阅读说明：本技术 树脂组合物、预浸料、带树脂的膜、带树脂的金属箔、覆金属箔层压板以及布线板 (Resin composition, prepreg, film with resin, metal foil with resin, metal-foil-clad laminate, and wiring board ) 是由 利光谦一 中村善彦 藤泽洋之 圆谷勇治 山内章裕 新保孝 于 2018-12-18 设计创作，主要内容包括：一种树脂组合物,其含有：下述式(1)所示的马来酰亚胺化合物；改性聚苯醚化合物,末端被具有碳-碳不饱和双键的取代基改性；以及交联剂,包含烯丙基化合物。<Image he="223" wi="700" file="DDA0002546601510000011.GIF" imgContent="drawing" imgFormat="GIF" orientation="portrait" inline="no"></Image>式(1)中,s表示1～5,R<Sub>A</Sub>、R<Sub>B</Sub>、R<Sub>C</Sub>及R<Sub>D</Sub>分别独立地表示氢原子、碳数1～5的烷基或苯基。(A resin composition comprising: a maleimide compound represented by the following formula (1); a modified polyphenylene ether compound, the terminal of which is modified with a substituent having a carbon-carbon unsaturated double bond; and a crosslinking agent comprising an allyl compound. In the formula (1), s represents 1 to 5, R A 、R B 、R C And R D Each independently represents a hydrogen atom, an alkyl group having 1 to 5 carbon atoms or a phenyl group.)

1. A resin composition characterized by comprising:

a maleimide compound represented by the following formula (1);

a modified polyphenylene ether compound, the terminal of which is modified with a substituent having a carbon-carbon unsaturated double bond; and

a crosslinking agent comprising an allyl compound;

in the formula (1), s represents 1 to 5, R_A、R_B、R_CAnd R_DEach independently represents a hydrogen atom, an alkyl group having 1 to 5 carbon atoms or a phenyl group.

2. The resin composition according to claim 1,

the crosslinking agent further comprises: a polyfunctional acrylate compound having 2 or more acryloyl groups in a molecule; and a polyfunctional methacrylate compound having 2 or more methacryloyl groups in the molecule.

3. The resin composition according to claim 2, characterized in that:

the multifunctional methacrylate compound comprises a dimethacrylate compound.

4. The resin composition according to any one of claims 1 to 3, characterized in that:

the allyl compound comprises at least one of triallyl isocyanurate and diallyl bisphenol.

5. The resin composition according to any one of claims 1 to 4, characterized in that:

the maleimide compound is contained in an amount of 10 to 60 parts by mass per 100 parts by mass of the total mass of the maleimide compound, the modified polyphenylene ether compound and the crosslinking agent.

6. The resin composition according to any one of claims 1 to 5, characterized in that:

the polyphenylene ether compound is contained in an amount of 10 to 75 parts by mass per 100 parts by mass of the total of the maleimide compound, the modified polyphenylene ether compound and the crosslinking agent.

7. The resin composition according to any one of claims 1 to 6, further comprising:

an inorganic filler pretreated with a silane coupling agent.

8. A prepreg characterized by comprising:

the resin composition or the semi-cured product of the resin composition according to any one of claims 1 to 7; and

a fibrous substrate.

9. A resin-bearing film characterized by comprising:

a resin layer comprising the resin composition according to any one of claims 1 to 7 or a semi-cured product of the resin composition; and

and supporting the membrane.

10. A resin-bearing metal foil, characterized by comprising:

a resin layer comprising the resin composition according to any one of claims 1 to 7 or a semi-cured product of the resin composition; and

a metal foil.

11. A metal-clad laminate characterized by comprising:

an insulating layer comprising a cured product of the resin composition according to any one of claims 1 to 7 or a cured product of the prepreg according to claim 8; and

a metal foil.

12. A wiring board characterized by comprising:

an insulating layer comprising a cured product of the resin composition according to any one of claims 1 to 7 or a cured product of the prepreg according to claim 8; and

and (6) wiring.

Technical Field

The present invention relates to a resin composition, a prepreg, a film with resin, a metal foil with resin, a metal-foil-clad laminate, and a wiring board.

Background

As the amount of information processing for various electronic devices increases, the mounting technology for high integration of semiconductor devices mounted thereon, high density wiring, and multilayering has been advancing. As a wiring board used in various electronic devices, for example, a wiring board that can cope with high frequencies such as a millimeter wave radar board used in a vehicle is demanded. In order to increase the signal transmission speed and reduce the loss during signal transmission, a substrate material used as a base material of a wiring board used in various electronic devices is required to have a low dielectric constant and a low dielectric loss tangent.

Polyphenylene ether is known to have excellent dielectric properties such as low dielectric constant and dielectric loss tangent, and also to have excellent low dielectric properties such as low dielectric constant and low dielectric loss tangent even in a high frequency band (high frequency region) from the MHz band to the GHz band. Therefore, polyphenylene ether has been studied as a molding material for high frequency signals. More specifically, the resin composition is preferably used as a substrate material or the like for forming a base material of a wiring board provided in an electronic device utilizing a high-frequency band.

On the other hand, molding materials such as substrate materials are required to have not only excellent low dielectric characteristics but also excellent heat resistance. Therefore, it is considered that the heat resistance is improved by modifying polyphenylene ether.

Examples of the substrate material include a prepreg and a laminate using a resin composition containing a modified polyphenylene ether. Patent document 1 describes a curable resin composition containing: a vinyl compound having a polyphenylene ether skeleton in the molecule; and bismaleimide compounds having a specified structure. Patent document 1 discloses the following: the curable resin composition can provide a cured product having a low dielectric constant and a low dielectric dissipation factor and excellent in heat resistance, mechanical properties, chemical resistance and flame retardancy, and is excellent in curability even in the presence of oxygen and capable of being cured at a low temperature.

Wiring boards used in various electronic devices are required to be less susceptible to external environmental changes and the like. For example, in order to be used as a wiring board even in a high-temperature environment, a cured product having excellent heat resistance such as a high glass transition temperature is required to be obtained as a base material for constituting a base material of the wiring board. In order to be used as a wiring board even in a high humidity environment, it is required to reduce water absorption of a substrate of the wiring board to suppress moisture absorption of the substrate of the wiring board. Further, for the base material of the wiring board, there are also required: even if water is absorbed, the low dielectric characteristics thereof can be maintained. Therefore, a substrate material used for a substrate constituting a wiring board is required to obtain a cured product which has low water absorption and can maintain low dielectric characteristics properly even after water absorption. That is, a substrate material used for a substrate constituting a wiring board is required to obtain a cured product in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed.

Disclosure of Invention

The present invention has been made in view of the above circumstances, and an object thereof is to provide a resin composition which can suitably obtain a cured product having a high glass transition temperature and a low water absorption rate and in which an increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. Further, the present invention aims to provide a prepreg, a resin-attached film, a resin-attached metal foil, a metal-clad laminate, and a wiring board, each of which is produced using the resin composition.

One aspect of the present invention relates to a resin composition comprising: a maleimide compound represented by the following formula (1); a modified polyphenylene ether compound, the terminal of which is modified with a substituent having a carbon-carbon unsaturated double bond; and a crosslinking agent comprising an allyl compound.

In the formula (1), s represents 1 to 5, R_A、R_B、R_CAnd R_DEach independently represents a hydrogen atom, an alkyl group having 1 to 5 carbon atoms or a phenyl group.

The above objects, features, and other objects, features, and advantages of the present invention will become more apparent from the following detailed description.

Drawings

Fig. 1 is a schematic cross-sectional view showing an example of a prepreg according to an embodiment of the present invention.

Fig. 2 is a schematic cross-sectional view showing an example of the metal-clad laminate according to the embodiment of the present invention.

Fig. 3 is a schematic cross-sectional view showing an example of a wiring board according to an embodiment of the present invention.

Fig. 4 is a schematic cross-sectional view showing an example of the metal foil with resin according to the embodiment of the present invention.

Fig. 5 is a schematic cross-sectional view showing an example of the resin-attached membrane according to the embodiment of the present invention.

Detailed Description

The embodiments according to the present invention will be described below, but the present invention is not limited to these embodiments.

[ resin composition ]

The resin composition according to the present embodiment contains: a maleimide compound represented by the following formula (1); a modified polyphenylene ether compound, the terminal of which is modified with a substituent having a carbon-carbon unsaturated double bond; and a crosslinking agent comprising an allyl compound.

