Epoxy resin composition

TECHNICAL FIELD
This invention relates to epoxy resin compositions. More particularly, this invention relates to epoxy resin compositions containing an epoxy resin as a substratal resin (main component). Further, this invention relates to epoxy resin compositions having excellent heat resistance, toughness, flexibility, resistance to cracking, mold releasability, hydrophobicity and curability. Since the epoxy resin compositions of this invention possesses the outstanding properties as described above, such compositions can be utilized advantageously in various fields, particularly in the fields of multilayer laminates, electroconductive pastes, protective films for electronic devices, adhesive agents, paints, coating materials, sealing materials, and molding materials.
BACKGROUND ART
Recently electronic and electric devices and transportation devices are becoming smaller and lighter in weight and have an increased performance, and this trend has emphasized the need for materials having an excellent heat resistance and moisture resistance.
Polyimide resins are universally known, as heat resistant resins, but since such resins are produced by a dehydration-condensation type reaction, the produced cured resin is liable to contain voids due to the water of condensation that occurs as a consequence of the reaction. These voids impair the reliability of the cured resin product. The polyimide itself is insoluble and unmeltable, and therefore, is not easily molded.
As polyimides having an improved moldability, such maleimide resins as bismaleimide and polymaleimide are known in the art. Bismaleimide, however, has a high melting point and therefore, has the disadvantage of a poor workability because the curing during the process of molding requires a protracted application of a high temperature generally exceeding 200.degree. C. (180.degree. to 350.degree. C. and 15 to 16 minutes). Bismaleimide is further disadvantageous in that it has a poor hydrophobicity and consequently, has a conspicuously poor reliability of the cured resin product. Polymaleimide has a curing temperature about 70.degree. to 80.degree. C. lower than that of bismaleimide, but the cured product of the polymaleimide has a disadvantage in that it is easily cracked and embrittled because of a high cross-link density and large residual strain.
The practice of using an epoxy resin having an excellent moldability, in the place of the maleimide resin, is also known in the art. Where the epoxy resin is used as a substratal resin, an amine, an acid anhydride, or a phenol is generally used in combination with the epoxy resin as a curing agent therefore, but the cured product obtained has an unsatisfactory heatproofing. The epoxy/phenol cure system, for example, has a glass transition point generally of from 140.degree. to 170.degree. C., and this glass transition point should be raised to a level above 190.degree. C., preferably above 200.degree. C.
SUMMARY OF THE INVENTION
A major object of this invention is to overcome the drawbacks of the prior art described above, and for this purpose, to provide an epoxy resin composition having an excellent heatproofing, toughness, flexibility, cracking resistance, mold releasability, and hydrophobicity, and consequently, advantageously usable in various fields.
The objects described above may be accomplished by using an epoxy resin composition containing an epoxy resin as a substratal resin, characterized by incorporating therein as a curing agent in an amount of from 30 to 120 parts by weight based on 100 parts by weight of the epoxy resin, a polyallyl phenol possessing in the molecular unit thereof a plurality of component units represented by the following formula I: ##STR1## (wherein a is an integer of from 1 to 4 inclusive).
For accomplishing the above-mentioned objects, the present invention also provides an epoxy resin composition comprising an epoxy resin as a substratal resin, 5 to 200 parts by weight, based on 100 parts by weight of the epoxy resin, of a polyallylphenol having a plurality of constitutive units represented by the following formula II: ##STR2## and 5 to 200 parts by weight, based on 100 parts by weight of the epoxy resin, of a polyphenol represented by the following formula III: ##STR3## wherein n is an integer of 1 to 6.
The epoxy resin composition according to a further aspect of the present invention, may comprise 100 parts of an epoxy resin having a naphthalene skeleton and 30 to 120 parts of a polyallylphenol having in its repeating unit a plurality of constitutive units represented by the following formula IV: ##STR4##
The epoxy resin composition according to, yet another aspect of the present invention, may comprise 100 parts of an epoxy resin having a naphthalene skeleton, 30 to 120 parts of polyallylphenol having in its repeating unit a plurality of constitutive units represented by the following formula V and 5 to 80 parts of a flexibilizer: ##STR5##
That is, the above-described objects of the present invention can be attained by providing an epoxy resin composition comprising an epoxy resin having a naphthalene skeleton and, incorporated therein, a predetermined amount of polyallylphenol as a curing agent, or an epoxy resin composition comprising the above-described composition and, further incorporated therein as a third component, a predetermined amount of a flexibilizer.
According to the present invention, the objects described above may also be accomplished by using an epoxy resin having a biphenyl structure as a base resin and a polyallylphenol represented by the following general formula VI as a curing agent, the resin containing a specific epoxy resin represented by the following general formula VII: ##STR6## wherein a is an integer of 1 to 4; ##STR7## wherein n is an integer of 0 to 4.

BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 8 are graphs showing the relationship between the time of PCT treatment (h) and the fraction defective (%) obtained in a relevant working example;
FIG. 9 is a schematic diagram of an aluminum-wired model device used for evaluation of moistureproofing;
FIGS. 10 to 17 are graphs each showing the relationship between the time of PCT treatment (h) and the fraction defective (%) obtained in a relevant working example;
FIG. 18 compares products of the conventional art and the products of this invention with respect to the relationship between the time of PCT treatment (h) and the fraction defective (%);
FIG. 19 is a graph showing the effect of the number of allyl groups on the surface of close contact.
FIGS. 20 to 33 are graphs each showing the relationship between the time of PCT treatment and the fraction of defective cured resin products.
FIG. 34 is a graph showing the relationship between the PCT time (hr) and the fraction defective (%);
FIG. 35 is a graph showing the relationship between the PCT time (hr) and the fraction defective (%);
FIG. 36 is a graph showing the relationship between the PCT time (hr) and the fraction defective (%);
FIG. 37 is a graph showing the relationship between the PCT time (hr) and the fraction defective (%);
FIG. 38 is a graph showing the relationship between the PCT time (hr) and the fraction defective (%);
FIG. 39 is a graph showing the relationship between the PCT time (hr) and the fraction defective (%); and
FIG. 40 is a graph showing the relationship between the PCT time (hr) and the fraction defective (%).

DESCRIPTION OF PREFERRED EMBODIMENTS
The epoxy resin to be used as the substratal resin in epoxy resin composition of this invention is not particularly limited. According to the knowledge acquired by the inventors, the epoxy resins advantageously usable herein include bisphenol A type epoxy resins, cresol novolak type epoxy resins, phenol novolak type epoxy resins, and tetramethyl biphenyl type epoxy resins such as glycidyl ether type epoxy resins, glycidyl amine type epoxy resins, halogenated epoxy resins, and naphthalene type epoxy resins, for example, which have at least two epoxy groups in the molecular unit thereof. These epoxy resins may be used either independently or in the form of a mixture of two or more members.
Biphenyl type epoxy resins are also advantageously usable as the epoxy resins composition. Desirable concrete examples of such epoxy resins include those disclosed in Japanese Unexamined Patent Publication No. 251,419/1988, i.e., the polymers of 4,4'-bis(2,3-epoxypropoxy)biphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethyl biphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethyl-2-chlorobiphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5-tetramethyl-2-bromobiphenyl; 4,4'-bis(2,3-epoxypropoxy-3,3',5,5'-tetraetnylbiphenyl; and 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetrabutylbiphenyl. These epoxy resins are available commercially. The product of Yuka-Shell Epoxy K.K. marketed under the product name "YX-4000H" is one example.
The polyallyl phenols advantageously usable as the curing agent in the epoxy resin composition of this invention are represented by the following formulas VIII, IX, X, and XI: ##STR8## (wherein k is 0 or an integer of 1 to 4 inclusive, m and m' each are an integer of 1 to 4 inclusive, and n is an integer of 1 to 4 inclusive). Here, it is understood that these polyallyl phenols have a better viscosity, workability, and improved heatproofing in proportion to an increase in the numerical values of l, m, and n in the formulas. These polyallyl phenols may be synthesized by a known method, or may be produced commercially. The product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product name of "SH-150AR" is one example.
By the use of a polyallyl phenol as the curing agent, the epoxy resin composition enables the cured resin product thereof to acquire an elected glass transition point of from 180.degree. to 220.degree. C., an improved heatproofing, and an augmented hydrophobicity. The merits are ascribable to the effects of the allyl group possessed by the polyallyl phenol. The amount of the polyallyl phenol to be incorporated in the epoxy resin composition is preferably from about 30 to about 120 parts by weight, based on 100 parts by weight of the epoxy resin. If the amount of the polyallyl phenol to be incorporated is less than 30 parts by weight, the curing reaction of the epoxy resin composition does not proceed sufficiently. If this amount exceeds 120 parts by weight, the cured resin product has a poor heatproofing.
In this invention, for the purpose of conferring flexibility on the cured resin product of the epoxy resin composition, it is desirable for the epoxy resin composition to be used in combination with a flexible-imparting agent which is selected from the group consisting of butadiene/acrylonitrile copolymer, polystyrene/polybutadiene/polystyrene terminal block copolymer, ethylene/propylene type terpolymers, ethylene/.alpha.-olefin copolymers, and epoxy group-containing silicone rubber powder.
It has been found that the addition of-the silicon-modified epoxy resin to the substratal resin is effective in improving the cured resin product simultaneously in the properties of a resistance to against cracking, flexibility, and mold releasability, and in improving the epoxy resin composition itself from the new point of heatproofing and waterproofing, compared with the ordinary epoxy resin composition. Silicon-modified epoxy resins of varying forms are usable for this purpose. A resin available from Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620" can be advantageously used, for example. This silicon-modified epoxy resin can be used in a varying amount in the epoxy resin composition, depending on the effect desired from the addition thereof. Although this amount is variable in a wide range, it is generally approximately from 5 to 80 parts by weight, based on 100 parts by weight of the epoxy resin. The reason for this particular range, as specifically demonstrated in the working examples to be cited hereinbelow, is that the effect of the addition is not manifested if this amount is less than 5 parts by weight and the heatproofing of the resin composition is impaired by a layer separation if the amount exceeds 80 parts by weight.
Imparting a satisfactory flexibility to the cured resin product can be attained by the addition of the silicon-modified epoxy resin. When the flexibility so imparted by the added silicon-modified epoxy resin is not sufficient, it can be improved by the additional use of a butadiene/acrylonitrile copolymer. The butadiene/acrylonitrile copolymer useful for this purpose is represented by the following formula: ##STR9## (wherein R.sup.1 and R.sup.2 each stand for a hydrogen atom or a hydrocarbon group such as alkyl group or aryl group, x and y stand for numerical values satisfying the expression 1.ltoreq.x/y.ltoreq.20, and z stands for an integer of from 5 to 20 inclusive).
Although the amount of the butadiene/acrylonitrile copolymer to be added is variable over a wide range, it is generally approximately from 5 to 80 parts by weight, based on 100 parts by weight of the epoxy resin in the epoxy resin composition. The reason for this particular range is that the effect of the addition is not manifested if the amount is less than 5 parts by weight and the epoxy resin composition has a poor heatproofing if the amount exceeds 80 parts by weight.
A polystyrene/polybutadiene/polystyrene terminal block copolymer, an ethylene/propylene type terpolymer, an ethylene/.alpha.-olefin copolymer, or a silicone rubber powder containing an epoxy group as a functional group may be added, when necessary for an improvement of the flexibility.
These flexibility-imparting agents may possess various structures, and are marketed in various forms. The product of Shell Chemical K.K. marketed under the trademark of "Kraton.RTM. G-1652" is available as a polystyrene/polybutadiene/polystyrene terminal block copolymer, the product of Japan Synthetic Rubber Co., Ltd. marketed under a product name of "JSR57P" as an ethylene/propylene type terpolmyer, the product of Mitsui Petrochemical Industries, Ltd. marketed under the trademark of "Tafmer.RTM.-P P-0280" as an ethylene/.alpha.-olefin copolymer, and the product of Toray-Dow Corning K.K. marketed under the trademark of "Torayfil E-601" as a silicone-rubber powder containing an epoxy group as a functional group, for example. These copolymers are effective in improving the toughness and flexibility of the cured resin product, and thus the resistance to cracking.
In the epoxy resin composition, the copolymer can be used in a varying amount depending on the effect desired to be derived from its addition. Although this amount is variable in a wide range, it is generally desired to be approximately from 5 to 80 parts by weight, based on 100 parts by weight of the epoxy resin. The reason for this particular range, as demonstrated in the working examples to be cited hereinbelow, is that the effect of the addition is not manifested if the amount is less than 5 parts by weight and the cured resin product has a poor heat-proofing if the amount exceeds 80 parts by weight.
The epoxy resin composition of this invention may contain therein a powdery inorganic component (such as, for example, fused silica, crystalline silica, alumina, and calcium carbonate) as a filler in an amount of approximately from 30 to 80% by weight, based on the total amount of the composition. This inorganic filler fails to manifest the effect of its addition if this amount is less than 30% by weight. Conversely, if this amount exceeds 85% by weight, the epoxy resin composition has a poor flowability, and consequently, workability.
Further, the epoxy resin composition according to this invention may incorporate therein the following components when necessary.
(1) A catalyst for promoting the curing reaction of epoxy resin with polyallyl phenol. The agents usable effectively herein include imidazole type compounds represented by 2-methyl imidazole, phosphine type compounds represented by triphenyl phosphine, and DBU (diazabicycloundecene) type compounds represented by phenol salts of DBU, for example.
(2) A coupling agent for enhancing the compatibility of the inorganic filler with the resin during the addition of the filler to the resin. The fillers effectively usable herein include silane type coupling agents represented by 3-aminopropyltriethoxy silane and titanium type coupling agents represented by tetraoctyl bis(phosphite) titanate, for example. Although the amount of the coupling agent is variable with the kind, amount, and specific surface area of the inorganic filler to be used and the minimum covering area of the coupling agent, it is desired to be approximately from 0.1 to 15 parts by weight in this invention.
(3) A mold release auxiliary agent selected from carnauba wax, stearic acid and metal salts thereof, montan wax, etc., a flame-retarding agent selected from among epoxy bromide resin, antimony trioxide, etc., and pigment such as carbon may be added.
(4) A coloring agent, a pigment, and a flame-retarding agent represented respectively by titanium dioxide, carbon black, and antimony trioxide may be incorporated.
The epoxy resin composition of this invention can be prepared by having the components mentioned above kneaded at a temperature of approximately from 60.degree. to 120.degree. C. by the use of a roll kneader or an extruder, for example. Further in this invention, the shaped article obtained by molding and curing the epoxy resin composition is desired to be given an aftercuring treatment for completing the curing reaction of the epoxy resin still proceeding in the cured resin product. The aftercuring treatment subsequent to the step of molding can be carried out by heat-treating the cured resin product for a prescribed time in a constant temperature bath kept at a temperature substantially equaling the temperature used in the molding treatment.
In the epoxy resin composition of this invention, the polyallyl phenol used as a curing agent acts on the epoxy resin used as a substratal resin effectively improving the heatproofing and hydrophobicity of the cured resin product, and in the presence of the specific silicon-modified resin, one member selected from among silicon-modified epoxy resin, butadiene-acrylonitrile copolymer, polystyrene/polybutadiene/polystyrene terminal block copolymer, ethylene/propylene type rubber, ethylene/.alpha.-olefin copolymers, and silicone rubber powder containing an epoxy group as a functional group and intended as a flexibility-imparting agent effectively functions as an agent for enhancing the cracking resistance and mold releasability. Thus, these additives simultaneously improve the flame-retarding property, flexibility, mold releasability, and cracking resistance. Further, the addition of the inorganic filler enhances the mechanical strength.
Now, this invention will be described more specifically with reference to working examples and comparative examples. Wherever "parts" is mentioned in the following examples, it will be construed as referring to "parts by weight" unless otherwise specified.
Examples 1 to 9 and Comparative Examples 1 to 4
The experiments covered herein represent cases using an epoxy resin composition comprising an epoxy resin, a polyallyl phenol, and a silicon-modified epoxy resin.
The following raw materials were used in these experiments:
Epoxy resin: A cresol novolak type epoxy resin (produced by Nippon Kayaku Co., Ltd. and marketed under product code of "EOCN-1025")
Polyallyl phenol: A product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product code of "SH-150AR"
Silicon-modified epoxy resin: A product of Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620"
A pertinent composition was prepared by placing these raw materials in a varying ratio indicated in Table 1 in a pressure kneader and kneading them simultaneously therein. A test piece of the composition was produced as follows.
