Phosphorus-containing cured benzoxazine resins and preparation thereof

Abstract

A series of novel phosphorus-containing cured benzoxazine resins, which are synthesized from dihydrobenzoxazine resins with reactive phosphorus-containing compounds. The cured benzoxazine resins have desired flame retardancy and high glass transition temperature, and are suitable for the fabrication of printed circuit board and the semiconductor encapsulant applications.

Description

FIELD OF THE INVENTION

The present invention is related to a series of novel phosphorus-containing cured benzoxazine resins, which are suitable for the fabrication of printed circuit board and the semiconductor encapsulation applications.

BACKGROUND OF THE INVENTION

Due to the rapid growth of 3C industries, electronic materials which can withstand high frequency and high-speed operation and has versatile multi-function are required. The printed circuit board reflects this trend by adopting thinner wiring and thickness of insulation layer, while maintaining the desired good reliability of the electronic products. Therefore, the insulation layer used must have a low dielectric constant, low dissipation factor, high glass transition temperature, and good high-temperature stability and flame retardancy.

Ball Grid Array (BGA) package technique has been developed to meet the trend of making more thinner electronic devices and high density ICs. The laminated board for BGA packaging, in addition to the basic properties required by the printed circuit board, must have the following characteristics: (1) excellent high-temperature stability, (2) high resistance to humidity, (3) high bonding strength, (4) high soldering-heat resistance, (5) flame retardancy, and (6) low dielectric constant.

P. W. Kopf, and E. R. Wagner discovered benzoxazines in the intermediates in the synthesis of phenolic resins in 1973, and H. Schreiber found out the benzoxazines can form a hard but brittle substance by self-curing upon heating in the same year (U.S. Pat. No. 2,255,504 (1973); and U.S. Pat. No. 2,323,936 (1973)). After that, many patents related to benzoxazine have been published, such as U.S. Pat. No. 4,501,864. 1985; U.S. Pat. No. 4,557,979. 1985; U.S. Pat. No. 5,543,516. 1996; JP 2001-106813; JP 2001-22045; JP 2001-240836; JP 2001-31095; JP 2002-145974; JP 2002-167425; JP 2003-12894; JP 2003-246844, wherein benzoxazines having two functionalities and multiple functionalities are synthesized. Benzoxazine-ring-containing compounds are stable at low temperature, and have excellent mechanical properties, high glass transition temperatures, high modulus, low moisture absorbance, low thermal expansion coefficient, high dimensional stability, and good electrical properties. Further, they can be self-polymerized in the absence of a promoter while no side products being generated. In view of these characteristics, benzoxazines are suitable for use as a high performance electronic material, and have been applied in coating, electrical laminate and encapsulant for semiconductors.

Flame retardancy is now a must to the electronic materials for more secure life safety. In order to enhance flame retardancy halogen-containing compounds or resins are added to the electronic materials as a flame retardant. Tetrabromobisphenol A is a typical example of the aromatic bromine compounds used as a flame retardant for epoxy resins. The advanced epoxy resin can be used in preparing a flame-retardant printed circuit board (FR-4) by impregnating glass fibers with the advanced epoxy resin and heating the resulting composite to cure the advanced epoxy resin. Furthermore, the advanced epoxy resin can be employed to encapsulate microelectronic devices, in which the advanced epoxy resin is cured at a high temperature with a curing agent, so that an encapsulant having a flame-retardant property is formed. Although the tetrabromobisphenol A—containing advanced epoxy resin shows flame retardant property, major problems encountered with this system are concerned with the generation of toxic and corrosive fumes during combustion such as dioxin and benzofuran. Recently, the semiconductor devices are directly soldered on the IC substrates in the fabrication of ICs, wherein that the semiconductor devices and the substrates both encounter a short period of time of high temperature (260° C., 30 sec). Further, the computing or controlling operations at high temperature are inevitable in some circumstances such as space near the car engines and summer time. Therefore, there is still a need in developing a electronic material, which is more stable at high temperature, for the fabrication of printed circuit boards and the semiconductor encapsulant.

Although benzoxazine resins have characteristics of a dihydrobenzoxazine compound contain more aryl groups and nitrogen element than general thermoset resins, which make benzoxazine resins have a better flame retardancy than other thermoset resins, but still fail to meet UL-94 V-0 level by itself. The conventional halo-containing epoxy resins or resins other than epoxy resins may be blended with the benzoxazine resins to improve the flame retardancy thereof; however, the excellent properties of the benzoxazine resins are often adversely affected.

SUMMARY OF THE INVENTION

The present invention discloses a phosphorus-containing compound as a ring-opening reagent for the benzoxazine resins, which can impart flame retardancy to the cured benzoxazine resins without sacrificing the excellent properties of the benzoxazine resins. The ring-opening reagent of the present invention is also able to cure the benzoxazine resins within a shorter period of time and at a lower temperature.

It is a primary object of this invention to provide a phosphorus-containing cured benzoxazine resin with good thermal stability, superior heat resistance, high glass transition temperature, storage stability and without environmental problem, which is suitable for use in making printed circuit boards and in semiconductor encapsulant applications. The cured benzoxazine resin of the present invention is prepared by reacting a benzoxazine resin with a phosphorus-containing ring-opening reagent, which can meet UL-94 V-0 flame retardancy at a phosphorous content of less than 1 wt % due to the synergistic effect of N and P elements in flame retardancy.

It is another object of this invention to provide a method for preparing a flame retardant phosphorus-containing cured benzoxazine resin by reacting a benzoxazine resin with a phosphorus-containing ring-opening reagent.

The phosphorus-containing cured benzoxazine resin disclosed in the present invention comprises the following chemical structures (I), (II) or (III): wherein the bracket in the formulas (I) to (III) represents a repeating unit, and the cured benzoxazine resin has more than one repeating units; G is G¹ or G²: wherein r=H, C1˜C6, or aryl, and n=0˜5;

X¹: wherein Ar is defined as above;

Y: wherein X has the same definition as X¹.

Preferably, G is G¹. More preferably, the cured benzoxazine resin comprises the chemical structure (I), wherein R is phenyl, and

X¹: More preferably, the cured benzoxazine resin comprises the chemical structure (II), wherein Y is —CH₂—.

Preferably, G is G². More preferably, the cured benzoxazine resin comprises the chemical structure (I), wherein R is phenyl, and

X¹: More preferably, the cured benzoxazine resin comprises the chemical structure (II), wherein Y is —CH₂—.

The present invention also discloses a phosphorus-containing cured benzoxazine resin comprising the following chemical structure (IV), (V) or (VI): wherein the bracket in the formulas (IV) to (VI) represents a repeating unit, and the cured benzoxazine resin has more than one repeating units; X¹, R and Y are defined as above; wherein X² has the same definition as X¹; R¹ has the same definition as R; and G is G¹ or G^2, wherein G¹ and G² are defined as above;

Preferably, G is G¹. More preferably, More preferably, wherein X² is —C(CH₃)₂—.

