Polymer composite formed article, printed wiring board using the formed article, and methods of producing them

Abstract

A thermoplastic polymer composite formed article or a thermoplastic polymer composite formed article formed from a thermoplastic polymer or a thermoplastic polymer and a fiber, wherein the fiber is arranged along a first plane and the molecular chains of the thermoplastic polymer or thermoplastic polymer is oriented in the direction intersecting with the first plane, and the molecular chains of the thermoplastic polymer or thermoplastic polymer has a degree (a) of orientation in a range of 0.5 or more and less than 1.0, and wherein the thermal expansion coefficients of said formed article in the direction along the first plane and in the direction intersecting with the first plane are both 5×10 −6 to 50×10 −6 (/K), and the difference between the thermal expansion coefficient in the direction along the first plane and the thermal expansion coefficient in the direction intersecting with the first plane is 30×10 −6 (/K) or less.

1 . An epoxy resin composite formed article composed of an epoxy resin and fibers, 
 wherein the fibers are arranged along a first plane and molecular chains of the epoxy resin are oriented in a direction intersecting with the first plane therein,    and that wherein a degree of orientation α of the molecular chains of the epoxy resin is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,      Degree of orientation α=(180−Δβ/180)   (1)    wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° at a fixed peak scatter angle in the X-ray diffraction measurement, and    wherein each of the thermal expansion coefficients of the epoxy resin composite formed article in the direction along the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less.    
   
   
       2 . The epoxy resin composite formed article according to  claim 1 , wherein the epoxy resin is a liquid crystalline epoxy resin having a mesogen group in its molecular.  
   
   
       3 . The epoxy resin composite formed article according to  claim 1 , wherein the fibers comprise at least one of a fiber cloth and single fibers.  
   
   
       4 . The epoxy resin composite formed article according to  claim 1 , wherein the fibers consist of at least one selected from glass fibers, ceramic fibers, carbon fibers, metal fibers, and organic fibers.  
   
   
       5 . A printed wiring board comprising: 
 an epoxy resin composite formed article composed of an epoxy resin and fibers, wherein the fibers are arranged along a first plane and molecular chains of the epoxy resin are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the epoxy resin is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,      Degree of orientation α=(180−αβ/180)   (1)    wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° at a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the epoxy resin composite formed article in the direction along the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less, and    an electrically conductive layer provided on at least one of a surface and inside of the epoxy resin composite formed article.    
   
   
       6 . A method for producing the epoxy resin composite formed article composed of an epoxy resin and fibers, wherein the fibers are arranged along a first plane and molecular chains of the epoxy resin are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the epoxy resin is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° at a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the epoxy resin composite formed article in the direction along the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less, said method comprising the steps of: 
 disposing the fibers within a cavity of a mold in such a manner that the fibers are arranged along the first plane,  
 impregnating the fibers with an epoxy resin composition by filling the cavity of the mold with the epoxy resin composition,  
 orienting molecular chains of the epoxy resin in a direction intersecting with the first plane, and  
 curing the epoxy resin composition while the orientation of the molecular chains of the epoxy resin is maintained.  
 
   
   
       7 . The method according to  claim 6 , wherein in the step of orienting the molecular chains of the epoxy resin, the orientation of the molecular chains of the epoxy resin is accomplished by application of a magnetic field thereto.  
   
   
       8 . A method for producing the printed wiring board including an epoxy resin composite formed article composed of an epoxy resin and fibers, wherein the fibers are arranged along a first plane and molecular chains of the epoxy resin are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the epoxy resin is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° at a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the epoxy resin composite formed article in the direction along the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less; and an electrically conductive layer provided on at least one of a surface and inside of the epoxy resin composite formed article, said method comprising the steps of: 
 disposing the fibers within a cavity of a mold in such a manner that the fibers are arranged along the first plane,  
 impregnating the fibers with an epoxy resin composition by filling the cavity of the mold with the epoxy resin composition,  
 orienting molecular chains of the epoxy resin in a direction intersecting with the first plane,  
 curing the epoxy resin composition while the orientation of the molecular chains of the epoxy resin is maintained, and  
 providing an electrically conductive layer on at least one of a surface and inside of the printed wiring board at least either prior to the step of disposing, or after the steps of impregnating, or curing.  
 
   
   
       9 . The method according to  claim 8 , wherein in the step of orienting, the orientation of the molecular chains of the epoxy resin is accomplished by application of a magnetic field thereto.  
   
