上を任意に組み合わせて用いてもよい。(D)硬化剤は、(B)エポキシ樹脂と反応して硬化させる機能を有し得る。
本発明の樹脂組成物は、さらに任意成分として(E)熱可塑性樹脂を含んでいてもよい。ここで説明する(E)熱可塑性樹脂は、(B)エポキシ樹脂に該当しない成分である。
本発明の樹脂組成物は、任意成分として(F)硬化促進剤を含んでいてもよい。(F)硬化促進剤は、(B)エポキシ樹脂の硬化を促進させる硬化触媒としての機能を有する。
本発明の樹脂組成物は、不揮発成分として、さらに任意の添加剤を含んでいてもよい。このような添加剤としては、例えば、エポキシアクリレート樹脂、ウレタンアクリレート樹脂、ウレタン樹脂、シアネート樹脂、ベンゾオキサジン樹脂、不飽和ポリエステル樹脂、フェノール樹脂、メラミン樹脂、シリコーン樹脂、エポキシ樹脂等の熱硬化性樹脂;4-ビニルフェニル、アクリロイル基、メタクリロイル基、マレイミド基(2,5-ジヒドロ-2,5-ジオキソ-1H-ピロール-1-イル基)等を有するラジカル重合性化合物;過酸化物系ラジカル重合開始剤、アゾ系ラジカル重合開始剤等のラジカル重合開始剤;ゴム粒子等の有機充填材;有機銅化合物、有機亜鉛化合物、有機コバルト化合物等の有機金属化合物;フタロシアニンブルー、フタロシアニングリーン、アイオディングリーン、ジアゾイエロー、クリスタルバイオレット、酸化チタン、カーボンブラック等の着色剤;ハイドロキノン、カテコール、ピロガロール、フェノチアジン等の重合禁止剤;シリコーン系レベリング剤、アクリルポリマー系レベリング剤等のレベリング剤;ベントン、モンモリロナイト等の増粘剤;シリコーン系消泡剤、アクリル系消泡剤、フッ素系消泡剤、ビニル樹脂系消泡剤等の消泡剤;ベンゾトリアゾール系紫外線吸収剤等の紫外線吸収剤;尿素シラン等の接着性向上剤;トリアゾール系密着性付与剤、テトラゾール系密着性付与剤、トリアジン系密着性付与剤等の密着性付与剤;ヒンダードフェノール系酸化防止剤等の酸化防止剤;スチルベン誘導体等の蛍光増白剤;フッ素系界面活性剤、シリコーン系界面活性剤等の界面活性剤;リン系難燃剤(例えばリン酸エステル化合物、ホスファゼン化合物、ホスフィン酸化合物、赤リン)、窒素系難燃剤(例えば硫酸メラミン)、ハロゲン系難燃剤、無機系難燃剤(例えば三酸化アンチモン)等の難燃剤;リン酸エステル系分散剤、ポリオキシアルキレン系分散剤、アセチレン系分散剤、シリコーン系分散剤、アニオン性分散剤、カチオン性分散剤等の分散剤;ボレート系安定剤、チタネート系安定剤、アルミネート系安定剤、ジルコネート系安定剤、イソシアネート系安定剤、カルボン酸系安定剤、カルボン酸無水物系安定剤等の安定剤等が挙げられる。(G)その他の添加剤は、1種を単独で用いてもよく、2種以上を任意の比率で組み合わせて用いてもよい。(G)その他の添加剤の含有量は当業者であれば適宜設定できる。
本発明の樹脂組成物は、上述した不揮発成分以外に、揮発性成分として、さらに任意の有機溶剤を含有する場合がある。(H)有機溶剤としては、公知のものを適宜用いることができ、その種類は特に限定されるものではない。(H)有機溶剤としては、例えば、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剤;酢酸メチル、酢酸エチル、酢酸ブチル、酢酸イソブチル、酢酸イソアミル、プロピオン酸メチル、プロピオン酸エチル、γ-ブチロラクトン等のエステル系溶剤;テトラヒドロピラン、テトラヒドロフラン、1,4-ジオキサン、ジエチルエーテル、ジイソプロピルエーテル、ジブチルエーテル、ジフェニルエーテル、アニソール等のエーテル系溶剤;メタノール、エタノール、プロパノール、ブタノール、エチレングリコール等のアルコール系溶剤;酢酸2-エトキシエチル、プロピレングリコールモノメチルエーテルアセテート、ジエチレングリコールモノエチルエーテルアセテート、エチルジグリコールアセテート、γ-ブチロラクトン、メトキシプロピオン酸メチル等のエーテルエステル系溶剤;乳酸メチル、乳酸エチル、2-ヒドロキシイソ酪酸メチル等のエステルアルコール系溶剤;2-メトキシプロパノール、2-メトキシエタノール、2-エトキシエタノール、プロピレングリコールモノメチルエーテル、ジエチレングリコールモノブチルエーテル(ブチルカルビトール)等のエーテルアルコール系溶剤;N,N-ジメチルホルムアミド、N,N-ジメチルアセトアミド、N-メチル-2-ピロリドン等のアミド系溶剤;ジメチルスルホキシド等のスルホキシド系溶剤;アセトニトリル、プロピオニトリル等のニトリル系溶剤;ヘキサン、シクロペンタン、シクロヘキサン、メチルシクロヘキサン等の脂肪族炭化水素系溶剤;ベンゼン、トルエン、キシレン、エチルベンゼン、トリメチルベンゼン等の芳香族炭化水素系溶剤等を挙げることができる。(H)有機溶剤は、1種単独で用いてもよく、2種以上を任意の比率で組み合わせて用いてもよい。
本発明の樹脂組成物は、例えば、任意の調製容器に(A)有機粒子、(B)エポキシ樹脂、(C)無機充填材、必要に応じて(D)硬化剤、必要に応じて(E)熱可塑性樹脂、必要に応じて(F)硬化促進剤、必要に応じて(G)その他の添加剤、及び必要に応じて(H)有機溶剤を、任意の順で及び/又は一部若しくは全部同時に加えて混合することによって、製造することができる。また、各成分を加えて混合する過程で、温度を適宜設定することができ、一時的に又は終始にわたって、加熱及び/又は冷却してもよい。また、加えて混合する過程において又はその後に、樹脂組成物を、例えば、ミキサーなどの撹拌装置又は振盪装置を用いて撹拌又は振盪し、均一に分散させてもよい。また、撹拌又は振盪と同時に、真空下等の低圧条件下で脱泡を行ってもよい。
本発明の樹脂組成物は、(A)有機粒子、(B)エポキシ樹脂、及び(C)無機充填材を含み、(A)有機粒子が、コア粒子とコア粒子を覆うミドル層とミドル層を覆うシェル層からなる3層のポリマーで形成された有機粒子を含む。このような樹脂組成物を用いることにより、誘電正接(Df)をより低く抑え且つデスミア処理(粗化処理)後のクラックの発生を抑えることができる硬化物を得ることができる。また、一実施形態において、得られる硬化物の銅箔密着性をより向上させることができる。
本発明の樹脂組成物は、絶縁用途の樹脂組成物、特に、絶縁層を形成するための樹脂組成物として好適に使用することができる。具体的には、絶縁層上に形成される導体層(再配線層を含む)を形成するための当該絶縁層を形成するための樹脂組成物(導体層を形成するための絶縁層形成用樹脂組成物)として好適に使用することができる。また、後述するプリント配線板において、プリント配線板の絶縁層を形成するための樹脂組成物(プリント配線板の絶縁層形成用樹脂組成物)として好適に使用することができる。本発明の樹脂組成物はまた、樹脂シート、プリプレグ等のシート状積層材料、ソルダーレジスト、アンダーフィル材、ダイボンディング材、半導体封止材、穴埋め樹脂、部品埋め込み樹脂等、樹脂組成物が必要とされる用途で広範囲に使用できる。
(1)基材に仮固定フィルムを積層する工程、
(2)半導体チップを、仮固定フィルム上に仮固定する工程、
(3)半導体チップ上に封止層を形成する工程、
(4)基材及び仮固定フィルムを半導体チップから剥離する工程、
(5)半導体チップの基材及び仮固定フィルムを剥離した面に、絶縁層としての再配線形成層を形成する工程、及び
(6)再配線形成層上に、導体層としての再配線層を形成する工程
本発明の樹脂組成物は、ワニス状態で塗布して使用することもできるが、工業的には一般に、該樹脂組成物を含有するシート状積層材料の形態で用いることが好適である。
本発明のプリント配線板は、本発明の樹脂組成物を硬化して得られる硬化物からなる絶縁層を含む。