Preferably, G is G². More preferably, Ar is phenyl, and More preferably, Ar is phenoxy, and wherein X² is —C(CH₃)₂—.

DETAILED DESCRIPTION OF THE INVENTION

A suitable method for preparing the phosphorus-containing cured benzoxazine resin comprising the chemical structure of (I), (II) or (III) defined above comprises reacting a phosphorus-containing compound having a chemical formula of G-H with a benzoxazine resin having the following formula (A), (B) or (C): wherein G, R, X¹, and Y are defined as above.

Preferably, G is G¹. More preferably, the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (A), wherein R is phenyl, and

X¹: More preferably, the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (B), wherein Y is —CH₂—.

Preferably, G is G₂. More preferably, the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (A), wherein R is phenyl, and

X¹: More preferably, the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (B), wherein Y is —CH₂—.

A suitable method for preparing the phosphorus-containing cured benzoxazine resin comprising the chemical structure of (IV), (V) or (VI) defined above comprises reacting a phosphorus-containing compound having the chemical formula of HO-Q-OH with a benzoxazine resin having the formula (A), (B) or (C) defined as above: wherein G, X², and R¹ are defined as above.

Preferably, G is G¹. More preferably, HO-Q-OH is More preferably, HO-Q-OH is wherein X² is —C(CH₃)₂—.

Preferably, G is G². More preferably, Ar is phenyl, and HO-Q-OH is More preferably, Ar is phenoxy, and HO-Q-OH is wherein X² is —C(CH₃)₂—.

One of the ring-opening reagents of the present invention, G¹-H, wherein is a commercially available phosphorus-containing compound, named 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide (hereinafter abbreviated as DOPO).

Another one of the ring-opening reagents of the present invention, G²-H, wherein wherein Ar is defined as above, may be diphenyl phosphate (hereinafter abbreviated as DPP), i.e. Ar being phenoxy, and diphenyl phosphine oxide (hereinafter abbreviated as DPPO), i.e. Ar is phenyl, both of which are commercially available.

Still another one of the ring-opening reagents of the present invention HO-Q-OH having the following formulas:

(DOPO—BQ, when G=G¹) (DOPO—NQ, when G=G¹) is not commercially available. DOPO—BQ and DOPO—NQ (G=G¹) can be synthesized from DOPO according to the methods disclosed in U.S. Pat. No, 6,291,626. When G is G², HO-Q-OH can be synthesized similarly to DOPO—BQ and DOPO—NQ but with DOPO replaced by G²-H.

When the ring-opening reagent of the present invention HO-Q-OH has the following structure: wherein G is defined as above, it can be synthesized by reacting a compound of G¹-CH₂—OH or G²-CH₂—OH: with the following bisphnol or biphenol compound: wherein G¹, G², Ar X² are defined as above. Detailed synthesis procedures can be seen in U.S. Pat. No. 6,797,821 B2.

The benzoxazine resin of (A), (B) or (C) used in the present invention may be synthesized through the following reactions: wherein X¹ and R are defined as above; wherein Y is defined as above.

The present invention can be better understood through the following examples which are merely illustrative, and not for limiting the scope of the present invention.

I. Preparation of Dihydrobenzoxazine Resins

PREPARATION OF EXAMPLE 1

Synthesis of Bisphenol-A Dihydrobenzoxazine (X¹═—C(CH₃)₂—)

34.2 g (0.15 mole) of bisphenol-A and 48.6 g (0.6 mole) of aqueous formaldehyde (37%) were added into a 4-neck reactor equipped with a stirrer, temperature controller, and condenser, and then 100 ml of 1,4-dioxane was added as a solvent. The mixture was stirred at room temperature, and to the resulting solution 27.9 g aniline in 30 ml 1,4-dioxane was dripped at a rate of one drop per second while stirring. Upon completion of the dripping the solution was heated and reacted under refluxing for 10 hours. The reaction mixture was dried in a rotary evaporator under vacuum to obtain a yellowish solid. The yellowish solid was dissolved in ethyl ether and washed with 3N aqueous NaOH three times, followed by 1 N aqueous HCl solution several times and pure water several times, before removing the solvent in vacuo. The dried solid was ground to obtain bisphenol-A dihydrobenzoxazine powder, which is yellowish white. m.p. 110° C. EA: Calcd.: C, 80.50%; H, 6.49%; N, 6.00%. Found: C, 80.00%; H, 6.56%; N, 6.08%.

PREPARATION EXAMPLE 2

Synthesis of Bisphenol-F Dihydrobenzoxazine (X¹═—CH₂—)

34.2 g (0.15 mole) of bisphenol-F and 48.6 g (0.6 mole) aqueous formaldehyde (37%) were added into a 4-neck reactor equipped with a stirrer, temperature controller, and condenser, and then 100 ml of 1,4-dioxane was added as a solvent. The mixture was stirred at room temperature, and to the resulting solution 27.9 g aniline in 30 ml 1,4-dioxane was dripped at a rate of one drop per second while stirring. Upon completion of the dripping the solution was heated and reacted under refluxing for 10 hours. The reaction mixture was dried in a rotary evaporator under vacuum to obtain yellow solid. The yellow solid was dissolved in ethyl ether and washed with 3N aqueous NaOH three times, followed by 1 N aqueous HCl solution several times and pure water several times, before removing the solvent in vacuo to obtain yellowish bisphenol-F dihydrobenzoxazine solid. EA: Calcd.: C, 80.18%; H, 5.99%; N, 6.45%. Found: C, 80.02%; H, 6.03%; N, 6.40%.

PREPARATION EXAMPLE 3

Synthesis of 4,4′-Biphenol Dihydrobenzoxazine (X¹═______)

27.9 g of 4,4′-biphenol and 48.6 g of aqueous formaldehyde (37%) were added into a 4-neck reactor equipped with a stirrer, temperature controller, and condenser, and then 80 ml of 1,4-dioxane was added as a solvent. The mixture was stirred at room temperature, and to the resulting solution 27.9 g aniline in 30 ml 1,4-dioxane was dripped at a rate of one drop per second while stirring. Upon completion of the dripping the solution was heated and reacted under refluxing for 10 hours. The reaction mixture was dried in a rotary evaporator under vacuum to obtain a pale orange solid. The pale orange solid was dissolved in ethyl ether and washed with 3N NaOH aqueous three times, followed by 1 N aqueous HCl solution several times and pure water several times, before removing the solvent in vacuo to obtain pale orange 4,4′-biphenol dihydrobenzoxazine solid. m.p. 170° C. EA: Calcd.: C, 80.00%; H, 5.71%; N, 6.66%. Found: C, 80.30%; H, 5.73%; N, 6.56%.