First, the composition resulting from the kneading was comminuted into a 8-mesh pass powder. This powder was placed in a press mold and compression molded therein at 200.degree. C. under 80 kg/cm.sup.2 for 20 minutes. The shaped mass thus obtained was subjected to an after-curing treatment at 200.degree. C. for eight hours.
The composition produced as described above was tested for various properties as follows:
Glass transition point: This property was determined with a thermomechanical analyzer (produced by Shinku Riko K.K.)
Flexural strength: This property was determined in accordance with the method specified in Japanese Industrial Standard (JIS) K-6911.
Crack: The occurrence of this phenomenon in a given test piece and the extent of the phenomenon were determined by observing a cross section of a given test piece (10.times.5.times. mm) under a microscope.
Absorbing ratio: This property was determined by the method (absorption of boiling water) specified in JIS K-6911.
Mold releasability: This property was determined by repeating the molding of a given composition on a chromium-plated plate, taking into count the cycles of the molding, and measuring the adhesive force.
Moistureproofness: This property was determined by subjecting a given sample to a PCT (pressure cooker test) treatment at 125.degree. C. under 2.3 atmospheres by the use of an aluminum-wired model device illustrated in FIG. 9 and testing the wire for electric resistance.
In FIG. 9, 1 stands for a gold wire, 2 for a lead, and 3 for an aluminum electrode. In the test, the circuit width and the circuit interval were respectively 10 .mu.m and 10 .mu.m.
The results are shown in Table 1 and FIG. 1 and FIG. 2. It is clearly noted from these results, particularly the results of Examples 1 to 5 and Comparative Examples 1 and 2 that the addition of a silicon-modified epoxy resin improved the toughness, mold releasability, and flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of a polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
TABLE 1__________________________________________________________________________ Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 Ex. 8 Ex. 9 CE 1 CE 2 CE 3 CE 4__________________________________________________________________________Composition Epoxy resin 100 100 100 100 100 100 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 30 50 90 120 70 70 20 130 Silicon-modified 5 20 40 60 80 20 20 20 20 2 90 30 30 epoxy resinGlass transition point (.degree.C.) 200 218 215 192 189 182 216 221 198 211 160 170 182Flexural strength 25.degree. C. 6 6 5 5 4 4 5 5 4 4 4 3 4(kg/mm.sup.2) 250.degree. C. 4 5 4 4 3 3 4 4 3 3 1 0 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x x xAbsorbing ratio (%) 0.4 0.4 0.4 0.3 0.3 0.4 0.3 0.3 0.3 0.4 0.3 0.7 0.3Mold releasability 1 cycle 6 6 5 4 4 5 5 5 6 8 4 6 6(kg/cm.sup.2) 5 cycles 3 1 0 0 0 2 2 2 3 7 0 4 5__________________________________________________________________________ Ex. = Example CE = Comparative Example
Examples 10 to 14 and Comparative Examples 5 and 6
The experiments covered herein represent cases using an epoxy resin composition comprising an epoxy resin, a polyallyl phenol, a silicon-modified epoxy resin, and a butadiene/acrylonitrile copolymer.
The following raw materials were used in these experiments.
Epoxy resin: A cresol novolak type epoxy resin (produced by Nippon Kayaku Co., Ltd. and marketed under product code of "EOCN-1025")
Polyallyl phenol: A product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product code of "SH-150AR"
Silicone-modified epoxy resin: A product of Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620"
Butadiene/acrylonitrile copolymer: A product of Ube Industries, Ltd. marketed under trademark designation of "Hycar CTBN1300"
A pertinent composition was prepared by placing the raw materials in a varying ratio indicated in Table 2 in a pressure kneader and kneading them simultaneously therein. Test pieces of these compositions and the test thereof for varying properties were carried out in the same manner as in Examples 1 to 9. The compositions were also tested for bleedout and package crack as follows.
Bleedout: The occurrence of this phenomenon on a given test piece (10.times.5.times.30 mm) and the extent of the phenomenon were determined by visually observing the surface of the test piece.
Package crack: The test for this phenomenon was performed by allowing a produced package to absorb moisture under the conditions of 85.degree. C. and 85% RH for 96 hours, immersing this package in a solder bath at 260.degree. C. for 20 seconds, and then visually examining the package.
The results are shown in Table 2 and in FIG. 3. It is clearly noted from these results, particularly the results of Examples 10 to 14 and Comparative Examples 5 and 6 that the addition of the butadiene/acrylonitrile copolymer improved the flexibility and toughness of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed production of a resin composition having an excellent hydrophobicity.
TABLE 2__________________________________________________________________________ Ex. 10 Ex. 11 Ex. 12 Ex. 13 Ex. 14 CE 5 CE 6__________________________________________________________________________Composition Epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 CTBN 5 20 40 60 80 2 90Glass transition point (.degree.C.) 188 185 180 177 173 200 150Flexural strength (kg/mm.sup.2) 25.degree. C. 8 8 9 7 6 6 4 250.degree. C. 6 6 5 4 3 4 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.5 0.5 0.5 0.6 0.6 0.4 0.8Mold releasability (kg/cm.sup.2) 1 cycle 7 7 6 6 7 7 9 5 cycles 2 2 2 1 3 2 5Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
Examples 15 to 19 and Comparative Examples 7 and 8
The experiments covered herein represent cases using an epoxy resin composition comprising an epoxy resin, a polyallyl phenol, a silicon-modified epoxy resin, and a polystyrene/polybutadiene/polystyrene terminal block copolymer.
The following raw materials were used in these experiments.
Epoxy resin: A cresol novolak type epoxy resin (produced by Nippon Kayaku Co., Ltd. and marketed under produce code of "COCN-1025"
Polyallyl phenol: A product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product Code of "SH-150AR"
Silicone-modified epoxy resin: A product of Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620"
Polystyrene/polybutadiene/polystyrene terminal block copolymer: A product of Shell Chemical K.K. marketed under the trademark of "Kraton G-1652"
A pertinent composition was prepared by placing these raw materials in a varying ratio indicated in Table 3 in a pressure kneader and kneading them simultaneously therein. Test pieces of these compositions and the test thereof for varying properties were carried out in the same manner as in Examples 1 to 9. The compositions were also tested for bleedout and package crack as follows:
Bleedout: In the same manner as in Examples 10 to 14.
Package crack: The test for this phenomenon was performed by molding a 84 bottle QFP, allowing the bottle to absorb moisture at 121.degree. C. for 24 hours, immersing the bottle in a solder bath at 260.degree. C. for 20 seconds, and examining the bottle to detect cracks, if any.
The results are shown in Table 3 and in FIG. 4. It is clearly noted from these results, particularly the results of Examples 15 to 19 and Comparative Examples 7 and 8 that the addition of the polystyrene/polybutadiene/polyester terminal block copolymer improved the flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
TABLE 3__________________________________________________________________________ Ex. 15 Ex. 16 Ex. 17 Ex. 18 Ex. 19 CE 7 CE 8__________________________________________________________________________Composition Epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 Terminal block copolymer 5 20 40 60 80 2 90Glass transition point (.degree.C.) 190 185 183 177 175 210 150Flexural strength (kg/mm.sup.2) 25.degree. C. 7 7 6 5 5 7 4 250.degree. C. 5 5 4 3 3 5 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.5 0.5 0.5 0.6 0.6 0.4 0.7Mold releasability (kg/cm.sup.2) 1 cycle 7 7 7 8 8 7 9 5 cycles 2 2 3 3 3 2 5Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
Examples 20 and 24 and Comparative Examples 9 and 10
The experiments covered herein represent cases using an epoxy resin composition comprising an epoxy resin, a polyallyl phenol, a silicon-modified epoxy resin, and an ethylene/propylene type terpolymer.
The following raw materials were used in these experiments.
Epoxy resin: A cresol novolak type epoxy resin (produced by Nippon Kayaku Co., Ltd. and marketed under product code "EOCN-1025")
Polyallyl phenol: A product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product code of "SH-150AR"
Silicone-modified epoxy resin: A product of Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620"
Ethylene/propylene type terpolymer: A product of Japan Synthetic Rubber Co., Ltd. marketed under product code "JSR57P"
A pertinent composition was prepared by placing these raw materials in a varying ratio indicated in Table 4 in a pressure kneader and kneading them simultaneously therein. The test pieces of these compositions and the test thereof for varying properties were carried out in the manner as in Examples 15 to 19.
The results are shown in Table 4 and in FIG. 5. It is clearly noted from the results, particularly the results of Examples 20 to 24 and Comparative Examples 9 and 10 that the addition of the ethylene/propylene type terpolymer improved the flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
TABLE 4__________________________________________________________________________ Ex. 20 Ex. 21 Ex. 22 Ex. 23 Ex. 24 CE 9 CE 10__________________________________________________________________________Composition Epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 Terpolymer 5 20 40 60 80 2 90Glass transition point (.degree.C.) 192 186 185 179 177 212 149Flexural strength (kg/mm.sup.2) 25.degree. C. 7 8 7 6 5 6 5 250.degree. C. 5 5 4 4 3 3 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.5 0.5 0.5 0.6 0.6 0.4 0.7Mold releasability (kg/cm.sup.2) 1 cycle 8 8 9 9 9 7 10 5 cycles 2 3 3 3 4 1 6Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
Examples 25 to 29 are Comparative Examples 11 and 12
The experiments covered herein represent cases using an epoxy resin composition comprising an epoxy resin, a polyallyl phenol, a silicon-modified epoxy resin, and an ethylene/.alpha.-olefin copolymer.
The following raw materials were used in these experiments.
Epoxy resin: A cresol novolak type epoxy resin (produced by Nippon Kayaku Co., Ltd. and marketed under product code of "EOCN-1025")
Polyallyl phenol: A product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product code of "SH-150AR"
Silicon-modified epoxy resin: A product of Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620"
Ethylene/.alpha.-olefin copolymer: A product of Mitsui Petrochemcial Industries, Ltd. marketed under the trademark "Tafmer-P P-0280:
A pertinent composition was prepared by placing these raw materials in a varying ratio indicated in Table 5 in a pressure kneader and kneading them simultaneously therein.
The test pieces of these compositions and the test thereof for varying properties were carried out in the same manner as in Examples 15 to 19.
The results are shown in Table 5 and FIG. 6. It is clearly noted from these results, particularly the results of Examples 25 to 29 and Comparative Examples 11 and 12 that the addition of the ethylene/.alpha.-olefin copolymer improved the flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
TABLE 5__________________________________________________________________________ Ex. 25 Ex. 26 Ex. 27 Ex. 28 Ex. 29 CE 11 CE 12__________________________________________________________________________Composition Epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 Ethylene/.alpha.-olefin copolymer 5 20 40 60 80 2 90Glass transition point (.degree.C.) 187 181 180 175 173 200 139Flexural strength (kg/mm.sup.2) 25.degree. C. 7 7 7 6 5 7 5 250.degree. C. 5 4 4 3 3 4 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.6 0.6 0.5 0.6 0.6 0.4 0.8Mold releasability (kg/cm.sup.2) 1 cycle 7 7 8 8 8 7 10 5 cycles 2 2 2 3 3 1 6Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
Examples 30 to 34 and Comparative Examples 13 and 14
The experiments covered herein represent cases using an epoxy resin composition comprising an epoxy resin, a polyallyl phenol, a silicon-modified epoxy resin, and a silicone powder containing an epoxy group.
The following raw materials were used in these experiments.
Epoxy resin: A cresol novolak type epoxy resin (produced by Nippon Kayaku Co., Ltd. and marketed under product code of "EOCN-1025")
Polyallyl phenol: A product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product code of "SH-150AR"
Silicon-modified epoxy resin: A product of Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620"
Silicone powder containing epoxy group: A product of Toray-Dow Corning K.K. marketed under the trademark "Torayfil E-601"
A pertinent composition was prepared by placing these raw materials in a varying ratio indicated in Table 6 in a pressure kneader and kneading them simultaneously therein. The test pieces of these compositions and the test thereof for varying properties were carried out in the same manner as in Examples 15 to 19.
The results are shown in Table 6 and in FIG. 7. It is clearly noted from these results, particularly the results of Examples 30 to 34 and Comparative Examples 13 and 14 that the addition of the silicone powder containing an epoxy group improved the flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
TABLE 6__________________________________________________________________________ Ex. 30 Ex. 31 Ex. 32 Ex. 33 Ex. 34 CE 13 CE 14__________________________________________________________________________Composition Epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 Silicon powder 5 20 40 60 80 2 90Glass transition point (.degree.C.) 193 191 190 187 185 210 165Flexural strength (kg/mm.sup.2) 25.degree. C. 8 9 9 8 8 7 6 250.degree. C. 6 7 8 7 6 4 3Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.4 0.4 0.3 0.3 0.4 0.4 0.5Mold releasability (kg/cm.sup.2) 1 cycle 6 6 6 7 7 6 8 5 cycles 1 1 2 2 2 1 4Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
Examples 35 to 39 and Comparative Examples 15 and 16
The experiments covered herein represent cases using an epoxy resin composition comprising an epoxy resin, a polyallyl phenol, a silicon-modified epoxy resin, and silica.
The following raw materials were used in these experiments.
Epoxy resin: A cresol novolak type epoxy resin(produced by Nippon Kayaku Co., Ltd. and marketed under product code of "EOCN-1025")
Polyallyl phenol: A product of Mitsubishi Petro-Chemical Co., Ltd. marketed under product code of "SH-150AR"
Silicon-modified epoxy resin: A product of Dai-Nippon Ink & Chemicals, Inc. marketed under product code of "SIN-620"
Silica: A product of Tatsumori K.K. marketed under product code "RD-8"
A pertinent composition was prepared by placing these raw materials in a varying ratio indicated in Table 7 in a pressure kneader and kneading them simultaneously therein. The test pieces of these compositions and the test thereof for varying properties were carried out in the same manner as in Examples 15 to 19. The compositions were tested further for viscosity by the flow tester method.
The results are shown in Table 7 and in FIG. 8. It is clearly noted from these results, particularly the results of Examples 35 to 39 and Comparative Examples 15 and 16 that the addition of silica improved the mechanical strength of a cured resin product, that the desirable amounts of addition were from 30 to 85% by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
TABLE 7__________________________________________________________________________ Ex. 35 Ex. 36 Ex. 37 Ex. 38 Ex. 39 CE 15 CE 16__________________________________________________________________________Composition Epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 Silica (%) 30 40 60 70 85 10 90Glass transition point (.degree.C.) 190 191 190 190 192 190 190Flexural strength (kg/mm.sup.2) 25.degree. C. 13 14 16 17 17 9 13 250.degree. C. 10 10 11 12 13 4 9Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xAbsorbing ratio (%) 0.3 0.2 0.2 0.1 0.1 0.5 0.1Mold releasability (kg/cm.sup.2) 1 cycle 6 6 5 5 5 6 5 5 cycles 1 1 1 0 0 2 0Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x xViscosity (P) 153 300 350 420 500 110 1000__________________________________________________________________________ Ex. = Example CE = Comparative Example
Examples 40 to 48 and Comparative Examples 17 to 20
The procedure of Examples 1 to 9 and Comparative Examples 1 to 4 was repeated, excepting a biphenyl type epoxy resin (produced by Yuka-Shell Epoxy K.K. and marketed under product code "YX-4000H") was used as an epoxy resin and the raw materials were kneaded in a varying ratio indicated in Table 8. The results are shown in Table 8 and in FIGS. 10 and 11.
TABLE 8__________________________________________________________________________ Ex. 40 Ex. 41 Ex. 42 Ex. 43 Ex. 44 Ex. 45 Ex. 46 Ex. 47 Ex. 48 CE 17 CE 18 CE CE__________________________________________________________________________ 20Composition(parts)Epoxy resin 100 100 100 100 100 100 100 100 100 100 100 100 100Polyallyl phenol 70 70 70 70 70 30 50 90 120 70 70 20 130Silicon-modified 5 20 40 60 80 20 20 20 20 2 90 30 30epoxy resinGlass transition point 210 227 225 200 198 190 226 230 202 220 165 173 185(.degree.C.)Flexural strength(kg/mm.sup.2)25.degree. C. 7 7 6 6 5 5 6 6 5 4 5 4 4250.degree. C. 5 6 5 5 4 4 4 4 4 3 2 1 0Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x .smallcircle. x xAbsorbing ratio (%) 0.3 0.3 0.3 0.2 0.2 0.3 0.2 0.2 0.2 0.3 0.3 0.7 0.4Mold releasability(kg/cm.sup.2)1 cycle 7 8 7 6 5 6 6 6 7 9 4 8 95 cycles 3 1 0 0 0 2 2 2 3 7 0 6 7__________________________________________________________________________ Ex. = Example CE = Comparative Example
It is clearly noted from these results, particularly the results of Examples 40 to 44 and Comparative Examples 17 and 18 that the addition of the silicon-modified epoxy resin improved the toughness, mold releasability, and flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
The biphenyl type epoxy resin used in these experiments was of the type disclosed in Japanese Unexamined Patent Publication No. 251,419/1988. The resin represented by the following general formula: ##STR10## (wherein R.sup.3 to R.sup.10 each stand for a hydrogen, a lower alkyl group of one to four carbon atoms, or a halogen atom). Desirable examples of R.sup.3 to R.sup.10 are hydrogen atom, methyl group, ethyl group, propyl group, butyl group, chlorine atom, and bromine atom.
