Primer, conductor foil with resin, laminated sheet and method of manufacturing laminated sheet

Abstract

A resin primer which can stick an insulator layer to a conductor foil, whose surface is not much roughened, with sufficient adhesive force, a conductor foil with resin, a laminated sheet and a method of manufacturing the same. The resin primer includes a resin having film-forming ability and a breaking energy of 0.15 J or more. The conductor foil with resin includes a conductor foil and the aforesaid resin primer. The laminated sheet includes the conductor foil, an insulating layer disposed facing the conductor foil, and a resin layer including the aforesaid resin primer disposed between the conductor foil and insulating layer so that it is in contact therewith. This laminated sheet can be manufactured by heating and pressurizing a laminate including the aforesaid conductor foil with resin, and a prepreg laminated on this resin.

1 . A resin primer containing a resin, wherein:
 said resin contains a polyamideimide, and the polyamideimide has a structural unit of a saturated hydrocarbon.   
     
     
         2 . A resin primer according to  claim 1 , wherein said structural unit is expressed by the following chemical formula (5): 
       
         
           
           
               
               
           
         
       
     
     
         3 . The resin primer according to  claim 1 , wherein said polyamideimide is obtained by the reaction of a diimide-dicarboxylic acid, obtained by reacting a diamine compound and anhydrous trimellitic acid, with a diisocyanate, the diamine compound being expressed by the following general formulae (6a), (6b) or (6c): 
       
         
           
           
               
               
           
         
       
       [in the formulae, R 61  is a hydrogen atom, or a hydroxyl, methoxy, methyl or halogenated methyl group, R 62  is one of the groups expressed by the following general formulae (7a), (7b), (7c) or (7d), an alkylene group having 1-3 carbon atoms, a halogenated alkylene group having 1-3 carbon atoms, a sulfonyl group, an ether group, a carbonyl group or a single bond, and R 63  is an alkylene group having 1-3 carbon atoms, a halogenated alkylene group having 1-3 carbon atoms, a sulfonyl group, an ether group or a carbonyl group: 
       
         
           
           
               
               
           
         
       
       where, in formula (7a), R 7  is an alkylene group having 1-3 carbon atoms, a halogenated alkylene group having 1-3 carbon atoms, a sulfonyl group, an ether group, a carbonyl group or a single bond; and the plural R 61 s may be respectively identical or different]. 
     
     
         4 . The resin primer according to  claim 3 , which further contains the compound expressed by the following general formula (8) as said diamine compound: 
       
         
           
           
               
               
           
         
       
       [in the formula, R 81  is a methylene group, sulfonyl group, ether group, carbonyl group or single bond, R 82  and R 83  are respectively a hydrogen atom, alkyl group, phenyl group or substituted phenyl group, and m is an integer from 1-50]. 
     
     
         5 . The resin primer according to  claim 3 , which contains an aromatic diisocyanate as said diisocyanate. 
     
     
         6 . The resin primer according to  claim 1 , further containing a reactive compound having a functional group which reacts with an amide group of said polyamideimide. 
     
     
         7 . A conductor foil with resin comprising a conductor foil and a resin layer provided on said conductor foil, wherein:
 the 10 point average roughness of the surface of said conductor foil is 3 μm or less; and   said resin layer is formed by coating the resin primer according to  claim 1  on the surface of said conductor foil.   
     
     
         8 . A conductor foil with resin comprising a conductor foil and a resin layer provided on said conductor foil, wherein:
 said conductor foil is a metal foil, and   said resin layer is formed by coating the resin primer according to  claim 1  on said metal foil.   
     
     
         9 . A laminated sheet obtained by heating and pressurizing a laminate comprising the conductor foil with resin according to  claim 7  and a prepreg laminated on said resin layer of said conductor foil with resin. 
     
     
         10 . A laminated sheet, comprising:
 a conductor foil;   an insulating layer containing a resin disposed facing said conductor foil; and   a resin layer comprising the resin primer according to  claim 1  disposed between said conductor foil and said insulating layer so that it is in contact therewith.   
     
     
         11 . The laminated sheet according to  claim 10 , wherein the 10 point average roughness of at least the surface of the conductor foil in contact with said resin layer is 3 μm or less. 
     
     
         12 . A method of manufacturing a laminated sheet by heating and pressurizing a laminate comprising the conductor foil with resin according to  claim 7 , and a prepreg laminated on said resin layer of said conductor foil with resin.