Patent ID: 6387205
Filing Date: 2002-05-14
Classification: B29B,B29C,B29K,B29L,B32B,C03C,C08J,D06N,H01L,H05K,Y10S,Y10T

Abstract:
A method of forming a core comprising the steps of:providing at least one sheet of a cloth having fibers and interstices between the fibers, a first coating of a selected thermosetting resin surrounding said fibers, with at least some of said interstices unfilled, a second coating of a thermosetting resin disposed over said first coating and essentially filling all said interstices unfilled by said first coating, said first coating being cured to at least 80% of full cure, said second coating being cured to between 20% and 40% of full cure, a rapid transition zone between said first and second coatings that is smooth, substantially continuous with crosslinking between said first and second coatings providing an essentially continuous polymer of two layers, and laminating said at least one sheet of material between two metal sheets by application of pressure and heat sufficient to essentially fully cure said resins impregnated in the cloth and form a laminate structure of said metal sheets and said sheet of material.