Examples 49 to 53 and Comparative Examples 21 and 22
The procedure of Examples 10 to 14 and Comparative Examples 5 and 5 was repeated, excepting a biphenyl type epoxy resin (produced by Yuka-Shell Epoxy K.K. and marketed under product code "YX-4000H") was used as an epoxy resin and the raw materials were kneaded at a varying ratio indicated in Table 9. The results are shown in Table 9 and in FIG. 12.
TABLE 9__________________________________________________________________________ Ex. 49 Ex. 50 Ex. 51 Ex. 52 Ex. 53 CE 21 CE 22__________________________________________________________________________Composition Biphenyl type epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 CTBN 5 20 40 60 80 2 90Glass transition point (.degree.C.) 202 200 193 188 180 205 150Flexural strength (kg/mm.sup.2) 25.degree. C. 9 9 10 10 8 6 4 250.degree. C. 7 8 8 7 4 4 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.4 0.4 0.5 0.5 0.6 0.4 0.8Mold releasability (kg/cm.sup.2) 1 cycle 9 9 7 6 7 7 9 5 cycles 4 3 2 1 3 2 5Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
It is clearly noted from these results, particularly the results of Examples 49 to 51 and Comparative Examples 21 and 22, that the use of the butadiene/acrylonitrile copolymer improved the flexibility and toughness of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
Examples 54 to 58 and Comparative Examples 23 and 24
The procedure of Examples 15 to 19 and Comparative Examples 7 and 8, excepting a biphenyl type epoxy resin (produced by Yuka-Shell Epoxy K.K. and marketed under product code "YX-4000H") was used as an epoxy resin and the raw materials were used in a varying ratio indicated in Table 10. The results are shown in Table 10 and in FIG. 13.
TABLE 10__________________________________________________________________________ Ex. 54 Ex. 55 Ex. 56 Ex. 57 Ex. 58 CE 23 CE 24__________________________________________________________________________Composition Biphenyl type epoxy resin 100 100 100 100 100 100 100(parts) Polyallyl phenol 70 70 70 70 70 70 30 Silicon-modified epoxy resin 30 30 30 30 30 30 30 Terminal block copolymer 5 20 40 60 80 2 90Glass transition point (.degree.C.) 200 198 195 188 186 220 162Flexural strength (kg/mm.sup.2) 25.degree. C. 8 8 7 6 6 8 4 250.degree. C. 6 6 5 4 3 5 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.4 0.4 0.5 0.5 0.6 0.4 0.7Mold releasability (kg/cm.sup.2) 1 cycle 8 8 8 9 9 7 11 5 cycles 1 3 4 4 4 2 8Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
It is clearly noted from these results, particularly the results of Examples 54 to 58 and Comparative Examples 23 and 24 that the addition of the polystyrene/polybutadiene/polystyrene terminal block copolymer improved the flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
Examples 59 to 63 and Comparative Examples 25 and 26
The procedure of Examples 20 to 24 and Comparative Examples 9 to 10 was repeated, excepting a biphenyl type-epoxy resin (produced by Yuka-Shell Epoxy K.K. and marketed under produce code "YX-4000H") and the raw materials were kneaded at a varying ratio indicated in Table 11. The results are shown in Table 11 and in FIG. 14.
TABLE 11__________________________________________________________________________ Ex. 59 Ex. 60 Ex. 61 Ex. 62 Ex. 63 CE 25 CE 26__________________________________________________________________________Composition (parts)Biphenyl type epoxy resin 100 100 100 100 100 100 100Polyallyl phenol 70 70 70 70 70 70 30Silicon-modified epoxy 30 30 30 30 30 30 30resinTerpolymer 5 20 40 60 80 2 90Glass transition point (.degree.C.) 205 200 198 195 185 220 150Flexural strength (kg/mm.sup.2)25.degree. C. 8 9 8 7 6 7 5250.degree. C. 6 6 5 5 3 3 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.4 0.5 0.5 0.5 0.6 0.4 0.7Mold releasability (kg/cm.sup.2)1 cycle 9 10 10 11 10 8 125 cycles 3 4 3 4 4 3 7Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
It is clearly noted from these results, particularly the results of Examples 59 to 63 and Comparative Examples 25 and 26 that the addition of the ethylene/propylene type terpolymer improved the flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
Examples 64 to 68 and Comparative Examples 27 and 28
The procedure of Examples 25 to 29 and Comparative Examples 11 and 12 was repeated, excepting a biphenyl type epoxy resin (produced by Yuka-Shell Epoxy K.K. and marketed under product code "YX-4000H" was used as an epoxy resin and the raw materials were kneaded at a varying ratio indicated in Table 12. The results are shown in Table 12 and in FIG. 15.
TABLE 12__________________________________________________________________________ Ex. 64 Ex. 65 Ex. 66 Ex. 67 Ex. 68 CE 27 CE 28__________________________________________________________________________Composition (parts)Biphenyl type epoxy resin 100 100 100 100 100 100 100Polyallyl phenol 70 70 70 70 70 70 30Silicon-modified epoxy 30 30 30 30 30 30 30resinEthylene/.alpha.-olefin 5 20 40 60 80 2 90copolymerGlass transition point (.degree.C.) 190 195 193 185 180 210 140Flexural strength (kg/mm.sup.2)25.degree. C. 8 8 8 7 6 7 5250.degree. C. 6 6 5 4 4 4 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.5 0.5 0.5 0.6 0.6 0.4 0.8Mold releasability (kg/cm.sup.2)1 cycle 8 9 9 9 10 7 125 cycles 4 4 4 5 5 3 7Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
It is clearly noted from these results, particularly the results of Examples 64 to 68 and Comparative Examples 27 and 28 that the addition of the ethylene/.alpha.-olefin copolymer improved the flexibility of a cured resin product, that the desirable amounts of addition were from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
Examples 69 to 73 and Comparative Examples 29 and 30
The procedure of Examples 30 to 34 and Comparative Examples 13 and 14 was repeated, excepting a biphenyl type epoxy resin (produced by Yuka-Shell Epoxy K.K. and marketed under produce code "YX-4000H" as an epoxy resin and the raw materials were kneaded at a varying ratio indicated in Table 13. The results are shown in Table 13 and in FIG. 16.
TABLE 13__________________________________________________________________________ Ex. 69 Ex. 70 Ex. 71 Ex. 72 Ex. 73 CE 29 CE 30__________________________________________________________________________Composition (parts)Biphenyl type epoxy resin 100 100 100 100 100 100 100Polyallyl phenol 70 70 70 70 70 70 30Silicon-modified epoxy 30 30 30 30 30 30 30resinSilicone powder 5 20 40 60 80 2 90Glass transition point (.degree.C.) 210 210 203 200 198 215 165Flexural strength (kg/mm.sup.2)25.degree. C. 9 10 10 10 8 8 6250.degree. C. 7 8 8 7 6 5 3Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Absorbing ratio (%) 0.4 0.3 0.3 0.3 0.4 0.4 0.5Mold releasability (kg/cm.sup.2)1 cycle 8 7 8 9 11 6 85 cycles 3 2 3 2 3 1 4Bleedout .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xPackage crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example
It is clearly noted from these results, particularly the results of Examples 69 to 73 and Comparative Examples 29 and 30 that the addition of the silicone powder containing an epoxy group improved the flexibility of a cured resin product, that the desirable amounts of addition are from 5 to 80 parts by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
Examples 74 to 78 and Comparative Examples 31 and 32
The procedure of Examples 35 to 39 and Comparative Examples 15 and 16 was repeated, excepting a biphenyl type epoxy resin (produced by Yuka-Shell Epoxy K.K. and marketed under product code "YX-4000H") was used as an epoxy resin and the raw materials were kneaded at a varying ratio indicated in Table 14. The results are shown in Table 14 and in FIG. 17.
TABLE 14__________________________________________________________________________ Ex. 74 Ex. 75 Ex. 76 Ex. 77 Ex. 78 CE 31 CE 32__________________________________________________________________________Composition (parts)Biphenyl type epoxy resin 100 100 100 100 100 100 100Polyallyl phenol 70 70 70 70 70 70 30Silicon-modified epoxy 30 30 30 30 30 30 30resinSilica (%) 30 40 60 70 85 10 90Glass transition point (.degree.C.) 203 200 202 205 200 200 210Flexural strength (kg/mm.sup.2)25.degree. C. 14 15 18 19 19 9 17250.degree. C. 12 12 15 17 15 4 10Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xAbsorbing ratio (%) 0.3 0.2 0.1 0.1 0.1 0.5 0.1Mold releasability (kg/cm.sup.2)1 cycle 8 7 6 5 4 6 55 cycles 3 2 2 0 0 2 0Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x xViscosity (P) 40 70 150 220 400 110 800__________________________________________________________________________ Ex. = Example CE = Comparative Example
It is clearly noted from these results, particularly the results of Examples 74 to 78 and Comparative Examples 31 and 32 that the addition of silica improved the mechanical strength of a cured resin product, that the desirable amounts of addition were from 30 to 85% by weight, and that the use of the polyallyl phenol as a curing agent allowed the production of a resin composition having an excellent hydrophobicity.
The relationship between the time for the PCT treatment (h) and the fraction defective (%) can be easily understood from the accompanying drawings. The products of the comparative examples (cresol novolak type epoxy/phenol novolak type) and the products of this invention (biphenyl type epoxy/polyallyl phenyl type) are compared with respect to this relationship in FIG. 18. It can be understood from the results of the diagram that the products of this invention have an excellent moistureproofing.
FIG. 19 is a graph showing the effect produced by the number of allyl groups in the polyallyl phenol as a curing agent on the area of close contact. More specifically, this diagram shows the number of allyl groups contained in one benzene ring as a function of the degree of close contact between resin/silicon (Si) chips and resin/stage surface (rear surface) of a 100 pin flat type package after immersion in the solder bath for an absorption of humidity. It is noted from this diagram that the hydrophobicity and freedom from stress were improved and the close contact was enhanced proportionally with the increase of the number of allyl groups.
The epoxy resin to be used as the substratal resin in the composition of the present invention is not particularly limited. Nevertheless, the examples of epoxy resin which may be advantageously used for the composition of the present invention are glycidyl ether type epoxy resins such as bisphenol A type epoxy resins, cresol novolak type epoxy resins, phenol novolak type epoxy resins, and biphenyl type epoxy resins, and epoxy resins having 2 or more epoxy groups in a molecule, e. g. glycidyl ester type epoxy resins, glycidyl amine type epoxy resins, and halogenated epoxy resins.
Biphenyl type epoxy resins are more preferable epoxy resins in the present invention, because the composition of the present invention, containing a biphenyl type epoxy resin as a substratal resin gives a cured product with more increased heat resistance and moisture resistance.
As desirable biphenyl type epoxy resins, there may be mentioned, e. g., those disclosed in Japanese Unexamined Patent Publication No. 251,419/1988, e.g., 4,4'-bis(2,3-epoxypropoxy)biphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethylbiphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethyl-2-chlorobiphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethyl-2-bromobiphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetraethylbiphenyl; 4,4'-bis(2,3-epoxy-propoxy)-3,3',5,5'-tetrabutylbiphenyl, and the like. These epoxy resins are represented by the general formula: ##STR11## wherein R and R' each is an epoxy functional group, and R.sup.1 and R.sup.8 each represents a lower alkyl group with 1 to 4 carbon atoms, or a halogen atom. Representative examples of the epoxy functional groups indicated by R and R' are 2,3-epoxypropoxy groups. As preferred examples of the groups indicated by R.sup.1 to R.sup.8, there may be mentioned a hydrogen atom, methyl group, ethyl group, propyl group, butyl group, chlorine atom, bromine atom, and the like. These epoxy resins are commercially available, and e. g., "YX-4000H" produced by Yuka-Shell Epoxy K.K., and the like may be advantageously used.
As a matter of course, epoxy resins may be used either each singly or as a mixture of 2 or more of them.
The polyallyl phenols used in the epoxy resin composition of the present invention function as a curing agent. As examples of preferable polyallyl phenols, there may be mentioned those represented by the formula: ##STR12## wherein m is an integer of 1 to 6.
It is understood that these polyallyl phenols come to have a higher viscosity, better workability, and become more improved in heat resistance, in proportion as the numerical value of m in the above formulae is increased. These polyallyl phenols may be synthesized by a known method, or as such polyallyl phenols, there may be utilized commercially available products including, e. g., those delivered as samples by Mitsubishi Petrochemical Co., Ltd. under the trade name of "SH-150 AR".
Polyallyl phenols used as curing agent elevate the glass transition temperature of the cured product, thus enabling the improvement of the heat resistance of the product, and also improving the hydrophobic nature thereof. The amount of the polyallyl phenol to be incorporated in the epoxy resin composition is preferably within the range between 5 and 200 parts by weight based on 100 parts by weight of the epoxy resin as a substratal resin. When this amount is less than 5 parts by weight, a sufficient development of the curing reaction of the epoxy resin composition cannot be expected, and when it exceeds 200 parts by weight, the glass transition temperature of the cured resin product lowers, resulting in impairment of the heat resistance of the cured resin product. The more preferable amount of polyallyl phenol to be incorporated in the epoxy resin composition is within the range between 50 and 100 parts by weight based on 100 parts by weight of the epoxy resin.
The polyphenol to be added to the composition of the present invention functions as a curing auxiliary agent, and is especially effective for the simultaneous improvement of the curability and mechanical strength of the present composition. This polyphenol is represented by the general formula: ##STR13## wherein n is an integer of 1 to 6.
These polyphenols may be synthesized by a known method, or as such polyphenols, there may be used commercially available ones including, e. g., the product marketed by Mitsubishi Petrochemical Co., Ltd. under the trade name of "SH-180".
The polyphenol used as a curing auxiliary agent may be incorporated in the composition of the present invention in an amount variable depending on the effect desired from the addition thereof, and this amount may generally be varied in a wide range. However, this amount is preferably within the range between 5 and 200 parts by weight based on 100 parts by weight of the epoxy resin, in general. When this amount is less than 5 parts by weight, the effect of the addition does not sufficiently exhibit, and when the polyphenol is incorporated in the composition of the present invention in a great quantity exceeding 200 parts by weight, the properties such as toughness of the cured resin product are deteriorated because polyphenols are fragile substances. The more preferable amount of the polyphenol to be incorporated in the composition of the present invention is within the range between 30 and 100 parts by weight based on 100 parts by weight of the epoxy resin.
To the composition of the present invention, there may be added, if necessary, one, or 2 or more of the flexibilizers listed hereinbelow in order to impart appropriate flexibility to a cured resin product obtained from the composition of the present invention.
(a) polystyrene/polybutadiene/polystyrene terminal block copolymer.
(b) ethylene/propylene type copolymers.
(c) ethylene/.alpha.-olefin copolymers.
(d) epoxy functional group-containing silicone rubber powder.
(e) silicon-modified epoxy resins.
As the ethylene/propylene type copolymer of the above-listed flexibilizers, terpolymers containing dicyclopentadiene or ethylidene norbornene as a third component monomer in addition to ethylene monomer and propylene monomer are favorable.
These flexibilizers may have various structures, and are virtually marketed in various forms. For instance, the polystyrene/polybutadiene/polystyrene terminal copolymer is commercially available as "Kraton G-1652" (produced by Shell Kagaku K.K.), the ethylene/propylene type copolymer as "JSR 57P" (produced by Nippon Gosei Gomu K.K.), the ethylene/.alpha.-olefin copolymer as "Tafmer PP-0280" (produced by Mitsui Sekiyu Kagaku K.K.), epoxy functional group-containing silicone rubber powder as "Torayfil E 601" (produced by Toray-Dow Corning K.K.) and the silicon-modified epoxy resin as "SIN-620" (produced by Dai-Nippon Ink Kagaku K.K.), respectively.
