Prepreg and method for manufacturing the same

A technology of prepreg and resin materials, applied in chemical instruments and methods, manufacturing printed circuit precursors, and other household appliances, can solve problems such as increased surface roughness, restrictions on forming fine wiring patterns, and deterioration of wiring bonding strength. Improve binding efficiency and prevent delamination

Inactive Publication Date: 2016-04-20
SAMSUNG ELECTRO MECHANICS CO LTD
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AI-Extracted Technical Summary

Problems solved by technology

However, since the inorganic filler protrudes to the surface of the prepreg, the bonding strength of the wiring deteriorates during the process of forming the wiring on the prepreg...
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Method used

[0041] By such a configuration, the prepreg of the embodiment of the present invention is formed with the first resin material 120 as a thermosetting resin having relatively excellent hardness in the process of complete hardening; and, by making the first Hardening in such a manner that the resin material 120 is disposed at the central portion of the core 110 can obtain a low coefficient of thermal expansion (CTE) and a high transition temperature (Tg), and allows the core 110 in which the first resin material 120 is impregnated to function as a The role of the core of the prepreg being formed in the film.
[0042] In addition, by including the curved portion 111 of the core 110 in localized regions of the hardened second resin material 130 and third resin material 140 (having an in...
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Abstract

The invention relates to a prepreg and a method for manufacturing the same. The prepreg comprises a core, a second resin material and a third resin material. A first resin material is immersed in the core, the second resin material is stacked on the top of the core, the third resin material is stacked on the bottom of the core, and an interface is formed between a bending part of the core and the first resin material.

Application Domain

Synthetic resin layered productsLamination +6

Technology Topic

Composite material

Image

  • Prepreg and method for manufacturing the same
  • Prepreg and method for manufacturing the same
  • Prepreg and method for manufacturing the same

Examples

  • Experimental program(1)

