# Patent

## Title
Dielectric material with low dielectric loss

## Abstract

The invention provides a dielectric material with low dielectric loss. The dielectric material comprises (i) 40 ̃80 parts by weight of polyphenylene ether resin having a Mw of 1000 ̃7000, a Mn of 1000 ̃4000 and Mw/Mn=1.0 ̃1.8; (ii) 5 ̃30 parts by weight of bismaleimide resins; and (iii) 5 ̃30 parts by weight of polymer additives, wherein the dielectric material has Dk of 3.75 ̃4.0 and Df of 0.0025 ̃0.0045. The dielectric material is suitably used in prepregs and insulation layers of a circuit board, because it has high Tg, low thermal expansion coefficient, low moisture absorption and excellent dielectric properties such as Dk and Df.

## Background
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to a dielectric material with low dielectric loss, particularly to a resin composition.
2. Related Art
As developed with wireless transmission products and technologies of transmitting high frequency, epoxy resin and novolak resin cannot satisfied for the advance application, especially high frequency printed circuit board (PCB). Fluorine-containing resin can be used as PCB with low dielectric loss. However, fluorine-containing resin is expensive and not easy to work, and thus limited to the use of military and astrodynamics. In addition, polyphenylene ether (PPE) resin has excellent mechanical property and dielectric property such as Dk and Df Therefore, the PPE resin is preferable to be used a material for high frequency PCB.
However, because the PPE resin is a thermal plastic resin, as applied in a copper-clad laminate, it may has disadvantages as follows: it is not easy to work due to a high melting viscosity of PPE resin, interlayer film is easy released in a solvent clean step during a process for manufacturing PCB due to a poor solvent resistance of PPE resin, and it is not easy to operate above a temperature of 250° C. in soldering process due to melting point close to Tg. Therefore, PPE resin has to be modified by curing so as to meet the requirement of using in PCB.
Curing modification of PPE resin generally has two manners: PPE resin may become curable resin by introducing crosslinking active functional groups to molecular structure of PPE resin. Alternatively, PPE resin may become co-mixing curable composite material by introducing other curable resins to molecular structure of PPE resin with co-mixing modification or interpenetrating network technology. However, PPE resin is likely incompatible with the active functional groups or curable resins, because the polar difference exists in their chemical structures. Alternatively, PPE resin may lose the excellent properties, after it conducts curing modification with the active functional groups or curable resins.
Therefore, there is a need to develop a material has excellent dielectric properties and other properties such as high Tg, low coefficient of thermal expansion and low water absorption of PCB requirement. Also, the material can be applied in the manufacture of high frequency PCB.
SUMMARY OF THE INVENTION
An object of the invention is to provide a dielectric material with low dielectric loss, which has excellent dielectric properties, low coefficient of thermal expansion and low water absorption.
To accomplish the above object, there is provided a dielectric material with low dielectric loss, which comprises (i) 40 ̃80 parts by weight of polyphenylene ether resin having a Mw of 1000 ̃7000, a Mn of 1000 ̃4000 and Mw/Mn=1.0 ̃1.8; (ii) 5 ̃30 parts by weight of bismaleimide; and (iii) 5 ̃30 parts by weight of polymer additives, wherein the dielectric material has Dk of 3.75 ̃4.0 and Df of 0.0025 ̃0.0045.
In the dielectric material with low dielectric loss of the invention, the polyphenylene ether resin is represented by the formula




wherein Y represents at least one C, O and benzene ring or the combination.
In the dielectric material with low dielectric loss of the invention, bismaleimide resins are selected from groups consisting of
Phenylmethane maleimide




wherein n≧1;
Bisphenol A diphenyl ether bismaleimide




3,3′-dimethyl-5,5′-diethyl-4,4′-diphenylethane bismaleimide




and

1,6-bismaleimide-(2,2,4-trimethyl)hexane.