PREPARATION EXAMPLE 4

Synthesis of DCPDNO Dihydrobenzoxazine

33.2 g (0.2 mole) of dicyclopentadiene novolac (hereinafter abbreviated as DCPDNO) and 32.4 g of aqueous formaldehyde (37%, 0.4 mole) were added into a 4-neck reactor equipped with a stirrer, temperature controller, and condenser, and then 100 ml of 1,4-dioxane was added as a solvent. The mixture was stirred at room temperature, and to the resulting solution 18.6 g (0.2 mole) aniline in 30 ml 1,4-dioxane was dripped at a rate of one drop per second while stirring. Upon completion of the dripping the solution was heated and reacted under refluxing for five hours. The reaction mixture was dried in a rotary evaporator under vacuum to obtain a dark brown solid. The dark.brown solid was dissolved in ethyl ether and washed with 3N aqueous NaOH three times, followed by 1 N aqueous HCl solution several times and pure water several times, before removing the solvent in vacuo to obtain DCPDNO dihydrobenzoxazine solid. The solid was ground to light brown powder. Softening point (SP) 143° C.

PREPARATION EXAMPLE 5

Synthesis of DDM Dihydrobenzoxazine

28.2 g (0.3 mole) of phenol and 18 g (0.6 mole) of paraformaldehyde were dissolved in 30 ml methanol and heated to refluxing temperature to obtain a suspension, which was stirred for two hours. The temperature of the stirred suspension was adjusted to 50° C., and 29.7 g (0.15 mole) of diamino diphenyl methane (hereinafter abbreviated as DDM) was added slowly. Upon completion of the addition, the mixture was heated and reacted under refluxing for three hours. The reaction mixture was dried in a rotary evaporator under vacuum, and the resulted solid was dissolved in ethyl ether and washed with 3N aqueous NaOH to remove unreacted phenol, followed by pure water several times, before removing the solvent in vacuum to obtain DDM dihydrobenzoxazine product. m.p. 182° C. EA (C₂₉H₂₆O₂N₂): Calcd.: C, 80.18%; H, 5.99%; N, 6.45%. Found: C, 80.28%; H, 6.01%; N, 6.32%.

PREPARATION EXAMPLE 6

Synthesis of DDS Dihydrobenzoxazine

28.2 g (0.3 mole) of phenol and 18 g (0.6 mole) of paraformaldehyde were dissolved in 30 ml methanol and heated to refluxing temperature to obtain a suspension, which was stirred for two hours. The temperature of the stirred suspension was adjusted to 50° C., and 37.2 g (0.15 mole) of diamino diphenyl sulfone (hereinafter abbreviated as DDS) was added slowly. Upon completion of the addition, the mixture was heated and reacted under refluxing for three hours. The reaction mixture was dried in a rotary evaporator under vacuum, and the resulted solid was dissolved in ethyl ether and washed with 3N aqueous NaOH to remove unreacted phenol, followed by pure water several times, before removing the solvent in vacuo to obtain DDS dihydrobenzoxazine product. m.p. 188° C. EA (C₂₈H₂₄O₄N₂S): Calcd.: C, 69.42%; H, 4.95%; N, 5.79%. Found: C, 69.53%; H, 5.04%; N, 5.63%.

PREPARATION EXAMPLE 7

Synthesis of DPPP Dihydrobenzoxazine

28.2 g (0.3 mole) of phenol and 18 g (0.6 mole) of paraformaldehyde were dissolved in 30 ml methanol and heated to refluxing temperature to obtain a suspension, which was stirred for two hours. The temperature of the stirred suspension was adjusted to 50° C., and 61.5 g (0.15 mole) of (diaminophenoxy) diphenyl propane (hereinafter abbreviated as DPPP) was added slowly. Upon completion of the adding the mixture was heated and reacted under refluxing for three hours. The reaction mixture was dried in a rotary evaporator under vacuum, and the resulted solid was dissolved in ethyl ether and washed with 3N aqueous NaOH to remove unreacted phenol, followed by pure water several times, before removing the solvent in vacuum to obtain DPPP dihydrobenzoxazine product. m.p. 176° C. EA (C₄₃H₃₈O₄N₂): Calcd.: C, 79.88%; H, 5.88%; N, 4.33%. Found: C, 80.05%; H, 5.94%; N, 4.07%.

PRPEPARTION EXAMPLE 8

Synthesis of DPDS Dihydrobenzoxazine

28.2 g (0.3 mole) of phenol and 18 g (0.6 mole) of paraformaldehyde were dissolved in 30 ml methanol and heated to refluxing temperature to obtain a suspension, which was stirred for two hours. The temperature of the stirred suspension was adjusted to 50° C., and 64.8 g (0.15 mole) of diaminophenoxy)diphenyl sulfone (hereinafter abbreviated as DPDS) was added slowly. Upon completion of the addition the mixture was heated and reacted under refluxing for three hours. The reaction mixture was dried in a rotary evaporator under vacuum, and the resulted solid was dissolved in ethyl ether and washed with 3N aqueous NaOH to remove unreacted phenol, followed by pure water several times, before removing the solvent in vacuum to obtain DPDS dihydrobenzoxazine product. m.p. 182° C. EA (C₄₀H₃₂O₆N₂S): Calcd.: C, 71.86%; H, 4.79%; N, 4.19%. Found: C, 72.03%; H, 4.84%; N, 4.06%.

PRPPARATION EXAMPLE 9

Synthesis of DDM-Naphthanol Dihydrobenzoxazine

43.3 g (0.3 mole) of 1-naphthanol and 18 g (0.6 mole) of paraformaldehyde were dissolved in 30 ml methanol and heated to refluxing temperature to obtain a suspension, which was stirred for two hours. The temperature of the stirred suspension was adjusted to 50° C., and 29.7 g (0.15 mole) of diamino diphenyl methane (hereinafter abbreviated as DDM) was added slowly. Upon completion of the addition the mixture was heated and reacted under refluxing for three hours. The reaction mixture was dried in a rotary evaporator under vacuum, and the resulted solid was dissolved in ethyl ether and washed with 3N aqueous NaOH to remove unreacted 1-naphthanol, followed by pure water several times, before removing the solvent in vacuum to obtain DDM-naphthanol dihydrobenzoxazine product. m.p. 184° C. EA (C₃₇H₃₀O₂N₂): Calcd.: C, 83.15%; H, 5.62%; N, 5.24%. Found: C, 83.37%; H, 5.71%; N, 5.01%.

II. Preparation of Phosphorus-Containing Ring-Opening Reagents

PREPARATION EXAMPLE P-1

(P-1: DOPO—BQ)

To a one liter four-inlet flask equipped with a temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 216 g (1 mole) DOPO (9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide), and 500 ml toluene were added. The mixture was heated to 70° C. and then stirred. The mixture was heated to a temperature of 90° C. and the stirring was continued until DOPO was dissolved completely. To this solution was added slowly 97 g (0.9 mole) of 1,4-benzoquinone (BQ), and the temperature thereof was increased to 110° C. and maintained at that temperature for two hours after the addition of BQ was completed. The mixture was then cooled to room temperature, filtered, and dried to obtain 2-(6-oxido-6H-dibenz<c,e><1,2>oxaphosphorin 6-yl)-1,4-benzenediol (DOPO'BQ)(P-1). Yield, 98%; m.p. 258-259° C.; phosphorus content, 9.56%.

