Resin material for inserting a lead frame and a molded component thereof

Abstract: A resin material (2) with excellent heat resistance and excellent adhesion to a lead frame (1) for insertion in an electronic component comprises: (A) 100 parts by weight of a polyarylene sulphide resin, (B) 0.1 to 30 parts by weight of an α-olefin copolymer graft-copolymerized with an unsaturated carboxylic acid or its anhydride, and (C) 10 to 300 parts by weight of a fibrous filler, a nonfibrous inorganic filler or a mixture thereof.

Description: The present invention relates to a resin material for inserting a lead frame in an electronic component. More particularly, the present invention is concerned with a resin material for inserting a lead frame which exhibits an inmproved adhesion to a lead frame and has excellent heat resistance, moldability and other general properties. The invention is also concerned with a molded component comprising the above-mentioned resin material and a lead frame inserted therein. As a method of mounting electronic components on a printed board, a surface packaging technology using an infra-red oven, which can realize a higher packaging density, is being widely used in place of the method wherein the terminal of an electronic component is passed through a hole of a printed board and then soldered to the rear of the board. In accordance with this trend, plastic packages for electronic components are usually required to be resistant to high temperatures so as to ensure their ability to resist soldering heat. Moreover, the solvent used as a cleaning liquid for electronic components is usually a strong acid or a strong alkali, which make it necessary for the printed board to have solvent resistance sufficient to resist the solvent during the cleaning. In respect of these requirements, a polyarylene sulphide resin is the most suitable material as a plastic package for electronic components. However, the polyarylene sulphide resin has a drawback that since its adhesion to a lead frame is poor, cleaning liquid can penetrate into gaps between the lead frame and the plastic during the cleaning of electronic components and thereby contaminate the electrical contacts. To cope with this drawback, it is a common practice in the art to take measures, such as one wherein a primer or an adhesive is applied to a lead frame prior to molding and one wherein an epoxy resin having a desirable adhesion to a metal is used for potting at the root of a lead frame protruding from the package after molding EP-A-0 044 136 addresses the above problems and proposes the addition of a tacky or adhesive polymer to the polyarylene sulphide resin to improve adhesion. However, such measures complicate the process and cause extreme cost increases. Therefore, a material having excellent adhesion to a lead frame has been desired in the art. The present inventors have found that a composition comprising a polyarylene sulphide resin as a principal component and, blended therewith, an α-olefin copolymer graft-copolymerized with an unsaturated carboxylic acid or its anhydride and an inorganic filler has excellent heat stability, generates no significant decomposition gas or evaporating gas at temperatures employed for extruding and molding the polyarylene sulphide resin, and exhibits excellent adhesion to a lead frame without suffering from a lowering in mechanical properties. Thus the present invention provides a resin material for inserting a lead frame, which comprises: (A) 100 parts by weight of a polyarylene sulphide resin, (B) 0.1 to 30 parts by weight of an α-olefin copolymer graft-copolymerized with an unsaturated carboxylic acid or its anhydride, and (C) 10 to 300 parts by weight of a fibrous filler, a nonfibrous inorganic filler or a mixture thereof. The invention also provides a molded component comprising the above-described resin material and a lead frame inserted therein. The base resin as component (A) of the resin material of the present invention is a polyarylene sulphide resin composed of principal recurring units of the formula -(-Ar-S-) wherein Ar is an arylene group. Examples of the arylene group (-Ar-) include: a p-phenylene group a m-phenylene group an o-phenylene group a substituted phenylene group wherein R represents an alkyl group preferably having 1 to 6 carbon atoms or a phenyl group and n is an integer of 1 to 4 a p,p'-phenylenesulphone group a p,p'-biphenylene group a p,p'-diphenylene ether group a p,p'-diphenylene carbonyl group and a naphthalene group The polyarylene sulphide resin may be a polymer comprising only one type of recurring unit selected from the arylene sulphide groups composed of the above-described arylene groups, namely, a homopolymer. In some cases, it is preferably a copolymer comprising different types of recurring units described above from the viewpoint of workability of the final composition. The hompolymer is particularly preferably a poly-p-phenylene sulphide (hereinafter referred to as "PPS") comprising a p-phenylene sulphide group as an arylene group and having a substantially linear molecular structure. The copolymer is preferably one comprising the above-described arylene group or a m-phenylene sulphide group in an amount of from 5 to 50 mol%, especially from 10 to 25 mol%. In this case, a copolymer comprising recurring units in a block form (for example, a copolymer described in Japanese Laid-Open Patent Specification No. 14228/1986) is more favorable than a copolymer comprising recurring units in a random form because the former has higher heat resistance and mechanical properties while retaining