In the dielectric material with low dielectric loss of the invention, the polymer additives are selected from groups consisting of
Homopolymers of Butadiene




wherein y=70% and x+z=30%;
Random copolymers of butadiene and styrene




wherein y=30%, x+z=70% and w=≧1, and the amount of styrene=25 wt %;
Maleinized Polybutadiene




wherein y=28% and x+z=72%, the amount of maleic anhydride=8 wt %;
Butadiene-styrene-divinylbenzene copolymer; and
Styrene Maleic Anhydride copolymer




wherein X=1 ̃8 and n≧1.
In the dielectric material with low dielectric loss of the invention, it is preferable that crosslinking agent is added to increase crosslinking density of resins. The crosslinking agents with 40-80 parts by weight may be selected from the following groups consisting of




In the dielectric material with low dielectric loss of the invention, it is preferable that catalyst is added to increase reaction of crosslinking agents and other resins. The catalysts includes at least one peroxide having 116° C.-128° C. for a half life of 10 hours with 2-8 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents. The suitable peroxides comprise dicumyl peroxide, α,α′-bis(tert-butylperoxy)diisopropyl benzene and 2,5-di(tert-butylperoxy)-2,5-dimethyl-3-hexyne.
In the dielectric material with low dielectric loss, it is preferable that filler is added to increase thermal conductivity and mechanical strength, and reduce thermal expansion. The suitable fillers may be fused silica, sphere-shaped silica, talc and aluminum silicate.
In order to increase flame retardation of the dielectric material of the invention, halogen-containing flame retardants and flame retardants without halogen may be used. The halogen-containing flame retardants may comprise decabromodiphenyl ethane. The flame retardants without halogen may comprise phosphor-containing flame retardants and phosphates. The phosphor-containing flame retardants and phosphates are produced by ALBEMARLE CO., LTD. The phosphates are like tetrakis(2,6-dimethylphenyl) 1,3-phenytene bisphosphate. tetrakis(2,6-dimethylphenyl) 1,3-phenylene bisphosphate can be represented by the formula,

[OC6H3(CH3)2]2P(O)OC6H4OP(O)[OC6H3(CH3)2]2 

The foregoing and other objects, features and advantages of the present invention will be apparent to those skilled in the art from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
No Drawings


DETAILED DESCRIPTION OF THE INVENTION
In one aspect of the present invention, there is provided a thermal curable dielectric material to produce a prepreg in a successive process in the following examples 4-1 to 4-7. The process uses the dielectric material as a coating on a substrate which may be a fiberglass cloth. The apparatus for producing the prepreg includes a pasting tank wherein there are provided a plurality of rolls. The pasting tank is filled with the dielectric material. A roll of fiberglass cloth may enter the pasting tank and pass the plurality of rolls. The fiberglass cloth is sufficiently impregnated with the dielectric material, and then surplus dielectric material is removed by a metering roller. A heat treatment for curing the dielectric material and removing the solvent is required at 100° C. to 350° C. for 1 minute to 5 hours, preferably at 150° C. to 300° C. for 1 minute to 3 hours. The prepreg is Obtained after the cured dielectric material is cooled down and the fiberglass cloth is wrapped.
A double-sided copper-clad laminate is produced by providing several prepregs in a neat stack between two electrodeposited copper foils, conducting a hot pressing process under 40 to 900 psi, raising temperature from 80° C. to 200° C. in 30 minutes, and then hot pressing at 200° C. for 120 minutes, and then cooling down to room temperature in 30 minutes in a vacuum pressing machine. The prepreg includes a fiberglass cloth of electrical grade 2116 and the dielectric material. Generally, a double-sided copper-clad laminate with a thickness of 1.0 mm is produced by providing 4 sheets of prepregs in a neat stack between two electrodeposited copper foils, with a thickness of 1.5 mm is produced by providing 7 sheets of prepregs, and with a thickness of 2.0 mm is produced by providing 10 sheets of prepregs.
The dielectric material of the present invention may form a stable homogeneous solution in a solvent with a low boiling point. The properties of a copper-clad laminate with the dielectric material of the invention were determined including Tg, heat decomposition temperature, heat decomposition time, solder heat resistance (288° C.), thermal expansion coefficient, water absorption, thermal conductivity, dielectric constant, dielectric loss tangent and flammability according to IPC-TM-650 test method manual. The determining results show the copper-clad laminate with the dielectric material of the invention has high Tg, excellent dielectric properties such as Dk and Df, low water absorption, high thermal resistance and high thermal conductivity. The copper-clad laminate is suitable used as a substrate for electronic elements and IC package.
EXAMPLES 