In the formula (1), s represents 1 to 5, R_A、R_B、R_CAnd R_DEach independently represents a hydrogen atom, an alkyl group having 1 to 5 carbon atoms or a phenyl group.

First, consider that: the resin composition can obtain a cured product which maintains the excellent low dielectric characteristics of polyphenylene ether by crosslinking the modified polyphenylene ether compound together with the maleimide compound and the crosslinking agent.

When the maleimide compound is contained in the resin composition, the glass transition temperature tends to be increased. According to the studies of the present inventors, if only a maleimide compound is added to a resin composition containing the modified polyphenylene ether compound and the crosslinking agent, the glass transition temperature can be raised, but the water absorption of a cured product of the resin composition is increased, and there are cases where the increase in dielectric constant and dielectric dissipation factor due to water absorption cannot be sufficiently suppressed after water absorption. That is, the low dielectric characteristics may not be sufficiently maintained after water absorption. The reason is presumed to be: when a maleimide compound is added to a resin composition, the glass transition temperature can be raised, but the water absorption of the cured product of the resulting resin composition tends to be high, and the low dielectric characteristics after water absorption tend not to be maintained. Therefore, the present inventors have conducted various studies and as a result have found that: in the maleimide compound, by containing the maleimide compound represented by the above formula (1) in the resin composition, the glass transition temperature can be raised, and also the increase in water absorption rate can be sufficiently suppressed, and low dielectric characteristics can be appropriately maintained even after water absorption.

Further, according to the studies conducted by the present inventors, if a maleimide compound is contained in a resin composition containing a modified polyphenylene ether compound, when the obtained resin composition is made into a varnish, the compatibility of the maleimide compound with respect to the resin composition containing a modified polyphenylene ether compound may be low, and an appropriate varnish may not be obtained. The reason is presumed to be: the maleimide compound has low solubility in a solvent used for varnish formation. Therefore, the present inventors have conducted various studies and as a result have found that: when the maleimide compound represented by the formula (1) is used as the maleimide compound and the crosslinking agent containing the allyl compound is used as the crosslinking agent, the compatibility of the resin composition containing the modified polyphenylene ether compound with the maleimide compound becomes high, and a varnish can be suitably obtained. The reason is presumed to be: the maleimide compound has high solubility in a solvent used for the varnish formation, and the allyl compound improves the compatibility of the modified polyphenylene ether compound with the maleimide compound represented by the formula (1).

As described above, the resin composition having the above-described structure is a resin composition which can suitably obtain a cured product having a high glass transition temperature and a low water absorption rate and sufficiently suppressing the increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

(Maleimide Compound)

The maleimide compound is not particularly limited as long as it is a maleimide compound represented by the above formula (1). The number of repetitions s is 1 to 5, preferably more than 1 and 5 or less. S is an average value of the number of repetitions (degree of polymerization). If s is too small, there is a tendency that sufficient crosslinking cannot be achieved even if the modified polyphenylene ether compound, the maleimide compound and the crosslinking agent are crosslinked. R_A、R_B、R_CAnd R_DEach independently represents a hydrogen atom, an alkyl group having 1 to 5 carbon atoms or a phenyl group. Namely, R_A、R_B、R_CAnd R_DThe groups may be the same or different. R_A、R_B、R_CAnd R_DRepresents a hydrogen atom, an alkyl group having 1 to 5 carbon atoms or a phenyl group. Among them, a hydrogen atom is preferable. Examples of the alkyl group having 1 to 5 carbon atoms include methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, pentyl, and neopentyl.

The molecular weight of the maleimide compound is preferably 150 to 2000, more preferably 400 to 1300 in number average molecular weight. The weight average molecular weight is preferably 150 to 2500, more preferably 400 to 1500. In the maleimide compound, the content of the bifunctional compound represented by the formula (1) wherein s is 1 is preferably 30 to 70% by mass, more preferably 50 to 70% by mass. The content of the trifunctional or higher polyfunctional compound represented by the formula (1) having s of 2 or more is preferably 30 to 70% by mass, more preferably 30 to 50% by mass. The maleimide compound may contain a monofunctional compound represented by the above formula (1) wherein s is 0, or a polyfunctional compound such as a heptafunctional compound or octafunctional compound represented by the above formula (1) wherein s is 6 or more, as long as the average value s of the number of repetitions (polymerization degree) is 1 to 5.

(modified polyphenylene ether Compound)

The modified polyphenylene ether compound used in the present embodiment is not particularly limited as long as it is a modified polyphenylene ether compound having a terminal modified with a substituent having a carbon-carbon unsaturated double bond.

The substituent having a carbon-carbon unsaturated double bond is not particularly limited. Examples of the substituent include a substituent represented by the following formula (2).

In the formula (2), p represents an integer of 0 to 10. In addition, Z represents an arylene group. Furthermore, R₁～R₃Are independent respectively. Namely, R₁～R₃The groups may be the same or different.Furthermore, R₁～R₃Represents a hydrogen atom or an alkyl group.

In formula (2), when p is 0, Z represents direct bonding to the polyphenylene ether terminal.

The arylene group is not particularly limited. Examples of the arylene group include: monocyclic aromatic groups such as phenylene groups; polycyclic aromatic groups which are not monocyclic but polycyclic aromatic such as naphthalene rings, and the like. The arylene group also includes derivatives in which a hydrogen atom bonded to an aromatic ring is substituted with a functional group such as an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group, or an alkynylcarbonyl group. The alkyl group is not particularly limited, and is preferably an alkyl group having 1 to 18 carbon atoms, and more preferably an alkyl group having 1 to 10 carbon atoms. Specific examples thereof include methyl, ethyl, propyl, hexyl and decyl groups.

Preferable specific examples of the substituent represented by the above formula (2) include a substituent represented by the following formula (3), a substituent containing a vinylbenzyl group, and the like.

In the formula (3), R₄Represents a hydrogen atom or an alkyl group. The alkyl group is not particularly limited, and is preferably an alkyl group having 1 to 18 carbon atoms, and more preferably an alkyl group having 1 to 10 carbon atoms. Specific examples thereof include methyl, ethyl, propyl, hexyl and decyl groups. Examples of the substituent represented by the formula (3) include an acrylate group and a methacrylate group.

Examples of the substituent containing a vinylbenzyl group include a substituent represented by the following formula (4).

More specifically, the substituent includes a vinylbenzyl group (vinylbenzyl group) such as a p-vinylbenzyl group and a m-vinylbenzyl group, a vinylphenyl group, an acrylate group, and a methacrylate group.

The modified polyphenylene ether compound preferably has a polyphenylene ether chain in a molecule, for example, a repeating unit (repeating unit) represented by the following formula (5) in a molecule.

In the formula (5), t represents 1 to 50. Furthermore, R₅～R₈Are independent respectively. Namely, R₅～R₈The groups may be the same or different. Furthermore, R₅～R₈Represents a hydrogen atom, an alkyl group, an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group or an alkynylcarbonyl group. Among them, a hydrogen atom and an alkyl group are preferable.

R₅～R₈Specific examples of the functional groups include the following groups.

The alkyl group is not particularly limited, and is preferably an alkyl group having 1 to 18 carbon atoms, and more preferably an alkyl group having 1 to 10 carbon atoms. Specific examples thereof include: methyl, ethyl, propyl, hexyl, decyl, and the like.

The alkenyl group is not particularly limited, and is preferably an alkenyl group having 2 to 18 carbon atoms, and more preferably an alkenyl group having 2 to 10 carbon atoms. Specific examples thereof include: vinyl, allyl, and 3-butenyl groups, and the like.

The alkynyl group is not particularly limited, and is preferably an alkynyl group having 2 to 18 carbon atoms, and more preferably an alkynyl group having 2 to 10 carbon atoms. Specific examples thereof include: ethynyl and prop-2-yn-1-yl (propargyl).

The alkylcarbonyl group is not particularly limited as long as it is a carbonyl group substituted with an alkyl group, and is preferably an alkylcarbonyl group having 2 to 18 carbon atoms, and more preferably an alkylcarbonyl group having 2 to 10 carbon atoms. Specific examples thereof include: acetyl, propionyl, butyryl, isobutyryl, pivaloyl, hexanoyl, octanoyl, cyclohexylcarbonyl, and the like.