Example Embodiment

[0026] The terms used herein are provided to explain the embodiments, but not to limit the present invention. Throughout the specification, unless the context clearly indicates otherwise, the singular form includes the plural form. In addition to the aforementioned numbers, components, steps, components, operations, elements, and/or groups, the term "comprising" used herein does not exclude the presence or addition of another component, step, operation, and/or device.
[0027] The advantages and features of the present invention and the method for implementing the present invention will be apparent by referring to the embodiments described in detail below in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but can be implemented in various different forms. The exemplary embodiments are only provided to complete the disclosure of the present invention and fully present the disclosure of the present invention to those skilled in the art. Throughout the specification, the same reference numerals indicate the same elements. For conciseness and clarity of description, the drawings show the structure in a general manner, and descriptions and details of well-known features and technologies may be omitted to avoid unnecessarily obscuring the discussion of the described embodiments of the present invention. In addition, the elements in the drawings may not be drawn to scale. For example, the size of some elements in the drawings may be exaggerated in comparison with other elements to help improve the understanding of the embodiments of the present invention. The same reference numbers in different drawings indicate the same elements.
[0028] The technical configuration of the object and the operational effects of the prepreg and the manufacturing method thereof according to the present invention will be described in detail with reference to the accompanying drawings, so that those skilled in the art can easily practice the present invention.
[0029] figure 1 It is a cross-sectional view showing a prepreg according to an embodiment of the present invention.
[0030] As shown in the figure, the prepreg 100 of the embodiment of the present invention includes a core 110, a second resin material 130, and a third resin material 140, wherein the first resin material 120 is immersed in the core 110, and the second resin material 130 is stacked on the core. On the upper part of 110, the third resin material 140 is stacked on the lower part of the core 110. At this time, the cover film 150 made of an insulating material or copper foil may also be stacked on the outer surfaces of the second resin material 130 and the third resin material 140.
[0031] Since the core may be formed with either woven cloth or glass cloth, and the core is a structure in which fibrous fabric or glass filaments are interwoven with each other, a high modulus (compared to resin materials) is produced by weaving in one or three rows. Therefore, when heat and pressure are applied in the process of stacking the resin material, the warpage generated by the prepreg can be minimized.
[0032] In the core 110, the bent portion 111 is formed at a position where the fabric or glass filaments are staggered in the vertical direction and the horizontal direction according to the arrangement. Since the height of the bent portion 111 varies along the virtual center line of the core according to the number of arrangement of the fabric or glass filaments, typically, the greater the number of arranged filaments, the higher the height of the bent portion. That is, the curved portion 111 may continuously form a convex surface 111a and a concave surface 111b, the convex surface 111a is a position where the convex fabric or glass filament intersects, and the concave surface 111b is a relatively concave other portion.
[0033] The first resin material 120 is immersed in the core 110; and, the first resin material 120 is formed in a thickness thinner than the maximum thickness of the core 110 including the bent portion 111. That is, the top and bottom surfaces of the first resin material 120 are located within the thickness range of the core 110, and the top and bottom surfaces of the first resin material 120 may be formed in a thickness range that does not deviate from the outside of the convex surface 111a of the core 110. In addition, the top surface and the bottom surface of the first resin material 120 may be formed in a thickness range that does not deviate from the concave surface of the concave surface 111 b of the core 110. At this time, in the case where the top surface and the bottom surface of the first resin material 120 are located in the concave surface 111b of the curved portion 111 of the core 110, the first resin material 120 may be smaller than the top and bottom surfaces of the first resin material 120. The case located on the convex surface 111a is formed with a thin thickness.
[0034] The core 110 is impregnated with a first resin material 120 to cover the top and bottom of the curved portion 111, and the first resin material 120 may be located at the curved portion 111 of the core 110 by curing the first resin material 120 due to thermosetting. At this time, in the process of thermal hardening, the first resin material 120 has its top and bottom surfaces located in the curved portion 111 by reducing its volume, so the first resin material 120 can be compared with the core 110 including the curved portion 111. Thin thickness is formed.
[0035] The first resin material 120 impregnated in the core 110 may be made of an organic material such as epoxy resin or resin, and the core 110 having a high modulus may be formed by impregnating the first resin material 120 to be cured in a fabric or glass fiber without gaps. In the space (except for the convex surface 111a or the concave surface 111b of the curved portion 111). At this time, the first resin material 120 is not limited to a resin material such as epoxy resin or resin, and it is applicable if it is a thermosetting resin as an organic material that can be impregnated between fabrics or glass filaments.
[0036] The second resin material 130 and the third resin material 140 are respectively stacked on the top and bottom of the core 110 in which the first resin material 120 is immersed. The second resin material 130 and the third resin material 140 may be formed with the same resin material, and may be formed in the same thickness. In addition, the second resin material 130 and the third resin material 130 are formed with the same thickness, and may be formed with resin materials having different physical properties.