TABLE 1







INFLUENCE OF PPE RESIN AMOUNT


EXAMPLE 4-1









AMOUNT OF PPE RESIN















C1
C2
C3
C4
C5
C6
C7



















PPE resin
SA9000
60
52.5
45
41
37.5
34
22.5


BMI resin
5100
15
15
15
15
15
15
15


Polybutadiene
Ricon100
10
10
10
10
10
10
10


Crosslinking
TAIC
15
22.5
30
34
37.5
41
52.5


agents


Flame
XP7866, phr
20
20
20
20
20
20
20


retardants


fillers
Fused silica,
20
20
20
20
20
20
20



phr


catalysts
Peroxide
2.5
2.5
2.5
2.5
2.5
2.5
2.5



119° C. for a



half life of



10 hrs


Tg, TMA
IPC-TM-650
206
224
229
221
212
213
212



2.4.24.3


coefficient of
IPC-TM-650
58/334
60/305
56/251
53/247
56/211
61/204
55/245


thermal
2.4.24


expansion


(α1/α2), ppm/° C.


water
PCT/121° C./
0.29
0.33
0.34
0.34
0.39
0.39
0.40


absorption
1 hr


288° C.
Dip288° C.
>600
>600
>600
>600
>600
>600
>600


thermal


resistance


Dk(2-10 GHz)
Cavity
3.93
3.89
3.89
3.89
3.90
3.86
3.87


Df(2-10 GHz)
Cavity
0.0057
0.0054
0.0048
0.0044
0.0040
0.0040
0.0039


flammability
UL94
V-0
V-0
V-0
V-0
V-0
V-0
V-0









Tg, Dk and Df were compared with different ratio and amount of PPE. The Tg level may be affected by the amount of PPE used. Also, the amount of PPE may also have an effect on the Dk and Df value. When the amount of PPE is high, Dk and Df may be high. When the amount of PPE is low, Dk and Df may be low. Typically, a low value for the Dk and Df is preferred. In addition, the thermal expansion coefficient may be raised when PPE is added, and BMI is added to balance the effect. In Table 1, part number SA9000 of PPE with chemical name of Polyphenylene Oxide (PPO) or Polyphenylene Ether (PPE) is produced by Sabic CO., LTD.







TABLE 2





INFLUENCE OF BMI RESIN SPECIES AND AMOUNT


EXAMPLE 4-2

















BMI RESIN


















A1
A2
A3
A4
A5
A6
A7
A8





PPE resin
SA9000
42.5
40
37.5
35
32.5
37.5
37.5
37.5


BMI resin
2300
0
0
0
0
0
0
15
0



4000
0
0
0
0
0
15
0
0



5100
5
10
15
20
25
0
0
0



TMH
0
0
0
0
0
0
0
15


Polybutadiene
Ricon100
10
10
10
10
10
10
10
10


Crosslinking
TAIC
42.5
40
37.5
35
32.5
37.5
37.5
37.5


agents


Flame
XP7866,
20
20
20
20
20
20
20
20


retardants
phr


fillers
Fused
20
20
20
20
20
20
20
20



silica,



phr


catalysts
Peroxide
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5



119° C.



for a half



life of 10 hrs


Tg, TMA
IPC-TM-650
210
212
212
211
211
212
222
195



2.4.24.3


Coefficient of
IPC-TM-650
60/296
58/250
56/211
54/207
50/197
55/260
45/170
45/288


thermal
2.4.24


expansion


(α1/α2),


ppm/° C.