PREPARATION EXAMPLE P-2

(P-2: DPPO—BQ)

To a one liter four-inlet flask equipped with a temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 202 g (1 mole) diphenyl phosphine oxide (DPPO) and 500 ml xylene were added. The mixture was heated to 70° C. and then stirred. The mixture was heated to a temperature of 90° C. and the stirring was continued until DPPO was dissolved completely. To this solution was added slowly 97 g (0.9 mole) of 1,4-benzoquinone, and the temperature thereof was increased to 110° C. and maintained at that temperature, for two hours after the addition of 1,4-benzoquinone was completed. The mixture was then cooled to room temperature to obtain solid, which was then filtered, and purified with THF to yield DPPO—BQ [P-2]. Yield, 92%; m.p. 167-169° C.; phosphorus content, 10.0%.

PREPARATION EXAMPLE P-3

(P-3: DOPO—NQ)

A bisphenol DOPO-NQ was prepared from 1 mole DOPO and 0.9 mole 1,4-naphthoquinone (NQ) according to the same procedures as described in Preparation Example P1. Yield, 85%; m.p. 282-283° C.; phosphorus content, 8.28%.

PREPARATION EXAMPLE P-4

(P-4: DPPO—NQ)

The procedures in Preparation Example P-2 were repeated to prepare DPPO—NQ (P-4), except that BQ was replaced by 1,4-NQ. Yield, 85%; m.p. 172° C.˜174° C.; phosphorous content, 8.61%.

PREPARATION EXAMPLE P-5

(P-5: ODOPM-BPA)

To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 228 g (1 mole) bisphenol-A (BPA) was added, heated to 170° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten BPA followed by adding slowly 246 g (1 mole) 2-(6-oxid-6H-dibenz<c,e><1,2>oxa-phosphorin-6-yl)methanol (ODOPM). The mixture was heated gradually to a temperature of 220° C. after the addition of ODOPM was completed. The substitution reaction was continued for four hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain ODOPM-BPA (P5). Yield, 98%; softening point, 125-132° C.; phosphorus content: 6.79%.

PREPARATION EXAMPLE P-6

(P-6: DPOM-BPA)

To an one liter four-inlet flask equipped with a thermocouple and temperature controller, a reflux condenser, a nitrogen feed and a mechanical stirrer, 228 g (1 mole) bisphenol-A (BPA) was added, heated to 170° C. and then stirred to a molten state. 0.7 g (0.3 wt %) potassium acetate was mixed with the molten BPA followed by adding slowly 264 g (1 mole) diphenoxy phosphoryl methanol (DPOM). The mixture was heated gradually to a temperature of 220° C. after the addition of DPOM was completed. The substitution reaction was continued for eight hours. The reaction product was dissolved in cyclohexanone, and washed with water several times before the solvent was evaporated under vacuum to obtain DPOM-BPA (P-6). Yield, 98%; softening point, 118-124° C.; phosphorus content: 6.54%.

III. Cured Benzoxazine Resins by Using Phosphorus-Containing Ring-Opening Reagents

EXAMPLES 1˜54

Ring-opening reagents having various phosphorus-containing groups were separately used to cure dihydrobenzoxazine resins (abbreviated as DBR), which were DOPO, DPPO, and P1˜P6 prepared above. DBR (prepared in Preparation Example 1˜9) and the above-mentioned ring-opening reagent were mixed in a weight ratio of DBR to the ring-opening reagent of 1:0.00, 1:0.05, 1:0.1, 1:0.15, and 1:0.2. The mixture was grounded into fine powder in a crucible and well mixed by stirring, which was then poured into a mold until it was filled with the powder mixture. The powder mixture was cured in the mold at 180° C. and 50 kg/cm² for a period of one hour, 200° C. for two hours, 220° C. for another two hours, and then at 240° C. for one hour to obtain a cured specimen.

CONTROL EXAMPLES 1˜9

Phenol formaldehyde novolac resin (abbreviated as PN), melamine-phenol formaldehyde novolac resin (abbreviated as MPN) and tetrabromo bisphenol-A (abbreviated as TBBA) were separately used to cure dihydrobenzoxazine resins (DBR). DBR (prepared in Preparation Example 1˜9) and the above-mentioned curing agent were mixed in a weight ratio of DBR to the ring-opening reagent of 1:0.00, 1:0.05, 1:0.1, 1:0.15, and 1:0.2. The mixture was grounded into fine powder in a crucible and well mixed by stirring, which was then poured into a mold until it was filled with the powder mixture. The powder mixture was cured in the mold at 180° C. and 50 kg/cm² for a period of one hour, 200° C. for two hours, 220° C. for another two hours, and then at 240° C. for one hour to obtain a cured specimen.

Table 1 lists dynamic mechanical properties, thermogravimetric analysis (TGA) and UL-94 flame retardancy test of the cured benzoxazine resins prepared in Examples 1˜54, and Control Examples. It can be seen form Table 1 that the flame retardant cured benzoxazine resins prepared from the phosphorus-containing ring-opening reagents of the present invention have a higher char yield, a high glass transition temperature (Tg), and an excellent flame retardancy including no fume and drip during combustion, which make them very suitable for the fabrication of printed circuit boards and the semiconductor encapsulant applications. Data in Table 1 also indicate that: (1) the novel flame retardant phosphorus-containing cured benzoxazine resins of the present invention can meet UL-94 V-0 flame retardancy when the phosphorous content thereof are generally less than about 1.20%, wherein the phosphorous content is even lower to about 0.68% for the ring-opening reagents DOPO and DPPO; (2) the cured benzoxazine resins prepared by ring-opening reagents of PN and the nitrogen-containing MPN in the Control Examples do not meet V-0 flame retardancy, and another one prepared by the bromine-containing TBBA can meet the V-0 flame retardancy only when the bromine content is greater than 10%; (3) among the cured benzoxazine resins of the present invention those prepared from 4,4′-biphenol dihydrobenzoxazine resin have the best performance, including the highest Tg, the best heat resistance, the higher char yield. The cured benzoxazine resin of the present invention prepared by 4,4′-biphenol dihydrobenzoxazine resin and DOPO—BQ (P-1, Preparation Example P-1) only requires 10% of the ring-opening reagent (DOPO—BQ, P-1) to impart flame retardancy (phosphorous content, 0.75%, Example 7), while the Tg does not substantially decline. That means the cured benzoxazine resin of the present invention not only have excellent flame retardancy but inherently posses the high Tg and high heat resistance from the benzoxazine resin.