The aforesaid flexibilizers are effective for improving the flexibility and toughness of the cured resin product and thereby improving the crack resistance thereof. In addition, these flexibilizers also possess a function of improving the moisture resistance of the cured resin product. Any of the flexibilizers is desirably added to the epoxy resin as a substratal resin in an amount ranging from 5 to 80 parts by weight based on 100 parts by weight of the epoxy resin. When this amount is less than 5 parts by weight, the effect of the addition is not exhibited, and when it exceeds 80 parts by weight, the heat resistance of the cured resin product is lowered.
The epoxy resin composition of the present invention may contain a powdery inorganic filler for the purpose of improving the mechanical strength of the cured resin product. As the inorganic filler, there may be mentioned fused silica, crystalline silica, alumina, calcium carbonate and the like. These fillers are added to the epoxy resin composition in an amount ranging preferably from 20 to 85% by weight based on the total weight of the composition. When this amount is less than 20% by weight, the expected effect cannot be achieved, and when it exceeds 85% by weight, the flowability of the composition is lowered to result in the lowering of the workability thereof, and the cured resin product obtained from the composition becomes liable to be cracked. In addition, to the composition of the present invention, there may be optionally added the components mentioned hereinbelow, if occasion demands.
(1) A curing catalyst for promoting the curing reaction of the epoxy resin as substratal resin, a polyallyl phenol as a curing agent, and a polyphenol as a curing auxiliary agent. As the curing catalyst, there are used imidazole type ones such as 2-methyl imidazole, phosphine type ones such as triphenyl phosphine. DBU type ones such as a phenol salt of diazabicycloundecene (DBU), and the like.
(2) A coupling agent for enhancing the compatibility of the inorganic filler with the resin when the inorganic filler is added to the resin. As the coupling agent, there may be mentioned, e. g., silane type coupling agents such as 3-aminopropyltriethoxysilane, titanium type coupling agents such as tetraoctyl bis(phosphite) titanate, or the like. Although the amount of the coupling agent to be incorporated in the composition of the present invention varies depending on the kind, amount and specific surface area of the inorganic filler to be used, and the minimum covering area of the coupling agent, it is desirably within the range between about 0.1 and 15 parts by weight, in the present invention.
(3) A mold release auxiliary agent (e. g., carnauba wax, stearic acid and metal salts thereof, montan wax, etc.)
(4) A flame-retarding agent (e. g., brominated epoxy resin, antimony trioxide, etc.)
(5) A pigment (e. g., carbon black, etc.)
(6) A coloring agent (e. g., titanium dioxide, etc.)
The epoxy resin composition of the present invention can be prepared by heating its ingredients at a temperature ranging from about 60.degree. to 120.degree. C. by the use of a befitting means such as rolls, kneader, extruder or the like. The epoxy resin composition of the present invention may be prepared by adoption of a mixing-in-solvent method, in which the ingredients are mixed under the dissolution thereof in a suitable solvent such as acetone and toluene. Furthermore, in the composition of the present invention, it is desirable to carry out postcuring treatment after molding in order to complete the curing reaction of the uncured epoxy resin in the cured resin product or the like. This postcuring subsequent to the molding may be carried out by heat-treating the cured resin product for a predetermined time in a constant temperature bath kept at a temperature substantially equaling to the temperature used in the molding.
The polyallyl phenol incorporated as a curing agent in the epoxy resin composition of the present invention elevates the glass transition temperature of the cured resin product, so as to enable the improvement of the heat resistance of the composition of the present invention, and more effectively functions for improving the hydrophobic nature, flexibility and crack resistance of the composition of the present invention, compared with polyimide type resins which are typical of the conventional heat resistant resins. The polyphenol to be added as a curing auxiliary agent not only improves the curability of the composition of the present invention but also enables the improvement of the mechanical strength of the cured resin product obtained from the composition.
The flexibilizer to be added to the epoxy resin composition of the present invention, if necessary, functions effectively for improving the flexibility of the cured resin product and consequently improving the crack resistance of the cured resin product. In addition, the inorganic filler to be added to the composition of the present invention enhances the mechanical strength of the cured resin product.
Next, the present invention will further be illustrated with reference to the working examples and comparative examples. In each of the following examples, "parts" indicate "parts by weight" unless otherwise specified. In addition, the cresol novolak type epoxy resin used in each of the following examples was "EOCN-1025" produced by Nippon Kayaku K.K., the biphenyl type epoxy resin used therein was "YX-4000H" produced by Yuka-Shell Epoxy K.K., the polyallyl phenol used therein was "SH-150AR" produced by Mitsubishi Yuka K.K. and the polyphenol used therein was "SH-180" produced also by Mitsubishi Yuka K.K.
The evaluations of the properties of the compositions and the cured resin products thereof prepared in each of the following examples were conducted according to the under-mentioned methods.
Glass transition point: This property was determined with a thermomechanical analyzer (produced by Shinku Riko K.K.).
Flexural strength: This property was determined in accordance with the method specified in Japanese Industrial Standard (JIS) K-6911.
Flexural modulus: This property was determined in accordance with the method specified in JIS K-6911.
Crack: The occurrence of this phenomenon in a given test piece and the extent of the phenomenon were determined by observing a cross section of a molded and cooled test piece (10.times.5.times.30 mm) under a microscope.
Water absorption ratio: This property was determined by the method specified in JIS K-6911.
Moisture resistance: This property was determined by evaluating the extent of the failure of a given sample, which had preliminarily been subjected to a PCT (pressure cooker test) treatment (125.degree. C./2.3 atm.), by the use of an aluminum-wired model device.
Package crack: This property was determined such that a 84-pin QFP (quad flat package) was molded and the thus obtained QFP was subjected to a moisture absorption treatment for 24 hours at a temperature of 121.degree. C. and a relative humidity of 100%, whereafter the thus treated QFP was immersed into a solder bath of 260.degree. C., and the occurrence of cracks was visually observed.
Gel time: This property was determined by measuring the curing time of a given sample on a hot plate (180.degree. C.).
Viscosity: This property was determined by a method using a flow tester.
In the following Examples 79 to 117 and Comparative Examples 33 to 48, a cresol novolak type resin was used as an epoxy resin as a substratal resin, and in Examples 118 to 156 and Comparative Examples 49 to 64, a biphenyl type epoxy resin was used:
Examples 79 to 87 and Comparative Examples 33 to 36
A cresol novolak type epoxy resin, a polyallyl phenol and a polyphenol were kneaded together in a pressure kneader, so that compositions with the compounding ratios set forth in Table 15 were prepared.
Next, the obtained compositions were, respectively, pulverized into 8 mesh pass powder, and the obtained powders were compression molded for 20 minutes at a temperature of 200.degree. C. and under a pressure of 80 kg/cm.sup.2, and then aftercured for 8 hours at a temperature of 200.degree. C., so that test pieces were prepared. The various properties of these test pieces were prepared. The various properties of these test pieces were determined according to the aforesaid methods. The obtained results are set forth in Table 15 and FIG. 20.
TABLE 15__________________________________________________________________________ Ex. 79 Ex. 80 Ex. 81 Ex. 82 Ex. 83 Ex. 84 Ex. 85 Ex. 86 Ex. 87 CE 33 CE 34 CE CE__________________________________________________________________________ 36Composition (parts)epoxy resin 100 100 100 100 100 100 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 5 50 100 200 70 70 2 210polyphenol 5 50 100 150 200 50 50 50 50 2 210 50 50Glass transition 135 198 200 210 228 210 205 190 178 173 145 230 140temperature (.degree.C.)Flexural strength(kg/mm.sup.2)25.degree. C. 7 8 10 13 12 9 9 10 9 6 5 5 4250.degree. C. 6 7 3 10 9 7 7 8 7 4 2 1 1Flexural modulus 600 640 680 720 780 730 675 620 570 580 320 800 420(kg/mm.sup.2)Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x xWater absorption rate 0.5 0.5 0.6 0.6 0.7 0.6 0.5 0.4 0.4 0.5 0.9 1.1 0.8(%)Gel time (s) 400 380 370 350 300 380 370 380 387 550 228 370 390Package crack x x x x x x x x x x x x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It can be seen from Table 15 that by the use of a polyallyl phenol in an amount ranging from 5 to 200 parts based on 100 parts of the epoxy resin, there may be obtained an epoxy resin composition excellent in the heat resistance of its cured product (having a high glass transition temperature). It can also be seen that the hydrophobic nature of the cured resin product, which may be judged by its water absorption ratio, is also excellent. In addition, by the use of a polyphenol as a curing auxiliary agent in an amount ranging from 5 to 200 parts, an epoxy resin composition having good curability could be obtained.
From FIG. 20 illustrating a graph of the PCT test results, showing the moisture resistances of cured products, it is clearly noted that the composition of the present invention gives its cured product having conspicuously better moisture resistance as compared with the compositions of the comparative examples.
As described above, it has clearly been seen that from the epoxy resin composition with which a polyallyl phenol curing agent and a polyphenol curing auxiliary agent have been blended, there is obtained a cured resin product having characteristics useful as multilayer laminate resins, electroconductive pastes, protective films for electronic devices, sealing materials, molding materials and the like, which are used in electronic.cndot.electric equipments, transport equipments or the like. Nevertheless, as shown in the evaluation results concerning package crack, it has been clarified that under solder bath immersion conditions after such severe PCT treatment described above, there occur some package cracks.
Examples 88 to 92 and Comparative Examples 37 and 38
In these examples, to a mixture of a cresol novolak type epoxy resin, a polyallyl phenol and a polyphenol, there was further added a polystyrene/polybutadiene/polystyrene terminal block copolymer ("Kraton G-1652" produced by Shell Kagaku K.K.) as a flexibilizer, and these substances were together kneaded in a pressure kneader, so that compositions with the compounding ratios set forth in Table 16 were prepared.
From each of the obtained compositions, test pieces were prepared in accordance with the procedures explained in Example 79, and the properties of the cured resin products obtained from the compositions were evaluated in the same manner as in Example 79. The results are set forth in Table 16 and FIG. 21.
TABLE 16__________________________________________________________________________ Ex. 88 Ex. 89 Ex. 90 Ex. 91 Ex. 92 CE 37 CE 38__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50polystyrene/polybutadiene/ 5 20 40 60 80 2 90polystyrene terminalblock copolymerGlass transition temperature (.degree.C.) 190 187 185 180 175 195 150Flexural strength (kg/mm.sup.2)25.degree. C. 9 9 8 8 7 8 4250.degree. C. 8 8 7 6 5 7 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.6 0.6 0.6 0.7 0.7 0.5 0.8Flexural modulus (kg/mm.sup.2) 600 580 560 500 450 630 320Gel time (s) 390 395 397 400 410 384 450Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 16 that by the addition of the polystyrene/polybutadiene/polystyrene terminal block copolymer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 21 that in these examples, there were obtained cured resin products with better moisture resistance than the cured products obtained from the compositions in Examples 79 to 87.
Examples 93 to 97 and Comparative Examples 39 and 40
Compounds having the compounding ratios set forth in Table 17 were prepared in the same manner as in Examples 88 to 92, with the exception that an ethylene/propylene type copolymer ("JSR 57P" produced by Nippon Gosei Gomu K.K.) was used as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 17 and FIG. 22.
TABLE 17__________________________________________________________________________ Ex. 93 Ex. 94 Ex. 95 Ex. 96 Ex. 97 CE 39 CE 40__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50ethylene/propylene 5 20 40 60 80 2 90type copolymerGlass transition temperature (.degree.C.) 195 190 188 178 178 195 140Flexural strength (kg/mm.sup.2)25.degree. C. 8 8 7 6 5 8 5250.degree. C. 6 6 5 5 4 7 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.6 0.6 0.6 0.7 0.7 0.5 0.8Flexural modulus (kg/mm.sup.2) 610 590 570 520 460 620 330Gel time (s) 395 398 405 410 415 380 460Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 17 that by the addition of an ethylene/propylene type copolymer as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 22 that in these examples, there were obtained cured resin products with better moisture resistance than the cured products obtained from the-composition in Examples 79 to 87.
Examples 98 to 102 and Comparative Examples 41 and 42
Compounds having the compounding ratios set forth in Table 18 were prepared in the same manner as in Examples 88 to 92, with the exception that an ethylene/.alpha.-olefin copolymer ("Tafmer PP-0280" produced by Mitsui Sekiyu Kagaku K.K.) was used as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 18 and FIG. 23.
TABLE 18__________________________________________________________________________ Ex. 98 Ex. 99 Ex. 100 Ex. 101 Ex. 102 CE 41 CE 42__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50ethylene/.alpha.-olefin 5 20 40 60 80 2 90copolymerGlass transition temperature (.degree.C.) 192 189 188 185 179 206 135Flexural strength (kg/mm.sup.2)25.degree. C. 8 8 7 7 7 7 6250.degree. C. 6 5 5 5 4 4 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.7 0.8 0.4 0.7 0.7 0.5 0.9Flexural modulus (kg/mm.sup.2) 600 580 570 530 470 620 320Gel time (s) 390 400 415 420 430 380 480Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 18 that by the addition of an ethylene/.alpha.-olefin copolymer as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 23 that in these examples, there were obtained cured resin products with better moisture resistance than the cured products obtained from the compositions in Examples 79 to 87.
Examples 103 to 107 and Comparative Examples 43 and 44
Compounds having the compounding ratios set forth in Table 19 were prepared in the same manner as in Examples 88 to 92, with the exception that epoxy functional group-containing silicone rubber powder ("Torayfil E-601" produced by Toray-Dow Corning K.K.) was used as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 19 and FIG. 24.
TABLE 19__________________________________________________________________________ Ex. 103 Ex. 104 Ex. 105 Ex. 106 Ex. 107 CE 43 CE 44__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50epoxy functional group- 5 20 40 60 80 2 90containing siliconepowderGlass transition temperature (.degree.C.) 195 190 187 180 175 195 160Flexural strength (kg/mm.sup.2)25.degree. C. 8 9 9 8 8 7 6250.degree. C. 7 7 6 6 5 5 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.5 0.5 0.4 0.4 0.5 0.5 0.6Flexural modulus (kg/mm.sup.2) 610 580 550 490 470 620 320Gel time (s) 390 405 410 420 425 385 440Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 19 that by the addition of epoxy functional group-containing silicone rubber powder as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 24 that in these examples, there were obtained cured resin products with better moisture resistance than the cured resin products obtained from the compositions in Examples 79 to 87.
Examples 108 to 112 and Comparative Examples 45 and 46
Compounds having the compounding ratios set forth in Table 20 were prepared in the same manner as in Examples 88 to 92, with the exception that a silicon-modified epoxy resin ("SIN-620" produced by Dai-Nippon Ink Kagaku K.K.) was used as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 20 and FIG. 25.
TABLE 20__________________________________________________________________________ Ex. 108 Ex. 109 Ex. 110 Ex. 111 Ex. 112 CE 45 CE 46__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50silicone-modified epoxy resin 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 195 190 187 180 175 195 160Flexural strength (kg/mm.sup.2)25.degree. C. 7 8 8 7 6 6 4250.degree. C. 6 6 6 5 4 4 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.5 0.5 0.4 0.4 0.5 0.5 0.6Flexural modulus (kg/mm.sup.2) 620 600 580 550 500 630 430Gel time (s) 400 400 410 415 420 390 495Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 20 that by the addition of a silicon-modified epoxy resin as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 25 that in these examples, there were obtained cured resin products with better moisture resistance than the cured resin products obtained from the compositions in Examples 79 to 87.
Examples 113 to 117 and Comparative Examples 47 and 48
In these examples, to a mixture of a cresol novolak type epoxy resin, a polyallyl phenol and a polyphenol, there was further added powdery silica ("RD-8" produced by Tatsumori K.K.) as an inorganic filler, and these substances were together kneaded in a pressure kneader, so that compositions having the compounding ratios set forth in Table 21 were prepared.
Test pieces were prepared from the obtained compositions, respectively, in accordance with the procedures explained in Examples 79 to 87, and the properties of the cured resin products obtained from these compounds were evaluated in the same manner as in Examples 79 to 87. The results are set forth in Table 21 and FIG. 26. In Table 21, the viscosities of the prepared compositions are also set forth.