water
PCT/121° C./
0.30
0.34
0.39
0.44
0.46
0.41
0.47
0.33


absorption
1 hr


288° C.
Dip288° C.
>600
>600
>600
>600
>600
>600
>600
>600


thermal


resistance


Dk(2-10 GHz)
Cavity
3.85
3.87
3.90
3.94
3.98
3.91
3.93
3.86


Df(2-10 GHz)
Cavity
0.0040
0.0041
0.0040
0.0042
0.0043
0.0042
0.0046
0.0041


flam-
UL94
V-0
V-0
V-0
V-0
V-0
V-1
V-0
V-0


mability












BMI RESIN

























Compar-ative




A9
A10
A11
A12
A13
A14
A15
example





PPE resin
SA9000
37
37
37
37
37
37.5
37
50


BMI resin
2300
8
0
8
0
0
5
4
0



4000
8
8
0
8
0
5
4
0



5100
0
8
0
0
8
5
4
0



TMH
0
0
8
8
8
0
4
0


Polybutadiene
Ricon100
10
10
10
10
10
10
10
0


Crosslinking
TAIC
37
37
37
37
37
37.5
37
50


agents


Flame
XP7866,
20
20
20
20
20
20
20
20


retardants
phr


fillers
Fused
20
20
20
20
20
20
20
20



silica,



phr


catalysts
Peroxide
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5



119° C.



for a half



life of 10 hrs


Tg, TMA
IPC-TM-650
208
204
205
200
214
210
207
218



2.4.24.3


Coefficient of
IPC-TM-650
50/210
57/278
45/230
52/268
54/290
53/240
49/225
64/325


thermal
2.4.24


expansion


(α1/α2),


ppm/° C.


water
PCT/121° C./
0.43
0.42
0.41
0.36
0.44
0.40
0.39
0.33


absorption
1 hr


288° C.
Dip288° C.
>600
>600
>600
>600
>600
>600
>600
>600


thermal


resistance


Dk(2-10 GHz)
Cavity
3.96
3.91
3.90
3.87
3.89
3.91
3.90
3.80


Df(2-10 GHz)
Cavity
0.0041
0.0041
0.0045
0.004
0.0039
0.0041
0.0043
0.0044


flam-
UL94
V-0
V-0
V-0
V-0
V-0
V-0
V-0
V-0


mability









The coefficient of thermal expansion was measured with different species and amount of BMI resin. The more the amount of BMI resin is, the lower the coefficient of thermal expansion is. In the example, there are three kinds of comparison comprising three groups that A1-A5 shows different amount of BMI with the same species, A6-A8 shows the same amount of BMI with different species and A9-A15 shows about the same total amount of BMI with more than two species. In Table 2, part numbers 2300, 4000, 5100 and TMH of BMI are produced by Daiwakasei Industry CO., LTD, in which part number 2300 has chemical name of phenyl methane maleimide, part number 4000 has chemical name of 2,2′-bis[4-(4-maleimidophenoxy)phenyl]propane, part number 5100 has chemical name of 3,3′-dimethyl-5,5′-diethyl-4,4′-diphenylmethane bismaleimide and part number TMH has chemical name of 1,6′-bismaleimide-(2,2,4-trimethyl)hexane.
It can be found from group A1-A5 that by increasing the amount of BMI resin, the thermal expansion coefficient would decrease. However, by increasing the amount of BMI resin, the water absorption would also increase. As to group A6-A8, different BMI resins may reduce the thermal expansion coefficient, but would also affect the water absorption. Regarding group A9-A15, different combination of BMI resins may reduce the thermal expansion coefficient, and affect the water absorption also. In the invention, the object of addition of BMI to the dielectric material is to reduce the thermal expansion coefficient. However, the more the amount of BMI resin is, the higher the water absorption is. Therefore, the polymer additives are added to reduce the water absorption.