The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.

TABLE 1
Results of dynamic mechanical properties, TGA and UL-94 flame retardancy test of cured benzoxazine resins
							Maximum
				Glass			thermal
	Ring-	Ring-		transition	Elasticity	5% loss	degradation		Burning
Sample	opening	opening		temperature	50° C.	temperature	temperature	Char yield (%)	time	UL-94V
Benzoxazine	reagent	reagent %		Tg (° C.)	dyne/cm	° C.	° C.	at 700° C.	(sec)	Classification
			P/N content
Ex. 1	DOPO	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.64/5.79	182	7.3	345	405	27	8	V-0
		10	1.23/5.54	172	7.1	339	401	26	3	V-0
		15	1.77/5.32	170	7.0	326	394	28	1	V-0
		20	2.26/5.11	168	6.8	321	388	32	0	V-0
Ex. 2	DPPO	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.60/5.81	179	7.6	343	404	23	12	V-1
		10	1.15/5.57	170	7.2	336	399	26	6	V-0
		15	1.66/5.36	167	7.1	325	391	27	2	V-0
		20	2.14/5.16	165	6.8	319	384	30	0	V-0
Ex. 3	DOPO	0	0.00/6.45	180	7.4	370	464	45	46	V-2
BPF		5	0.68/6.15	178	7.2	369	492	38	6	V-0
		10	1.30/5.87	172	7.0	364	481	40	2	V-0
		15	1.86/5.61	168	6.8	361	475	43	0	V-0
		20	2.38/5.38	166	6.7	355	472	46	0	V-0
Ex. 4	DPPO	0	0.00/6.45	180	7.4	370	464	45	46	V-2
BPF		5	0.64/6.16	176	7.3	359	483	35	9	V-0
		10	1.22/5.90	169	6.9	354	476	38	5	V-0
		15	1.76/5.66	163	7.0	348	470	40	2	V-0
		20	2.25/5.44	162	7.1	341	465	44	0	V-0
Ex. 5	DOPO	0	0.00/6.45	182	7.5	396	436	37	57	V-2
DDM		5	0.68/6.15	177	7.3	382	432	32	6	V-0
		10	1.30/5.87	172	7.2	371	428	33	2	V-0
		15	1.86/5.61	168	7.0	365	423	35	0	V-0
		20	2.38/5.38	165	6.9	363	415	38	0	V-0
Ex. 6	DPPO	0	0.00/6.45	182	7.5	396	464	37	57	V-2
DDM		5	0.64/6.16	175	7.3	378	431	31	7	V-0
		10	1.22/5.90	170	7.1	367	425	32	3	V-0
		15	1.76/5.66	163	7.2	364	418	34	1	V-0
		20	2.25/5.44	160	6.8	358	412	37	0	V-0
Ex. 7	P-1	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.34/5.84	187	7.6	380	432	41	13	V-1
		10	0.69/5.62	182	7.3	381	430	43	6	V-0
		15	1.05/5.39	182	7.2	381	427	48	3	V-0
		20	1.43/5.16	178	6.9	379	423	48	1	V-0
Ex. 8	P-2	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.34/5.85	175	7.1	376	434	36	52	V-2
		10	0.69/5.63	172	6.8	374	428	38	38	V-2
		15	1.06/5.41	168	6.5	374	425	39	17	V-1
		20	1.44/5.18	165	6.2	371	422	41	5	V-0
Ex. 9	P-3	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.34/5.81	187	7.6	383	437	41	11	V-1
		10	0.68/5.52	185	7.5	381	435	44	6	V-0
		15	1.04/5.30	181	7.3	379	431	47	2	V-0
		20	1.39/5.04	180	7.1	377	430	49	1	V-0
Ex. 10	P-4	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.34/5.82	178	7.2	373	421	35	50	V-2
		10	0.69/5.58	175	6.8	371	420	39	35	V-2
		15	1.04/5.33	175	6.3	369	417	41	14	V-1
		20	1.40/5.07	170	6.1	367	414	43	3	V-0
Ex. 11	P-5	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.34/5.76	187	7.3	378	435	41	14	V-1
		10	0.67/5.46	184	7.1	383	438	41	7	V-0
		15	1.00/5.16	180	6.9	385	431	43	4	V-0
		20	1.36/4.86	179	6.8	372	425	43	1	V-0
Ex. 12	P-6	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.34/5.75	175	7.3	375	425	35	46	V-2
		10	0.69/5.44	173	6.8	373	421	37	32	V-2
		15	1.00/5.13	169	6.5	371	421	38	17	V-1
		20	1.34/4.82	166	6.1	369	417	40	3	V-0
Ex. 13	P-1	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.37/6.41	203	7.7	390	450	58	12	V-1
		10	0.75/6.14	197	7.7	387	448	59	6	V-0
		15	1.15/5.87	194	7.5	385	445	60	3	V-0
		20	1.55/5.59	190	7.2	381	442	62	3	V-0
Ex. 14	P-2	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.37/6.42	189	7.5	387	412	57	31	V-2
		10	0.76/6.16	185	7.3	385	409	58	17	V-1
		15	1.15/5.90	183	7.1	381	407	59	8	V-0
		20	1.56/5.63	179	6.9	376	397	59	6	V-0
Ex. 15	P-3	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.37/6.37	204	7.8	390	452	58	12	V-1
		10	0.75/6.07	201	7.5	388	448	58	7	V-0
		15	1.12/5.76	197	7.4	385	448	59	2	V-0
		20	1.51/5.46	194	7.3	382	445	61	2	V-0
Ex. 16	P-4	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.37/6.38	196	7.5	385	415	58	33	V-2
		10	0.75/6.09	192	7.3	381	412	59	21	V-1
		15	1.13/5.79	189	7.2	377	405	59	7	V-0
		20	1.52/5.49	185	6.9	374	399	61	5	V-0
Ex. 17	P-5	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.36/6.30	199	7.6	388	450	59	12	V-1
		10	0.73/5.94	198	7.5	391	448	58	5	V-0
		15	1.10/5.59	189	7.2	382	443	59	3	V-0
		20	1.45/5.23	185	6.8	379	439	60	2	V-0
Ex. 18	P-6	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.37/6.29	188	7.5	383	403	57	34	V-2
		10	0.73/5.93	184	7.0	380	399	57	20	V-1
		15	1.08/5.56	181	6.9	377	396	58	8	V-0
		20	1.44/5.20	176	6.8	371	393	58	5	V-0
Ex. 19	P-1	0	0.00/5.05	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.28/4.89	187	7.6	398	449	35	56	V-2
		10	0.58/4.74	185	7.4	396	447	37	13	V-1
		15	0.89/4.57	185	7.3	393	443	37	7	V-0
		20	1.22/4.40	180	7.1	390	441	39	3	V-0
Ex. 20	P-2	0	0.00/5.05	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.29/4.91	175	7.3	383	437	32	54	V-2
		10	0.58/4.75	171	7.0	381	433	33	38	V-2
		15	0.89/4.60	168	67	377	431	35	20	V-1
		20	1.23/4.43	163	6.5	374	427	36	8	V-0
Ex. 21	P-3	0	0.00/5.05	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.28/4.88	185	7.8	397	449	35	37	V-2
		10	0.58/4.69	183	7.6	397	447	37	20	V-1
