The present invention relates to a flame retardant resin material and a flame retardant resin composition, and more particularly to a flame retardant resin material and a flame retardant resin composition which are improved in flame retardancy, thermal stability or thermal decomposition resistance, and moisture resistance.
In order to prevent flame, it is required that resin compositions has a flame retardancy. Usually, halogen flame retardants are used as flame retardants whilst antimony trioxide is used as a co-flame retardant co-used along with the flame retardant. The halogen flame retardants generate harmful halogen substances, typically dioxins. The antimony trioxide as the co-flame retardant has a chronic toxicity. For those reasons, the above substances raise a problem in safety in fire or waste disposal. Phosphoric flame retardants such as red phosphorus and ester phosphate are effective to avoid the above problem. Those phosphoric flame retardants provide influences to moisture resistance of the resin compositions. Particularly, insulators for electronic components are required to have a high reliability. Those phosphoric flame retardants are a problem in use for the insulators for electronic components.
On the other hand, epoxy resin compositions are superior in mechanical properties, adhesive property, chemical resistance property, heat resistance and insulating properties, for which reason the epoxy resin compositions are used in various fields in adhesive, coating materials, laminated plates, molding materials and injection materials. In case of the epoxy resin compositions, halogen flame retardants are used as flame retardants whilst antimony trioxide is used as a co-flame retardant. If the flame retardant and the co-flame retardant are used for the epoxy resin composition, problems in not only safety but also corrosion of metals are raised. If those epoxy resin compositions are used as insulators for the electronic components, corrosion resistance to interconnections under high temperature is lowered, whereby reliability of the electronic device is deteriorated. For this reason, it had been required to develop other epoxy resin compositions free from the halogen flame retardant and antimony trioxide.
It was investigated to improve the flame retardancy of the resin material by introducing a triazine ring into a molecular structure of an epoxy resin or a phenol resin. In Japanese laid-open patent publication No. 8-311142, it is disclosed that mixtures of phenols with compounds having triazine rings and with aldehydes or phenol condensates such as phenol triazine resins are used as a hardening agent for the epoxy resin compositions. In Japanese laid-open patent publication No. 10-279657, it is disclosed that a phenol triazine epoxy resin obtained by glycidyl-etherification of the above described phenol triazine resin is used as a main component of the epoxy resin composition.
There is, however, the following problem in introducing the triazine rings into the molecular structures of the epoxy resins and the phenol resins.
The flame retardancy of the resin compositions including the phenol triazine resins and the phenol triazine epoxy resins is exhibited due to a flame reducing mechanism by flame resistant gases which contain, as a main component, nitrogen compounds generated by decomposition of triazines. If in order to emphasize the flame reducing effect, a content of nitrogen in the resin composition is increased, then the resistance to the thermal decomposition of the resin composition is deteriorated, whereby the flame retardancy is thus deteriorated. Since triazines have hydrophilicity, the increase in content of the triazines (nitrogen) in the resin composition causes a remarkable reduction in moisture resistance.
Consequently, it is difficult to further improve the flame retardancy of the resin composition by introducing nitrogen compounds into the molecular structure of the resin composition.
In the above circumstances, it had been required to develop a novel flame retardant resin material and a novel flame retardant resin composition free from the above problems.
Accordingly, it is an object of the present invention to provide a novel flame retardant resin material free from the above problems.
It is a further object of the present invention to provide a novel flame retardant resin material having a high frame retardancy.
It is a still further object of the present invention to provide a novel flame retardant resin material having a high thermal stability or a high thermal decomposition resistance.
It is yet a further object of the present invention to provide a novel flame retardant resin material having a high moisture resistance.
It is further more of the present invention to provide a novel flame retardant resin composition free from the above problems.
It is moreover object of the present invention to provide a novel flame retardant resin composition having a high frame retardancy.
It is another object of the present invention to provide a novel flame retardant resin composition having a high thermal stability or a high thermal decomposition resistance.
It is still another object of the present invention to provide a novel flame retardant resin composition having a high moisture resistance.
The present invention provides a flame retardant phenol resin material which includes a phenol condensate, wherein a poly-aromatic compound obtained by a reaction of phenols (A) to aromatics (B) except for phenols and a heterocyclic compound (C) including nitrogen as heteroatom are condensed via aldehydes (D).
The present invention also provides a flame retardant epoxy resin material which includes an epoxy resin obtained by glycidyl-etherification of at least a part of phenolic hydroxyl groups of a poly-aromatic compound obtained by a reaction of phenols (A) to aromatics (B) except for phenols and a heterocyclic compound (C) including nitrogen as heteroatom are condensed via aldehydes (D).
The present invention also provides a flame retardant resin composition including a flame retardant phenol resin material which includes a phenol condensate, wherein a poly-aromatic compound obtained by a reaction of phenols (A) to aromatics (B) except for phenols and a heterocyclic compound (C) including nitrogen as heteroatom are condensed via aldehydes (D).
The present invention also provides a flame retardant resin composition including a flame retardant epoxy resin material which includes an epoxy resin obtained by glycidyl-etherification of at least a part of phenolic hydroxyl groups of a poly-aromatic compound obtained by a reaction of phenols (A) to aromatics (B) except for phenols and a heterocyclic compound (C) including nitrogen as heteroatom are condensed via aldehydes (D).
The above and other objects, features and advantages of the present invention will be apparent from the following descriptions.