Halogen-Free Resin Composition for High-Frequency Flame Retardancy

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Solution Overview

Problem

Current resin compositions fail to provide sufficient dielectric characteristics for high-frequency applications above 10 GHz while maintaining adequate flame retardancy, particularly in 5G communication systems and millimeter wave radar, where existing solutions like PTL 1 do not fully meet the high demand for dielectric performance.

Innovation Solution

A resin composition incorporating a phosphate ester-based flame retardant with an aromatic hydrocarbon group and a polyphenylene ether derivative having ethylenically unsaturated bonds, along with a maleimide compound, to enhance dielectric properties and flame retardancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a large amount of phosphorus-containing flame retardant is added to achieve sufficient flame retardancy in halogen-free materials, then flame retardancy is improved, but dielectric characteristics deteriorate

Engineering Contradiction:

Improveflame retardancyVSAvoiddielectric characteristics

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes the chemical structure parameters of the flame retardant by using phosphate esters with specific aromatic hydrocarbon groups, and adjusts the addition amount to an optimized range (0.2-5% by mass based on solid components excluding inorganic fillers) to achieve both flame retardancy and good dielectric characteristics

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite resin composition combining polyphenylene ether derivative (with ethylenically unsaturated bonds at both ends) and phosphate ester-based flame retardant, where the specific combination and ratio of components work synergistically to achieve both flame retardancy and excellent dielectric properties for high-frequency applications

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional brominated flame retardants are used to achieve good flame retardancy, then flame retardancy is improved, but environmental safety deteriorates

Engineering Contradiction:

Improveflame retardancyVSAvoidenvironmental safety

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and eliminates harmful halogen elements (bromine and chlorine) from the flame retardant system, replacing conventional brominated flame retardants with halogen-free phosphate ester-based alternatives that maintain flame retardancy without producing toxic combustion products

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the previously harmful halogen-containing flame retardants into beneficial halogen-free alternatives, where the phosphate ester-based flame retardant provides both flame retardancy and environmental safety by eliminating toxic brominated dibenzodioxin and furan production during incineration

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS11905412B2Resin composition, prepreg, laminate, multilayer printed wiring board, and semiconductor package

Publication Date: 2024.02.20 RESONAC CORP

AI summary

The present invention relates to a resin composition containing a phosphate ester-based flame retardant (A) having an aromatic hydrocarbon group containing two or more aromatic ring structures and a polyphenylene ether derivative (B) having an ethylenically unsaturated bond-containing group at both ends.