[0037] The second resin material 130 and the third resin material 140 may be formed with thermosetting resin or ultraviolet light curing resin. The thermosetting resin can be urea resin, melamine resin, bismaleimide resin, polyurethane resin, resin with benzoxazine ring, cyanate ester resin, bisphenol S type epoxy resin, bisphenol F type ring Oxygen resin and copolymer epoxy resin of bisphenol S and bisphenol F, etc., but it is not limited thereto; and, if it is a well-known thermosetting resin, it may be used without limitation.
[0038] In addition, the ultraviolet light curing resin mainly uses acrylic resin, but it is not limited thereto; and, if it is a well-known ultraviolet light curing resin, it can be applied without limitation.
[0039] Although the second resin material 130 and the third resin material 140 will be explained in further detail in the method for manufacturing the following prepreg, in the semi-hardened state (stage B), they are stacked by being coated on the cover film 150 On the top and bottom of the core 110; and since they are compressed by applying heat and pressure to harden them in a predetermined thickness, one surface to be stacked is brought into contact with the core 110 in which the first resin material 120 is immersed.
[0040] At this time, on a plane, the first resin material 120 immersed in the core 110, the second resin material 130 arranged on the top of the core 110, and the third resin material 140 arranged on the bottom of the core 110 are stacked with interfaces; And, the interfaces formed between the first resin material 120 and the second resin material 130 and the first resin material 120 and the third resin material 140 may be located in the bent portion 111 of the core 110. That is, the interface between the first resin material 120 and the second resin 130 and the interface between the first resin material 120 and the third resin material 140 are formed between the top and bottom of the convex surface 111a or the concave surface 111b of the curved portion 111. Between, and to achieve the combination of resin materials.
[0041] Through such a configuration, the prepreg of the embodiment of the present invention is formed with the first resin material 120 as a thermosetting resin, which has relatively excellent hardness in the process of being completely cured; and, by making the first resin material 120 The core 110 is hardened in a manner that is arranged in the central part of the core 110, a low coefficient of thermal expansion (CTE) and a high transition temperature (Tg) can be obtained, and the core 110 in which the first resin material 120 is immersed is allowed to be formed in The role of the core of the prepreg in the film.
[0042] In addition, by including the bent portion 111 of the core 110 in a local area of ​​the hardened second resin material 130 and the third resin material 140 (having an interface with the first resin material 120), the first resin material 120 and the second resin material 120 can be improved. The resin material 130 and the bonding efficiency between the first resin material 120 and the third resin material 140 can prevent delamination between the resin materials.
[0043] More specifically, by positioning the interfaces between the first resin material 120 and the second resin material 130 and the first resin material 120 and the third resin material 140 inside the curved portion 111 of the core 110, the convex portion of the curved portion 111 is formed. The portion of the fabric or glass filament of the surface 111a can be combined with the first resin material 120 by immersing the portions of the second resin material 130 and the third resin material 140 in the convex surface 111a of the curved portion 111. The role of firmly connecting the second resin material 130 and the third resin material 140 to the first resin material 120.
[0044] The thus-configured prepreg according to an embodiment of the present invention may further include an inorganic filler in the core 110 in which the first resin material 120 is impregnated. The reason why the first resin material 120 impregnated in the core 110 further contains an inorganic filler is that although the first resin material 120, which is only a thermosetting resin or an ultraviolet curable resin, is impregnated in the core 110, the resin Hardening improves the rigidity of the core 110; however, since the core 110 is not prone to thermal deformation due to an increase in the thermal expansion coefficient, it can be warped by maintaining a low thermal expansion coefficient due to the content of the inorganic filler during the thermal compression process Deformation is minimized.
[0045] On the other hand, the second resin material 130 and the third resin material 140 are formed with resins having different physical properties. That is, they may be made of thermosetting resins or ultraviolet curable resins having different coefficients of thermal expansion (CTE).
[0046] At this time, the prepreg 100 of the embodiment of the present invention can control the overall warping direction of the prepreg 100, because when it is stacked on the top and bottom of the core 110, it can be constructed by making the second resin material 130 and the third resin material 140 There are resins having different thermal expansion coefficients so that they are arranged to be warped in the same direction or different directions of the first resin material 120 due to heat and pressure. In addition, since the second resin material 130 and the third resin material 140 are formed with resins that have the same thermal expansion coefficients that warp in opposite directions when they have the same physical properties, parallel prepregs without warpage can be manufactured.
[0047] On the other hand, the first resin material 120 immersed in the core 110 and the second resin material 130 stacked on the top of the core and the third resin material 140 stacked on the bottom of the core may be formed with different coefficients of thermal expansion (CTE ) Resin, and any one of the second resin material 130 and the third resin material 140 may be formed with a resin having the same CTE as that of the first resin material 120.