		15	0.88/4.51	181	7.3	392	445	39	9	V-0
		20	1.19/4.32	175	7.1	390	443	41	4	V-0
Ex. 22	P-4	0	0.00/5.05	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.28/4.88	177	7.1	384	439	33	46	V-2
		10	0.58/4.71	175	7.1	381	437	34	38	V-2
		15	0.88/4.53	171	6.9	378	433	36	18	V-1
		20	1.20/4.34	168	6.5	372	431	38	8	V-0
Ex. 23	P-5	0	0.00/5.05	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.28/4.73	182	7.3	396	443	33	55	V-2
		10	0.56/4.53	184	7.3	396	441	34	16	V-1
		15	0.97/4.32	182	6.9	404	439	35	7	V-0
		20	1.37/4.10	179	6.8	396	437	36	4	V-0
Ex. 24	P-6	0	0.00/5.05	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.28/4.83	168	7.3	385	437	31	56	V-2
		10	0.57/4.61	167	6.7	378	433	32	41	V-2
		15	0.86/4.39	161	6.3	374	431	33	20	V-1
		20	1.15/4.16	159	6.1	371	431	35	7	V-0
Ex. 25	P-1	0	0.00/6.45	182	7.5	396	436	37	57	V-2
DDM		5	0.36/6.21	182	7.7	393	438	41	15	V-1
		10	0.73/5.96	180	7.5	391	436	43	6	V-0
		15	1.11/5.69	176	7.2	388	433	47	2	V-0
		20	1.50/5.43	173	6.9	385	430	49	2	V-0
Ex. 26	P-2	0	0.00/6.45	182	7.5	396	436	37	57	V-2
DDM		5	0.36/6.22	175	7.2	386	428	37	43	V-2
		10	0.74/5.98	173	6.9	384	425	39	37	V-2
		15	1.12/5.73	170	6.5	381	423	42	17	V-1
		20	1.52/5.47	163	6.3	379	421	43	3	V-0
Ex. 27	P-3	0	0.00/6.45	182	7.5	396	436	37	57	V-2
DDM		5	0.36/6.17	185	7.7	394	439	43	15	V-1
		10	0.72/5.88	182	7.5	391	439	46	6	V-0
		15	1.09/5.59	180	7.3	387	435	48	3	V-0
		20	1.47/5.31	179	7.3	385	433	50	1	V-0
Ex. 28	P-4	0	0.00/6.45	182	7.5	396	436	37	57	V-2
DDM		5	0.36/6.18	173	7.2	385	431	39	43	V-2
		10	0.73/5.91	171	6.9	383	427	42	34	V-2
		15	1.10/5.63	167	6.5	381	427	42	15	V-1
		20	1.48/5.34	164	6.1	378	423	45	5	V-0
Ex. 29	P-5	0	0.00/6.45	182	7.5	396	436	37	57	V-2
DDM		5	0.36/6.11	178	7.3	396	433	40	13	V-1
		10	0.71/5.77	177	7.3	393	431	42	6	V-0
		15	1.06/5.44	173	7.1	391	429	45	2	V-0
		20	1.41/5.11	170	6.8	388	427	46	1	V-0
Ex. 30	P-6	0	0.00/6.45	182	7.5	396	436	37	57	V-2
DDM		5	0.36/6.10	175	7.1	384	427	39	39	V-2
		10	0.71/5.75	174	6.9	381	427	40	31	V-2
		15	1.06/5.41	171	6.7	377	423	43	15	V-1
		20	1.40/5.07	165	6.4	374	421	44	1	V-0
Ex. 31	P-1	0	0.00/5.79	188	7.8	401	439	39	51	V-2
DDS		5	0.33/5.59	185	7.8	395	441	43	17	V-1
		10	0.66/5.39	183	7.5	393	437	45	8	V-0
		15	1.01/5.17	179	7.5	393	437	49	4	V-0
		20	1.37/4.96	176	7.2	390	433	51	3	V-0
Ex. 32	P-2	0	0.00/5.79	188	7.8	401	439	39	51	V-2
DDS		5	0.33/5.60	178	7.3	387	431	41	39	V-2
		10	0.66/5.41	174	6.9	384	429	43	27	V-1
		15	1.02/5.20	170	6.6	381	427	44	17	V-1
		20	1.38/4.99	166	6.3	377	423	45	5	V-0
Ex. 33	P-3	0	0.00/5.79	188	7.8	401	439	39	51	V-2
DDS		5	0.32/5.56	187	7.8	397	441	43	13	V-1
		10	0.65/5.33	185	7.5	395	437	46	7	V-0
		15	0.99/5.09	182	7.4	392	437	49	2	V-0
		20	1.34/4.85	179	7.1	388	435	52	1	V-0
Ex. 34	P-4	0	0.00/5.79	188	7.8	401	439	39	51	V-2
DDS		5	0.32/5.57	179	7.2	388	435	41	36	V-2
		10	0.65/5.34	176	7.1	385	431	43	24	V-1
		15	0.99/5.11	173	6.7	381	427	45	15	V-1
		20	1.35/4.88	169	6.4	379	427	47	3	V-0
Ex. 35	P-5	0	0.00/5.79	188	7.8	401	439	39	51	V-2
DDS		5	0.32/5.51	185	7.4	395	435	41	15	V-1
		10	0.64/5.24	183	7.1	394	433	43	7	V-0
		15	0.97/4.96	180	7.1	391	431	46	4	V-0
		20	1.29/4.69	176	6.8	388	429	48	3	V-0
Ex. 36	P-6	0	0.00/5.79	188	7.8	401	439	39	51	V-2
DDS		5	0.32/5.50	171	7.3	385	431	41	47	V-2
		10	0.64/5.22	167	7.0	383	427	43	27	V-1
		15	0.96/4.93	163	6.7	380	423	45	15	V-1
		20	1.28/4.65	160	6.4	377	421	45	4	V-0
Ex. 37	P-1	0	0.00/4.33	176	7.5	385	416	34	53	V-2
DPPP		5	0.25/4.22	180	7.7	381	433	39	23	V-1
		10	0.50/4.10	175	7.4	378	431	40	17	V-1
		15	0.78/3.98	171	7.3	375	429	41	7	V-0
		20	1.07/3.85	166	7.0	374	426	43	5	V-0
Ex. 38	P-2	0	0.00/4.33	176	7.5	385	416	34	53	V-2
DPPP		5	0.25/4.22	173	7.2	377	433	36	43	V-2
		10	0.51/4.11	171	6.9	375	425	38	35	V-2
		15	0.78/3.99	166	6.5	374	423	40	21	V-1
		20	1.07/3.87	161	6.3	371	421	41	15	V-1
Ex. 39	P-3	0	0.00/4.33	176	7.5	385	416	34	53	V-2
DPPP		5	0.24/4.20	181	7.6	385	435	39	23	V-1
		10	0.50/4.07	178	7.5	382	433	43	17	V-1
		15	0.77/3.92	174	7.4	379	431	44	8	V-0
		20	1.05/3.78	171	7.2	377	429	45	5	V-0
Ex. 40	P-4	0	0.00/4.33	176	7.5	385	416	34	53	V-2
DPPP		5	0.25/4.21	165	7.2	376	423	36	43	V-2
		10	0.50/4.08	163	6.9	373	421	37	35	V-2
		15	0.77/3.94	160	6.6	371	419	39	28	V-1
		20	1.05/3.80	159	6.4	369	417	41	15	V-1
Ex. 41	P-5	0	0.00/4.33	176	7.5	385	416	34	53	V-2
DPPP		5	0.24/4.17	175	7.5	383	431	38	30	V-2
		10	0.49/4.01	172	7.2	383	431	40	21	V-1
		15	0.75/3.85	169	6.9	381	427	41	11	V-1
		20	1.02/3.68	167	6.7	378	425	42	5	V-0
Ex. 42	P-6	0	0.00/4.33	176	7.5	385	416	34	53	V-2
DPPP		5	0.24/4.17	167	7.1	379	421	36	49	V-2
		10	0.49/4.00	164	6.7	374	419	39	35	V-2
		15	0.75/3.83	160	6.4	372	417	40	28	V-1
		20	1.01/3.66	157	6.1	368	413	41	19	V-1
Ex. 43	P-1	0	0.00/4.19	182	7.7	390	441	35	53	V-2
DPDS		5	0.24/4.09	186	7.6	391	441	41	24	V-1
		10	0.49/3.98	180	7.4	387	439	41	19	V-1
		15	0.75/3.86	177	7.2	384	437	43	9	V-0
		20	1.03/3.73	175	6.7	382	435	45	5	V-0
Ex. 44	P-2	0	0.00/4.19	182	7.7	378	441	35	53	V-2
DPDS		5	0.24/4.09	174	7.1	390	431	37	44	V-2
		10	0.49/3.98	170	6.7	378	429	38	37	V-2
