Barrier material formation composition, barrier material, production method for barrier material, product, and production method for product

Abstract

The present invention provides a barrier material formation composition comprising a silane oligomer, at least a part of the silane oligomer being modified with a metal alkoxide.

Claims

1. A barrier material formation composition comprising a silane monomer selected from the group consisting of alkyltrialkoxysilane, aryltrialkoxysilane, and tetraalkoxysilane, and an oligomer of silane, at least a part of the oligomer of silane being modified with a metal alkoxide, and the oligomer of silane having a silicon atom bonded to three oxygen atoms, wherein the content of the silane monomer is 100 parts by mass or less relative to 100 parts by mass of the oligomer of silane.

2. The composition according to claim 1, wherein the ratio of the total number of silicon atoms bonded to three oxygen atoms each and silicon atoms bonded to four oxygen atoms each relative to the total number of silicon atoms in the oligomer of silane is 50% or more.

3. The composition according to claim 1, wherein the silane monomer contains a silicon atom bonded to three or four oxygen atoms.

4. The composition according to claim 1, wherein the metal alkoxide is an aluminum alkoxide.

5. A production method for a barrier material formation composition, comprising: a first step of providing an oligomer of silane oligomer with at least a part thereof modified with a metal alkoxide; and a second step of mixing the oligomer of silane and a silane monomer selected from the group consisting of alkyltrialkoxysilane, aryltrialkoxysilane, and tetraalkoxysilane to obtain a barrier material formation composition, wherein the content of the silane monomer is 100 parts by mass or less relative to 100 parts by mass of the oligomer of silane.

6. The production method according to claim 5, wherein the first step comprises a step of causing a reaction between an oligomer of silane and a metal alkoxide to modify at least a part of the oligomer of silane with the metal alkoxide.

7. The production method according to claim 5, wherein the first step comprises a step of causing a reaction between a silane monomer and a metal alkoxide to form an oligomer of silane with at least a part thereof modified with the metal alkoxide.

8. A production method for a barrier material, comprising a step of heating the barrier material formation composition according to claim 1 to form a barrier material.

9. A production method for a product having a moisture resistant treated member comprising: a first step of applying the barrier material formation composition according to claim 1 to a member; and a second step of heating the applied composition to form a barrier material on the member.

10. A production method for a product having a first member and a second member joined to the first member, and a moisture resistant treated joint between the first member and the second member, the production method comprising: a first step of disposing the barrier material formation composition according to claim 1 between a first member and a second member; and a second step of heating the composition to form a barrier material to join the first member to the second member via the barrier material.

11. A production method for a product having a moisture resistant member, the production method comprising: a first step of heating the barrier material formation composition according to claim 1 to make a moisture resistant member having a barrier material; and a second step of putting a plurality of members including the moisture resistant member together.

Description

EXAMPLES

(1) The present invention is more specifically described with reference to Examples as follows, though the present invention is not limited thereto.

Example 1

(2) [Barrier Material Formation Composition 1]

(3) After mixing of 3.8 parts by mass of aluminum sec-butoxide (manufactured by Matsumoto Fine Chemical Co., Ltd., product name: AL-3001, hereinafter abbreviated as “AL-3001”), 7.6 parts by mass of tert-butyl alcohol (manufactured by Wako Pure Chemical Industries, Ltd.), 0.3 parts by mass of water, and 64.9 parts by mass of a silane oligomer (product name: XR31-B1410, manufactured by Momentive Performance Materials), a reaction was performed at 70° C. for 1 hour. Subsequently, 23.4 parts by mass of methyltrimethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., product name: KBM-13, hereinafter abbreviated as “MTMS”) was mixed therewith to obtain a barrier material formation composition 1.

(4) [Substrate with Barrier Material 1 for Evaluation]

(5) One side of a 0.4 mm thick copper-clad laminate MCL-E-705G (product name, manufactured by Hitachi Chemical Co., Ltd.) was masked and immersed in a copper etching solution to remove the copper foil on the single side, so that a 40 mm square base substrate was made. Subsequently, the barrier material formation composition 1 was applied to the side of the base substrate with the copper foil removed so as to have a thickness of 35 μm after drying and dried at 150° C. for 4 hours. A barrier material was thus formed on the substrate, and a substrate with barrier material 1 for evaluation was obtained.