[0048] In addition, since in the embodiment of the present invention, the second resin material 130 stacked on top of the core 110 in which the first resin material 120 is immersed and the second resin material 130 stacked on the core 110 in which the first resin material 120 is immersed are The third resin material 140 at the bottom is formed with the same thickness, and in the process of manufacturing the prepreg, the top and bottom may be formed symmetrically with respect to the core 110. Therefore, during the thermal compression of the manufacturing process, the prepreg 100 according to the embodiment of the present invention can easily handle the warpage problem by arranging the resin as follows: the second resin material 130 and the third resin material 140 have different thermal expansions Coefficient, and has physical properties that bend in opposite directions during thermal compression.
[0049] Hereinafter, a method for manufacturing a prepreg thus constructed according to an embodiment of the present invention will be explained.
[0050] First, FIG. 2 is a process flow diagram showing a method for manufacturing a prepreg according to an embodiment of the present invention, Figure 2A with Figure 2B Is a cross-sectional view showing the core, Figure 2C Is a cross-sectional view showing the resin material stacked on the top and bottom of the core, Figure 2D It is a cross-sectional view showing a prepreg in which resin materials are stacked on the top and bottom of the core.
[0051] As shown in the figure, the prepreg according to the embodiment of the present invention prepares a fabric or glass filament woven into one to three rows of woven fabric or glass cloth core 110. The core 110 as described above is formed with a fabric having a curved portion 111, and the curved portion 111 may be formed by stacking the fabric or glass filaments on the top surface and the bottom surface.
[0052] After that, like Figure 2A As shown, the first resin material 120 is entirely coated, covering the bent portion 111 of the core 110. The first resin material 120 is impregnated between the fabric of the core 110, and the core 110 is hardened by thermosetting or UV curing (refer to Figure 2B ). At this time, when the first resin material 120 shrinks in the core 110 during hardening, the first resin material 120 is formed in a thickness thinner than the thickness of the bent portion 111 including the core 110.
[0053] The first resin material 120 immersed in the core 110 may maintain a hardening level in a semi-hardened state (ie, B stage) or in a fully hardened state (ie, C stage). In the case where the first resin material 120 is maintained in a semi-hardened state, if other resin materials are stacked and the other resin materials are compressed in a subsequent step, complete hardening may be performed.
[0054] After that, like Figure 2C As shown, the second resin material 130 is stacked on the top surface of the core 110 in which the first resin material 120 is immersed, and the third resin material 140 is stacked on the bottom surface of the core 110 in which the first resin material 120 is immersed. . The second resin material 130 and the third resin material 140 can be obtained by coating a resin material in a predetermined thickness on the cover film 150 made of an insulating film or copper foil, and can be in a semi-hardened state (ie, B-stage) The second resin material 130 and the third resin material 140 are coated.
[0055] After stacking the second resin material 130 on the top surface of the core 110 and stacking the third resin material 140 on the bottom surface of the core 110, the resin stack material is pressed by applying heat and pressure around the core 110. The pressing method of the resin stacked material may be a pressing method such as V-pressing, V-lamination, or rolling, and a predetermined heat may be applied when the resin stacked material is pressed.
[0056] When the second resin material 130 and the third resin material 140 are in contact with the core 110 by hot pressing, the surface for bonding with the first resin material 120 immersed in the core 110 is unified with the first resin material 120 by phase shifting. Combined ( Figure 2D ). At this time, the interfaces between the first resin material 120 and the second resin material 130 and the first resin material 120 and the third resin material 130 are located inside the curved portion 111 of the core 110. That is, the interface is formed at a position that does not deviate from the thickness range of the core 110 including the bent portion 111. Therefore, the interfaces between the first resin material 120 and the second resin material 130 and the first resin material 120 and the third resin material 140 are formed by the bent portion 111.
[0057] As such, when parts of the second resin material 130 and the third resin material 140 are immersed in the bent portion 111 of the core 110, the first resin material 120 and the second resin material 130, as well as the first resin material 120 and the third resin material When the interface between 140 is formed inside the bent portion 111 of the core 110, the lift or delamination between the resin materials can be prevented by causing the bent portion 111 of the core 110 to perform a bonding action between resins.
[0058] image 3 It is a process flow diagram showing a method for manufacturing a prepreg according to another embodiment of the present invention.
[0059] As shown in the figure, different from that shown in FIG. 2, when the second resin material 130 and the third resin material 140 are formed without immersing the first resin material 120 on the core 110 in advance, according to the present invention The method for manufacturing a prepreg of the embodiment collectively forms the first resin material 120 on the outermost surface, and the core 110 is interposed between the second resin material 130 and the third resin material 140, and is pressed in the block to be formed .
[0060] More specifically, according to the method for manufacturing a prepreg of an embodiment of the present invention, the second resin material 130 and the third resin material 140 are plated at a predetermined thickness on one surface of the cover film 150 made of an insulating film or a copper film. on.
[0061] After that, since the first resin material 120 is stacked on the second resin material 130 and the third resin material 140, the first resin material 120 is formed in a thickness thinner than that of the second resin material 130 and the third resin material 140. In addition, it is preferable to form the first resin material 120, the second resin material 130, and the third resin material 140 in a semi-hardened state (ie, B-stage).