		15	0.76/3.87	167	6.3	376	427	41	28	V-1
		20	1.04/3.75	162	6.1	372	425	42	14	V-0
Ex. 45	P-3	0	0.00/4.19	182	7.7	390	441	35	53	V-2
DPDS		5	0.24/4.07	187	7.6	388	441	40	23	V-1
		10	0.48/3.94	183	7.5	385	441	44	17	V-1
		15	0.74/3.81	181	7.3	385	439	44	9	V-0
		20	1.01/3.68	179	7.1	381	435	47	8	V-0
Ex. 46	P-4	0	0.00/4.19	182	7.7	390	441	35	53	V-2
DPDS		5	0.24/4.07	171	7.3	378	437	39	41	V-2
		10	0.48/3.95	168	6.9	375	435	39	33	V-2
		15	0.75/3.83	165	6.6	370	431	41	29	V-1
		20	1.02/3.69	163	6.3	365	431	43	17	V-1
Ex. 47	P-5	0	0.00/4.19	182	7.7	390	441	35	53	V-2
DPDS		5	0.23/4.04	180	7.3	389	437	39	29	V-1
		10	0.48/3.89	178	7.3	385	433	41	21	V-1
		15	0.73/3.73	174	7.0	383	433	42	10	V-0
		20	0.98/3.58	171	6.8	380	431	43	7	V-0
Ex. 48	P-6	0	0.00/4.19	182	7.7	390	441	35	53	V-2
DPDS		5	0.24/4.04	170	7.4	378	434	38	45	V-2
		10	0.48/3.88	167	6.9	375	431	40	37	V-2
		15	0.73/3.72	164	6.5	372	427	41	28	V-1
		20	0.98/3.56	161	6.3	370	425	41	15	V-1
Ex. 49	P-1	0	0.00/5.24	184	7.8	392	441	37	61	V-2
DDM-NA		5	0.29/5.08	189	7.7	387	443	42	21	V-1
		10	0.60/4.90	181	7.3	385	438	44	15	V-1
		15	0.92/4.73	180	7.3	381	435	47	5	V-0
		20	1.26/4.54	176	7.0	379	431	49	2	V-0
Ex. 50	P-2	0	0.00/5.24	184	7.8	392	441	37	61	V-2
DDM-NA		5	0.24/4.09	173	7.3	381	433	38	47	V-2
		10	0.49/3.98	170	6.9	377	429	39	37	V-2
		15	0.76/3.87	167	6.5	374	425	41	28	V-1
		20	1.04/3.75	165	6.3	372	425	43	15	V-1
Ex. 51	P-3	0	0.00/5.24	184	7.8	392	441	37	61	V-2
DDM-NA		5	0.29/5.05	186	7.8	388	443	43	19	V-1
		10	0.59/4.86	184	7.5	388	439	48	15	V-1
		15	0.91/4.66	181	7.5	384	437	48	6	V-0
		20	1.23/4.46	179	7.2	381	434	51	3	V-0
Ex. 52	P-4	0	0.00/5.24	184	7.8	392	441	37	61	V-2
DDM-NA		5	0.29/5.06	174	7.4	383	435	39	41	V-2
		10	0.60/4.87	173	7.1	381	431	41	33	V-2
		15	0.91/4.68	170	6.6	376	429	43	21	V-1
		20	1.24/4.48	167	6.2	371	426	45	9	V-1
Ex. 53	P-5	0	0.00/5.24	184	7.8	392	441	37	61	V-2
DDM-NA		5	0.29/5.01	182	7.6	390	437	40	21	V-1
		10	0.59/4.79	179	7.3	385	435	43	17	V-0
		15	0.89/4.55	177	7.1	383	431	45	7	V-0
		20	1.19/4.32	176	6.8	379	427	47	5	V-0
Ex. 54	P-6	0	0.00/5.24	184	7.8	392	441	37	61	V-2
DDM-NA		5	0.29/5.01	171	7.4	381	433	39	49	V-2
		10	0.59/4.77	169	6.9	376	430	41	30	V-2
		15	0.88/4.53	168	6.5	372	427	43	21	V-1
		20	1.19/4.29	164	6.3	372	425	45	13	V-1
Control Ex. 1	PN	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.00/5.92	180	7.8	368	402	34	63	V-2
		10	0.00/5.77	178	7.9	375	399	36	63	V-2
		15	0.00/5.61	177	7.4	370	396	35	68	V-2
		20	0.00/5.44	175	7.1	364	391	32	69	V-2
Control Ex. 2	PN	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.00/6.48	207	7.8	398	445	57	46	V-2
		10	0.00/6.31	207	7.6	404	441	56	49	V-2
		15	0.00/6.12	202	7.3	398	441	57	49	V-2
		20	0.00/5.92	200	7.3	391	436	57	54	V-2
Control Ex. 3	PN	0	0.00/4.94	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.00/4.84	185	7.5	412	431	31	68	V-2
		10	0.00/4.74	184	7.3	415	426	31	72	V-2
		15	0.00/4.63	185	7.1	387	421	30	75	V-2
		20	0.00/4.52	183	7.0	385	417	29	76	V-2
Control Ex. 4	MPN	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	0.00/6.51	189	7.8	379	432	36	78	V-2
		10	0.00/6.98	190	7.8	393	426	38	72	V-2
		15	0.00/7.47	188	7.6	403	423	38	70	V-2
		20	0.00/7.98	186	.73	402	416	39	58	V-2
Control Ex. 5	MPN	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	0.00/7.13	207	8.1	397	445	56	68	V-2
		10	0.00/7.62	207	7.8	399	436	56	72	V-2
		15	0.00/8.14	202	7.6	401	433	58	70	V-2
		20	0.00/8.66	176	7.6	388	431	57	66	V-2
Control Ex. 6	MPN	0	0.00/4.94	183	7.6	391	441	30	72	V-2
DCPDNO		5	0.00/5.34	184	7.5	392	432	29	68	V-2
		10	0.00/5.77	185	7.3	399	429	30	65	V-2
		15	0.00/6.21	183	7.3	394	425	31	65	V-2
		20	0.00/6.68	185	7.1	393	419	34	67	V-2
			Br/N content
Control Ex. 7	TBBA	0	0.00/6.06	184	7.5	364	414	35	61	V-2
BPA		5	3.43/5.70	176	7.4	361	411	35	51	V-2
		10	6.80/5.36	172	7.2	361	397	37	28	V-2
		15	10.11/5.02	166	7.1	359	391	38	9	V-1
		20	13.37/4.68	161	6.8	356	385	39	3	V-0
Control Ex. 8	TBBA	0	0.00/6.66	206	7.8	396	448	58	39	V-2
BIP		5	3.75/6.23	197	7.5	393	438	58	46	V-2
		10	7.39/5.82	193	7.5	391	433	58	23	V-2
		15	10.94/5.42	185	7.3	389	427	59	7	V-0
		20	14.38/5.03	176	7.1	386	421	59	1	V-0
Control Ex. 9	TBBA	0	0.00/4.94	183	7.6	391	441	30	72	V-2
DCPDNO		5	2.89/4.69	177	7.3	388	435	32	57	V-2
		10	5.78/4.45	173	7.1	385	431	32	58	V-2
		15	8.68/4.21	167	6.8	381	426	33	20	V-1
		20	11.59/3.97	161	6.7	379	419	35	6	V-0
Benzoxazine:
BPA: Bisphenol-A benzoxazine (Preparation Example 1)
BPF: Bisphenol-F benzoxazine (Preparation Example 2)
BIP: 4,4′-Biphenol benzoxazine (Preparation Example 3)
DCPDNO: DCPDNO benzoxazine (Preparation Example 4)
DDM: DDM benzoxazine (Preparation Example 5)
DDS: DDS benzoxazine (Preparation Example 6)
DPPP: DPPP benzoxazine (Preparation 7)
DPDS: DPDS benzoxazine (Preparation 8)
DDM-NA: DDM-naphthanol benzoxazine (Preparation Example 9)
Ring-opening reagent:
DOPO
DPPO
P-1: DOPO-BQ
P-2: DPPO-BQ
P-3: DOPO-NQ
P-4: DPPO-NQ
P-5: ODOPM-BPA
P-6: DPOM-BPA
PN: Phenol formaldehyde novolac resin
MPN: Melamine-phenol formaldehyde novolac
TBBA: Tetrabromo bisphenol A