TABLE 21__________________________________________________________________________ Ex. 113 Ex. 114 Ex. 115 Ex. 116 Ex. 117 CE 47 CE 48__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50silica (%) 30 40 60 70 85 10 90Glass transition temperature (.degree.C.) 185 186 185 185 185 184 186Flexural strength (kg/mm.sup.2)25.degree. C. 13 14 16 17 17 9 13250.degree. C. 9 9 10 10 11 3 9Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xWater absorption ratio (%) 0.3 0.2 0.2 0.1 0.1 0.5 0.1Flexural modulus (kg/mm.sup.2) 800 1000 1200 1400 1800 700 1900Gel time (s) 370 365 360 350 340 380 320Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x xViscosity (P) 150 320 360 430 510 120 1300__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 21 that when an inorganic filler is added to the composition in an amount ranging from 20 to 85% by weight based on the total weight of the composition, the mechanical strength of the cured product obtained from the composition can be advantageously improved without greatly lowering the flowability of the composition. In addition, it is noted from FIG. 26 that the moisture resistance of the cured products is also good.
Examples 118 to 126 and Comparative Examples 49 and 52
Compositions were prepared in the same manner as in Examples 79 to 87 with the exception that a biphenyl type epoxy resin was used instead of cresol novolak type epoxy resin, and the various properties of the cured test pieces obtained from the compositions were evaluated. The prepared compositions were as set forth in Table 22. The obtained results are set forth in Table 22 and FIG. 27.
TABLE 22__________________________________________________________________________ Ex. 118 Ex. 119 Ex. 120 Ex. 121 Ex. 122 Ex. 123 Ex. 124 Ex. 125 Ex. 126 CE 49 CE 50 CE CE__________________________________________________________________________ 52Composition (parts)epoxy resin 100 100 100 100 100 100 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 5 50 100 200 70 70 2 210polyphenol 5 50 100 150 200 50 50 50 50 2 210 50 50Glass transition 190 217 220 225 240 223 220 200 183 180 135 223 135temperature (.degree.C.)Flexural strength(kg/mm.sup.2)25.degree. C. 9 10 11 14 13 10 10 10 9 7 6 5 4250.degree. C. 6 7 8 11 10 8 8 8 7 4 3 2 1Flexural modulus 590 630 670 710 770 720 663 610 560 570 810 790 410(kg/mm.sup.2)Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x xWater absorption ratio 0.4 0.4 0.5 0.5 0.6 0.4 0.3 0.3 0.3 0.4 0.8 1.0 0.9(%)Gel time (s) 420 400 390 360 310 370 380 390 410 570 240 380 400Package crack x x x x x x x x x x x x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It can be seen from Table 22 that by the change of the substratal resin into a biphenyl type epoxy resin, the heat resistance of the cured products was furthermore improved. In addition, from FIG. 27, a significant improvement is recognized also in moisture resistance. However, in the compositions of Examples 118 to 126, some package cracks were caused under solder bath immersion conditions after particularly severe PCT treatment, like in the compositions of Examples 79 to 87.
Examples 127 to 131 and Comparative Examples 53 and 54
The procedures in Examples 118 to 126 were repeated with the exception that to a mixture of a polyallyl phenol and polyphenol, there was further added a polystyrene/polybutadiene/polystyrene terminal block copolymer ("Kraton G-1652" produced by Shell Kagaku K.K.) as a flexibilizer, so as to prepare compositions. The prepared compositions are as set forth in Table 23, and the obtained results are set forth in Table 23 and FIG. 28.
TABLE 23__________________________________________________________________________ Ex. 127 Ex. 128 Ex. 129 Ex. 130 Ex. 131 CE 53 CE 54__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50polystyrene/polybutadiene/ 5 20 40 60 80 2 90polystyrene terminalblock copolymerGlass transition temperature (.degree.C.) 185 182 180 178 175 190 142Flexural strength (kg/mm.sup.2)25.degree. C. 10 10 9 9 8 9 4250.degree. C. 8 9 7 6 5 8 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.5 0.5 0.5 0.6 0.6 0.4 0.8Flexural modulus (kg/mm.sup.2) 595 570 550 490 450 620 300Gel time (s) 400 410 420 420 425 395 455Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 23 that by the addition of a polystyrene/polybutadiene/polystyrene terminal block copolymer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured product obtained from the epoxy resin was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 28 that in these examples, there were obtained cured resin products with better moisture resistance than the cured products obtained from the compositions in Examples 118 to 126.
Examples 132 to 136 and Comparative Examples 55 and 56
Compounds having the compounding ratios set forth in Table 24 were prepared in the same manner as in Examples 127 and 131, with the exception that an ethylene/propylene type copolymer ("JSR 57P" produced by Nippon Gosei Gomu K.K.) was used as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 24 and FIG. 29.
TABLE 24__________________________________________________________________________ Ex. 132 Ex. 133 Ex. 134 Ex. 135 Ex. 136 CE 55 CE 56__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50ethylene/propylene type 5 20 40 60 80 2 90copolymerGlass transition temperature (.degree.C.) 185 182 178 175 170 185 130Flexural strength (kg/mm.sup.2)25.degree. C. 9 9 8 7 6 8 5250.degree. C. 7 7 6 5 4 6 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.5 0.5 0.5 0.6 0.6 0.4 0.7Flexural modulus (kg/mm.sup.2) 600 585 560 510 455 610 320Gel time (s) 400 410 415 420 420 390 345Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 24 that by the addition of an ethylene/propylene type copolymer as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 29 that in these examples, there were obtained cured resin products with better moisture resistance than the cured products obtained from the compositions in Examples 118 to 126.
Examples 137 to 141 and Comparative Examples 57 and 58
Compounds having the compounding ratios set forth in Table 25 were prepared in the same manner as in Examples 127 to 131, with the exception that an ethylene/.alpha.-olefin copolymer ("Tafmer PP-0280" produced by Mitsubishi Sekiyu Kagaku K.K.) as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 25 and FIG. 30.
TABLE 25__________________________________________________________________________ Ex. 137 Ex. 138 Ex. 139 Ex. 140 Ex. 141 CE 57 CE 58__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50.alpha.-olefin copolymer 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 185 180 178 175 170 185 125Flexural strength (kg/mm.sup.2)25.degree. C. 9 9 8 7 7 8 5250.degree. C. 7 6 5 5 4 4 2Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.5 0.5 0.5 0.6 0.6 0.4 0.8Flexural modulus (kg/mm.sup.2) 595 575 565 520 465 610 310Gel time (s) 400 410 420 425 440 390 490Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 25 that by the addition of an ethylene/.alpha.-olefin copolymer as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, flexibility of the cured resin product obtained from the composition was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 30 that in these examples, there were obtained cured resin products with outstandingly good moisture resistance as compared with the cured products obtained from the compositions in Examples 118 to 126.
Examples 142 to 146 and Comparative Examples 59 and 60
Compounds having the compounding ratios set forth in Table 26 were prepared in the same manner as in Examples 127 to 131, with the exception that epoxy functional group-containing silicone rubber powder ("Torayfil E-601" produced by Toray-Dow Corning K.K.) was used as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 26 and FIG. 31.
TABLE 26__________________________________________________________________________ Ex. 142 Ex. 143 Ex. 144 Ex. 145 Ex. 146 CE 59 CE 60__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50epoxy functional group- 5 20 40 60 80 2 90containing silicone powderGlass transition temperature (.degree.C.) 190 185 180 175 173 190 155Flexural strength (kg/mm.sup.2)25.degree. C. 9 10 10 9 8 8 6250.degree. C. 7 8 8 7 6 5 3Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.4 0.3 0.3 0.3 0.3 0.4 0.5Flexural modulus (kg/mm.sup.2) 600 575 545 480 465 610 310Gel time (s) 400 410 420 430 435 390 450Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 26 that by the addition of epoxy functional group-containing silicone rubber powder as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin composition was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 31 that in these examples, there were obtained cured resin products with outstandingly good moisture resistance as compared with the cured products obtained from the compositions in Examples 118 to 126.
Examples 147 to 151 and Comparative Examples 61 and 62
Compounds having the compounding ratios set forth in Table 27 were prepared in the same manner as in Examples 127 to 131, with the exception that a silicon-modified epoxy resin ("SIN-620" produced by Dai-Nippon Ink Kagaku K.K.) was used as a flexibilizer, and the properties of the cured test pieces obtained from these compositions were evaluated. The results are set forth in Table 27 and FIG. 32.
TABLE 27__________________________________________________________________________ Ex. 147 Ex. 148 Ex. 149 Ex. 150 Ex. 151 CE 61 CE 62__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 70polyphenol 50 50 50 50 50 50 50silicon-modified epoxy 5 20 40 60 80 2 90resinGlass transition temperature (.degree.C.) 190 185 184 177 175 190 160Flexural strength (kg/mm.sup.2)25.degree. C. 8 9 9 10 7 6 4250.degree. C. 7 8 8 9 5 5 1Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle.Water absorption ratio (%) 0.4 0.4 0.3 0.3 0.4 0.4 0.5Flexural modulus (kg/mm.sup.2) 610 600 575 545 490 620 420Gel time (s) 410 410 415 420 427 395 500Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 27 that by the addition of a silicon-modified epoxy resin as a flexibilizer to the epoxy resin in an amount ranging from 5 to 80 parts based on 100 parts of the epoxy resin, the flexibility of the cured resin product obtained from the epoxy resin composition, the flexibility of the cured product obtained from the composition was improved and the occurrence of package crack was controlled. In addition, it can be noted from FIG. 32 that in these examples, there were obtained cured resin products with outstandingly good moisture resistance as compared with the cured resin products obtained from the compositions in Examples 118 to 126.
Examples 152 to 156 and Comparative Examples 63 and 64
In these examples, to a mixture of a biphenyl type epoxy resin, a polyallyl phenol and a polyphenol, there was further added powdery silica ("RD-8" produced by Tatsumori K.K.) as an inorganic filler, and these substances were together kneaded in a pressure kneader, so that compositions having the compounding ratios set forth in Table 28 were prepared.
Test pieces were prepared from the obtained compositions, respectively, in accordance with the procedures explained in Examples 118 to 126, and the properties of the cured resin products obtained from these compositions were evaluated in the same manner as in Examples 79 to 87. The results are set forth in Table 28 and FIG. 33. In Table 28, viscosities of the prepared compositions are also set forth.
TABLE 28__________________________________________________________________________ Ex. 152 Ex. 153 Ex. 154 Ex. 155 Ex. 156 CE 63 CE 64__________________________________________________________________________Composition (parts)epoxy resin 100 100 100 100 100 100 100polyallyl phenol 70 70 70 70 70 70 30polyphenol 50 50 50 50 50 50 50silica (%) 30 40 60 70 85 10 90Glass transition temperature (.degree.C.) 180 180 180 180 183 185 185Flexural strength (kg/mm.sup.2)25.degree. C. 14 15 17 18 19 9 14250.degree. C. 12 13 15 16 15 6 10Crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. xWater absorption ratio (%) 0.2 0.2 0.1 0.1 0.1 0.4 0.1Flexural modulus (kg/mm.sup.2) 800 980 1100 1400 1700 670 1800Package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x xViscosity (P) 110 120 200 240 300 80 1000__________________________________________________________________________ Ex. = Example CE = Comparative Example .smallcircle. . . . Crack or package crack did not occur. x . . . Crack or package crack occurred.
It is clearly seen from Table 28 that when an inorganic filler is added to the composition in an amount ranging from 20 to 85% by weight based on the total weight of the composition, the mechanical strength of the cured resin product obtained from the composition can be advantageously improved without greatly lowering the flowability of the composition. In addition, it is noted from FIG. 33 that the moisture resistance of the cured resin product is remarkably good.
As explained in detail in the foregoing, the epoxy resin composition of the present invention, comprising an epoxy resin as a substratal resin, a polyallyl phenol curing agent and a polyphenol curing auxiliary agent, is excellent in curability, and can produce therefrom cured resin products excellent in heat resistance. Accordingly, the present epoxy resin composition is very useful as multilayer laminate resins, electroconductive pastes, protective films for electronic devices, sealing materials, adhesives, coatings and molding materials, which are used in electronic.cndot.electric equipments, transportation equipments or the like.
In addition, the epoxy resin composition of the present invention, comprising further added a polyallyl phenol curing agent and a polyphenol curing auxiliary agent can produce therefrom a cured resin product with sufficient flexibility for displaying or exhibiting excellent crack resistance. In addition, the present epoxy resin composition with an added inorganic filler can produce therefrom a cured product with excellent mechanical strength.
In the composition of the present invention, examples of the epoxy resin having a naphthalene skeleton used as a substratal resin include epoxy resins represented by the following formula XII: ##STR14## wherein R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5 and R.sub.6 which may be the same or different each represents a hydrogen atom, a halogen atom or an alkyl group having 1 to 4 carbon atoms and n is 0 to 10, provided that at least one of R.sub.1 to R.sub.6 represents a halogen atom or an alkyl group having 1 to 4 carbon atoms, and epoxy resins represented by the following formula XIII: ##STR15## wherein n is 2 or 3.
As described in Japanese Patent Unexamined Patent Publication (Kokai) Nos. 61-73719, 1-268712 and 1-268715, these epoxy resins are produced by reacting dihydroxynaphthalane or trihydroxynaphthalene with epichlorohydrin. Examples of the dihydroxynaphthalene include compounds represented by the following formula XIV: ##STR16## or compounds represented by the following formula XV: ##STR17## wherein R.sub.1, R.sub.2, R.sub.3, R.sub.4, R.sub.5 and R.sub.6 which may be the same or different each represents a hydrogen atom, a halogen atom or an alkyl group having 1 to 4 carbon atoms, provided that at least one of R.sub.1 to R.sub.6 represents a halogen atom or an alkyl group having 1 to 4 carbon atoms. The trihydroxy naphthalene includes compounds represented by the following formula XVI: ##STR18## or compounds represented by the following formula (XVII): ##STR19## wherein R.sub.1, R.sub.2, R.sub.3, R.sub.4 and R.sub.5 which may be the same or different each represents a hydrogen atom, a halogen atom or an alkyl group having 1 to 4 carbon atoms, provided that at least one of R.sub.1 to R.sub.5 represents a halogen atom or an alkyl group having 1 to 4 carbon atoms.
Since the substratal resin according to the present invention has a naphthalene skeleton, an improvement in the heat resistance and hydrophobicity of the cured product can be attained over cured products of conventional resins widely used in the art, such as bisphenol A epoxy resin, cresol novolak epoxy resin and phenol novolak epoxy resin. With respect to the structure of the substratal resin, any of a bifunctional type and a polyfunctional type including a novolak structure may be applied to the composition of the present invention so far as the resin is an epoxy resin having a naphthalene skeleton.
The use of polyallylphenol as the curing agent can improve the hydrophobicity of the cured product by virtue of the presence of the allyl group and further imparts flexibility of the cured product, which can contribute also to an improvement in the toughness. In general, there is a tendency that the addition of an elastomer for the purpose of imparting the flexibility gives rise to a lowering in the moisture resistance. However, the allyl group in the polyallylphenol can prevent the lowering in the moisture resistance. Such a polyallylphenol is a compound having in its repeating unit a plurality of constitutive units represented by the following formula XVIII: ##STR20##
Examples of the compound of this type include compounds represented by the following formula XIX: ##STR21## wherein n is an integer of 1 to 5, and compounds represented by the following formula XX: ##STR22## wherein n is an integer of 1 to 5.
The above-described polyallyl phenol is incorporated in an amount of 30 to 120 parts based on 100 parts of the epoxy resin in the composition. When the amount of incorporation is less than 30 parts, no effect can be attained by the addition. On the other hand, when the amount of incorporation exceeds 120 parts, unfavorable phenomena, such as phase separation, occur, which gives rise to a deterioration in properties, such as heat resistance and moisture resistance.
As described above, in the present invention, the use of polyallylphenol as the curing agent can impart flexibility to the cured product. When the flexibility is still unsatisfactory, the following flexibilizers may be added according to need. Examples of a flexibilizer or plasticizer include rubbers, such as natural rubber, isoprene rubber, styrene-butadiene rubber, butadiene rubber, butyl rubber, ethylene-propylene rubber, chloroprene rubber, acrylonitrile butadiene rubber, hydrogenated nitrile rubber, silicone rubber, acrylic rubber, epichlorohydrin rubber, fluororubber, chlorosulfonated polyethylene, chlorinated polyethylene and polyetheric special rubber, block polymer type elastomers, such as those having a styrene-butadiene-sytrene structure, urethane thermoplastic elastomers produced by a polyaddition reaction wherein use is made of a short-chain glycol and a diisocyanate as a hard phase and a long-chain polyol as a soft phase and ester thermoplastic elastomers produced by a polycondensation reaction wherein use is made of polybutylene terephthalate as a hard phase and a long-chain polyol or a polyester as a soft phase, olefin thermoelastomers including a blend of polypropylene with ethylene-propylene rubber, 1,2-polybutadiene thermoplastic elastomers and silicone-modified epoxy resins. Particularly preferred examples of the flexibilizer include polystyrene/polybutadiene/polystyrene terminal block copolymer, ethylene/propylene-based terpolymer, ethylene/.alpha.-olefin copolymer, epoxy-containing silicone rubber powder, silicone-modified epoxy resin and butadiene/acrylonitrile copolymer.