The alkenylcarbonyl group is not particularly limited as long as it is a carbonyl group substituted with an alkenyl group, and is preferably an alkenylcarbonyl group having 3 to 18 carbon atoms, and more preferably an alkenylcarbonyl group having 3 to 10 carbon atoms. Specific examples thereof include acryloyl, methacryloyl and crotonyl groups.

The alkynyl carbonyl group is not particularly limited as long as it is a carbonyl group substituted with an alkynyl group, and for example, an alkynyl carbonyl group having 3 to 18 carbon atoms is preferable, and an alkynyl carbonyl group having 3 to 10 carbon atoms is more preferable. Specific examples thereof include a propioyl group and the like.

The weight average molecular weight (Mw) of the modified polyphenylene ether compound used in the present embodiment is not particularly limited. Specifically, the concentration is preferably 500 to 5000, more preferably 800 to 4000, and still more preferably 1000 to 3000. Here, the weight average molecular weight may be a value measured by a general molecular weight measurement method, and specifically, may be a value measured by Gel Permeation Chromatography (GPC). Further, in the case where the modified polyphenylene ether compound has a repeating unit represented by the above formula (5) in the molecule, m is preferably a value such that the weight average molecular weight of the modified polyphenylene ether compound is within the above range. Specifically, t is preferably 1 to 50.

When the weight average molecular weight of the modified polyphenylene ether compound is within the above range, the modified polyphenylene ether compound has not only excellent low dielectric characteristics of polyphenylene ether, and excellent heat resistance of a cured product, but also excellent moldability. This is considered to be based on the following reason. In general polyphenylene ethers, if the weight average molecular weight is within the above range, the molecular weight is relatively low, and therefore the heat resistance of the cured product tends to decrease. In this regard, it is believed that: since the modified polyphenylene ether compound has the above unsaturated double bond at the terminal, a cured product can obtain sufficiently high heat resistance. Further, it is considered that: if the weight average molecular weight of the modified polyphenylene ether compound is within the above range, the moldability is also excellent because the molecular weight is relatively low. Thus, it is believed that: the modified polyphenylene ether compound has an effect of providing a cured product having excellent heat resistance and excellent moldability.

In addition, the average number of the substituents (the number of terminal functional groups) that each molecule of the modified polyphenylene ether compound has at the molecular terminal in the modified polyphenylene ether compound used in the present embodiment is not particularly limited. Specifically, the number of the cells is preferably 1 to 5, more preferably 1 to 3, and still more preferably 1.5 to 3. If the number of terminal functional groups is too small, it tends to be difficult to obtain sufficient heat resistance of the cured product. Further, if the number of terminal functional groups is too large, the reactivity becomes too high, and there is a possibility that problems such as a decrease in storage stability of the resin composition or a decrease in flowability of the resin composition may occur. That is, if the modified polyphenylene ether compound is used, there is a possibility that molding defects such as voids are generated at the time of multilayer molding, which may cause problems in moldability due to insufficient fluidity, and it is difficult to obtain a highly reliable wiring board.

The number of terminal functional groups of the modified polyphenylene ether compound is as follows: a numerical value representing an average value of the substituents per molecule of all the modified polyphenylene ether compounds present in 1 mole of the modified polyphenylene ether compound, etc. The number of terminal functional groups can be measured, for example, by measuring the number of hydroxyl groups remaining in the resulting modified polyphenylene ether compound and calculating the amount of decrease in the number of hydroxyl groups compared with the polyphenylene ether before modification. The amount of decrease from the number of hydroxyl groups of the polyphenylene ether before modification is the number of terminal functional groups. The number of hydroxyl groups remaining in the modified polyphenylene ether compound can be determined by adding a quaternary ammonium salt (tetraethylammonium hydroxide) associated with hydroxyl groups to a solution of the modified polyphenylene ether compound and measuring the UV absorbance of the mixed solution.

The intrinsic viscosity of the modified polyphenylene ether compound used in the present embodiment is not particularly limited. Specifically, it is preferably 0.03 to 0.12dl/g, more preferably 0.04 to 0.11dl/g, and still more preferably 0.06 to 0.095 dl/g. If the intrinsic viscosity is too low, the molecular weight tends to be low, and it tends to be difficult to obtain low dielectric properties such as a low dielectric constant and a low dielectric loss tangent. Further, if the intrinsic viscosity is too high, the viscosity tends to be high, and sufficient fluidity cannot be obtained, and the moldability of the cured product tends to be low. Therefore, if the intrinsic viscosity of the modified polyphenylene ether compound is within the above range, excellent heat resistance and moldability of the cured product can be achieved.

The intrinsic viscosity herein means the intrinsic viscosity measured in methylene chloride at 25 ℃ and more specifically, for example, a value measured by a viscometer as a 0.18g/45ml solution in methylene chloride (liquid temperature 25 ℃). Examples of the viscometer include AVS500 Visco System manufactured by schottky (Schott) corporation.

Examples of the modified polyphenylene ether compound include a modified polyphenylene ether compound represented by the following formula (6) and a modified polyphenylene ether compound represented by the following formula (7). Further, as the modified polyphenylene ether compound, these modified polyphenylene ether compounds may be used alone, or these two modified polyphenylene ether compounds may be used in combination.

In the formulae (6) and (7), R₉～R₁₆And R₁₇～R₂₄Each independently represents a hydrogen atom, an alkyl group, an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group or an alkynylcarbonyl group. X₁And X₂Each independently represents a substituent having a carbon-carbon unsaturated double bond. A and B represent repeating units represented by the following formula (8) and the following formula (9), respectively. In the formula (7), Y represents a linear, branched or cyclic hydrocarbon having 20 or less carbon atoms.

In the formulae (8) and (9), m and n each represent 0 to 20. R₂₅～R₂₈And R₂₉～R₃₂Each independently represents a hydrogen atom, an alkyl group, an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group or an alkynylcarbonyl group.

The modified polyphenylene ether compound represented by the formula (6) and the modified polyphenylene ether compound represented by the formula (7) are not particularly limited as long as they satisfy the above-described constitution. Specifically, in the formulae (6) and (7), R is as defined above₉～R₁₆And R₁₇～R₂₄Are independent respectively. That is to say that the first and second electrodes,R₉～R₁₆and R₁₇～R₂₄The groups may be the same or different. Furthermore, R₉～R₁₆And R₁₇～R₂₄Represents a hydrogen atom, an alkyl group, an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group or an alkynylcarbonyl group. Among them, a hydrogen atom and an alkyl group are preferable.

In the formulae (8) and (9), m and n each preferably represent 0 to 20 as described above. In addition, the sum of m and n is preferably a value of 1 to 30. Therefore, it is more preferable that m represents 0 to 20, n represents 0 to 20, and the total of m and n represents 1 to 30. Furthermore, R₂₅～R₂₈And R₂₉～R₃₂Are independent respectively. Namely, R₂₅～R₂₈And R₂₉～R₃₂The groups may be the same or different. Furthermore, R₂₅～R₂₈And R₂₉～R₃₂Represents a hydrogen atom, an alkyl group, an alkenyl group, an alkynyl group, a formyl group, an alkylcarbonyl group, an alkenylcarbonyl group or an alkynylcarbonyl group. Among them, a hydrogen atom and an alkyl group are preferable.

R₉～R₃₂And R in the above formula (5)₅～R₈The same is true.

In the formula (7), Y is a linear, branched or cyclic hydrocarbon having 20 or less carbon atoms as described above. Examples of Y include a group represented by the following formula (10).

In the formula (10), R₃₃And R₃₄Each independently represents a hydrogen atom or an alkyl group. Examples of the alkyl group include a methyl group and the like. Examples of the group represented by formula (10) include methylene, methylmethylene, and dimethylmethylene is preferred.

In the above formulae (6) and (7), X₁And X₂Each independently is a substituent having a carbon-carbon unsaturated double bond. As the substituent X₁And X₂The substituent is not particularly limited as long as it is a substituent having a carbon-carbon unsaturated double bond. As said substituent X₁And X₂Examples thereof include a substituent represented by the above formula (2). In the modified polyphenylene ether compound represented by the formula (6) and the modified polyphenylene ether compound represented by the formula (7), X is₁And X₂The substituents may be the same or different.