[0062] At this time, although the first resin material 120 may be stacked after the second resin material 130 and the third resin material 140 are stacked on the cover film 150 in advance, different resin materials may be stacked on the cover film at the same time by double-layer coating. 150 on. In addition, when the first resin material 120 formed on the second resin material 130 and the third resin material 140 is immersed in the core 110 to be hardened, the second resin material stacked on the cover film 150 may be formed with the same thickness 130 and the third resin material 140, considering the shrinkage percentage of the resin material, it is preferable to control the thickness without exceeding the thickness range of the core 110.
[0063] After that, the core 110 is arranged between the second resin material 130 and the second resin material respectively stacked on the first resin material 120, and the second resin material 130 and the third resin material 140 are thermally compressed around the core 110 On the top and bottom of the block, prepregs 100 of three types of resin materials are sequentially stacked.
[0064] versus figure 1 Similar to the illustrated embodiment, the interface of the second resin material 130 and the third resin material 140 in contact with the first resin material 120 by the method for manufacturing the prepreg may be located in the bent portion 111 of the core 110.
[0065] On the other hand, FIGS. 4 and 5 are process cross-sectional views showing a method for manufacturing a prepreg according to another embodiment of the present invention, and FIG. 4 is a diagram showing that the second resin material stacked on the core is formed to be more Three process flow diagrams of thin resin material, FIG. 5 is a process flow diagram showing that the third resin material stacked on the core is formed to be thinner than the second resin material.
[0066] As shown in the figure, the second resin material 130 is stacked on top of the core 110 in which the first resin material 120 is immersed and the third resin material 140 is stacked on the core 110 in which the first resin material 120 is immersed. In the step on the bottom of the prepreg according to the embodiment of the present invention, resin materials having different thicknesses may be stacked as the second resin material 130 and the third resin material 140.
[0067] That is, as shown in FIG. 4, of the two types of resin materials stacked on the top and bottom of the core 110, the second resin material 130 stacked on the top may be formed to be larger than the third resin material 140 stacked on the bottom. thin.
[0068] In addition, as shown in FIG. 5, of the two types of resin materials stacked on the top and bottom of the core 110, the third resin material 140 stacked on the bottom may be formed to be larger than the second resin material 130 stacked on the top. thin.
[0069] As such, if the second resin material 130 and the third resin material 140 having different thicknesses are stacked on the top and bottom of the core 110, they are passed through a pressing method such as V-pressing, V-laminating or rolling (with image 3 The embodiment is similar to) Apply heat and pressure around the core 110 to press the resin stack material.
[0070] At this time, as shown in FIGS. 4 and 5, by forming one of the second resin material 130 or the third resin material 140 to be thinner than the other resin material, different materials can be stacked around the core 110. Resin materials are used to manufacture film-type prepregs.
[0071] In addition, when stacked by forming an interface in the first resin material 120 (the second resin material 130 and the third resin material 140 are immersed in the core 110 and the bent portion 111 of the core 110), the embodiment shown in FIGS. 4 and 5 is stacked. In the case of the prepreg manufactured by the manufacturing method of the example, the circuit is formed on the surface of a resin material having a thin thickness, and the resin material having a thin thickness among the resin materials of different thicknesses around the core 110 is stacked on one of the core 110 On the surface, a circuit pattern inserted in a resin material may be formed, and the resin material with a relatively thick thickness is stacked on the other surface of the core 110.
[0072] Therefore, the prepreg of the embodiment of the present invention can be manufactured as a thin film by reducing the thickness of the resin material stacked around the core 110 and inserting a circuit pattern into each surface of the resin material and the resin material.
[0073] By positioning the interfaces between the first resin material and the second resin material immersed in the core and the first resin material and the third resin material immersed in the core in the bent portion of the core, delamination or delamination between the resin materials can be prevented. The core can be lifted, and the core can function as a bond between the resin materials by immersing the top and bottom portions of the core including the bent portion above the central portion.
[0074] In addition, the present invention can easily manufacture parallel prepregs that do not generate warpage by forming a resin material, wherein the resin material is stacked on the top and bottom of a core having different resin materials, and is arranged as follows: Different thermal expansion coefficients cause warpage to occur in the same direction or in different directions.
[0075] The above description illustrates the invention. In addition, the above description only shows and explains the preferred embodiments of the present invention, but it should be understood that the present invention can be used in various other combinations, modifications and environments, and can be within the scope of the inventive concept as expressed herein. Make changes and modifications consistent with the above teachings and/or the prior art. The embodiments described above are intended to further explain the best way to practice the present invention, and enable those skilled in the art to use the present invention in such or other embodiments, and have various requirements for specific applications or use of the present invention. change. Therefore, the description is not intended to limit the present invention to the form described herein. In addition, the claims should be construed to include alternative embodiments.

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