Examples of the butadiene/acrylonitrile copolymer include copolymers represented by the following formula: ##STR23## wherein 1.ltoreq.p/q.ltoreq.20 and r is 5 to 20.
The above-described flexibilizers may have various structures. In fact, they are commercially available in various forms. For instance, the polystyrene/polybutadiene/polystyrene terminal block copolymer is commercially available as "Kraton G-1652" (produced by Shell Kagaku K.K.), the ethylene/propylene type rubber as "JSR 57P" (produced by Nippon Gosei Gomu K.K.), the ethylene/.alpha.-olefin copolymer as "Tafmer P P-0280" (produced by Mitsui Sekiyu Kagaku K.K.), the epoxy functional group-containing silicone rubber powder as "Torayfil E 601" (produced by Toray-Dow Corning K.K.), the silicon-modified epoxy resin as "SIN-620" (produced by Dainippon Ink and Chemicals, Inc.), and the butadiene/acrylonitrile copolymer as CTBN1008 (produced by Ube Industries, Ltd.), respectively.
Any of the above-described flexibilizer is desirably added to the epoxy resin as the substratal resin in an amount ranging from 5 to 80 parts by weight based on 100 parts by weight of the epoxy resin. When this amount is less than 5 parts by weight, the effect of the addition is not exhibited, and when it exceeds 80 parts by weight, the heat resistance of the cured resin product is lowered.
The epoxy resin composition of the present invention may contain an inorganic filler for the purpose of improving the mechanical strength of the cured resin product. As the inorganic filler, there may be mentioned, for example, powdery materials, such as fused silica, crystalline silica, alumina, calcium carbonate and the like. These fillers are added to the epoxy resin composition in an amount ranging preferably from 30 to 95 parts based on the total weight of the composition. When this amount is less than 30 parts, the expected effect cannot be achieved, and when it exceeds 95 parts, the flowability of the composition is lowered to result in the lowering of the workability thereof.
In addition, to the composition of the present invention, there may be optionally added the components mentioned hereinbelow, if occasion demands.
(1) A curing accelerator for promoting the curing reaction of the epoxy resin with a curing agent and a curing auxiliary agent. As the curing accelerator, there are used imidazole type curing accelerators, such as 2-methyl imidazole, phosphine type curing accelerators, such as triphenyl phosphine, and DBU (diazabicycloundecene) type curing accelerators, such as a phenol salt of DBU.
(2) A coupling agent for enhancing the compatibility of the inorganic filler with the resin when the inorganic filler is added to the resin. As the coupling agent, there may be mentioned, e. g., silane type coupling agents, such as 3-aminopropyltriethoxysilane, titanium type coupling agents or the like. Although the amount of the coupling agent to be incorporated in the composition of the present invention varies depending on the kind, amount and specific surface area of the inorganic filler to be used, and the minimum covering area of the coupling agent, it is desirably within the range between about 0.1 and 15 parts, in the present invention.
(3) A mold release auxiliary agent, e. g., carnauba wax, stearic acid or a metal salt thereof or montan wax, may be used.
(4) A colorant, a pigment, a flame-retarding agent and a flame-retarding auxiliary agent, for example, titanium dioxide, carbon black, brominated epoxy resin, antimony trioxide, etc.
The epoxy resin composition of the present invention can be prepared by heating the above-described ingredients at a temperature ranging from about 60.degree. to 120.degree. C. by the use of means such as rolls, kneader, extruder or the like. Furthermore, in the composition of the present invention, it is desirable to carry out postcuring treatment after molding in order to complete the curing reaction of the uncured epoxy resin in the cured resin product or the like. This postcuring subsequent to the molding may be carried out by heat-treating the cured resin product for a predetermined time in a constant temperature bath kept at a temperature substantially equal to the temperature used in the molding.
In the epoxy resin composition according to the present invention, the use of an epoxy resin having a naphthalene skeleton as a substratal resin, the addition of polyallylphenol as a curing agent and the addition of a flexibilizer, for example, a polystyrene/polybutadiene/polystyrene terminal block copolymer, an ethylene/propylene type rubber, an ethylene/.alpha.-olefin copolymer, a silicone rubber powder having an epoxy group as a functional group, a particular silicone-modified epoxy resin and a butadiene//acrylonitrile copolymer can effectively serve to improve the heat resistance, moisture resistance, toughness, flexibility, low thermal expansion and crack resistance. Further, the addition of an inorganic filler contributes also to an improvement in the mechanical strength.
The present invention will now be described in more detail with reference to the following Examples and Comparative Examples, though it is not limited to these Examples only.
EXAMPLES
Examples 157 to 161 and Comparative Examples 65 to 67
In the following Examples and Comparative Examples, use was made of the following starting materials.
(1) Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 (an epoxy resin produced by co-condensing cresol with .beta.-naphthol in a ratio of 1:1) produced by Dainippon Ink and Chemicals, Inc.
(2) Polyallylphenol [a polyallylphenol represented by the formula II wherein n is 1 to 4 (in all the following Examples, use was made of this polyallylphenol)].
(3) Epoxy resin:
Cresol novolak epoxy resin (EOCN-1025 produced by Nippon Kayaku Co., Ltd.).
The compositions in the following Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh pass powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hrs.
The compositions thus produced were subjected to evaluation of properties as follows.
Glass transition point: this property was determined with a thermomechanical analyzer (produced by Shinku Riko Inc.)
Flexural strength: This property was determined in accordance with the method specified in Japanese Industrial Standards (JIS) K-6911.
Flexural modulus: This property was determined in accordance with the method specified in Japanese Industrial Standards (JIS) K-6911.
Water absorption ratio: This property was determined in accordance with the method specified in Japanese Industrial Standards (JIS) K-6911.
Coefficient of thermal expansion: A coefficient of thermal expansion, .alpha., was determined at a temperature range of from room temperature to the glass transition temperature in the determination of the glass transition temperature.
The results are provided in Table 29.
TABLE 29__________________________________________________________________________ Comp. Comp. Comp. Ex. 157 Ex. 158 Ex. 159 Ex. 160 Ex. 161 Ex. 65 Ex. 66 Ex. 67__________________________________________________________________________Composition (parts)naphthalene epoxy resin 100 100 100 100 100 100 100 0cresol novolak epoxy 0 0 0 0 0 0 0 100polyallylphenol 30 50 70 90 120 20 130 70Glass transition temperature (.degree.C.) 180 195 200 215 190 170 173 160Flexural strength (kg/mm.sup.2)25.degree. C. 8 9 11 10 8 6 5 7250.degree. C. 5 7 9 8 7 2 2 1Flexural modulus (kg/mm.sup.2) 650 630 630 620 600 720 663 610Water absorption ratio (%) 0.30 0.28 0.25 0.23 0.21 0.40 0.35 0.43Coefficient of thermal expansion (.alpha.) 5.3 5.2 4.9 5.1 5.4 -- -- 6.2__________________________________________________________________________
It can be seen from Table 29 that the use of an epoxy resin having a naphthalene skeleton as a substratal resin and polyallylphenol as a curing agent can provide resin compositions having excellent heat resistance, moisture resistance and toughness. Further, it can also be seen that good results can be obtained when the amount of addition of the polyallyphenol is 30 to 120 parts by weight based on 100 parts by weight of the epoxy resin.
Examples 162 to 166 and Comparative Examples 68 and 69
In these Examples, use was made of the following starting materials.
Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 produced by Dainippon Ink and Chemicals, Inc.
Polyallylphenol: the same as described in Examples 157-161 and Comparative Examples 65-67.
Flexibilizer: Kraton G-1652 (a polystyrene/polybutadiene/polystyrene terminal block copolymer produced by Shell Kagaku K.K.).
The compositions in the following Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh pass powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hrs.
The compositions thus produced were subjected to evaluation of properties as follows.
Glass transition point: This property was determined with a thermomechanical analyzer (produced by Shinku Riko Inc.)
Flexural strength: This property was determined in accordance with the method specified in Japanese Industrial Standards (JIS) K-6911.
Flexural modulus: This property was determined in accordance with the method specified in Japanese Industrial Standards (JIS) K-6911.
Water absorption ratio: This property was determined in accordance with the method specified in Japanese Industrial Standards (JIS) K-6911.
Moisture resistance: This property was determined by evaluating the extent of the failure of a given sample, which had preliminarily been subjected to a PTC (pressure cooker test) treatment (125.degree. C./2.3 atm), by the use of an aluminum-wired model device (see FIG. 9). In this test, the resistance across aluminum electrodes in the device was measured.
Package crack: This property was determined such that an 84-pin QFP (quad flat package) was molded and the thus obtained QFP was subjected to a moisture absorption treatment for 24 hr at a temperature of 121.degree. C. and a relative humidity of 100%, whereafter the thus treated QFP was immersed into a solder bath of 260.degree. C., and the occurrence of cracks was visually observed.
The results are given in Table 30 and FIG. 34.
TABLE 30__________________________________________________________________________ Comp. Comp. Ex. 162 Ex. 163 Ex. 164 Ex. 165 Ex. 166 Ex. 68 Ex. 69__________________________________________________________________________Compo- naphthalene epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 70 70 70 70 70 70 70(parts) terminal block copolymer 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 198 195 190 185 178 190 142Flexural strength 25.degree. C. 11 10 9 9 8 9 4(kg/mm.sup.2) 250.degree. C. 8 9 7 6 5 8 1Flexural modulus (kg/mm.sup.2) 620 600 580 520 490 630 400Water absorption ratio (%) 0.25 0.28 0.30 0.33 0.40 0.25 0.6Package crack .largecircle. .largecircle. .largecircle. .largecircle. .largecircle. X X__________________________________________________________________________
It can be seen from Table 30 that the addition of a polystyrene/butadiene/polystyrene terminal block copolymer contributes to an improvement in the flexibility of the cured product and that good results can be obtained when the amount of addition of the copolymer is 5 to 80 parts. It can also be seen that the use of a polyallylphenol as the curing agent can provide a resin composition having an excellent hydrophobicity.
In FIG. 34, the device was evaluated as defective when even one defective circuit was found in 100 circuits as a population parameter, and the percentage occurrence of defective device was determined and expressed as the fraction defective (%) (the same shall apply hereinafter).
Examples 167 to 171 and Comparative Examples 70 and 71
In the Examples and Comparative Examples, use was made of the following starting materials.
Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 produced by Dainippon Ink and Chemicals, Inc.
Polyallylphenol: the same as described in Examples 157-161 and Comparative Examples 65-67.
Flexibilizer: JSR 57P (an ethylene/propylene-based terpolymer produced by Nippon Gosei Gomu K.K.).
The compositions in the Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh pass powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hr.
The compositions thus produced were subjected to evaluation of properties; glass transition point, flexural strength, flexural modulus, water absorption ratio, moisture resistance, and package crack, as in Examples 162-166 and Comparative Examples 68 and 69.
The results are given in Table 31 and FIG. 35.
TABLE 31__________________________________________________________________________ Comp. Comp. Ex. 167 Ex. 168 Ex. 169 Ex. 170 Ex. 171 Ex. 70 Ex. 71__________________________________________________________________________Compo- naphthalene epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 70 70 70 70 70 70 70(parts) terpolymer 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 195 190 186 178 175 195 140Flexural strength 25.degree. C. 10 9 8 7 6 10 5(kg/mm.sup.2) 250.degree. C. 8 7 5 5 4 8 1Flexural modulus (kg/mm.sup.2) 620 600 580 540 495 630 420Water absorption ratio (%) 0.25 0.27 0.30 0.34 0.38 0.25 0.60Package crack .largecircle. .largecircle. .largecircle. .largecircle. .largecircle. X X__________________________________________________________________________
It can be seen from Table 31 that the addition of an ethylene/propylene-based terpolymer contributes to an improvement in the flexibility of the cured product and that good results can be obtained when the amount of addition of the terpolymer is 5 to 80 parts. It can be seen from FIG. 35 that the use of a polyallylphenol as the curing agent can provide a resin composition having an excellent hydrophobicity. Further, the addition of a polyphenol can provide an epoxy resin composition having a good curability.
Examples 172 to 176 and Comparative Examples 72 and 73
In the Examples and Comparative Examples, use was made of the following starting materials.
Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 produced by Dainippon Ink and Chemicals, Inc.
Polyallylphenol: the same as in Examples 157-161 and Comparative Examples 65-67.
Flexibilizer: "Tafmer P P-0280" (an ethylene/.alpha.-olefin copolymer produced by Mitsui Sekiyu Kagaku K.K.).
The compositions in the Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hr.
The compositions thus produced were subjected to evaluation of properties as described in Examples 162-166 and Comparative Examples 68 and 69.
The results are given in Table 32 and FIG. 36.
TABLE 32__________________________________________________________________________ Comp. Comp. Ex. 172 Ex. 173 Ex. 174 Ex. 175 Ex. 176 Ex. 72 Ex. 73__________________________________________________________________________Compo- naphthalene epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 70 70 70 70 70 70 70(parts) .alpha.-olefin copolymer 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 195 190 185 178 175 185 125Flexural strength 25.degree. C. 10 10 8 7 7 10 5(kg/mm.sup.2) 250.degree. C. 8 7 6 5 4 8 1Flexural modulus (kg/mm.sup.2) 617 600 580 565 500 620 450Water absorption ratio (%) 0.30 0.33 0.37 0.42 0.45 0.30 0.70Package crack .largecircle. .largecircle. .largecircle. .largecircle. .largecircle. X X__________________________________________________________________________
It can be seen from Table 32 that the addition of an ethylene/.alpha.-olefin copolymer contributes to an improvement in the flexibility of the cured product and that good results can be obtained when the amount of addition of the copolymer is 5 to 80 parts. It can be seen from FIG. 36 that the use of a polyallylphenol as the curing agent can provide a resin composition having an excellent hydrophobicity.
Examples 177 to 181 and Comparative Examples 74 and 75
In the Examples and Comparative Examples, use was made of the following starting materials.
Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 produced by Dainippon Ink and Chemicals, Inc.
Polyallylphenol: the same as in Examples 157-161 and Comparative Examples 65-67.
Flexibilizer: Torayfil E 601 (an epoxy-group-containing silicone rubber powder produced by Toray-Dow Corning K.K.).
The compositions in the Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh pass powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hr.
The compositions thus produced were subjected to evaluation of properties as described in Examples 162-166 and Comparative Examples 68 and 69.
The results are given in Table 33 and FIG. 37.
TABLE 33__________________________________________________________________________ Comp. Comp. Ex. 177 Ex. 178 Ex. 179 Ex. 180 Ex. 181 Ex. 74 Ex. 75__________________________________________________________________________Compo- naphthalene epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 70 70 70 70 70 70 70(parts) silicone powder 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 195 190 184 180 175 195 165Flexural strength 25.degree. C. 11 10 10 9 8 11 5(kg/mm.sup.2) 250.degree. C. 8 8 7 7 6 8 2Flexural modulus (kg/mm.sup.2) 610 585 555 520 440 615 410Water absorption ratio (%) 0.24 0.25 0.29 0.32 0.38 0.25 0.45Package crack .largecircle. .largecircle. .largecircle. .largecircle. .largecircle. X X__________________________________________________________________________
It can be seen from Table 33 that the addition of an epoxy-group-containing silicone powder contributes to an improvement in the flexibility of the cured product and that good results can be obtained when the amount of addition of the silicone powder is 5 to 80 parts. It can be seen from FIG. 37 that the use of polyallylphenol as the curing agent can provide a resin composition having an excellent hydrophobicity. Further, the addition of a polyphenol can provide an epoxy resin composition having a good curability.
Examples 182 to 186 and Comparative Examples 76 and 77
In the Examples and Comparative Examples, use was made of the following starting materials.
Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 produced by Dainippon Ink and Chemicals, Inc.
Polyallylphenol: the same as in Examples 157-161 and Comparative Examples 65-67.