More specific examples of the modified polyphenylene ether compound represented by the above formula (6) include, for example, a modified polyphenylene ether compound represented by the following formula (11).

More specific examples of the modified polyphenylene ether compound represented by the above formula (7) include, for example, a modified polyphenylene ether compound represented by the following formula (12) and a modified polyphenylene ether compound represented by the following formula (13).

In the formulae (11) to (13), m and n are the same as those in the formulae (8) and (9). In the above formulae (11) and (12), R is₁～R₃And p and R in the above formula (2)₁～R₃And p are the same. In the formulae (12) and (13), Y is the same as Y in the formula (7). In the above formula (13), R₄And R in the above formula (3)₄The same is true.

The average number of the substituents (the number of terminal functional groups) per molecule of the modified polyphenylene ether in the modified polyphenylene ether compound used in the present embodiment is within the above range, and for example, in the case of the modified polyphenylene ether compounds represented by the above formulae (11) to (13), the number is preferably 1 to 2, more preferably 1.5 to 2.

The method for synthesizing the modified polyphenylene ether compound used in the present embodiment is not particularly limited as long as it can synthesize a modified polyphenylene ether compound end-modified with a substituent having a carbon-carbon unsaturated double bond. Specifically, there may be mentioned: a method of reacting a compound to which a substituent having a carbon-carbon unsaturated double bond and a halogen atom are bonded with polyphenylene ether, and the like.

Examples of the compound to which a substituent having a carbon-carbon unsaturated double bond and a halogen atom are bonded include: and compounds to which substituents represented by the above formulae (2) to (4) and halogen atoms are bonded. Specific examples of the halogen atom include a chlorine atom, a bromine atom, an iodine atom and a fluorine atom, and among them, a chlorine atom is preferable. Specific examples of the compound to which a substituent having a carbon-carbon unsaturated double bond and a halogen atom are bonded include p-chloromethylstyrene and m-chloromethylstyrene.

The polyphenylene ether as a raw material is not particularly limited as long as it is a polyphenylene ether which can finally synthesize a predetermined modified polyphenylene ether compound. Specific examples thereof include: and compounds containing polyphenylene ether such as polyphenylene ether or poly (2, 6-dimethyl-1, 4-phenylene ether) containing "2, 6-dimethylphenol" and "at least one of bifunctional phenol and trifunctional phenol" as a main component. The bifunctional phenol is a phenol compound having two phenolic hydroxyl groups in the molecule, and examples thereof include tetramethylbisphenol a. The trifunctional phenol is a phenol compound having three phenolic hydroxyl groups in the molecule.

The method for synthesizing the modified polyphenylene ether compound includes the above-mentioned methods. Specifically, the polyphenylene ether and the compound to which a substituent having a carbon-carbon unsaturated double bond and a halogen atom are bonded are dissolved in a solvent and stirred. Thus, the polyphenylene ether is reacted with the compound to which the substituent having a carbon-carbon unsaturated double bond and the halogen atom are bonded, to obtain the modified polyphenylene ether compound used in the present embodiment.

The reaction is preferably carried out in the presence of an alkali metal hydroxide. This is considered to allow the reaction to proceed satisfactorily. The reason is considered to be that: the alkali metal hydroxide functions as a dehydrohalogenation agent, specifically, as an acid desalting agent. Namely, it is considered that: the alkali metal hydroxide removes hydrogen halide from the phenol group of polyphenylene ether and the compound to which the substituent having a carbon-carbon unsaturated double bond and the halogen atom are bonded, whereby the substituent having a carbon-carbon unsaturated double bond is bonded to the oxygen atom of the phenol group in place of the hydrogen atom of the phenol group of polyphenylene ether.

The alkali metal hydroxide is not particularly limited as long as it can function as a dehalogenation agent, and examples thereof include sodium hydroxide and the like. The alkali metal hydroxide is usually used in the form of an aqueous solution, specifically, as an aqueous sodium hydroxide solution.

The reaction conditions such as the reaction time and the reaction temperature are not particularly limited as long as they are different depending on the compound to which the substituent having a carbon-carbon unsaturated double bond and the halogen atom are bonded and the reaction can be favorably carried out. Specifically, the reaction temperature is preferably room temperature to 100 ℃, and more preferably 30 to 100 ℃. In addition, the reaction time is preferably 0.5 to 20 hours, and more preferably 0.5 to 10 hours.

The solvent used in the reaction is not particularly limited as long as it can dissolve the polyphenylene ether and the compound to which the substituent having a carbon-carbon unsaturated double bond and the halogen atom are bonded, and does not inhibit the reaction of the polyphenylene ether and the compound to which the substituent having a carbon-carbon unsaturated double bond and the halogen atom are bonded. Specific examples thereof include toluene.

The above reaction is preferably carried out in the presence of not only an alkali metal hydroxide but also a phase transfer catalyst. That is, the reaction is preferably carried out in the presence of an alkali metal hydroxide and a phase transfer catalyst. This is thought to allow the reaction to proceed better. This is considered to be based on the following reason. Consider that: this is because the phase transfer catalyst has a function of introducing an alkali metal hydroxide, is soluble in two phases of a polar solvent phase such as water and a nonpolar solvent phase such as an organic solvent, and can move between these phases. Specifically, it is considered that: when an aqueous sodium hydroxide solution is used as the alkali metal hydroxide and an organic solvent such as toluene which is incompatible with water is used as the solvent, even if the aqueous sodium hydroxide solution is added dropwise to the solvent for reaction, the solvent and the aqueous sodium hydroxide solution are separated, and the sodium hydroxide hardly migrates into the solvent. Thus, it is considered that: the aqueous sodium hydroxide solution added as the alkali metal hydroxide hardly contributes to the promotion of the reaction. In contrast, it is considered that: when the reaction is carried out in the presence of the alkali metal hydroxide and the phase transfer catalyst, the alkali metal hydroxide migrates into the solvent in a state in which the phase transfer catalyst is introduced, and the aqueous sodium hydroxide solution easily contributes to the promotion of the reaction. Thus, it is believed that: if the reaction is carried out in the presence of an alkali metal hydroxide and a phase transfer catalyst, the above reaction will proceed better.

The phase transfer catalyst is not particularly limited, and examples thereof include quaternary ammonium salts such as tetra-n-butylammonium bromide.

The resin composition used in the present embodiment preferably contains: the modified polyphenylene ether compound obtained as described above is used as a modified polyphenylene ether compound.

(crosslinking agent)

The crosslinking agent used in the present embodiment is not particularly limited as long as it contains an allyl compound, forms a crosslink in a resin composition containing the modified polyphenylene ether compound and the maleimide compound, and cures the resin composition. The crosslinking agent may contain a crosslinking agent other than the allyl compound as long as it contains the allyl compound, and the crosslinking agent may be a crosslinking agent composed of the allyl compound.

The allylated compound is not particularly limited as long as it is a compound having an allyl group in the molecule. As the allyl compound, for example, triallyl isocyanurate (TAIC), bisphenol in which an aromatic hydrogen element is substituted with an allyl group, and the like can be preferably used. Examples of bisphenols in which the aromatic hydrogen element is substituted with an allyl group include diallyl bisphenols such as 2, 2' -diallyl bisphenol a (dabpa). These may be used alone or in combination of two. It is preferably used. Examples thereof include: combinations of triallyl isocyanurate (TAIC) and diallyl bisphenols such as 2, 2' -diallyl bisphenol A (DABPA), and the like. When such a combination is used, the content of TAIC is preferably equal to or greater than the content of diallyl bisphenol, in view of the fact that the resin fluidity of the resin composition is lowered when the resin composition is stored at 40 ℃. In addition, considering that the resin fluidity of the resin composition is lowered when the resin composition is stored at 40 ℃, it is more preferable to use only TAIC as the allyl compound, rather than to use TAIC and diallylbisphenol in combination.

