Phenol resin composition

Patent metadata

Field	Value
Publication number	US-12435216-B2
Application number	US-202017631712-A
Country	US
Kind code	B2
Filing date	Aug 6, 2020
Priority date	Aug 8, 2019
Publication date	Oct 7, 2025
Grant date	Oct 7, 2025

Abstract

A phenol resin composition used in a resin molded body for which a plating process is applied to a surface includes component (A), which is phenol resin and component (B), which is calcium carbonate.

First claim

The invention claimed is:

1. A phenol resin composition used in a resin molded body for which a plating process is applied to a surface, the phenol resin composition comprising the following components (A), (B) and a filler other than the component (B):
(A) a phenol resin; and
(B) calcium carbonate,
wherein the content of the component (B) in the resin composition is 1% by mass or more and 50% by mass or less with respect to the entire resin composition,
an average particle diameter d50 of the component (B) is 0.5 μm or more and 20 μm or less, and
the content of the filler other than the component (B) in the resin composition is 0.5% by mass or more and 50% by mass or less with respect to the entire resin composition.

2. The phenol resin composition according to claim 1 ,
wherein the component (A) includes a resol-type phenol resin and a novolac-type phenol resin.

3. The phenol resin composition according to claim 1 ,
wherein an average particle diameter d 50 of the component (B) is 0.1 μm or more and 30 μm or less.

4. The phenol resin composition according to claim 1 ,
wherein the component (A) includes a resol-type phenol resin and a novolac-type phenol resin, and
an average particle diameter d 50 of the component (B) is 0.1 μm or more and 30 μm or less.

5. The phenol resin composition according to claim 1 , further comprising:
a component (C), which is an elastomer.

6. The phenol resin composition according to claim 5 ,
wherein the component (C) includes one or two or more selected from the group consisting of a butadiene rubber, a butadiene acrylonitrile copolymer, and a modified polyvinyl alcohol.

7. The phenol resin composition according to claim 5 ,
wherein the resin molded body has a sea-island structure and the component (C) is present in an island phase.

8. The phenol resin composition according to claim 1 ,
wherein, for a cured product obtainable by curing the phenol resin composition at 180° C. for 4 hours after molding at 175° C. for 3 minutes, a linear expansion coefficient in a range of 40° C. to 150° C., measured by thermomechanical analysis at a temperature rise rate of 5° C./min, is 5 ppm/° C. or higher and 25 ppm/° C. or lower.

9. The phenol resin composition according to claim 1 ,
wherein a flexural strength of a cured product obtainable by curing the thermosetting resin composition at 180° C. for 4 hours after molding at 175° C. for 3 minutes is 50 MPa or more.

10. The phenol resin composition according to claim 1 ,
wherein a flexural modulus of a cured product obtainable by curing the thermosetting resin composition at 180° C. for 4 hours after molding at 175° C. for 3 minutes is 10.0 GPa or more.

11. A molded body comprising:
a cured product of the phenol resin composition according to claim 1 ; and
a plating layer provided in contact with a surface of the cured product.

12. The molded body according to claim 11 ,
wherein the cured product has a roughened layer on a bonding surface with the plating layer, and the plating layer is provided inside a recess provided in the roughened layer.

13. The molded body according to claim 11 ,
wherein the plating layer is a layer including one or two or more selected from the group consisting of Cu, Ni, Al, Fe, Au, and an alloy thereof.

14. The molded body according to claim 11 ,
wherein a thickness of the plating layer is 0.1 μm or more and 60 μm or less.

Assignees

• Sumitomo Bakelite Co

Inventors

• Ochiai Yuki
• Mochizuki Shunsuke

Classifications

• C08L2205/035

  containing four or more polymers in a blend · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L61/06 Primary

  of aldehydes with phenols · CPC title

• C08K2201/005

  Additives being defined by their particle size in general · CPC title

• C08K2201/003

  Additives being defined by their diameter · CPC title