Flexibilizer: SIN-260 (silicone-modified epoxy resin produced by Dainippon Ink and Chemicals, Inc.)
The compositions in the Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh pass powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hr.
The compositions thus produced were subjected to evaluation of properties as described in Examples 162-166 and Comparative
Examples 68 and 69.
The results are given in Table 34 and FIG. 38.
TABLE 34__________________________________________________________________________ Comp. Comp. Ex. 182 Ex. 183 Ex. 184 Ex. 185 Ex. 186 Ex. 76 Ex. 77__________________________________________________________________________Compo- naphthalene epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 70 70 70 70 70 70 70(parts) silicone-modified epoxy resin 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 193 187 183 178 175 190 160Flexural strength 25.degree. C. 10 10 9 8 7 10 5(kg/mm.sup.2) 250.degree. C. 8 8 7 7 5 8 1Flexural modulus (kg/mm.sup.2) 615 600 585 535 495 620 430Water absorption ratio (%) 0.25 0.28 0.30 0.30 0.35 0.25 0.45Package crack .largecircle. .largecircle. .largecircle. .largecircle. .largecircle. X X__________________________________________________________________________
It can be seen from Table 34 that the addition of a silicone-modified epoxy resin contributes to an improvement in the flexibility of the cured produce and that good results can be obtained when the amount of addition of the resin is 5 to 80 parts. It can be seen from FIG. 38 that the use of a polyallylphenol as the curing agent can provide a resin composition having an excellent hydrophobicity.
Examples 187 to 191 and Comparative Examples 78 and 79
In the Examples and Comparative Examples, use was made of the following starting materials.
Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 produced by Dainippon Ink and Chemicals, Inc.
Polyallylphenol: the same as in Examples 157-161 and Comparative Examples 65-67.
Flexibilizer: CTBN 1008 (a butadiene/acrylonitrile copolymer produced by Ube Industries, Ltd.)
The compositions in the Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh pass powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hr.
The compositions thus produced were subjected to evaluation of properties as described in Examples 162-166 and Comparative Examples 68 and 69.
The results are given in Table 35 and FIG. 39.
TABLE 35__________________________________________________________________________ Comp. Comp. Ex. 187 Ex. 188 Ex. 189 Ex. 190 Ex. 191 Ex. 78 Ex. 79__________________________________________________________________________Compo- naphthalene epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 70 70 70 70 70 70 30(parts) CTBN 5 20 40 60 80 2 90Glass transition temperature (.degree.C.) 192 185 180 178 173 195 155Flexural strength 25.degree. C. 10 10 9 8 8 10 4(kg/mm.sup.2) 250.degree. C. 8 8 7 7 4 8 1Flexural modulus (kg/mm.sup.2) 625 600 580 540 480 625 400Water absorption ratio (%) 0.27 0.30 0.32 0.35 0.40 0.25 0.60Package crack .largecircle. .largecircle. .largecircle. .largecircle. .largecircle. X X__________________________________________________________________________
It can be seen from Table 35 that the addition of a butadiene/acrylonitrile copolymer contributes to an improvement in the flexibility of the cured product and that good results can be obtained when the amount of addition of the copolymer is 5 to 80 parts. It can be seen from FIG. 39 that the use of a polyallylphenol as the curing agent can provide a resin composition having an excellent hydrophobicity.
Examples 192 to 196 and Comparative Examples 80 and 81
In the Examples and Comparative Examples, use was made of the following starting materials.
Epoxy resin having a naphthalene skeleton:
EPICLON EXA-4300 produced by Dainippon Ink and Chemicals, Inc.
Polyallylphenol: the same as in Examples 1-5 and Comparative Examples 65-67.
Flexibilizer: RD-8 (an inorganic silica (silica) manufactured by Tatsumori Ltd.)
The compositions in the Examples and Comparative Examples were prepared by kneading starting compounds with each other in a pressure kneader. Specimens were prepared as follows.
At the outset, an 8-mesh pass powder was provided from the composition prepared by kneading, transferred to a press mold, subjected to compression molding at 200.degree. C. under a pressure of 80 kg/cm.sup.2 for 20 min. and further subjected to aftercuring at 200.degree. C. for 8 hr.
The compositions thus produced were subjected to evaluation of properties as described in Examples 162-166 and Comparative Examples 68 and 69.
Further, viscosity was determined by a method using a flow tester.
The results are given in Table 36 and FIG. 40.
TABLE 36__________________________________________________________________________ Comp. Comp. Ex. 192 Ex. 193 Ex. 194 Ex. 195 Ex. 196 Ex. 80 Ex. 81__________________________________________________________________________Compo- naphthalene epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 70 70 70 70 70 70 70(parts) silica (%) 30 40 60 70 95 10 98Glass transition temperature (.degree.C.) 200 200 200 200 200 200 200Flexural strength 25.degree. C. 13 14 15 17 18 10 15(kg/mm.sup.2) 250.degree. C. 11 12 14 15 15 8 10Flexural modulus (kg/mm.sup.2) 820 980 1200 1450 1700 670 2000Water absorption ratio (%) 0.23 0.20 0.18 0.14 0.13 0.25 0.10Package crack .largecircle. .largecircle. .largecircle. .largecircle. .largecircle. X XViscosity (P) 80 100 150 200 350 80 2000__________________________________________________________________________
It can be seen from Table 36 that the addition of an inorganic filler contributes to an improvement in the mechanical strength of the cured product and that good results can be obtained when the amount of addition of the inorganic filler is 30 to 95%. It can be seen from FIG. 40 that the use of a polyallylphenol as the curing agent can provide a resin composition having an excellent hydrophobicity.
As described above, in the present invention, a resin composition having excellent heat resistance, moisture resistance, toughness, flexibility and crack resistance can be provided by using an epoxy resin having a naphthalene skeleton as a substratal resin, a particular polyallyphenol as a curing agent, and further adding a particular flexibilizer. Further, the addition of an inorganic filler can provide a resin composition having an excellent mechanical strength.
Examples of the epoxy resins having a biphenyl skeletal structure in the present invention include polymers of 4,4'-bis(2,3-epoxypropoxy)biphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethylbiphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethyl-2-cholorbiphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetramethyl-2-bromobiphenyl; 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetraethylbiphenyl and 4,4'-bis(2,3-epoxypropoxy)-3,3',5,5'-tetrabutylbiphenyl. The biphenyl skeletal structure of such resins can be represented by the following general formula (XXI) (refer Japanese Unexamined Patent Publication (Koaki) No. 63-251419) ##STR24## wherein each of R.sup.1 to R.sup.8 represents hydrogen or a C.sub.1 to C.sub.4 lower alkyl group or a halogen atom.
Preferred examples of R.sup.1 to R.sup.8 include a hydrogen atom, a methyl group, an ethyl group, a propyl group, a butyl group, a chlorine atom and a bromine atom.
The hydrophobic property, heat resistance and toughness can be improved by the use of the epoxy resin having a biphenyl skeletal structure as the base resin. Since such resins are crystalline and have a low viscosity at the time of melting, the flow property can be improved during transfer molding.
Polyallylphenol that is used as the curing agent in the epoxy resin composition according to the present invention is represented by the formula XXII and preferably, by the formula XXIII or XXIV ##STR25## wherein a is an integer of 1 to 4; ##STR26## where m is an integer of 1 to 4; ##STR27## wherein n is an integer of 1 to 4.
The greater the values m and n in the formulas given above, the greater becomes the viscosity, so that the resin can be solidified and a working factor during dry blend becomes high. At the same time, the heat resistance can be improved, too. Such a polyallylphenol can be easily synthesized with a known method. Generally, m and n are 1 to 4 and preferably, within the range of 1 to 3.
When polyallylphenol is used as the curing agent, the glass transition temperature of the cured product can be improved to 180.degree. C. to 220.degree. C., and the hydrophobic property can be improved, too. These effects are brought forth by the allyl group contained in polyallylphenol. Generally, this polyallyphenol is blended in such an amount that the hydroxyl group of polyallyphenol is equivalent to the epoxy group of the epoxy resin in the resin composition, but depending on the case, this amount may be greater or smaller by 5 to 20 parts by weight than the equivalent as the boundary. When polyallylphenol is blended in excess, the allyl group in the composition increases and for this reason, the hydrophobic property can be improved. When it is blended in a smaller amount, the unreacted epoxy resin improved adhesion (for example, adhesion between a Si chip and a molding resin in semiconductor molding) and improves reliability of the device.
It has been found out that the epoxy resin of the formula (1) that is added in the present invention is effective for simultaneously improving curability, mold releasability, mechanical strength and heat resistance, in particular. Mold releasability necessary at the time of molding is affected by the degree of progress of a reaction system, that is, by the hardness. In other words, when the molded article is uncured, its adhesion with the mold is great and the molded article is difficult to release from the mold. Particularly, the reactivity of the tetramethylbiphenyl type epoxy resin is low, and the apparent reaction rate of the system becomes high as a whole due to the addition of the epoxy resin of the formula (1). Accordingly, during transfer molding, the primary curing reaction proceeds between a specific epoxy and polyallylphenol, and a desired hardness can be obtained within a short time. A part of the unreacted biphenyl type epoxy resin is completely cured by post-cure. It has high compatibility with the epoxy resin having the biphenyl skeletal structure and with polyallyphenol, and voids are unlikely to occur in the cured product.
The epoxy resin represented by the formula (1) described above can be used in various blend amounts in the epoxy resin composition in accordance with a desired addition effect. Though this blend amount can generally be changed over a broad range, it is generally preferably from about 10 to about 120 parts by weight on the basis of 100 parts by weight of the base resin. As will be explained in detail in the later-appearing Examples of this invention, a desired effect of the addition cannot be obtained if the blend amount is less than 10 parts by weight, and if the blend amount exceeds 120 parts by weight, toughness of the cured product gets deteriorated due to the brittle property of the cured product and at the same time, hydrophobicity drops. More preferably, the blend amount is within the range of 20 to 80 parts by weight.
To impart flexibility and toughness to the cured product, the following flexibility imparting agents may be added in the present invention, whenever necessary:
1) polystyrene/polybutadiene/polystyrene terminated block copolymers
2) ethylene/propylene type terpolymers
3) ethylene/.alpha.-olefin copolymer
4) silicone rubber characterized by containing an epoxy resin as a functional group
5) silicone modified epoxy resin, and
6) butadiene acrylonitrile.
The flexibility imparting agents described above can assume various structures. As a matter of fact, they are commercially available on the market in various forms. For example, the polystyrene/polybutadiene/polystyrene terminated block copolymer is available as "Crayton G-1652" (a product of Shell Chemical), the ethylene/propylene type rubber is available as "JSR 57P" (a product of Nippon Gosei Bomu K.K.), the ethylene/.alpha.-olefin copolymer is available as "Toughmer P P-0280" (a product of Mitsui Petrochemical Co.), the silicone rubber powder characterized by containing an epoxy resin as a functional group is available as "Torayfil E601" (a product of Toray Dow-Corning), the silicone modified epoxy resin is available as "SIN-620" (a product of Dai-Nippon Ink Kagaku K.K.), and butadiene acrylonitrile is available as "Hycar CTBN 1300" (a product of Ube Kosan K.K.). A product expressed by the following formula is also available as the butadiene/acrylonitrile copolymer. ##STR28##
In the formula given above, each of R.sup.3 and R.sup.10 represents a substituted or unsubstituted hydrocarbon such as an alkyl group or an aryl group, x and y each is a positive integer satisfying the relation 1.ltoreq.x/y.ltoreq.20, and z is an integer of 5 to 20.
Preferably, 5 to 80 parts by weight of each of these compounds is added on the basis of 100 parts by weight of the epoxy resin as the principal component in the epoxy resin composition. If the amount is less than 5 parts, the effect of addition does not appear and if it exceeds 80 parts, layer separation develops and moisture resistance drops. Preferably, the amount of addition of the silicone modified epoxy resin is from 5 to 200 parts by weight, and when it is added, mold releasability from the mold at the time of molding can be improved without substantially lowering hydrophobicity and moisture resistance.
Preferably, the amount of addition of a powdery inorganic filler such as molten silica, crystalline silica, alumina, calcium carbonate, etc., is within the range of 20 to 95 wt %. For, if the amount is smaller than 20 wt %, the effect of addition does not appear and if it is greater than 95 wt %, the working factor might drop due to the drop in flowability. The form of the inorganic filler may be either amorphous or spherical, and their mixture can also be used.
The melt viscosity of the epoxy resin having the biphenyl skeletal structure as the base resin and polyallylphenol, is extremely low, and this makes it possible to charge the filler in a high density. On the other hand, the melt viscosity of the specific epoxy resin represented by the formula (1) is low, too, and the increase of viscosity due to the addition hardly occurs. Accordingly, charging of up to 95 wt %, that has been difficult according to the prior art, has now become possible.
Further, the following components can be added to the composition of the present invention, whenever necessary.
(1) A curing promoter for promoting the curing reaction between the epoxy resin, the curing agent and the curing assistant:
Examples of the curing promoters include an imidazole type curing promoter such as 2-methylimidazole, a phosphine type curing promoter such as triphenylphosphine, a DBU (diazabicycloundecene) type curing promoter such as a phenol salt of DBU, and so forth.
(2) A coupling agent for improving compatibility with the resin when an inorganic filler is added:
Examples include a silane type coupling agent such as 3-aminopropyltriethoxysilane, or a titanium type coupling agent such as tetraoctylbis(phosphite) titanate. Preferably, the amount of addition of the coupling agent is from 0.1 to 15 parts, though this amount varies with the kind, amount and specific surface area of the inorganic filler used and with the minimum covering area of the coupling agent.
(3) It is possible to add carnauba wax, stearic acid and its metallic salt, montan wax, etc., as a mold releasing assistant, a brominated epoxy resin, antimony trioxide, etc., as a flame-retardant, and carbon black as a pigment.
The resin composition according to the present invention can be prepared by heating the components described above at about 60.degree. to about 120.degree. C. by using such means as a roll, a kneader, an extruder, or the like. In the present invention, after-cure is preferably carried out after molding in order to complete the curing reaction of the unreacted epoxy resin, etc., in the cured product. After-cure after molding may be effected by heat-treatment inside a thermostat having substantially the same temperature as the temperature during molding, for a predetermined time.
In the epoxy resin composition according to the present invention, polyallylphenol as the curing agent so functions as to effectively improve the heat resistance and hydrophobicity of the cured product in the epoxy resin used as the base resin, and the addition of the specific epoxy resin of the formula (1) can accomplish the improvement of curability. The polystyrene/polybutadiene/polystyrene terminate block copolymer, the ethylene/propylene type rubber, the ethylene/.alpha.-olefin copolymer, the silicone rubber powder characterized by containing the epoxy group as a functional group, the specific silicone modified epoxy resin or butadiene acrylonitrile as the flexibility imparting agent operates effectively as the crack resistance improving agent and the mold releasability improving agent. As a result, the improvement in flexibility, toughness, mold releasability and crack resistance can simultaneously be accomplished. Furthermore, when the inorganic filler is added, the mechanical strength, too, can be improved.
Next, the present invention will be explained in further detail with reference to the following non-limitative Examples and Comparative Examples.
Examples 197 to 202 and Comparative Examples 82 and 83
These Examples and Comparative Examples used the following starting materials:
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000 having the chemical structure expressed by the following formula; epoxy equivalent=195 ##STR29## polyallylphenol Mitsubishi Yuka Sh-150AR having the chemical structure expressed by the formula (5); hydroxyl equivalent=155
epoxy resin
Yuka-Shell epoxy E1032H60 having the chemical structure expressed by the formula (1); epoxy equivalent=166
curing promoter (triphenylphosphine)
K. I. Kasei PP-360, having the chemical structure expressed by the following formula: ##STR30##
The composition illustrated in Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader. By the way, the amounts of the epoxy and hydroxyl groups associated with the curing reaction were set to be equivalent to each other. Each testpiece was prepared in the following way.
First of all, the composition obtained by kneading was converted to powder of 8-mesh pass, and this powder was tableted. After transfer molding at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes, the resulting molded article was after-cured at 180.degree. C. for 5 hours.
Characteristic of each of the compositions obtained in this way were evaluated in the following way.
glass transition temperature: measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
water absorption ratio: JIS K6911
gel time: Curing time on a hot plate (180.degree. C.) was measured.
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
As can be understood from Examples 197 to 202 and Comparative Examples 82 and 83, the resin compositions having excellent curability could be obtained without lowering heat resistance and hydrophobicity by using polyallylphenol as the curing agent and by adding the specific epoxy resin. It was also found out that the amounts of addition was preferably 10 to 200 parts by weight on the basis of 100 parts of the base resin.
TABLE 37__________________________________________________________________________ Comparative Example Example 197 198 199 200 201 202 82 83__________________________________________________________________________Compo- biphenyl epoxy resin 100 100 100 100 100 100 100 100sition polyallylphenol 89 98 117 154 173 192 84 201(part) specific epoxy resin 10 20 40 80 100 120 5 130 curing promoter 2 2 2 2 2 2 2 2glass transition temp. (.degree.C.) 190 195 205 220 230 235 180 240flexural strength 25.degree. C. 6 7 7 8 9 7 5 6 250.degree. C. 5 6 6 6 7 5 2 3water absorption ratio (%) 0.30 0.30 0.31 0.31 0.33 0.34 0.28 0.38gel time (s) 70 65 60 50 45 35 80 30package crack x x x x x x x x__________________________________________________________________________
Examples 203 to 206 and Comparative Examples 84 and 85
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions illustrated in Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader. Each testpiece was prepared in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way:
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
water absorption ratio: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% FJ/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
It could be understood from Examples 203 to 206 and Comparative Examples 84 and 85 that characteristics were hardly affected even when the blend amount of polyallylphenol was increased and decreased within the range of .+-.20 parts with respect to the value at which the epoxy group and the phenolic hydroxyl group were equivalent, but when the blend amount exceeded 20 parts, layer separation and inferior curing occurred, and the characteristics dropped.
TABLE 38______________________________________ Comparative Example Example 203 204 205 206 84 85______________________________________Compo- biphenyl type epoxy 100 100 100 100 100 100sition resin(part) polyallylphenol 97 107 127 137 87 137 specific epoxy resin 40 40 40 40 40 47 curing promoter 2 2 2 2 2 2glass transition temp. (.degree.C.) 190 198 207 200 180 170flexural strength 25.degree. C. 6 7 7 7 5 4(kg/mm.sup.2) 250.degree. C. 5 5 6 5 3 2water absorption ratio (%) 0.33 0.32 0.30 0.30 0.35 0.34gel time (s) 68 65 55 67 75 70package crack x x x x x x______________________________________
Examples 207 to 211 and Comparative Examples 86 and 87
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
polystyrene/polybutadiene/polystyrene terminate block copolymer
Crenton G-1652 (a product of Shell Chemical)
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions illustrated in these Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader, respectively. Each testpiece was prepared in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way.
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
water absorption ratio: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
It could be understood from Examples 207 to 211 and Comparative Examples 86 and 87 that flexibility of the cured product could be improved by adding the polystyrene/polybutadiene/polystyrene terminated block copolymer, the amount of addition was from 5 to 80 parts, the resin compositions having excellent hydrophobicity could be obtained by using polyallylphenol as the curing agent, and the resin composition having excellent curability could be obtained by adding the specific epoxy resin.
TABLE 39__________________________________________________________________________ Comparative Example Example 207 208 209 210 211 86 87__________________________________________________________________________Compo- biphenyl type epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 117 117 117 117 117 117 117(part) specific epoxy resin 40 40 40 40 40 40 40 terminal block copolymer 5 20 40 60 80 2 90 curing promoter 2 2 2 2 2 2 2glass transition temp. (.degree.C.) 205 200 195 190 183 205 160flexural strength 25.degree. C. 7 8 9 8 6 7 4(kg/mm.sup.2) 250.degree. C. 5 6 7 7 5 5 2flexural elastic modulus 700 670 630 580 550 720 500(kg/mm.sup.2)water absorption ratio (%) 0.31 0.32 0.35 0.37 0.38 0.30 0.40gel time (s) 60 60 60 60 60 60 60package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________
Examples 212 to 216 and Comparative Examples 88 and 89
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
ethylene/propylene type terpolymer
JSR 57P (a product of Nippon Gosei Gomu)
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions illustrated in these Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader. Each testpiece was produced in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way.
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
water absorption ratio: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
It could be understood from Examples 212 to 216 and Comparative Examples 88 and 89 that flexibility of the cured product could be improved by adding the ethylene/propylene type terpolymer, the amount of addition was preferably from 5 to 80 parts, the resin compositions having excellent hydrophobicity could be obtained by using polyallylphenol as the curing agent, and the resin composition having excellent curability could be obtained by adding the specific epoxy resin.
TABLE 40______________________________________ Comparative Example Example 212 213 214 215 216 88 89______________________________________Compo- biphenyl 100 100 100 100 100 100 100sition type epoxy(part) resin polyallyl- 117 117 117 117 117 117 117 phenol specific 40 40 40 40 40 40 40 epoxy resin terpolymer 5 20 40 60 80 2 90 curing 2 2 2 2 2 2 2 promoterglass transition temp. 205 203 198 195 188 205 163(.degree.C.)flexural 25.degree. C. 7 9 9 8 6 7 5strength 250.degree. C. 6 6 7 6 4 5 2(kg/mm.sup.2)flexural elastic 705 680 625 570 545 720 510modulus (kg/mm.sup.2)water absorption ratio 0.32 0.35 0.36 0.38 0.38 0.30 0.50(%)gel time (s) 60 60 60 60 60 60 60package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x______________________________________
Examples 217 to 221 and Comparative Examples 90 and 91
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
ethylene/.alpha.-olefin copolymer
Toughmer-P P-0280 (a product of Mitsui Petrochemical)
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions of these Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader. Each testpiece was prepared in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way.
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
water absorption ratio: JIS K6911
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
It could be understood from Examples 217 to 221 and Comparative Examples 90 and 90 that flexibility of the cured product could be improved by adding the ethylene/.alpha.-olefin copolymer, the amount of addition was preferably from 5 to 80 parts, and the resin composition having excellent hydrophobicity could be obtained by adding polyallylphenol as the curing agent. Further, the epoxy resin composition having excellent curability could be obtained by adding the specific epoxy resin.
TABLE 41______________________________________ Comparative Example Example 217 218 219 220 221 90 91______________________________________Compo- biphenyl 100 100 100 100 100 100 100sition type epoxy(part) resin polyallyl- 117 117 117 117 117 117 117 phenol specific 40 40 40 40 40 40 40 epoxy resin .alpha.-olefin 5 20 40 60 80 2 90 copolymer curing 2 2 2 2 2 2 2 promoterglass transition temp. 205 200 198 193 185 205 150(.degree.C.)flexural 25.degree. C. 8 9 8 7 6 7 5strength 250.degree. C. 6 7 6 5 4 4 2(kg/mm.sup.2)flexural elastic 703 692 630 580 560 720 520modulus (kg/mm.sup.2)water absorption ratio 0.32 0.35 0.37 0.38 0.40 0.32 0.51(%)gel time (s) 60 60 60 60 60 60 60package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x______________________________________
Examples 222 to 226 and Comparative Examples 92 and 93
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
epoxy-containing silicone powder
Torayfil E-601 (Toray Dow Corning)
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions of these Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader. Each testpiece was prepared in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way.
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
water absorption ratio: JIS K6911
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
It could be understood from Examples 222 to 226 and Comparative Examples 92 and 93 that flexibility of the cured product could be improved by adding the ethylene/.alpha.-olefin copolymer, the amount of addition was preferably from 5 to 80 parts, and the resin composition having excellent hydrophobicity could be obtained by adding polyallylphenol as the curing agent. Further, the epoxy resin composition having excellent curability could be obtained by adding the specific epoxy resin.
TABLE 42______________________________________ Comparative Example Example 222 223 224 225 226 92 93______________________________________Compo- biphenyl 100 100 100 100 100 100 100sition type epoxy(part) resin polyallyl- 117 117 117 117 117 117 117 phenol specific 40 40 40 40 40 40 40 epoxy resin silicone 5 20 40 60 80 2 90 powder curing 2 2 2 2 2 2 2 promoterglass transition temp. 210 213 207 200 198 207 175(.degree.C.)flexural 25.degree. C. 9 9 11 10 8 8 5strength 250.degree. C. 7 8 8 7 6 5 3(kg/mm.sup.2)flexural elastic 700 690 670 620 570 715 530modulus (kg/mm.sup.2)water absorption ratio 0.32 0.31 0.31 0.32 0.32 0.32 0.45(%)gel time (s) 60 60 60 60 60 60 60package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x______________________________________
Examples 227 to 233 and Comparative Examples 94 and 95
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
silicone modified epoxy resin
SIN-620 (a product of Dai-Nippon Ink Chemicals), epoxy equivalent=252
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions illustrated in these Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader. The epoxy group and the hydroxyl group were set to be equivalent to each other. Each testpiece was prepared in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way.
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
water absorption ratio: JIS K6911
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
mold releasability: The relation between the number of times of molding and bonding power when a molded article was released from the mold, when molding was carried out repeatedly using a chromium plated mold, was examined.
The results in the Examples of the present invention and in Comparative Examples are tabulated in Table 43.
It could be understood from Examples 227 to 233 and Comparative Examples 94 and 95 that toughness, flexibility and mold releasability of the cured product could be improved by adding the silicone modified epoxy resin, the amount of addition was preferably from 5 to 200 parts, and the resin composition having excellent hydrophobicity could be obtained by using polyallyphenol as the curing agent. The epoxy resin composition having excellent curability could also be obtained by adding the specific epoxy resin.
TABLE 43__________________________________________________________________________ Comparative Example Example 227 228 229 230 231 232 233 94 95__________________________________________________________________________Compo- biphenyl type epoxy resin 100 100 100 100 100 100 100 100 100sition polyallylphenol 120 135 154 172 198 215 240 118 246(part) specific epoxy resin 40 40 40 40 40 40 40 40 40 silicone modified epoxy resin 5 30 60 90 130 160 200 2 210 curing promoter 2 2 2 2 2 2 2 2 2glass transition temp. (.degree.C.) 208 205 207 205 200 195 190 203 180flexural strength 25.degree. C. 8 8 9 10 10 9 8 8 7(kg/mm.sup.2) 250.degree. C. 6 6 7 8 7 7 6 6 4flexural elastic modulus (kg/mm.sup.2) 702 685 670 630 560 505 500 705 495water absorption ratio (%) 0.31 0.30 0.29 0.28 0.29 0.29 0.31 0.31 0.37mold releasability once 20 20 17 15 10 9 8 25 6(kg/cm.sup.2) 5 times 6 4 3 2 1 1 0 10 0gel time (s) 55 53 51 50 50 45 42 55 42package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x__________________________________________________________________________
Examples 234 to 238 and Comparative Examples 96 and 97
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
butadiene acrylonitrile
Hycar CTBN1300 (a product of Ube Kosan)
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions illustrated in these Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader, respectively. Each testpiece was prepared in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way.
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
water absorption ratio: JIS K6911
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
The results in the Examples of the present invention and in Comparative Examples are tabulated in Table 44.
It could be understood from Examples 234 to 238 and Comparative Examples 96 and 97 that toughness and flexibility of the cured product could be improved by adding the butadiene acrylonitrile, the amount of addition was preferably from 5 to 80 parts, and the resin composition having excellent hydrophobicity could be obtained by using polyallylphenol as the curing agent. Further, the epoxy resin composition having excellent curability could be obtained by adding the specific epoxy resin.
TABLE 44______________________________________ Comparative Example Example 234 235 236 237 238 96 97______________________________________Compo- biphenyl 100 100 100 100 100 100 100sition type epoxy(part) resin polyallyl- 117 117 117 117 117 117 117 phenol specific 40 40 40 40 40 40 40 epoxy resin CTBN 5 20 40 60 80 2 90 curing 2 2 2 2 2 2 2 promoterglass transition temp. 207 205 198 190 183 205 160(.degree.C.)flexural 25.degree. C. 9 9 10 9 8 6 4strength 250.degree. C. 7 8 8 7 5 4 1(kg/mm.sup.2)flexural elastic 705 690 620 580 530 705 520modulus (kg/mm.sup.2)water absorption ratio 0.32 0.34 0.37 0.38 0.38 0.32 0.40(%)gel time (s) 60 60 60 60 60 60 60package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x x______________________________________
Examples 239 to 243 and Comparative Examples 98 and 99
These Examples and Comparative Examples used the following starting materials.
biphenyl type epoxy resin
Yuka-Shell epoxy YX-4000
polyallylphenol
Mitsubishi Yuka SH-150AR
epoxy resin
Yuka-Shell epoxy E1032H60
inorganic filler (silica)
RD-8 (a product of Tatsumori)
curing promoter (triphenylphosphine)
K. I. Kasei PP-360
The compositions illustrated in these Examples and Comparative Examples were prepared by kneading the starting materials by a press kneader. Each testpiece was prepared in the following way.
First, each of the resulting compositions obtained by kneading was converted to powder of 8-mesh pass, and after this powder was tableted, transfer molding was carried out at 180.degree. C. and 40 kg/cm.sup.2 for 5 minutes. The resulting molded article was after-cured at 180.degree. C. for 5 hours.
The characteristics of the resulting compositions were evaluated in the following way.
glass transition temperature:
measured by thermo-mechanical analyzer (a product of Shinku Riko)
flexural strength: JIS K6911
flexural elastic modulus: JIS K6911
gel time: Curing time on a hot place (180.degree. C.) was measured.
water absorption ratio: JIS K6911
package crack: An 84-pin QFP was molded, was subjected to hygroscopic treatment at 121.degree. C./100% RH/24 hours, and was then dipped into solder at 260.degree. C., and occurrence of cracks was examined.
viscosity: measured by flow tester process
It could be understood from Examples 239 to 243 and Comparative Examples 98 and 99 that the mechanical strength of the cured product could be improved by adding the inorganic filler, the amount of addition was preferably from 20 to 95%, and the resin composition having excellent hydrophobicity could be obtained by using polyallylphenol as the curing agent. Further, the epoxy resin composition having excellent curability could be obtained by adding the specific epoxy resin.
TABLE 45__________________________________________________________________________ Comparative Example Example 239 240 241 242 243 98 99__________________________________________________________________________Compo- biphenyl type epoxy resin 100 100 100 100 100 100 100sition polyallylphenol 117 117 117 117 117 117 117(parts) specific epoxy resin 40 40 40 40 40 40 40 silica (wt %) 30 40 60 80 95 10 97 curing promoter 2 2 2 2 2 2 2glass transition temp. (.degree.C.) 208 209 208 208 208 208 208flexural strength 25.degree. C. 16 16 18 19 19 9 17(kg/mm.sup.2) 250.degree. C. 14 13 15 17 15 4 10flexural elastic modulus (kg/mm.sup.2) 980 1100 1400 1800 1960 700 2500water absorption ratio (%) 0.28 0.25 0.23 0.19 0.15 0.35 0.23gel time (s) 60 54 48 40 34 60 30package crack .smallcircle. .smallcircle. .smallcircle. .smallcircle. .smallcircle. x xviscosity (P) 50 70 150 320 500 40 2000__________________________________________________________________________
According to the present invention, a resin composition having excellent heat-resistance, flexibility, toughness, crack resistance, hydrophobicity and curability can be obtained by using polyallylphenol as the curing agent for the epoxy resin as the base resin, by adding the specific epoxy resin, and further adding, whenever necessary, the specific flexibility imparting agent. Furthermore, a resin composition having excellent mechanical strength can be obtained by adding the inorganic filler.
INDUSTRIAL APPLICABILITY
This invention can be advantageously utilized for the production of a resin composition having an excellent heatproofing, toughness, flexibility, cracking resistance, mold releasability, and hydrophobicity.

Number	Date	Country
2-222407	Aug 1990	JPX
3-170161	Jul 1991	JPX
PCT/JP91/01134	Aug 1991	WOX
3-294278	Nov 1991	JPX
4-128883	May 1992	JPX
4-239638	Sep 1992	JPX
5-134683	Jun 1993	JPX

Number	Name	Date
4131632	Suzuki	Dec 1978
4390664	Kanayama	Jun 1983
4687832	Ehara et al.	Aug 1987
4978810	Kanayama et al.	Dec 1990
5001174	Yanagisawa et al.	Mar 1991
5077375	Saito et al.	Dec 1991
5087766	Kanayama et al.	Feb 1992

	Number	Date	Country
	972811	Nov 1992
	194623	Feb 1994
	115570	Sep 1993

	Number	Date	Country
Parent	227318	Apr 1994
Parent	64667	May 1993

Epoxy resin composition

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