Example 2

(6) [Barrier Material Formation Composition 2]

(7) After mixing of 3.8 parts by mass of AL-3001, 7.6 parts by mass of tert-butyl alcohol, 0.3 parts by mass of water, and 64.9 parts by mass of a silane oligomer (product name: XR31-B2733, manufactured by Momentive Performance Materials), a reaction was performed at 70° C. for 1 hour. Subsequently, 23.4 parts by mass of tetraethoxysilane (manufactured by Wako Pure Chemical Industries, Ltd., hereinafter abbreviated as “TEOS”) was mixed therewith to obtain a barrier material formation composition 2.

(8) [Substrate with Barrier Material 2 for Evaluation]

(9) A barrier material was formed on a substrate in the same manner as in Example 1 except that the barrier material formation composition 1 was changed to the barrier material formation composition 2, so that a substrate with barrier material 2 for evaluation was obtained.

Example 3

(10) [Barrier Material Formation Composition 3]

(11) A barrier material formation composition 3 was obtained in the same manner as in Example 2, except that 23.4 parts by mass of MTMS was mixed instead of TEOS.

(12) [Substrate with Barrier Material 3 for Valuation]

(13) A barrier material was formed on a substrate in the same manner as in Example 1 except that the barrier material formation composition 1 was changed to the barrier material formation composition 3, so that a substrate with barrier material 3 for evaluation was obtained.

Example 4

(14) [Barrier Material Formation Composition 4]

(15) After mixing of 3.8 parts by mass of AL-3001, 7.6 parts by mass of tert-butyl alcohol, 0.3 parts by mass of water, and 64.9 parts by mass of a silane oligomer (product name: TSR-165, manufactured by Momentive Performance Materials), a reaction was performed at 70° C. for 1 hour. Subsequently, 23.4 parts by mass of TEOS was mixed therewith to obtain a barrier material formation composition 4.

(16) [Substrate with Barrier Material 4 for Evaluation]

(17) A barrier material was formed on a substrate in the same manner as in Example 1 except that the barrier material formation composition 1 was changed to the barrier material formation composition 4, so that a substrate with barrier material 4 for evaluation was obtained.

Example 5

(18) [Barrier Material Formation Composition 5]

(19) A barrier material formation composition 5 was obtained in the same manner as in Example 1, except that 23.4 parts by mass of TEOS was mixed instead of MTMS and that 2.0 parts by mass of CR15 (product name, manufactured by Momentive Performance Materials) was further mixed as a curing catalyst.

(20) [Substrate with Barrier Material 5 for Evaluation]

(21) A barrier material was formed on a substrate in the same manner as in Example 1 except that the barrier material formation composition 1 was changed to the barrier material formation composition 5, so that a substrate with barrier material 5 evaluation was obtained.

Example 6

(22) [Barrier Material Formation Composition 6]

(23) To the barrier material formation composition 2 in Example 2, 2.0 parts by mass of a curing catalyst (CR15) was further mixed, so that a barrier material formation composition 6 was obtained.

(24) [Substrate with Barrier Material 6]

(25) A barrier material was formed on a substrate in the same manner as in Example 1 except that the barrier material formation composition 1 was changed to the barrier material formation composition 6, so that a substrate with barrier material 6 for evaluation was obtained.

Example 7

(26) [Barrier Material Formation Composition 7]

(27) To the barrier material formation composition 3 in Example 3, 2.0 parts by mass of a curing catalyst (CR15) was further mixed, so that a barrier material formation composition 7 was obtained.

(28) [Substrate with Barrier Material 7 for Evaluation]

(29) A bather material was formed on a substrate in the same manner as in Example 1, except that the barrier material formation composition 1 was changed to the barrier material formation composition 7, so that a substrate with barrier material 7 for evaluation was obtained.

Example 8

(30) [Barrier Material Formation Composition 8]

(31) A barrier material formation composition 8 was obtained in the same manner as in Example 2, except that 23.4 parts by mass of methyl silicate MS53A (product name, manufactured by Colcoat Co., Ltd.) was mixed instead of TEOS.

(32) [Substrate with Barrier Material 8 for Evaluation]

(33) A substrate with barrier material 8 for evaluation was obtained in the same manner as in Example 1, except that the barrier material formation composition 1 was changed to the barrier material formation composition 8.

