US 12,247,124 B2
Resin sheet
Yasutaka Watanabe, Tokyo (JP); Yasunori Karasawa, Tokyo (JP); and Kazue Uemura, Tokyo (JP)
Assigned to LINTEC CORPORATION, Tokyo (JP)
Appl. No. 17/792,615
Filed by LINTEC CORPORATION, Tokyo (JP)
PCT Filed Jan. 15, 2021, PCT No. PCT/JP2021/001207
§ 371(c)(1), (2) Date Jul. 13, 2022,
PCT Pub. No. WO2021/145416, PCT Pub. Date Jul. 22, 2021.
Claims priority of application No. 2020-005184 (JP), filed on Jan. 16, 2020; and application No. 2020-126347 (JP), filed on Jul. 27, 2020.
Prior Publication US 2023/0090587 A1, Mar. 23, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. C08L 79/08 (2006.01); C08G 8/10 (2006.01); C08G 73/12 (2006.01); C08J 5/18 (2006.01); C08K 3/22 (2006.01); C08K 3/38 (2006.01); C08K 5/3492 (2006.01); C09D 179/08 (2006.01); H01L 23/29 (2006.01); H01L 23/31 (2006.01); H05K 1/03 (2006.01)
CPC C08L 79/08 (2013.01) [C08G 8/10 (2013.01); C08G 73/127 (2013.01); C08J 5/18 (2013.01); C08K 3/22 (2013.01); C08K 3/38 (2013.01); C08K 5/3492 (2013.01); C09D 179/08 (2013.01); H01L 23/295 (2013.01); H01L 23/31 (2013.01); H05K 1/03 (2013.01); C08J 2379/08 (2013.01); C08K 2003/2227 (2013.01); C08K 2003/385 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A resin sheet made using a resin composition comprising a thermosetting component (A) and a thermally conductive filler (C), wherein
the thermosetting component (A) comprises a first maleimide resin (A1), a second maleimide resin (A2), and a third maleimide resin (A3),
the first maleimide resin (A1) is a maleimide resin that is solid at a temperature of 25 degrees C. and has two or more maleimide groups in one molecule, at least a pair of the maleimide groups being bonded by a bonding group whose main chain comprises four or more methylene groups,
the second maleimide resin (A2) is represented by a formula (1) below or a formula (4) below,
the third maleimide resin (A3) is a maleimide resin that is liquid at a temperature of 25 degrees C. and has two or more maleimide groups in one molecule, at least a pair of the maleimide groups being bonded by a bonding group whose main chain comprises four or more methylene groups,
the first maleimide resin (A1) is represented by a formula (A1) below,
the third maleimide resin (A3) is represented by a formula (7) below,
a thermal diffusion rate of the resin sheet after being thermally cured is 1.0×10−6 m2/s or more, and
when a cross section (P) of the resin sheet taken by cutting the resin sheet in a vertical direction to a surface of the resin sheet is observed in an area (P1), a condition represented by a numerical formula (F1) below is satisfied, the area (P1) being defined by a square whose sides are four times as large as a thickness of the resin sheet, the area (P1) including two surfaces of the resin sheet,
0.25≤Ld/Lt≤1  (F1)
where Ld is a vertical length of a filler particle having a largest cross-sectional diameter in the vertical direction of the thermally conductive filler (C), and Lt is a length of the resin sheet in the vertical direction,

OG Complex Work Unit Chemistry
where, in the formula (A1):
n11 is an integer of 0 or more, and an average of n11 is in a range from 0.5 to 5,
L11 and L12 are each independently a substituted or unsubstituted alkylene group having 4 or more carbon atoms, in the alkylene group, at least one of —CH2— is optionally replaced with —CH2—O—, when a hydrogen atom of the alkylene group is replaced with a substituent, the substituent is an alkyl group having 1 to 14 carbon atoms or an alkoxy group having 1 to 14 carbon atoms, and the substituents are optionally bonded with each other to form an alicyclic or heterocyclic structure, and
X11 is each independently a group not having a substituted or unsubstituted alkylene group having 4 or more carbon atoms,

OG Complex Work Unit Chemistry
where, in the formula (1):
k is an integer of 1 or more, and an average of k is in a range from 1 to 10,
m1 and m2 are each independently an integer of 1 or more and 2 or less, and a sum of m1 and m2 is 3 or less,
n1 and n2 are each independently an integer of 0 or more and 4 or less,
R1 and R2 are each independently an alkyl group having 1 to 6 carbon atoms,

OG Complex Work Unit Chemistry
where, in the formula (4):
R3 to R6 are each independently a hydrogen atom or an alkyl group having 1 to 6 carbon atoms, L1 is an alkylene group having 1 to 3 carbon atoms, L2 and L3 are each independently an alkylene group having 1 to 2 carbon atoms, or an arylene group having 6 to 10 carbon atoms, p and q are each independently 0 or 1, and a sum of the carbon atoms of L1, L2 and L3 in a form of an alkylene group or alkylene groups is 3 or less,

OG Complex Work Unit Chemistry
where, in the formula (7):
n is an integer of 0 or more, and an average of n is in a range from 0.5 to 5,
L4 and L5 are each independently a substituted or unsubstituted alkylene group having 4 or more carbon atoms, in the alkylene group, at least one of —CH2— is optionally replaced with —CH2—O—, when a hydrogen atom of the alkylene group is replaced with a substituent, the substituent is an alkyl group having 1 to 10 carbon atoms or an alkoxy group having 1 to 10 carbon atoms, and the substituents are optionally bonded to form an alicyclic structure, and
X is each independently a group not having a substituted or unsubstituted alkylene group having 4 or more carbon atoms.