Examples of the crosslinking agent other than the allyl compound include styrene, divinylbenzene, acrylate compounds, methacrylate compounds, polybutadiene, and maleimide compounds other than the maleimide compounds represented by the above (1). Examples of the acrylate compound include a polyfunctional acrylate compound having 2 or more acryloyl groups in the molecule, such as tricyclodecane dimethanol diacrylate. Examples of the methacrylate compound include a polyfunctional methacrylate compound having 2 or more methacryloyl groups in the molecule, such as tricyclodecane dimethanol Dimethacrylate (DCP). Further, as the crosslinking agent other than the allyl compound, for example: a polyfunctional vinyl compound having 2 or more vinyl groups in the molecule, such as the polybutadiene, and a vinylbenzyl compound such as styrene or divinylbenzene having a vinylbenzyl group in the molecule. Among them, it is preferable to have 2 or more carbon-carbon double bonds in the molecule. Specific examples thereof include a polyfunctional acrylate compound, a polyfunctional methacrylate compound, a polyfunctional vinyl compound, and divinylbenzene. Among them, a polyfunctional acrylate compound and a polyfunctional methacrylate compound are preferable, a dimethacrylate compound is more preferable, and tricyclodecane dimethanol Dimethacrylate (DCP) is further preferable. Consider that: when these compounds are used, crosslinking can be more favorably formed by a curing reaction, and the heat resistance of a cured product of the resin composition according to the present embodiment can be further improved. The crosslinking agent may be used alone or in combination of two or more kinds. Further, as the crosslinking agent, a compound having 2 or more carbon-carbon double bonds in the molecule and a compound having 1 carbon-carbon double bond in the molecule may be used in combination. Specific examples of the compound having 1 carbon-carbon double bond in the molecule include a monovinyl compound having 1 vinyl group in the molecule, such as styrene.

As described above, the crosslinking agent contains the allyl compound, and preferably further contains a crosslinking agent other than the allyl compound. The crosslinking agent other than the allyl compound is preferably the polyfunctional acrylate compound or the polyfunctional methacrylate compound, and more preferably a dimethacrylate compound. That is, as described above, the crosslinking agent is preferably used in combination with: the allyl compound; and, at least one of the multifunctional acrylate compound and the multifunctional methacrylate compound, more preferably in combination with: the allyl compound; and, a dimethacrylate compound. By containing the allyl compound, the resin composition obtained is a resin composition which can obtain a cured product as follows: namely, a cured product which has a high glass transition temperature, has a low water absorption rate, and can maintain low dielectric characteristics properly even after water absorption. The reason is considered to be that: the allyl compound can suitably exert the effect of adding the maleimide compound. Further, since the allyl compound can improve the compatibility of the maleimide compound with the modified polyphenylene ether compound, it is possible to suitably obtain a resin composition which can give a cured product which can increase the glass transition temperature, has low water absorption, and can suitably maintain low dielectric characteristics even after water absorption, by adding the allyl compound. On the other hand, since the volatility of the allyl compound is relatively high, it is considered that: the glass transition temperature can be further increased by using a crosslinking agent containing not only an allyl compound but also a dimethacrylate compound having a lower volatility than the allyl compound. Therefore, by using the allyl compound and the dimethacrylate compound in combination, the resin composition obtained becomes a resin composition which can obtain a cured product as follows: namely, a cured product which has a further increased glass transition temperature, has a low water absorption rate, and can suitably maintain low dielectric characteristics even after water absorption. Further, by containing a dimethacrylate compound having a relatively low volatility as a crosslinking agent, moldability can be improved.

The crosslinking agent may contain any crosslinking agent other than the allyl compound as long as it contains the allyl compound as described above. The crosslinking agent may be a crosslinking agent composed of an allyl compound. That is, the content of the allyl compound may be 100 parts by mass with respect to 100 parts by mass of the crosslinking agent. Further, the crosslinking agent may be a crosslinking agent composed of an allyl compound, or a crosslinking agent other than the allyl compound and the allyl compound may be used in combination, and therefore, the content of the allyl compound is preferably in the following range with respect to the total amount of the crosslinking agent. The content of the allyl compound is preferably 20 to 100 parts by mass, more preferably 30 to 90 parts by mass, and still more preferably 60 to 90 parts by mass, based on 100 parts by mass of the crosslinking agent. If the allyl compound is too small, the effect of adding the allyl compound tends to be not sufficiently exhibited. That is, the compatibility of the maleimide compound with the modified polyphenylene ether compound tends to be insufficiently improved. Therefore, it is likely to be difficult to exhibit the effects of adding a maleimide compound, that is, it is difficult to obtain a cured product which can increase the glass transition temperature, has a low water absorption rate, and can maintain low dielectric characteristics appropriately even after water absorption. That is, it tends to be difficult to obtain a cured product which can increase the glass transition temperature, has a low water absorption rate, and can maintain low dielectric characteristics properly even after water absorption.

(content)

The maleimide compound is preferably contained in an amount of 10 to 60 parts by mass, more preferably 20 to 50 parts by mass, and still more preferably 25 to 40 parts by mass, based on 100 parts by mass of the total of the maleimide compound, the modified polyphenylene ether compound, and the crosslinking agent. The content of the modified polyphenylene ether compound is preferably 10 to 75 parts by mass, more preferably 20 to 60 parts by mass, and still more preferably 30 to 50 parts by mass, based on 100 parts by mass of the total of the maleimide compound, the modified polyphenylene ether compound, and the crosslinking agent. The content of the crosslinking agent is preferably 10 to 50 parts by mass, more preferably 20 to 40 parts by mass, and still more preferably 25 to 35 parts by mass, based on 100 parts by mass of the maleimide compound, the modified polyphenylene ether compound, and the crosslinking agent in total. The content of the allyl compound is preferably within the above range relative to 100 parts by mass of the crosslinking agent, and is preferably 10 to 50 parts by mass, more preferably 15 to 40 parts by mass, and still more preferably 20 to 30 parts by mass relative to 100 parts by mass of the total of the maleimide compound, the modified polyphenylene ether compound, and the crosslinking agent. When the respective contents of the maleimide compound, the modified polyphenylene ether compound, the crosslinking agent and the allyl compound are within the above ranges, the obtained resin composition can suitably obtain a cured product having a higher glass transition temperature, a lower water absorption rate and further suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

(other Components)

The resin composition according to the present embodiment may contain components (other components) other than the maleimide compound, the modified polyphenylene ether compound and the crosslinking agent as necessary within a range not to impair the effects of the present invention. The resin composition according to the present embodiment may further contain additives such as a silane coupling agent, a flame retardant, an initiator, an antifoaming agent, an antioxidant, a heat stabilizer, an antistatic agent, an ultraviolet absorber, a dye or pigment, a lubricant, and an inorganic filler. The resin composition may contain a thermosetting resin such as an epoxy resin, an unsaturated polyester resin, and a thermosetting polyimide resin in addition to the modified polyphenylene ether compound.

As described above, the resin composition according to the present embodiment may contain a silane coupling agent. The silane coupling agent may be contained in the resin composition, or may be contained in a form in which a silane coupling agent having been subjected to a pre-surface treatment is added to an inorganic filler contained in the resin composition. Among these, the silane coupling agent is preferably contained as a silane coupling agent pre-surface-treated with respect to the inorganic filler, and more preferably contained as a silane coupling agent pre-surface-treated with respect to the inorganic filler, and the resin composition also contains a silane coupling agent. The prepreg may be a silane coupling agent that is pre-surface treated with a fibrous substrate.

Examples of the silane coupling agent include silane coupling agents having at least one functional group selected from the group consisting of a vinyl group, a styryl group, a methacryloyl group, an acryloyl group, and a phenylamino group. That is, examples of the silane coupling agent include: and compounds having at least one of a vinyl group, a styryl group, a methacryloyl group, an acryloyl group, and a phenylamino group as a reactive functional group and having a hydrolyzable group such as a methoxy group or an ethoxy group.

Examples of the silane coupling agent include a silane coupling agent having a vinyl group, such as vinyltriethoxysilane and vinyltrimethoxysilane. Examples of the silane coupling agent include a styrene group-containing silane coupling agent such as p-styryltrimethoxysilane and p-styryltriethoxysilane. Examples of the silane coupling agent having a methacryloyl group include 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-methacryloxypropyltriethoxysilane, 3-methacryloxypropylmethyldiethoxysilane and 3-methacryloxypropylethyldiethoxysilane. Examples of the silane coupling agent include a silane coupling agent having an acryloyl group, such as 3-acryloxypropyltrimethoxysilane and 3-acryloxypropyltriethoxysilane. Examples of the silane coupling agent include a silane coupling agent having a phenylamino group such as N-phenyl-3-aminopropyltrimethoxysilane and N-phenyl-3-aminopropyltriethoxysilane.