(I)内層基板上に、樹脂シートを、樹脂シートの樹脂組成物層が内層基板と接合するように積層する工程
(II)樹脂組成物層を硬化(例えば熱硬化)して絶縁層を形成する工程
本発明の半導体装置は、本発明のプリント配線板を含む。本発明の半導体装置は、本発明のプリント配線板を用いて製造することができる。
ビスフェノールAF型エポキシ樹脂(「NC-3000H」、日本化薬社製、エポキシ当量約290g/eq.)5部と、ナフタレン型エポキシ樹脂(「HP-4032SS」、DIC社製、エポキシ当量:144g/eq.)10部、ビスフェノール系エポキシ樹脂(日鉄ケミカル&マテリアル社製「ZX-1059」、エポキシ当量約165g/eq.)5部を、ソルベントナフサ30部及びシクロヘキサノン10部中に、撹拌しながら加熱溶解させた。これにより、エポキシ樹脂溶液を得た。
実施例1において、活性エステル系硬化剤(DIC社製「HPC-8150-62T」、活性基当量約229g/eq.、固形分62質量%のトルエン溶液)48.4部のかわりに活性エステル系硬化剤(DIC社製「HPC-8000-65T」、活性基当量約223g/eq.、固形分65質量%のトルエン溶液)46部を使用した。以上の事項以外は実施例1と同様にしてワニス状の樹脂組成物2を調製した。
実施例1において、3層状有機粒子(アイカ工業社製「AC3601」、スチレン/2-エチルヘキシルアクリレート/スチレン粒子)4部を使用しなかった。以上の事項以外は実施例1と同様にしてワニス状の樹脂組成物3を調製した。
実施例1において、3層状有機粒子(アイカ工業社製「AC3601」、スチレン/2-エチルヘキシルアクリレート/スチレン粒子)4部の代わりに2層状有機粒子(ダウ・ケミカル日本社製「EXL-2655」、ブタジエン/メチルメタクリレート・スチレン粒子)4部を使用した。以上の事項以外は実施例1と同様にしてワニス状の樹脂組成物4を調製した。
実施例1において、3層状有機粒子(アイカ工業社製「AC3601」、スチレン/2-エチルヘキシルアクリレート/スチレン粒子)4部の代わりに2層状有機粒子(アイカ工業社製「AC3401N」、ブタジエン/メチルメタクリレート粒子)4部を使用した。以上の事項以外は実施例1と同様にして樹脂組成物5を調製した。
実施例2において、3層状有機粒子(アイカ工業社製「AC3601」、スチレン/2-エチルヘキシルアクリレート/スチレン粒子)4部を2層状有機粒子(アイカ工業社製「AC3401N」、ブタジエン/メチルメタクリレート粒子)4部に変えた。以上の事項以外は実施例2と同様にして樹脂組成物6を調製した。
実施例1において、3層状有機粒子(アイカ工業社製「AC3601」、スチレン/2-エチルヘキシルアクリレート/スチレン粒子)4部をブチルアクリレート/メチルメタクリレート粒子(アイカ工業社製「AC3816N」)4部に変えた。以上の事項以外は実施例1と同様にして樹脂組成物7を調製した。
支持体として、アルキド樹脂系離型剤(リンテック社製「AL-5」)で離型処理したPETフィルム(東レ社製「ルミラーR80」、厚み38μm、軟化点130℃、以下「離型PET」ということがある。)を用意した。
作製例1で作製した樹脂シートを残銅率60%になるように直径350μmの円形の銅パッド(銅厚35μm)を400μm間隔で格子状に形成したコア材(日立化成工業社製「E705GR」、厚さ400μm)の両面にバッチ式真空加圧ラミネーター(ニッコー・マテリアルズ社製2ステージビルドアップラミネーター「CVP700」)を用いて、樹脂組成物層が前記の内層基板と接合するように、内層基板の両面にラミネートした。このラミネートは、30秒間減圧して気圧を13hPa以下とした後、温度100℃、圧力0.74MPaにて30秒間圧着することにより、実施した。これを、130℃のオーブンに投入して30分間加熱し、次いで170℃のオーブンに移し替えて30分間加熱した。