Example 9

(34) [Barrier Material Formation Composition 9]

(35) After mixing of 3.8 parts by mass of AL-3001, 7.6 parts by mass of tert-butyl alcohol, 0.3 parts by mass of water, and 64.9 parts by mass of MTMS, a reaction was performed at 70° C. for 1 hour. Subsequently, 23.4 parts by mass of TEOS was mixed therewith, and 2.0 parts by mass of a curing catalyst (CR15) was further mixed with the resultant to obtain a barrier material formation composition 9.

(36) [Substrate with Barrier Material 9 for Evaluation]

(37) A substrate with barrier material 9 for evaluation was obtained in the same manner as in Example 1, except that the barrier material formation composition 1 was changed to the barrier material formation composition 9.

Comparative Example 1

(38) [Comparative Substrate 1 for Evaluation]

(39) A 0.4 mm thick, 40 mm square copper-clad laminate MCL-E-705G was used as the substrate for evaluation in Comparative Example 1 (Comparative substrate 1 for evaluation).

Comparative Example 2

(40) [Comparative Substrate 2 for Evaluation]

(41) A base substrate made by the method described in Example 1 was used as the substrate for evaluation in Comparative Example 2 (Comparative substrate 2 for evaluation).

(42) The water absorption ratio under constant temperature and humidity and the dehumidification ratio under high temperature of the substrates for evaluation obtained in Examples and Comparative Examples were measured and evaluated by the following method. The results are shown in Table 1.

(43) <(1) Measurement of Water Absorption Ratio Under Constant Temperature and Humidity>

(44) The substrate for evaluation was dried at 130° C. for 1 hour in a safety oven (product name: SPHH-202, manufactured by Espec Corp.) to obtain a measurement sample. The mass of the obtained measurement sample was measured to determine the initial mass m1. Subsequently, the measurement sample was treated in an atmosphere at 85° C./85% RH in a constant temperature and humidity chamber (product name: SE-44CI-A, manufactured by KATO Inc.) for 100 hours, so that a sample after the constant temperature and humidity treatment was obtained. The mass of the measurement sample after the constant temperature and humidity treatment was measured to determine the mass m2 after the constant temperature and humidity treatment. From the initial mass m1 and the mass m2 after the constant temperature and humidity treatment, the water absorption ratio Q.sub.A (%) was determined based on the following expression.
Q.sub.A=100×(m1−m2)/m2

(45) <(2) Measurement of Dehumidification Ratio Under High Temperature>

(46) The measurement sample after the constant temperature and humidity treatment in (1) described above was dried at 130° C. for 1 hour in a safety oven (product name: SPHH-202, manufactured by Espec Corp.) to obtain a measurement sample after the high temperature treatment. The mass m3 of the measurement sample after the high temperature treatment was measured, and the dehumidification ratio Q.sub.D (%) was determined from m1, m2 and m3 described above based on the following expression.
Q.sub.D=100×{1−(m3−m2)/(m1−m2)}

(47) TABLE-US-00001 TABLE 1 Water absorption ratio Dehumidification ratio Example 1 0.26 98.4 Example 2 0.21 98.6 Example 3 0.29 98.4 Example 4 0.24 98.2 Example 5 0.20 98.6 Example 6 0.20 98.8 Example 7 0.27 98.6 Example 8 0.19 98.8 Example 9 0.20 98.6 Comparative Example 1 0.09 66.6 Comparative Example 2 0.46 65.2

(48) From the comparison between Examples 1 to 9 and Comparative Example 2, it was confirmed that the water absorption ratio under constant temperature and humidity was sufficiently suppressed by the barrier materials in Examples 1 to 9, and that the barrier materials in Examples 1 to 9 thus have excellent moisture resistance. Further, from the comparison between Examples 1 to 9 and Comparative Example 1, it was also confirmed that the barrier materials in Examples 1 to 9 are excellent in the dehumidification ratio, which is an index of the capability to allow the internal water to escape to the outside, as compared with the case of covering with a copper plate.

(49) Further, the water absorption ratio after the measurement of the dehumidification ratio was about 0.03% in Comparative Example 1, whereas it was less than 0.005% in Examples 1 to 9. Thus, it was confirmed that use of the barrier materials in Examples 1 to 9 enables the internal water content to be significantly reduced by drying.

(50) The light transmittance at 550 nm per 1 mm thickness of the barrier materials formed in Examples 1 to 9 was measured, resulting in 95% or more in any of Examples.