As described above, the resin composition according to the present embodiment may contain a flame retardant. The flame retardant is contained, whereby the flame retardancy of a cured product of the resin composition can be improved. The flame retardant is not particularly limited. Specifically, in the field of using a halogen-based flame retardant such as a bromine-based flame retardant, for example: ethylene bis-pentabromobenzene (ethylene bis-bromobenzene) with melting point above 300 deg.C, ethylene bis-tetrabromo-imide (ethylene bis-bromoimide), decabromodiphenyl ether, and tetradecylbenzoxy benzene. Consider that: by using a halogen flame retardant, halogen desorption at high temperature can be suppressed, and a decrease in heat resistance can be suppressed. Further, in the field where halogen-free is required, there are listed: phosphate ester-based flame retardants, phosphazene-based flame retardants, bis-diphenyloxyphosphonate-based flame retardants, and hypophosphite-based flame retardants. Specific examples of the phosphate-based flame retardant include condensed phosphates of dixylyl phosphate. Specific examples of the phosphazene flame retardant include phenoxyphosphazene. Specific examples of the bisdiphenylphosphineoyl flame retardant include xylylene bis (diphenylphosphineoyl) oxide. Specific examples of the hypophosphite-based flame retardant include metal hypophosphite salts of dialkylaluminum hypophosphite. As the flame retardant, each of the exemplified flame retardants may be used alone, or two or more kinds may be used in combination.

As described above, the resin composition according to the present embodiment may contain an initiator (reaction initiator). The polyphenylene ether resin composition can undergo a curing reaction even when it is formed from a modified polyphenylene ether compound and a crosslinking-type curing agent. Further, only the modified polyphenylene ether can also be subjected to a curing reaction. However, depending on the process conditions, it is sometimes difficult to raise the temperature until curing proceeds, and therefore a reaction initiator may be added. The reaction initiator is not particularly limited as long as it can accelerate the curing reaction of the modified polyphenylene ether and the crosslinking-type curing agent. Specific examples thereof include: oxidizing agents such as α, α ' -bis (t-butylperoxy-m-isopropyl) benzene, 2, 5-dimethyl-2, 5-di (t-butylperoxy) hexane, benzoyl peroxide, 3 ', 5, 5 ' -tetramethyl-1, 4-diphenoquinone, chloranil, 2, 4, 6-tri-t-butylphenoxy, t-butylperoxy isopropyl monocarbonate, and azobisisobutyronitrile. Further, a metal carboxylate or the like may be used in combination as necessary. Accordingly, the curing reaction can be further accelerated. Among them, α' -bis (t-butylperoxy-m-isopropyl) benzene is preferably used. Since α, α' -bis (t-butylperoxy-m-isopropyl) benzene has a high reaction initiation temperature, it is possible to suppress the acceleration of the curing reaction and the decrease in the storage stability of the polyphenylene ether resin composition at a time when curing is not necessary, such as when the prepreg is dried. Further, α, α' -bis (t-butylperoxy-m-isopropyl) benzene has low volatility and therefore does not volatilize during drying and storage of the prepreg, and has good stability. The reaction initiator may be used alone or in combination of two or more.

As described above, the resin composition according to the present embodiment may contain a filler such as an inorganic filler. The filler is not particularly limited, and may be added to improve the heat resistance and flame retardancy of a cured product of the resin composition. In addition, by containing a filler, heat resistance, flame retardancy, and the like can be further improved. Specific examples of the filler include: silica such as spherical silica, metal oxides such as alumina, titanium oxide and mica, metal hydroxides such as aluminum hydroxide and magnesium hydroxide, talc, aluminum borate, barium sulfate and calcium carbonate. Among these, silica, mica and talc are preferable, and spherical silica is more preferable. In addition, one kind of the filler may be used alone, or two or more kinds may be used in combination. Further, as the filler, a filler which is used as it is or which is surface-treated with a silane coupling agent may be used. When the filler is contained, the content (filler content) thereof is preferably 30 to 270% by mass, more preferably 50 to 250% by mass, based on the resin composition.

By using the resin composition according to the present embodiment, a prepreg, a metal foil-clad laminate, a wiring board, a resin-containing metal foil, and a resin-containing film can be obtained as described below.

Fig. 1 is a schematic cross-sectional view showing an example of a prepreg 1 according to an embodiment of the present invention.

As shown in fig. 1, a prepreg 1 according to the present embodiment includes: the resin composition or the prepreg 2 of the resin composition; and a fibrous substrate 3. The prepreg 1 includes: the resin composition or the prepreg 2 of the resin composition; and a fibrous substrate 3 present in the resin composition or the prepreg 2 of the resin composition.

In the present embodiment, the semi-cured product is a product obtained by curing the resin composition to such an extent that the resin composition can be further cured. That is, the semi-cured product is a product in a state in which the resin composition is semi-cured (B-staged). For example, if the resin composition is heated, the viscosity is initially gradually decreased, then curing is started, and the viscosity is gradually increased. In this case, the semi-curing may be performed in a period from the start of viscosity increase to the time before complete curing.

The prepreg obtained using the resin composition according to the present embodiment may be a prepreg including a semi-cured product of the resin composition as described above, or may be a prepreg including an uncured resin composition itself. That is, the prepreg may be a prepreg including a semi-cured product of the resin composition (the resin composition of the second stage) and a fibrous substrate, or may be a prepreg including a resin composition before curing (the resin composition of the first stage) and a fibrous substrate.

In the production of a prepreg, the resin composition 2 is often used in a form of varnish prepared so as to permeate into the fibrous substrate 3, which is a substrate for forming the prepreg. That is, the resin composition 2 is usually a resin varnish prepared in a varnish form in many cases. The varnish-like resin composition (resin varnish) can be prepared, for example, as follows.

First, each component soluble in an organic solvent is put into the organic solvent and dissolved. At this time, heating may be performed as necessary. Then, an organic solvent-insoluble component used as needed is added, and the resulting mixture is dispersed in a predetermined dispersion state by using a ball mill, a bead mill, a planetary mixer, a roll mill, or the like, thereby preparing a varnish-like resin composition. The organic solvent used herein is not particularly limited as long as it is an organic solvent that can dissolve the maleimide compound, the modified polyphenylene ether compound, the crosslinking agent, and the like, and does not inhibit the curing reaction. Specific examples thereof include toluene and Methyl Ethyl Ketone (MEK).

The method for producing the prepreg is not particularly limited as long as the prepreg can be produced. Specifically, in the case of producing a prepreg, the resin composition used in the present embodiment is often used as a resin varnish prepared in a varnish form as described above.

Specific examples of the fibrous substrate include glass cloth, aramid cloth, polyester cloth, glass nonwoven cloth, aramid nonwoven cloth, polyester nonwoven cloth, pulp paper, and cotton linter paper. In addition, if a glass cloth is used, a laminate excellent in mechanical strength can be obtained, and a glass cloth subjected to a flattening treatment is particularly preferable. As the flattening processing, specifically, for example, a method of continuously pressing a glass cloth with a press roll at an appropriate pressure to flatten the yarn is exemplified. The thickness of the fibrous substrate to be used is, for example, 0.01mm to 0.3 mm.

The method for producing the prepreg is not particularly limited as long as the prepreg can be produced. Specifically, in the case of producing a prepreg, the resin composition according to the present embodiment is often used as a resin varnish prepared in a varnish form as described above.

Examples of the method for producing the prepreg 1 include: a method of impregnating the fibrous substrate 3 with the resin composition 2 (for example, the resin composition 2 prepared in a varnish state) and then drying the impregnated fibrous substrate.

The resin composition 2 is impregnated into the fibrous substrate 3 by dipping, coating, or the like. The impregnation may be repeated as many times as necessary. In this case, the composition and the amount of impregnation may be adjusted to the final desired composition by repeatedly impregnating the resin composition with a plurality of resin compositions having different compositions or concentrations.

The fibrous substrate 3 impregnated with the resin composition (resin varnish) 2 is heated under a desired heating condition (for example, at 80 ℃ to 180 ℃ for 1 minute to 10 minutes). By heating, the prepreg 1 can be obtained before curing (a stage) or in a semi-cured state (b stage).