TABLE 3





INFLUENCE OF POLYMER ADDITIVES SPECIES AND AMOUNT


EXAMPLE 4-3

















POLYMER ADDITIVES

















B1
B2
B3
B4
B5
B6
B7





PPE resin
SA9000
40
37.5
35
32.5
30
37.5
37.5


BMI resin
5100
15
15
15
15
15
15
15


Polybutadiene
Ricon100
5
10
15
20
25
0
0



Ricon130MA8
0
0
0
0
0
10
0



Ricon150
0
0
0
0
0
0
10



Ricon257
0
0
0
0
0
0
0


SMA
S:M = 3:1
0
0
0
0
0
0
0



S:M = 4:1
0
0
0
0
0
0
0



S:M = 5:1
0
0
0
0
0
0
0



S:M = 6:1
0
0
0
0
0
0
0



S:M = 8:1
0
0
0
0
0
0
0


Crosslinking
TAIC
40
37.5
35
32.5
30
37.5
37.5


agents


Flame retardant
XP7866, phr
20
20
20
20
20
20
20


Fillers
Fused silica, phr
20
20
20
20
20
20
20


catalysts
Peroxide 119° C.
2.5
2.5
2.5
2.5
2.5
2.5
2.5



for a half life of



10 hrs


Tg, TMA
IPC-TM-650
221
212
200
194
186
213
217



2.4.24.3


coefficient of
IPC-TM-650
53/201
56/211
64/220
67/260
74/300
58/265
57/270


thermal expansion
2.4.24


(α1/α2), ppm/° C.


water absorption
PCT/121° C./1 hr
0.43
0.39
0.35
0.32
0.28
0.45
0.43


288° C. thermal
Dip288° C.
>600
>600
>600
>600
>600
>600
>600


resistance


Dk(2-10 GHz)
Cavity
3.93
3.90
3.87
3.86
3.84
3.92
3.90


Df(2-10 GHz)
Cavity
0.0043
0.0040
0.0041
0.0040
0.0039
0.0045
0.0044


flammability
UL94
V-0
V-0
V-0
V-1
V-1
V-0
V-0












POLYMER ADDITIVES





















Comparative




B9
B10
B11
B12
B13
example





PPE resin
SA9000
37.5
37.5
37.5
37.5
37.5
42.5


BMI resin
5100
15
15
15
15
15
15


Polybutadiene
Ricon100
0
0
0
0
0
0



Ricon130MA8
0
0
0
0
0
0



Ricon150
0
0
0
0
0
0



Ricon257
0
0
0
0
0
0


SMA
S:M = 3:1
10
0
0
0
0
0



S:M = 4:1
0
10
0
0
0
0



S:M = 5:1
0
0
10
0
0
0



S:M = 6:1
0
0
0
10
0
0



S:M = 8:1
0
0
0
0
10
0


Crosslinking
TAIC
37.5
37.5
37.5
37.5
37.5
42.5


agents


Flame retardants
XP7866, phr
20
20
20
20
20
20


fillers
Fused silica, phr
20
20
20
20
20
20


catalysts
Peroxide 119° C.
2.5
2.5
2.5
2.5
2.5
2.5



for a half life of



10 hrs


Tg, TMA
IPC-TM-650
220
215
210
206
195
222



2.4.24.3


coefficient of
IPC-TM-650
45/232
48/237
50/245
51/240
53/260
45/200


thermal expansion
2.4.24


(α1/α2), ppm/° C.