substantially equal workability. The polyarylene sulphide resin to be used as component (A) in the present invention is not particularly limited but includes those subjected to oxidative cross-linking or thermal cross-linking. However, a substantially linear polymer having a low degree of cross-linking prepared by the polycondensation of a bifunctional monomer is preferred. Especially, a substantially linear polymer having a melt viscosity of 1 x 10 to 5 x 5 x 10⁵P, preferably 50 to 5 x 10⁴P, more favorably 100 to 5 x 10⁴P, as measured under conditions of a temperature of 310°C and a shear rate of 5/sec, is suitable. When the melt viscosity is lower than 10 P, the fluidity is so high that melt molding is difficult. In this case, even if a molded article is obtained, the mechanical properties of the article are disadvantageously low. On the other hand, when the melt viscosity is higher that 5 x 10⁵ P, the fluidity is so poor that melt molding is difficult. The α-olefin copolymer to be added as component (B) in the present invention must have an unsaturated carboxylic aced or its anhydride grafted thereonto. When an α-olefin not having an unsaturated carboxylic acid or its anhydride grafted thereon is added, the adhesion to a lead frame cannot be improved in the least. A copolymer comprising maleic anhydride as the unsaturated carboxylic acid or its anhydride and having a degree of grafting of 1.0 to 5.0% is particularly preferred. When the degree of grafting is lower than 1.0%, the adhesion to a lead frame cannot be sufficiently improved. On the other hand, when it is higher than 5.0%, a large amount of a decomposition gas or evaporating gas occurs disadvantageously during the extrusion or molding. From the viewpoint of preventing the occurrence of the decomposition gas or evaporating gas, it is preferred that a copolymer comprising ethylene/ethyl acrylate as a principal chain structure be used as the α-olefin copolymer. The amount of addition of component (B) is preferably 0.1 to 30 parts by weight based on 100 parts by weight of the polyarylene sulphide resin (A). when the amount of component (B) is too small, the adhesion to a lead frame is poor. On the other hand, when it is too large, the mechanical properties and heat resistance are insufficient. The filler to be used as component (C) in the present invention is an essential component for lowering the molding shrinkage ratio and the coefficient of linear expansion and for improving the adhesion to a lead frame. The filler may be fibrous or non-fibrous (a particulate or flaky form). Of the above fillers, particulate and flaky fillers are preferred because they are highly effective in suppressing the anisotropy of the molding shrinkage ratio and the coefficient of linear expansion. Examples of the filler include silicates, such as silica, quartz powder, glass beads, glass powder, calcium silicate, aluminium silicate, kaolin, talc, clay, diatomaceous earth and wollastonite, metal oxides, such as iron oxide, titanium oxide, zinc oxide and alumina, metal carbonates, such as calcium carbonate and magnesium carbonate, metal sulphates, such as calcium and barium sulphate, silicon carbide, silicon nitride, boron nitride and various metal powders. Of these, silica, talc and glass beads are particularly preferred. Mica, glass flake, etc are preferred as the flaky filler. The filler is particularly preferably a finely divided mica powder. With respect to the grain size of of the flaky filler, the smaller the better. It is generally desired that the average grain size be not larger than 200 µm. The fibrous filler is incorporated in order to improve the properties, such as mechanical strength and heat resistance. Examples of the fibrous filler include inorganic fibrous materials, such as glass fiber, asbestos fiber, silica fiber, silica/alumina fiber, zirconia fiber, boron nitride fiber, silicon nitride fiber, boron fiber and potassium titanate fiber. In addition, it is also possibe to use an organic fibrous material having a high melting temperature, such as polyamide, fluororesin and acrylic resin. A combination of a glass fiber having an average fiber length of from 30 to 500 µm with a particulate or flaky filler is particularly preferred. A combination of at least one member selected from a finely divided mica powder, talc and glass beads with glass fiber is particularly effective in improving the adhesion to a lead frame. If necessary, these fillers are used in combination with a binder or a surface treatment. Examples of the binder and surface treatment include functional compounds, such as epoxy compounds, isocyanate compounds, silane compounds and titanate compounds. These compounds may be used for the preliminary surface treatment or binding treatment of the filler. Alternatively, they may be added during the preparation of the material. In particular, organic silanes, especially an aminoalkoxysilane, a mercaptoalkoxysilane and a vinylalkoxysilane are suitable. The amount of the inorganic filler as component (C) is 10 to 300 parts by weight, preferably 50 to 200 parts by weight based on 100 parts by weight of polyarylene sulphide resin (A). When the amount is too small, the molding shrinkage ratio and the coefficient of linear expansion are too large and the adhesion to a lead frame cannot be sufficiently improved. On the other hand, when it is too large, the moldability is poor and the mechanical strength of the final molded article is insufficient. Further, the composition of the present invention may suitably contain known materials which are generally added to ordinary thermoplastic