Epoxy-Polyarylate Laminates for Heat Resistance and Plating Adhesion
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Solution Overview
Problem
Thermosetting epoxy resin compositions with a naphthalene structure fail to achieve a glass transition temperature of 180 °C or higher, leading to insufficient heat resistance, and increasing the blending ratio of the active ester compound to improve this also reduces plating adhesion.
Innovation Solution
A laminated structure comprising a resin layer with specific components: epoxy resin, polyarylate compound with a bisphenol structure and ester group, inorganic filler, and solvent, with a controlled mass loss rate of 3.0% or less after heating, forming a cured product with low surface roughness, excellent plating adhesion, and high heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the crosslink density is increased to improve heat resistance, then the glass transition temperature increases, but the plating adhesion deteriorates
Solution Approach 1:
The invention changes the chemical structure parameters of the ester compound from a naphthalene structure to a decalin structure, which fundamentally alters the molecular geometry and packing characteristics. This structural parameter change allows achieving high crosslink density (for heat resistance) without the surface roughness issues that plague naphthalene-based compounds (which harm plating adhesion). The decalin structure's saturated cyclic framework provides different steric and electronic properties compared to the aromatic naphthalene ring.
Solution Approach 2:
The invention creates a composite resin system combining epoxy resin with a specific decalin-based ester compound and silane-modified epoxy resin. This composite formulation synergistically achieves both high heat resistance (through crosslinking) and good plating adhesion (through controlled surface properties). The multiple resin components work together to balance the competing requirements of crosslink density and surface quality.
2Temperature
If the blending ratio of active ester compound is increased to increase crosslink density, then the glass transition temperature increases, but the surface roughness increases
Solution Approach 1:
The invention fundamentally changes the molecular structure parameter of the ester compound from aromatic (naphthalene) to alicyclic (decalin). This structural transformation alters how the molecules pack and interact at the surface, enabling high crosslink density to be achieved through bulk chemistry without creating the surface roughness that characterizes naphthalene-based systems. The saturated decalin ring provides different van der Waals interactions and steric effects compared to the planar aromatic ring.
Solution Approach 2:
The invention achieves different local properties within the resin system: the decalin-based ester compound provides bulk crosslinking (high glass transition temperature) while maintaining smooth surface characteristics. The silane-modified epoxy resin component specifically addresses surface quality by providing controlled surface energy and morphology. This spatial differentiation of functions resolves the contradiction between bulk heat resistance and surface smoothness.
3Temperature
If the crosslink density is increased to improve heat resistance, then the glass transition temperature increases, but the adhesion to plating layer deteriorates
Solution Approach 1:
The invention changes the chemical structure parameters of the ester compound from naphthalene to decalin, which fundamentally alters the surface properties and interfacial interactions. This structural parameter change enables achieving high crosslink density (for heat resistance) without the surface roughness and chemical composition issues at the interface that harm plating adhesion. The decalin structure provides different polarity and surface energy characteristics compared to the aromatic naphthalene ring.
Solution Approach 2:
The invention creates a composite resin system that balances bulk properties (heat resistance through crosslinking) with interfacial properties (plating adhesion). The combination of epoxy resin, decalin-based ester compound, and silane-modified epoxy resin works synergistically to achieve both high glass transition temperature and excellent adhesion to plating layers, resolving the contradiction between these two critical performance parameters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The laminated structure achieves a cured product with a surface roughness of less than 0.30 µm, peel strength from plating of 3.0 N/cm or more, and a glass transition temperature of 180 °C or more, addressing the issues of adhesion and heat resistance.
Implementation Method 1
the resin layer has a mass loss rate of 3.0 % by mass or less after heating the resin layer at a temperature of 100 °C. under atmospheric pressure for 20 minutes
Implementation Method 2
the resin layer comprises (A) an epoxy resin; (B) a polyarylate compound having a bisphenol structure and an ester group
Data Source
AI summary
The present invention provides a laminated structure capable of forming a cured product having a low roughness surface, excellent plating adhesion, and excellent heat resistance. The laminated structure of the present invention is a laminated structure comprising a first film and a resin layer provided on the first film, which is characterized by that the resin layer comprises (A) an epoxy resin, (B) a polyarylate compound having a bisphenol structure and an ester group, (C) an inorganic filler, and (D) a solvent, the (C) inorganic filler is comprised in the resin layer in an amount of 38 to 82 % by mass on a solid amount basis, and the resin layer has a mass loss rate of 3.0 % by mass or less after heating the resin layer at a temperature of 100 °C. under atmospheric pressure for 20 minutes.