Claims

1. A phosphorus-containing cured benzoxazine resin comprising the following chemical structure (I), (II) or (III):

2. The cured benzoxazine resin as defined in claim 1, wherein G is G1.

3. The cured benzoxazine resin as defined in claim 2 comprising the chemical structure (I), wherein R is phenyl, and X1:

4. The cured benzoxazine resin as defined in claim 2 comprising the chemical structure (II), wherein Y is —CH2—.

5. The cured benzoxazine resin as defined in claim 1, wherein G is G2.

6. The cured benzoxazine resin as defined in claim 5 comprising the chemical structure (I), wherein R is phenyl, and X1:

7. The cured benzoxazine resin as defined in claim 5 comprising the chemical structure (II), wherein Y is —CH2—.

8. A phosphorus-containing cured benzoxazine resin comprising the following chemical structure (IV), (V) or (VI):

9. The cured benzoxazine resin as defined in claim 8, wherein G is G1.

10. The cured benzoxazine resin as defined in claim 9, wherein

11. The cured benzoxazine resin as defined in claim 9, wherein

12. The cured benzoxazine resin as defined in claim 8, wherein G is G2.

13. The cured benzoxazine resin as defined in claim 12, wherein Ar is phenyl, and

14. The cured benzoxazine resin as defined in claim 12, wherein Ar is phenoxy, and

15. A method for preparing a phosphorus-containing cured benzoxazine resin, said cured benzoxazine resin comprising the chemical structure of (I), (II) or (III) defined in claim 1, said method comprising reacting a phosphorus-containing compound having a chemical formula of G-H with a benzoxazine resin having the following formula (A), (B) or (C):

16. The method as defined in claim 15, wherein G is G1.

17. The method as defined in claim 16, wherein the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (A), wherein R is phenyl, and X1:

18. The method as defined in claim 16, wherein the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (B), wherein Y is —CH2—.

19. The method as defined in claim 15, wherein G is G2.

20. The method as defined in claim 19, wherein the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (A), wherein R is phenyl, and X1:

21. The method as defined in claim 19, wherein the phosphorus-containing compound, G-H, is reacted with the benzoxazine resin having the formula of (B), wherein Y is —CH2—.

22. A method for preparing a phosphorus-containing cured benzoxazine resin, said cured benzoxazine resin comprising the chemical structure of (IV), (V) or (VI) defined in claim 8, said method comprising reacting a phosphorus-containing compound having the chemical formula of HO-Q-OH with a benzoxazine resin having the following formula (A), (B) or (C):

23. The method as defined in claim 22, wherein G is G1.

24. The method as defined in claim 23, wherein HO-Q-OH is

25. The method as defined in claim 23, wherein HO-Q-OH is

26. The method as defined in claim 22, wherein G is G2.

27. The method as defined in claim 26, wherein Ar is phenyl, and HO-Q-OH is

28. The method as defined in claim 26, wherein Ar is phenoxy, and HO-Q-OH is