and thermosetting resins, i.e. stabilizers such as antioxidants and ultraviolet absorbers, antistatic agents, flame retardants, colorants such as dyes and pigments, lubricants and crystallization accelerators according to the desired performance. The resin material for inserting a lead frame according to the present invention can be prepared by employing the equipment and method generally used for the preparation of a synthetic resin composition. Specifically, necessary components may be mixed with each other and kneaded and extruded with a single-screw or a twin-scre extruder to prepare a molding pellet. ALternatively, part of the necessary components may be mixed as a master batch and melt extruded. Further, it is possible to employ a method which comprises pulverizing part or the whole of the polyarylene sulphide resin for the purpose of improving the dispersion, blending the components with each other and melt-extruding the mixture. The molded component having a lead frame inserted therein according to the present invention can be obtained by molding the above-described resin material according to the conventional metal insert injection molding method. That is, the shaped component can be produced at high efficiency by placing a lead frame in a predetermined position within a mold and performing injection molding. Figure 1 is one embodiment of a molded component having a lead frame inserted therein according to the present invention, wherein (A) is a plan view and (B) and (C) are side views. Figure 2 is a partially enlarged view of Figure 1 (A) showing the portion of measurement in an ink penetration test in the Examples. The reference numerals in the Figures indicate the following items: 1: lead frame (copper-made) [in the drawing, black portion] 2: resin portion [in the drawing, hatched portion] 3: lead frame terminals 4: gate portion 5: portion of measurement in an ink penetration test 1: ink penetration distance Examples The present invention will now be described in more detail with reference to the following non-limiting Examples. Examples 1 to 13 The materials listed in Table 1 were added in amounts specified in Tabale 1 to a polyarylene sulphide resin, and blended by means of an blender for 2 minutes. The blend was melt-kneaded by means of an extruder at a cylinder termperature of 310°C and molded into resin material pellets. The pellets were injection-molded by means of an injection molding machine at a cylinder temperature of 320°C by making use a mold having a lead frame placed therein, therby preparing a test piece having a lead frame inserted therein as shown in Figure 1. One terminal side of the test piece was immersed in a specific fluorescent ink (PEP fluorescent penetrant F-6A-SP; a product of Eishin Co., Ltd) to the half length of the test piece at room temperature for 15 minutes. The adhesion of the resin to the metallic lead frame was evaluated by the distance (1) of ink penetration between the resin and the lead frame due to capillary action. The maximum measurable ink penetration distance was 14 mm. The results are given in Table 1 wherein the flexural properties of a separately prepared standard test piece are also given. Comparative Examples 1 to 9 The same polyarylene sulphide resin as that of the Examples was prepared, and the materials listed in Table 2 were added thereto in amounts specified in Table 2, thereby producing a resin material (pellets). This was evaluated in the same manner as that of the Examples. The results are given in Table 2.

Claims: A resin material for insertion of a lead frame therein, which comprises: (A) 100 parts by weight of a polyarylene sulphide resin, (B) 0.1 to 30 parts by weight of an α-olefin copolymer graft-copolymerized with an unsaturated carboxylic acid or its anhydride, and (C) 10 to 300 parts by weight of a fibrous filler, a nonfibrous inorganic filler or a mixture thereof. A resin material according to claim 1, wherein the polyarylene sulphide resin (A) is a substantially linear polymer having a low degree of cross-linking and prepared by the polycondensation of a bifunctional monomer. A resin material according to claim 1, wherein the polyarylene sulphide resin (A) is a poly-p-phenylene sulphide homopolymer having a substantially linear molecular structure. A resin material according to claim 1, wherein the polyarylene sulphide resin (A) is a copolymer comprising 5 to 50 mol % of a p-phenylene sulphide group or a m-phenylene sulphide group. A resin material according to any preceding claim, wherein the unsaturated carboxylic acid or its anhydride constituting component (B) is maleic anhydride. A resin material according to any one of claims 1 to 4, wherein the α-olefin copolymer constituting component (B) is an ethylene/ethyl acrylate resin. A resin material according to any preceding claim, wherein the amount of component (B) is 5.0 to 20 parts by weight based on 100 parts by weight of the polyarylene sulphide resin (A). A resin material according to any preceding claim, wherein component (C) comprises a combination of at least one of powdery mica, talc and glass beads with glass fiber. A resin material according to any preceding claim, wherein the amount of component (C) is 50 to 200 parts by weight based on 100 parts by weight of the polyarylene sulphide resin (A). A molded component comprising a resin material according to any preceding claim and a lead frame inserted therein.

Inventors: NAKAI MIKIO, NAKAI, MIKIO
Applicants: POLYPLASTICS CO, POLYPLASTICS CO. LTD.
Application year: 1990
Main classification: H01L23
IPC codes: C08L81, H01L23, C08K3, C08K7