さらに支持層を剥離し、得られた回路基板を、膨潤液であるアトテックジャパン(株)のスエリングディップ・セキュリガントPに60℃で10分間浸漬した。次に、粗化液であるアトテックジャパン(株)のコンセントレート・コンパクトP(KMnO4:60g/L、NaOH:40g/Lの水溶液)に80℃で30分間浸漬した。最後に、中和液であるアトテックジャパン(株)のリダクションソリューション・セキュリガントPに40℃で5分間浸漬した。粗化処理後の回路基板の銅パッド部を100個観察し、樹脂組成物層のクラックの有無を確認し、下記の評価基準で評価した。
「〇」:クラックが10個以下である場合
「×」:クラックが10個より多い場合
作製例1で作製した樹脂シートから、保護フィルムを剥がして、200℃にて90分間加熱して樹脂組成物層を熱硬化させた後、支持体を剥離した。得られた硬化物を、幅2mm、長さ80mmの試験片に切断した。該試験片について、アジレントテクノロジーズ社製「HP8362B」を用いて、空洞共振摂動法により測定周波数5.8GHz、測定温度23℃にて比誘電率(Dk)、誘電正接(Df)を測定した。3本の試験片について測定を行い、平均値を算出し、当該平均値に基づいて以下の評価基準で評価した。
「〇」:比誘電率(Dk)が3.5以下且つ誘電正接(Df)が0.0040以下の場合
「×」:比誘電率(Dk)が3.5を上回る或いは誘電正接(Df)が0.0040を上回る場合
(1)銅箔の下地処理
三井金属鉱山社製「3EC-III」(電界銅箔、35μm)の光沢面をマイクロエッチング剤((メック社製「CZ8101」)にて1μmエッチングして銅表面の粗化処理を行い、次いで防錆処理(CL8300)を施した。さらに、130℃のオーブンで30分間加熱処理した。この銅箔をCZ銅箔という。
内層回路を形成したガラス布基材エポキシ樹脂両面銅張積層板(銅箔の厚さ18μm、基板の厚さ0.4mm、パナソニック社製「R1515A」)の両面をマイクロエッチング剤(メック社製「CZ8101」)にて1μmエッチングして銅表面の粗化処理を行った。
作製例1で作製した樹脂シートから保護フィルムを剥がして、樹脂組成物層を露出させた。バッチ式真空加圧ラミネーター(ニッコー・マテリアルズ社製、2ステージビルドアップラミネーター「CVP700」)を用いて、樹脂組成物層が内層基板と接するように、上記(2)で用意した内層基板の両面にラミネートした。ラミネートは、30秒間減圧して気圧を13hPa以下に調整した後、120℃、圧力0.74MPaにて30秒間圧着させることにより実施した。次いで、100℃、圧力0.5MPaにて60秒間熱プレスを行った。その樹脂組成物層上に、CZ銅箔の処理面を、上記と同様の条件で、ラミネートした。そして、200℃、90分の硬化条件で樹脂組成物層を硬化して絶縁層を形成することで、評価基板を作製した。
上記(3)で作製した評価基板を150×30mmの小片に切断した。小片の銅箔部分に、カッターを用いて幅10mm、長さ100mmの部分の切込みをいれて、銅箔の一端を剥がしてつかみ具で掴み、室温中にて、50mm/分の速度で垂直方向に35mmを引き剥がした時の荷重(kgf/cm)を測定し、剥離強度を求めた。測定には、引っ張り試験機(TSE社製「AC-50C-SL」)を使用した。測定は日本工業規格(JIS C6481)に準拠して行い、銅箔密着性(密着強度)について以下の評価基準で評価した。
「〇」:密着強度が0.60kgf/cm以上
「×」:密着強度が0.60kgf/cm未満
Claims (18)
- (A)有機粒子、(B)エポキシ樹脂、及び(C)無機充填材を含む樹脂組成物であって、
(A)成分が、コア粒子とコア粒子を覆うミドル層とミドル層を覆うシェル層からなる3層のポリマーで形成された有機粒子を含み、