   
       10 . A method for producing the epoxy resin composite formed article composed of an epoxy resin and fibers, wherein the fibers are arranged along a first plane and molecular chains of the epoxy resin are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the epoxy resin is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° at a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the epoxy resin composite formed article in the direction along the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less, said method comprising the steps of: 
 preparing an epoxy resin composition containing the fibers,  
 filing a cavity of a mold with the epoxy resin composition in such a manner that a major axis of each of the fibers are arranged along the first plane,  
 orienting molecular chains of the epoxy resin in a direction intersecting with the first plane, and  
 curing the epoxy resin composition, while the orientation of the molecular chains of the epoxy resin is maintained.  
 
   
   
       11 . A thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, 
 wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,      Degree of orientation α=(180−Δβ/180)   (1)    wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and    wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less.    
   
   
       12 . The thermoplastic polymer composite formed article according to  claim 11 , wherein the thermoplastic polymer is a liquid crystalline polymer having a mesogen group in its molecular.  
   
   
       13 . The thermoplastic polymer composite formed article according to claims  12 , wherein the liquid crystalline polymer is at least one selected from aromatic polyester, aromatic polyamide, and aromatic polyesteramide.  
   
   
       14 . The thermoplastic polymer composite formed article according to  claim 11 , wherein the fibers comprise at least one of a fiber cloth and single fibers.  
   
   
       15 . The thermoplastic polymer composite formed article according to  claim 11 , wherein the fibers consist of at least one selected from glass fibers, ceramic fibers, carbon fibers, metal fibers, and organic fibers.  
   
   
       16 . A printed wiring board formed of the thermoplastic polymer composite formed article comprising: 
 a thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,      Degree of orientation α=(180−Δβ/180)   (1)    wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less; and    an electrically conductive layer is provided on at least one of a surface and inside of the thermoplastic polymer composite formed article.    
   
   
       17 . A method for producing the thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1. as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less, said method comprising the steps of: 
 disposing the fibers within a cavity of a mold in such a manner that the fibers are arranged along the first plane,  
 impregnating the fibers with a thermoplastic polymer composition by filling the cavity of the mold with the thermoplastic polymer composition,  
 orienting molecular chains of the thermoplastic polymer in a direction intersecting with the first plane, and  
 solidifying the thermoplastic polymer composition while the orientation of the molecular chains of the thermoplastic polymer is maintained.  
 
   
   
       18 . A method for producing the thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less, said method comprising the steps of: 
 forming a preform of a thermoplastic polymer composition containing the thermoplastic polymer,  
 disposing the preform and the fibers within a cavity of a mold in such a manner the preform and the fibers are arranged along the first plane,  
 impregnating the fibers with a thermoplastic polymer composition by melting the preform,  
 orienting molecular chains of the thermoplastic polymer in a direction intersecting with the first plane, and  
 solidifying the thermoplastic polymer composition while the orientation of the molecular chains of the thermoplastic polymer is maintained.  
 
   
   
       19 . A method for producing the thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less, said method comprising the steps of: 
 preparing a thermoplastic polymer composition containing the thermoplastic polymer and the fibers,  
 filing a cavity of a mold with the thermoplastic polymer composition in such a manner that a major axis of each of the fibers are arranged along the first plane,  
 orienting molecular chains of the thermoplastic polymer in a direction intersecting with the first plane, and  
 solidifying the thermoplastic polymer composition, while the orientation of the molecular chains of the thermoplastic polymer is maintained.  
 
   
   
       20 . The method according to  claim 17 , wherein in the step of orienting the molecular chains of the thermoplastic polymer in the direction intersecting with the first plane, the orientation of the molecular chains of the thermoplastic polymer is accomplished by application of a magnetic field thereto.  
   
   
       21 . A method for producing the printed wiring board including a thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less; and an electrically conductive layer provided on at least one of a surface and inside of the thermoplastic polymer composite formed article, said method comprising the steps of: 
 disposing the fibers within a cavity of a mold in such a manner that the fibers are arranged along the first plane,  
 impregnating the fibers with a thermoplastic polymer composition by filling the cavity of the mold with the thermoplastic polymer composition,  
 orienting molecular chains of the thermoplastic polymer in a direction intersecting with the first plane,  
 solidifying the thermoplastic polymer composition while the orientation of the molecular chains of the thermoplastic polymer is maintained, and  
 providing an electrically conductive layer on at least one of a surface and inside of the printed wiring board at least either prior to the step of disposing, or after the steps of impregnating, or solidifying.  
 