The resin composition according to the present embodiment is a resin composition that can suitably obtain a cured product that has a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. Therefore, a prepreg comprising the resin composition or a prepreg of the resin composition is a prepreg which can suitably obtain a cured product having a high glass transition temperature and a low water absorption rate and sufficiently suppressing the increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption. The prepreg is capable of producing a wiring board having a high glass transition temperature, a low water absorption rate, and sufficiently suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

Fig. 2 is a schematic cross-sectional view showing an example of the metal-clad laminate 11 according to the embodiment of the present invention.

As shown in fig. 2, the metal foil-clad laminate 11 includes: an insulating layer 12 containing a cured product of the prepreg 1 shown in fig. 1; and a metal foil 13 laminated together with the insulating layer 12. That is, the metal-clad laminate 11 includes: an insulating layer 12 containing a cured product of the resin composition; and a metal foil 13 provided on the insulating layer 12. The insulating layer 12 may be formed of a cured product of the resin composition or a cured product of the prepreg. The thickness of the metal foil 13 is not particularly limited, and varies depending on the performance and the like required for the wiring board to be finally obtained. The thickness of the metal foil 13 may be appropriately set according to the intended purpose, and is preferably 0.2 to 70 μm, for example. The metal foil 13 may be, for example, a copper foil, an aluminum foil, or the like, and when the metal foil is thin, a carrier-attached copper foil including a release layer and a carrier may be used to improve handling properties.

The method for producing the metal-clad laminate 11 is not particularly limited as long as the metal-clad laminate 11 can be produced. Specifically, a method of manufacturing the metal foil-clad laminate 11 using the prepreg 1 is exemplified. Examples of the method include: a method of producing a metal foil-clad laminate 11 having both surfaces covered with a metal foil or one-side covered with a metal foil by taking one prepreg 1 or stacking a plurality of prepregs 1, further stacking a metal foil 13 such as a copper foil on both upper and lower surfaces or one surface of each prepreg, and heating and pressing the metal foil 13 and the prepreg 1 to laminate them integrally. That is, the metal foil-clad laminate 11 is obtained by laminating a metal foil 13 on a prepreg 1 and performing heat and pressure molding. The heating and pressing conditions may be appropriately set according to the thickness of the metal foil-clad laminate 11 to be produced, the type of the composition of the prepreg 1, and the like. For example, the temperature may be set to 170 to 210 ℃, the pressure may be set to 3.5 to 4MPa, and the time may be set to 60 to 150 minutes. The metal foil-clad laminate may be manufactured without using a prepreg. Examples thereof include: a method in which a varnish-like resin composition is applied to a metal foil to form a layer containing the resin composition on the metal foil, and then the resultant is heated and pressed.

The resin composition according to the present embodiment is a resin composition that can suitably obtain a cured product that has a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. Therefore, the metal-clad laminate having an insulating layer comprising a cured product of the resin composition has a high glass transition temperature and a low water absorption rate, and sufficiently suppresses an increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption. The metal-clad laminate is a metal-clad laminate which can produce a wiring board having a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption.

Fig. 3 is a schematic cross-sectional view showing an example of the wiring board 21 according to the embodiment of the present invention.

As shown in fig. 3, the wiring board 21 according to the present embodiment includes: an insulating layer 12 used by curing the prepreg 1 shown in fig. 1; and a wiring 14 formed by laminating the insulating layer 12 and a part of the metal foil 13. That is, the wiring board 21 includes: an insulating layer 12 containing a cured product of the resin composition; and a wiring 14 provided on the insulating layer 12. The insulating layer 12 may be formed of a cured product of the resin composition or a cured product of the prepreg.

The method for producing the wiring board 21 is not particularly limited as long as the wiring board 21 can be produced. Specifically, a method of manufacturing the wiring board 21 using the prepreg 1 is exemplified. Examples of the method include: a method of forming a wiring board 21 in which a wiring is provided as a circuit on the surface of the insulating layer 12 by etching or the like the metal foil 13 on the surface of the metal-clad laminate 11 produced as described above to form a wiring. That is, the wiring board 21 can be obtained by removing a part of the metal foil 13 on the surface of the metal foil-clad laminate 11 to form a circuit. In addition to the above-described methods, examples of a method for forming a circuit include a method for forming a circuit by a Semi-Additive Process (SAP) or a Modified Semi-Additive Process (MSAP). The wiring board 21 has the insulating layer 12 which has a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption.

The wiring board has a high glass transition temperature and a low water absorption rate, and sufficiently suppresses the increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

Fig. 4 is a schematic cross-sectional view showing an example of the metal foil 31 with resin according to the present embodiment.

As shown in fig. 4, the metal foil 31 with resin according to the present embodiment includes: an insulating layer 32 comprising the resin composition or a prepreg of the resin composition; and a metal foil 13. The resin-attached metal foil 31 has a metal foil 13 on the surface of the insulating layer 32. That is, the metal foil with resin 31 includes: the insulating layer 32; and a metal foil 13 laminated together with the insulating layer 32. The resin-coated metal foil 31 may further include another layer between the insulating layer 32 and the metal foil 13.

The resin layer 32 may contain a semi-cured product of the resin composition described above, or may contain an uncured resin composition. That is, the metal foil 31 with resin may include: a resin layer comprising a semi-cured product of the resin composition (the resin composition of the second stage); and a resin-attached metal foil including: a resin layer comprising the resin composition before curing (the resin composition of the first stage); and a resin-coated metal foil of the metal foil. Further, as the resin layer, a fibrous substrate may be contained or not contained as long as the resin composition or the semi-cured product of the resin composition is contained. In addition, the same material as the fibrous substrate of the prepreg can be used for the fibrous substrate.

Further, as the metal foil, a metal foil used in the metal foil-clad laminate may be used without limitation. Examples of the metal foil include copper foil and aluminum foil.

The resin-coated metal foil 31 and the resin-coated film 41 may be provided with a coating film, if necessary. By providing the cover film, it is possible to prevent the entry of foreign matter and the like. The cover film is not particularly limited, and examples thereof include a polyolefin film, a polyester film, a polymethylpentene film, and a film formed by providing a release agent layer on these films.

The method for producing the resin-attached metal foil 31 is not particularly limited as long as the resin-attached metal foil 31 can be produced. The resin-coated metal foil 31 can be produced by applying the varnish-like resin composition to the metal foil 13 and heating the applied varnish-like resin composition. The varnish-like resin composition is applied to the metal foil 13 by using, for example, a knife coater. The resin composition to be coated is heated, for example, at 80 ℃ to 180 ℃ and 1 minute to 10 minutes. The heated resin composition is formed on the metal foil 13 as an uncured resin layer 32.

The resin composition according to the present embodiment is a resin composition that can suitably obtain a cured product that has a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. Therefore, the resin-equipped metal foil provided with the resin layer containing the resin composition or the semi-cured product of the resin composition is a resin-equipped metal foil which can suitably obtain a cured product having a high glass transition temperature, a low water absorption rate, and sufficiently suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption. The resin-coated metal foil can be used for manufacturing a wiring board having a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. The multilayer wiring board can be manufactured by, for example, being laminated on a wiring board. A wiring board obtained by using the resin-containing metal foil has a high glass transition temperature, a low water absorption rate, and sufficiently suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

Fig. 5 is a schematic cross-sectional view showing an example of the resin-attached film 41 according to the present embodiment.

As shown in fig. 5, the resin-attached film 41 according to the present embodiment includes: a resin layer 42 containing the resin composition or a semi-cured product of the resin composition; and a support film 43. The resin-attached film 41 includes: the resin layer 42; and a support film 43 laminated together with the resin layer 42. The resin-attached film 41 may further include another layer between the resin layer 42 and the support film 43.

The resin layer 42 may contain a semi-cured product of the resin composition described above, or may contain the resin composition before curing. That is, the resin-attached film 41 may include: a resin layer comprising a semi-cured product of the resin composition (the resin composition of the second stage); and a resin-attached film supporting the film, and may include: a resin layer comprising the resin composition before curing (the resin composition of the first stage); and a resin-bearing membrane supporting the membrane. Further, as the resin layer, a fibrous substrate may be contained or not contained as long as the resin composition or the semi-cured product of the resin composition is contained. As the fibrous substrate, the same material as that of the prepreg can be used.

In addition, as the support film 43, a support film used in a film with resin may be used without limitation. Examples of the support film include electrically insulating films such as polyester films, polyethylene terephthalate (PET) films, polyimide films, polyoxamide films, polyetheretherketone films, polyphenylene sulfide films, polyamide films, polycarbonate films, and polyarylate films.