water absorption
PCT/121° C./1 hr
0.46
0.45
0.43
0.43
0.40
0.56


288° C. thermal
Dip288° C.
>600
>600
>600
>600
>600
>600


resistance


Dk(2-10 GHz)
Cavity
3.95
3.95
3.93
3.91
3.90
3.93


Df(2-10 GHz)
Cavity
0.0085
0.0073
0.0064
0.0056
0.0042
0.0043


flammability
UL94
V-0
V-0
V-0
V-0
V-0
V-0









The water absorption was measured with different species and amount of polymer additives. Polybutadiene (PB) and styrene-maleic anhydride (SMA) were used as the polymer additives in the invention. It can be found from using the different amount of PB with the same species that by increasing the amount of PB, the water absorption would decrease. However, with the increasing amount of PB, the coefficient of thermal expansion would also increase. As to using different species of PB in combination with SMA, it shows SMA can reduce the water absorption and the coefficient of thermal expansion, but Df may remain high. However, PB can be used to reduce Df. In Table 3, part numbers Ricon100, Ricon130MA8, Ricon150 and Ricon257 of PB are produced by Sartomer CO., LTD, in which part number Ricon 100 has chemical name of butadiene styrene copolymer, part number Ricon130MA8 has chemical name of butadiene adducted with maleic anhydride, part number Ricon 150 has chemical name of polybutadiene resin and Ricon 257 has chemical name of polybutadiene grafted with styrene and benzene in toluene solution. In Table 3, SMA with S:M=3:1 indicates that the ratio of styrene to maleic anhydride is 3 to 1. Generally, the ratios are about 1:1 ̃12:1.







TABLE 4







INFLUENCE OF DIFFERENT SPECIES


OF CROSSLINKING AGENTS









CROSSLINKING AGENT










EXAMPLE 4-4
D1
D2
D3














PPE resin
SA9000
37.5
37.5
37.5


BMI resin
5100
15
15
15


polybutadiene
Ricon100
10
10
10


Crosslinking
TAC
37.5
0
0


agents
TAIC
0
37.5
0



TBS
0
0
37.5


Flame
XP7866, phr
20
20
20


retardants


fillers
Fused silica, phr
20
20
20


catalysts
Peroxide 119° C.
2.5
2.5
2.5



for a half life



of 10 hrs


Tg, TMA
IPC-TM-650
183
212
202



2.4.24.3


coefficient
IPC-TM-650
59/273
56/211
50/250


of thermal
2.4.24


expansion


(α1/α2),


ppm/° C.


water
PCT/121° C./1 hr
0.39
0.39
0.12


absorption


288° C.
Dip288° C.
>600
>600
>600


thermal


resistance


Dk(2-10 GHz)
Cavity
3.95
3.90
3.75


Df(2-10 GHz)
Cavity
0.0039
6.0040
0.0035


flammability
UL94
V-0
V-0
V-0









The dielectric material of the invention may comprise at least one crosslinking agent with 40-80 parts by weight selected from the following groups consisting of Triallyl cyanurate (TAC), Triallyl isocyanurate (TAIC) and 4-tert-butylstyrene. The properties of a copper-clad laminate with the dielectric material of the invention were measured with different species of crosslinking agents. It can be found by using TAC that Tg and the coefficient of thermal expansion were poor, and water absorption, Dk and Df were of ordinary level. As to TAIC, all the properties of a copper-clad laminate with the dielectric material of the invention were of ordinary level. Regarding 4-tert-butylstyrene, the coefficient of thermal expansion, water absorption and Df were excellent, but Dk is low,







TABLE 5







INFLUENCE OF DIFFERENT SPECIES OF FLAME RETARDANTS









FLAME RETARDANTS











EXAMPLE 4-5
E1
E2
E3
E4















PPE resin
SA9000
37.5
37.5
37.5
37.5


BMI resin
5100
15
15
15
15


polybutadiene
Ricon100
10
10
10
10


Crosslinking
TAIC
37.5
37.5
37.5
37.5


agents


Flame
Decabromodiphenyl
10
0
0
0


retardants
Ethane, pbr



XP7866, phr
0
20
15
10



Tetrakis(2,6-di-
0
0
5
10



methylphenyl)



1,3-phenylene



bisphosphate, phr


fillers
Fused silica, phr
20
20
20
20


catalysts
Peroxide 119° C.
2.5
2.5
2.5
2.5



for a half life



of 10 hrs


Tg, TMA
IPC-TM-650
224
212
226
180



2.4.24.3


coefficient
IPC-TM-650
55/233
56/211
65/267
67/339


of thermal
2.4.24


expansion


(α1/α2),


ppm/° C.