   
   
       22 . A method for producing the printed wiring board including a thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less, and an electrically conductive layer provided on at least one of a surface and inside of the thermoplastic polymer composite formed article, said method comprising the steps of: 
 forming a preform of a thermoplastic polymer composition containing the thermoplastic polymer,  
 disposing the preform and the fibers within a cavity of a mold in such a manner the preform and the fibers are arranged along the first plane,  
 impregnating the fibers with an thermoplastic polymer composition by melting the preform,  
 orienting molecular chains of the thermoplastic polymer in a direction intersecting with the first plane,  
 solidifying the thermoplastic polymer composition while the orientation of the molecular chains of the thermoplastic polymer is maintained, and  
 providing an electrically conductive layer on at least one of a surface and inside of the printed wiring board at least either prior to the step of disposing, or after the steps of impregnating, or solidifying.  
 
   
   
       23 . A method for producing the printed wiring board according to  claim 16 , including a thermoplastic polymer composite formed article composed of a thermoplastic polymer and fibers, wherein the fibers are arranged along a first plane and molecular chains of the thermoplastic polymer are oriented in a direction intersecting with the first plane therein, wherein a degree of orientation α of the molecular chains of the thermoplastic polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,  
       Degree of orientation α=(180−Δβ/180)   (1)  
     wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and wherein each of the thermal expansion coefficients of the thermoplastic polymer composite formed article in the direction along to the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less: and an electrically conductive layer provided on at least one of a surface and inside of the thermoplastic polymer composite formed article, said method comprising the steps of: 
 preparing a thermoplastic polymer composition containing the thermoplastic polymer and the fibers,  
 filing a cavity of a mold with the thermoplastic polymer composition in such a manner that a major axis of each of the fibers are arranged along the first plane,  
 orienting molecular chains of the thermoplastic polymer in a direction intersecting with the first plane, and  
 solidifying the thermoplastic polymer composition, while the orientation of the molecular chains of the thermoplastic polymer is maintained, and  
 providing an electrically conductive layer on at least one of a surface and inside of the printed wiring board at least either prior to the step of disposing, or after the steps of impregnating, or solidifying.  
 
   
   
       24 . The method according to  claim 21 , wherein in the step of orienting the molecular chains of the thermoplastic polymer in the direction intersecting with the first plane, the orientation of the molecular chains of the thermoplastic polymer is accomplished by application of a magnetic field thereto.  
   
   
       25 . A polymer composite formed article composed of a polymer and fibers, 
 wherein the fibers are arranged along a first plane and molecular chains of the polymer are oriented in a direction intersecting with the first plane therein, and that wherein a degree of orientation α of the molecular chains of the polymer is in a range of 0.5 or more and less than 1, as determined by the following expression (1) based on X-ray diffraction measurement,      Degree of orientation α=(180−Δβ/180)   (1)    wherein Δβ represents a full width at half maximum in an intensity distribution measured in an azimuth angle direction from 0 to 360° with a fixed peak scatter angle in the X-ray diffraction measurement, and    wherein each of the thermal expansion coefficients of the polymer composite formed article in the direction along the first plane and in the direction intersecting with the first plane is in a range of 5×10 −6  to 50×10 −6  (/K) and a difference between the thermal expansion coefficients in the direction along the first plane and in the direction intersecting with the first plane is 30×10 −6  (/K) or less.    
   
   
       26 . The method according to  claim 18 , wherein in the step of orienting the molecular chains of the thermoplastic polymer in the direction intersecting with the first plane, the orientation of the molecular chains of the thermoplastic polymer is accomplished by application of a magnetic field thereto.  
   
   
       27 . The method according to  claim 19 , wherein in the step of orienting the molecular chains of the thermoplastic polymer in the direction intersecting with the first plane, the orientation of the molecular chains of the thermoplastic polymer is accomplished by application of a magnetic field thereto.  
   
   
       28 . The method according to  claim 22 , wherein in the step of orienting the molecular chains of the thermoplastic polymer in the direction intersecting with the first plane, the orientation of the molecular chains of the thermoplastic polymer is accomplished by application of a magnetic field thereto.  
   
   
       29 . The method according to  claim 23 , wherein in the step of orienting the molecular chains of the thermoplastic polymer in the direction intersecting with the first plane, the orientation of the molecular chains of the thermoplastic polymer is accomplished by application of a magnetic field thereto.