(A)成分において、コア粒子及びシェル層が、それぞれ、ガラス転移温度又は融点が40℃以上のポリマーで形成され、且つミドル層が、ガラス転移温度20℃以下のポリマーで形成され、
(A)成分において、ミドル層を形成するポリマーが、アルキル(メタ)アクリレート類及び共役ジエン類から選ばれる1種以上のモノマー由来の構造を構成単位として含み、
シェル層を形成するポリマーが、アルキル(メタ)アクリレート類及び芳香族ビニル類から選ばれる1種以上のモノマー由来の構造を構成単位として含み、
コア粒子を形成するポリマーが、芳香族ビニル類由来の構造を構成単位として含み、
(A)成分の含有量が、0.5~5質量%であり、
(B)成分の含有量が、1~15質量%であり、
(C)成分の含有量が、65~85質量%である樹脂組成物(ただし、ウレタン変性エポキシ樹脂を含有する樹脂組成物を除く)。 - (A)有機粒子、(B)エポキシ樹脂、及び(C)無機充填材を含む樹脂組成物であって、
(A)成分が、コア粒子とコア粒子を覆うミドル層とミドル層を覆うシェル層からなる3層のポリマーで形成された有機粒子を含み、
(A)成分において、コア粒子及びシェル層が、それぞれ、ガラス転移温度又は融点が40℃以上のポリマーで形成され、且つミドル層が、ガラス転移温度20℃以下のポリマーで形成され、
(A)成分において、ミドル層を形成するポリマーが、アルキル(メタ)アクリレート類及び共役ジエン類から選ばれる1種以上のモノマー由来の構造を構成単位として含み、
シェル層を形成するポリマーが、アルキル(メタ)アクリレート類及び芳香族ビニル類から選ばれる1種以上のモノマー由来の構造を構成単位として含み、
コア粒子を形成するポリマーが、芳香族ビニル類由来の構造を構成単位として含み、
(A)成分の含有量が、0.5~5質量%であり、
(B)成分の含有量が、1~15質量%であり、
(C)成分の含有量が、65~85質量%であるプリント配線板用の樹脂組成物。 - (A)成分において、コア粒子の平均半径とミドル層の平均厚みの比(コア粒子:ミドル層)が、1:200~1:0.02であり、コア粒子の平均半径とシェル層の平均厚みの比(コア粒子:シェル層)が、1:200~1:0.02である、請求項1~3の何れか1項に記載の樹脂組成物。
- (D)硬化剤をさらに含む、請求項1~4の何れか1項に記載の樹脂組成物。
- (D)成分が、活性エステル系硬化剤を含む、請求項5に記載の樹脂組成物。
- (D)成分が、フェノール系硬化剤を含む、請求項5又は6に記載の樹脂組成物。
- (E)熱可塑性樹脂をさらに含む、請求項1~7の何れか1項に記載の樹脂組成物。
- (E)成分が、フェノキシ樹脂を含む、請求項8に記載の樹脂組成物。
- (E)成分の重量平均分子量(Mw)が、5,000以上である、請求項8又は9に記載の樹脂組成物。
- (F)硬化促進剤をさらに含む、請求項1~10の何れか1項に記載の樹脂組成物。
- 樹脂組成物の硬化物の誘電正接(Df)が、5.8GHz、23℃で測定した場合、0.0040以下である、請求項1~11の何れか1項に記載の樹脂組成物。
- 樹脂組成物の硬化物の比誘電率(Dk)が、5.8GHz、23℃で測定した場合、3.5以下である、請求項1~12の何れか1項に記載の樹脂組成物。
- 請求項1~13の何れか1項に記載の樹脂組成物の硬化物。
- 請求項1~13の何れか1項に記載の樹脂組成物を含有する、シート状積層材料。
- 支持体と、当該支持体上に設けられた請求項1~13の何れか1項に記載の樹脂組成物から形成される樹脂組成物層と、を有する樹脂シート。
- 請求項1~13の何れか1項に記載の樹脂組成物の硬化物からなる絶縁層を備えるプリント配線板。
- 請求項17に記載のプリント配線板を含む、半導体装置。
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