water
PCT/121° C./1 hr
0.43
0.39
0.37
0.30


absorption


288° C.
Dip288° C.
>60
>600
>600
>600


thermal


resistance


Dk(2-10 GHz)
Cavity
3.83
3.90
3.87
3.85


Df(2-10 GHz)
Cavity
0.0043
0.0040
0.0040
0.0037


flammability
UL94
V-0
V-0
V-0
V-0









If desired, the dielectric material of the invention may optionally comprise flame retardants. A halogen-containing flame retardant of decabromodiphenyl ethane with 7-15 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents may be added to the dielectric material of the invention. The dielectric material of the invention may comprise at least one flame retardant without halogen with 12-14 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents selected from the following groups consisting of phosphor-containing flame retardants and phosphates. The phosphor-containing flame retardants and phosphates are produced by ALBEMARLE CO., LTD. The phosphates are like tetrakis(2,6-dimethylphenyl) 1,3-phenylene bisphosphate.







TABLE 6







INFLUENCE OF DIFFERENT SPECIES OF FILLERS


EXAMPLES 4-6









FILLERS















F1
F2
F3
F4
F5
F6
F7



















PPE resin
SA9000
37.5
37.5
37.5
37.5
37.5
37.5
37.5


BMI resin
5100
15
15
15
15
15
15
15


polybutadiene
Ricon100
10
10
10
10
10
10
10


Crosslinking
TAIC
37.5
37.5
37.5
37.5
37.5
37.5
37.5


agents


Flame
XP7866, phr
20
20
20
20
20
20
20


retardants


fillers
Fused silica,
0
20
10
10
30
25
45



phr



Ball type
20
0
10
0
0
0
0



silica


catalysts
Peroxide
2.5
2.5
2.5
2.5
2.5
2.5
2.5



119° C. for a



half life of



10 hrs


Tg, TMA
IPC-TM-650
210
212
214
220
208
215
195



2.4.24.3


coefficient of
IPC-TM-650
53/220
56/211
52/225
58/260
45/210
50/220
40/205


thermal
2.4.24


expansion


(α1/α2), ppm/° C.


water
PCT/121° C./1 hr
0.41
0.39
0.40
0.39
0.38
0.40
0.36


absorption


288° C. thermal
Dip288° C.
>600
>600
>600
>600
>600
>600
>600


resistance


Dk(2-10 GHz)
Cavity
3.87
3.90
3.88
3.85
3.96
4.01
4.06


Df(2-10 GHz)
Cavity
0.0039
0.0040
0.0040
0.0040
0.0041
0.0043
0.0045


flammability
UL94
V-0
V-0
V-0
V-0
V-0
V-0
V-0









The dielectric material of the invention may optionally comprise fillers. The suitable fillers such as fused silica and sphere-shaped silica may be used. The suitable amount of filler is 8-50 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents. It can be found from the fused silica and the sphere-shaped silica with the same amount that the sphere-shaped silica has lower Dk and Df than the fused silica.







TABLE 7





INFLUENCE OF DIFFERENT AMOUNT AND SPECIES OF CATALYSTS


EXAMPLE 4-7

















CATALYSTS














G1
G2
G3
G4





PPE resin
SA9000
37.5
37.5
37.5
37.5


BMI resin
5100
15
15
15
15


polybutadiene
Ricon100
10
10
10
10


Crosslinking
TAIC
37.5
37.5
37.5
37.5


agents


Flame
XP7866, phr
20
20
20
20


retardants


fillers
Ball type silica
20
20
20
20


catalysts
Peroxide 116° C. for a
0
0
0
0



half life of 10 hrs



Peroxide 119° C. for a
2.5
3
7
8



half life of 10 hrs



Peroxide 128° C. for a
0
0
0
0



half life of 10 hrs


Tg, TMA
IPC-TM-650
212
220
222
227



2.4.24.3


coefficient of
IPC-TM-650
56/211
53/225
49/220
50/180


thermal
2.4.24


expansion


(α1/α2),


ppm/° C.