The resin-attached film 41 may be provided with a cover film or the like as needed. By providing the cover film, it is possible to prevent the entry of foreign matter and the like. The cover film is not particularly limited, and examples thereof include polyolefin films, polyester films, and polymethylpentene films.

The support film and the cover film may be films subjected to surface treatment such as matte treatment, corona treatment, mold release treatment, and roughening treatment, if necessary.

The method for producing the resin-attached film 41 is not particularly limited as long as the resin-attached film 41 can be produced. Examples of the method for producing the resin-attached film 41 include a method in which the varnish-like resin composition is applied to the support film 43 and heated. The varnish-like resin composition is applied to the support film 43 by using a knife coater, for example. The resin composition to be coated is heated, for example, at 80 ℃ to 180 ℃ and 1 minute to 10 minutes. The heated resin composition is formed on the support film 43 as an uncured resin layer 42.

The resin composition according to the present embodiment is a resin composition that can suitably obtain a cured product that has a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. Therefore, a resin-carrying film provided with a resin layer containing the resin composition or a semi-cured product of the resin composition is a resin-carrying film which can suitably obtain a cured product having a high glass transition temperature, a low water absorption rate, and sufficiently suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption. Further, the resin-attached film can be used for manufacturing a wiring board having a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. For example, the multilayer wiring board can be manufactured by peeling the support film after laminating it on the wiring board, or by peeling the support film and laminating it on the wiring board. A wiring board obtained using the resin-containing film has a high glass transition temperature, a low water absorption rate, and sufficiently suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

The present specification discloses the techniques of the various embodiments as described above, and the main techniques thereof are summarized as follows.

One aspect of the present invention relates to a resin composition comprising: a maleimide compound represented by the following formula (1); a modified polyphenylene ether compound, the terminal of which is modified with a substituent having a carbon-carbon unsaturated double bond; and a crosslinking agent comprising an allyl compound.

In the formula (1), s represents 1 to 5, R_A、R_B、R_CAnd R_DAre respectively provided withIndependently represents a hydrogen atom, an alkyl group having 1 to 5 carbon atoms or a phenyl group.

According to this configuration, a resin composition can be provided which can suitably obtain a cured product having a high glass transition temperature and a low water absorption rate and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption.

The reason is considered as follows.

First, consider that: the resin composition can obtain a cured product which maintains the excellent low dielectric characteristics of polyphenylene ether by crosslinking the modified polyphenylene ether compound together with the maleimide compound and the crosslinking agent.

Further, if the maleimide compound is contained in the resin composition, the glass transition temperature tends to be increased. On the other hand, if the maleimide compound is contained in the resin composition, the water absorption of the cured product of the resin composition increases, and the dielectric constant and the dielectric dissipation factor tend to decrease after water absorption. On the other hand, when the maleimide compound represented by the above formula (1) is used, the glass transition temperature can be increased, the increase in water absorption rate can be sufficiently suppressed, and the increase in dielectric constant and dielectric loss tangent due to water absorption can be sufficiently suppressed even after water absorption.

Further, if the maleimide compound is contained in the resin composition containing the modified polyphenylene ether compound, when the obtained resin composition is made into a varnish, the compatibility of the maleimide compound with respect to the resin composition containing the modified polyphenylene ether compound tends to be low, and an appropriate varnish tends not to be obtained. The reason is considered to be that: the maleimide compound has low solubility in a solvent used for varnish formation. On the other hand, if the maleimide compound represented by the above formula (1) is used as the maleimide compound and a crosslinking agent containing an allyl compound is used as the crosslinking agent, the compatibility of the resin composition containing a modified polyphenylene ether compound with the maleimide compound becomes high, and a varnish can be suitably obtained. The reason is considered to be that: the maleimide compound has high solubility in a solvent used for the varnish formation, and the allyl compound improves the compatibility of the modified polyphenylene ether compound with the maleimide compound represented by the formula (1).

Based on the above, consider that: the resin composition having the above-mentioned structure can suitably provide a cured product which has a high glass transition temperature and a low water absorption rate and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption.

Further, in the resin composition, it is preferable that: the crosslinking agent further includes at least one of "a multifunctional acrylate compound having 2 or more acryloyl groups in the molecule" and "a multifunctional methacrylate compound having 2 or more methacryloyl groups in the molecule", more preferably: the multifunctional methacrylate compound comprises a dimethacrylate compound.

According to this configuration, a resin composition can be provided which can suitably obtain a cured product having a higher glass transition temperature, a low water absorption rate, and further suppressed increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

The reason is considered to be that: as the crosslinking agent, by using a crosslinking agent containing not only an allyl compound but also a dimethacrylate compound having a lower volatility than the allyl compound, the glass transition temperature can be further increased. Further, it is considered that: the moldability can also be improved by including a dimethacrylate compound having a relatively low volatility as a crosslinking agent.

Further, in the resin composition, it is preferable that: the allyl compound comprises at least one of triallyl isocyanurate and diallyl bisphenol.

According to this configuration, a resin composition can be provided which can suitably obtain a cured product having a further separated glass transition temperature, a lower water absorption rate, and further suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

Further, in the resin composition, it is preferable that: the maleimide compound is contained in an amount of 10 to 60 parts by mass per 100 parts by mass of the total of the maleimide compound, the modified polyphenylene ether compound and the crosslinking agent.

According to this configuration, a resin composition can be provided which can suitably obtain a cured product having a higher glass transition temperature and a lower water absorption rate and further suppressing the increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

The reason is considered to be that: the effect of adding the maleimide compound represented by the above formula (1) is more suitably exhibited.

Further, in the resin composition, it is preferable that: the polyphenylene ether compound is contained in an amount of 10 to 75 parts by mass per 100 parts by mass of the total of the maleimide compound, the modified polyphenylene ether compound and the crosslinking agent.

According to this configuration, a resin composition can be provided which can suitably obtain a cured product having a higher glass transition temperature and a lower water absorption rate and further suppressing the increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

The reason is considered to be that: the effect of adding the maleimide compound represented by the above formula (1) is more suitably exhibited.

Further, in the resin composition, it is preferable that: and an inorganic filler pretreated with a silane coupling agent.

According to this configuration, a resin composition can be provided which can suitably obtain a cured product having a higher glass transition temperature and a lower water absorption rate and further suppressing the increase in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption.

Further, another aspect of the present invention relates to a prepreg comprising: the resin composition or a semi-cured product of the resin composition; and a fibrous substrate.

According to this configuration, a prepreg can be provided which can suitably obtain a cured product having a high glass transition temperature and a low water absorption rate and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption.

Further, another aspect of the present invention relates to a resin-bearing film comprising: a resin layer comprising the resin composition or a semi-cured product of the resin composition; and a support film.

According to this configuration, a resin-attached film having a high glass transition temperature and a low water absorption rate and having sufficiently suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption can be provided.

Further, another aspect of the present invention relates to a resin-coated metal foil comprising: a resin layer comprising the resin composition or a semi-cured product of the resin composition; and a metal foil.

According to this configuration, the resin-attached metal foil can be provided which has a high glass transition temperature and a low water absorption rate, and in which even after water absorption, the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed.

Further, another aspect of the present invention relates to a metal-clad laminate comprising: an insulating layer comprising a cured product of the resin composition or a cured product of the prepreg; and a metal foil.

According to this configuration, it is possible to provide a metal-clad laminate having a high glass transition temperature and a low water absorption rate, and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption.

Further, another aspect of the present invention relates to a wiring board comprising: an insulating layer comprising a cured product of the resin composition or a cured product of the prepreg; and wiring.

According to this configuration, a wiring board having a high glass transition temperature and a low water absorption rate and having sufficiently suppressed increases in dielectric constant and dielectric dissipation factor due to water absorption even after water absorption can be provided.

According to the present invention, a resin composition can be provided which can suitably obtain a cured product having a high glass transition temperature and a low water absorption rate and in which the increase in dielectric constant and dielectric dissipation factor due to water absorption is sufficiently suppressed even after water absorption. Further, the present invention can provide a prepreg, a resin-attached film, a resin-attached metal foil, a metal-clad laminate, and a wiring board obtained using the resin composition.

The present invention will be further specifically described below with reference to examples, but the scope of the present invention is not limited by the following examples.