water
PCT/121° C./1 hr
0.39
0.43
0.47
0.60


absorption


288° C. thermal
Dip288° C.
>600
>600
>600
>600


resistance


Dk(2-10 GHz)
Cavity
3.90
3.91
3.90
3.96


Df(2-10 GHz)
Cavity
0.0040
0.0042
0.0045
0.0049


flammability
UL94
V-0
V-0
V-0
V-0












CATALYSTS















G5
G6
G7
G8
G9





PPE resin
SA9000
37.5
37.5
37.5
37.5
37.5


BMI resin
5100
15
15
15
15
15


polybutadiene
Ricon100
10
10
10
10
10


Crosslinking
TAIC
37.5
37.5
37.5
37.5
37.5


agents


Flame
XP7866, phr
20
13
13
13
13


retardants


fillers
Ball type silica
20
13
13
13
13


catalysts
Peroxide 116° C. for a
2.5
0
1.5
1.5
1



half life of 10 hrs



Peroxide 119° C. for a
0
0
0
1.5
1



half life of 10 hrs



Peroxide 128° C. for a
0
2.5
1.5
0
1



half life of 10 hrs


Tg, TMA
IPC-TM-650
208
225
220
209
215



2.4.24.3


coefficient of
IPC-TM-650
57/230
50/230
47/226
52/220
50/235


thermal
2.4.24


expansion


(α1/α2),


ppm/° C.


water
PCT/121° C./1 hr
0.42
0.38
0.40
0.42
0.38


absorption


288° C. thermal
Dip288° C.
>600
>600
>600
>600
>600


resistance


Dk(2-10 GHz)
Cavity
3.88
3.91
3.92
3.93
3.91


Df(2-10 GHz)
Cavity
0.0039
0.0040
0.0041
0.0042
0.0039


flammability
UL94
V-0
V-0
V-0
V-0
V-0









The dielectric material of the invention may optionally comprise catalysts including peroxides having 116° C.-128° C. for a half life of 10 hours. The suitable amount of peroxide is 2-8 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents. The preferable catalyst is a peroxide having 119° C. for a half life of 10 hours.
The dielectric material of the invention may comprise PPE, but not comprise epoxy resin. The desired values of Dk and/or Df cannot be obtained, if epoxy resin is added to the dielectric material of the invention. When reacting epoxy resin with the dielectric material of the invention, the open rings of the epoxy resin may produce excess OH groups, therefore causing the Dk and Df value to remain high and unable to decrease.

## Claims

1. A dielectric resin composition with low dielectric loss comprising:
(i) 40-80 parts by weight of polyphenylene ether (PPE) resin having a Mw of 1000-7000, a Mn of 1000-4000 and Mw/Mn=1.0-1.8;
(ii) 5-30 parts by weight of bismaleimide resins; and
(iii) 5-30 parts by weight of polymer additives, wherein the dielectric resin composition has Dk of 3.75-4.0 and Df of 0.0025-0.0045,

wherein polyphenylene ether resin is represented by the formula




wherein Y represents at least one C, O and benzene ring or the combination.

2. The dielectric resin composition with low dielectric loss of claim 1, wherein bismaleimide resins are selected from groups consisting of
phenylmethane maleimide




wherein n≧1;
bisphenol A diphenyl ether bismaleimide




3,3′-dimethyl-5,5′-diethyl-4,4′-diphenylethane bismaleimide




and 1,6-bismaleimide-(2,2,4-trimethyl)hexane

3. The dielectric resin composition with low dielectric loss of claim 1, wherein the polymer additives are selected from groups consisting of:
homopolymers of butadiene




wherein y=70% and x+z=30%;
random copolymers of butadiene and styrene




wherein y=30%, x+z=70% and w=≧1, the amount of styrene=25 wt %;
maleinized polybutadiene




wherein y=28% and x+z=72%, the amount of maleic anhydride=8 wt %;
butadiene-styrene-divinylbenzene copolymer; and
styrene maleic anhydride copolymer




wherein X=1 ̃8 and n≧1.