CURABLE COMPOSITIONS CONTAINING A POLYEPOXIDE AND A HALOGENATED BISPHENOL

Abstract: An improvement in curable compositions which comprise a polyglycidyl ether such as the triglycidyl­ ether of tris(hydroxyphenyl)methane and a halogenated dihydric phenol such as tetrabromobisphenol A, the improvement being employing as the halogenated dihydric phenol one in which the halogen atoms are meta with respect to the hydroxyl groups such as 2,2′,6,6′-tetra­ bromo-3,3′,5,5′-tetramethyl-4,4′-biphenol. These compositions can be cured by heating in the presence or absence of a catalyst for reacting epoxy groups with phenolic hydroxyl groups such as 2-methyl imidazole. These compositions are particularly useful in the preparation of electrical laminates.

Description: The present invention pertains to curable compositions containing polyglycidyl ethers of a polyphenol and halogenated bisphenols. Compositions containing glycidyl ethers of bisphenols and halogenated bisphenols have been employed in the preparation of electrical laminates. However, they are usually lacking in one or more properties such as thermal performance, moisture resistance and high temperature mechanical strength and the like. U. S 4,604,317 issued August 5, 1986 (EP-A-205 455) provides curable compositions which result in cured compositions having an improvement in one or more of the properties selected from thermal stability, glass transition temperature, elevated temperature mechanical strength, moisture resistance, chemical resistance and toughness and the like. The present invention pertains to a composition comprising (a) at least one of (1) at least one epoxy resin represented by formulas I, II, III, IV, V or VI wherein each A′ is independently a divalent hydrocarbyl group having from 1 to 12 carbon atoms, -S-, -S-S-, -SO-, -SO 2-, -CO- , or -O-; each B is represented by the formula each B′ is represented by the formula each B″ is represented by the formula each R is independently hydrogen or an alkyl group having from 1 to 4 carbon atoms; each Q is independently hydrogen or a hydrocarbyl group having from 1 to 10 carbon atoms; each R' is independently hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10 carbon atoms or a halogen; m has a value of n-1; m' has a value of n'-1; m" has a value of n"-1; whereby each of m, m' and m'' has at least the value zero each n, n' and n" independently has a value from zero to 3; q has a value from zero to 4, preferably 0.1 to 2, more preferably 0.5 to 1.5; each y independently has an average value from 1 to 5; y' has an average value of from zero to 3 and each z and z' independently has a value from zero to 3; (2) the reaction product of (a) at least one epoxy resin as defined in component (A-1); and (b) at least one dihydric or polyhydric phenol represented by the following formulas VII, VIII or IX wherein A is a divalent hydrocarbon group having from 1 to 12 carbon atoms, -O-, -S-, -S-S-, -SO-, -SO₂-, or -CO-; each A″ is independently a divalent hydrocarbon group having from 1 to 6 carbon atoms, each Y is independently hydrogen, a halogen or a hydrocarbyl or hydrocarbyloxy group having from 1 to 10 carbon atoms; each Y′ is independently hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10, preferably from 1 to 4, carbon atoms, a halogen atom or a hydroxyl group; and n has a value of zero or 1; and wherein components (A-2-a) and (A-2-b) are present in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.01:1 to 0.5:1, preferably from 0.05:1 to 0.25:1, most preferably from 0.1:1 to 0.2:1; or (3) mixtures thereof; and (B) at least one halogenated dihydric or polyhydric phenol represented by formulas X, XI or XII wherein A, A″, Y, Y′ and n are as defined hereinbefore; each X is a halogen, preferably bromine; and wherein components (A) and (B) are present in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.7:1 to 1.1:1, preferably from 0.85:1 to 1:1, most preferably from 0.9:1 to 0.95:1; and characterized by employing as at least a portion of component (B), a halogenated dihydric phenol wherein at least 5, preferably at least 30, most preferably at least 50 percent of the halogen atoms present in component B are in the meta position with respect to the hydroxyl groups. The composition of the present invention may also contain, if desired, (C) an effective quantity of at least one catalyst for effecting the reaction between components (A) and (B); and (D) from zero to 50, preferably from 10 to 45, most preferably from 30 to 40, percent by weight of the combined weight of components (A), (B), (C) and (D) of at least one solvent. The present invention also pertains to substrates impregnated with the aforementioned compositions and to laminates prepared therefrom. The present invention provides curable compositions which result in cured compositions having an improvement in one or more of the properties selected from glass transition temperature, resistance to decomposition, moisture resistance, toughness and elevated temperature mechanical strength, and the like. Particularly suitable epoxy resins which can be employed herein include, for example, the triglycidyl ether of tris(hydroxyphenyl)methane, higher molecular weight homologs thereof, trisepoxides advanced with dihydric phenols, phenol-formaldehyde epoxy novolac resins, cresol-formaldehyde epoxy novolac resins, resorcinol-formaldehyde epoxy novolac resins, phenolglyoxal epoxy novolac resins, and mixtures thereof. Also suitable as an epoxy resin which can be employed herein are those glycidyl ethers of phenol-aldehyde novolac resins wherein at least a portion of the two functional materials has been removed. These epoxy resins are disclosed in copending US-A-4 649 188. Particularly suitable dihydric phenols and halogenated dihydric phenols include, for example, bisphenol A, tetrabromobisphenol A, bisphenol S, tetrabromobisphenol S, biphenol, tetrabromobiphenol, tetrabromodihydroxybenzophenone, resorcinol, tetrabromoresorcinol, and mixtures thereof. Multifunctional phenolic compounds, those having an average functionality of greater than 2, can be employed in this invention together with the diphenolic compounds, if desired, so as to change the cure behavior of the composition. Particularly suitable multifunctional phenolic compounds include, for example, phenol-formaldehyde condensation products having an average functionality of from 3 to 8, phenol-hydroxybenzaldehyde condensation products having an average functionality from of 3 to 7 and cresol-formaldehyde condensation products having an average functionality of from 3 to 8. Suitable halogenated dihydric phenols and polyhydric phenols having the hologen atoms in the meta position with respect to the hydroxyl groups which can be employed herein include, for example, those represented by the following formulas XIII and XIV wherein A is a divalent hydrocarbyl group having from 1 to 12, preferably from 1 to 6 carbon atoms, -S-, -S-S-, -SO-, -SO₂-, -CO- or -O-; each A″ is independently a divalent hydrocarbon group having from 1 to 6 carbon atoms; each R is independently hydrogen or a hydrocarbyl or hydrocarbyloxy group having from 1 to 10, preferably from 1 to 4 carbon atoms; each X is independently hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10, preferably from 1 to 4 carbon atoms or a halogen atom, preferably chlorine or bromine, most preferably bromine, with the proviso that at least one of the X groups is a halogen atom; each Y' independently is hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10, preferably from 1 to 4 carbon atoms, a halogen atom or a hydroxyl group; and n has a value of zero or 1. Particularly suitable halogenated dihydric phenols having at least one halogen atom in the meta position with respect to the hydroxyl group include, for example, 2,2',6,6'-tetrabromo-3,3',5,5'-tetramethyl-4,4'-biphenol, 2,2'6-tribromo-3,3',5,5'-tetramethyl-4,4'-biphenol, 2,2-bis-(2,6-dibromo-3,5-dimethylhydroxyphenyl)ethane, 2,2-bis-(2,6-dibromo-3,5-dimethylhydroxyphenyl)methane, and combinations thereof. The halogenated dihydric phenols wherein the halogen atoms are meta with respect to the hydroxyl groups and which also have hydrocarbyl or hydrocarbyloxy groups attached to the ring can be prepared by oxidative coupling of 2,6-dimethylphenol using palladium over carbon catalyst at 80°C in the presence of oxygen gas. This product is then treated with hydrogen gas and palladium over carbon catalyst to make 3,3',5,5'-tetramethyl-4,4'-biphenol. This product is then reacted with bromine to yield 2,2',6,6'-tetrabromo-3,3',5,5'-tetramethyl-4,4'-biphenol. Those halogenated dihydric phenols wherein the halogen atoms are meta with respect to the hydroxyl groups and which do not have hydrocarbyl or hydrocarbyloxy groups attached to the ring can be prepared by dealkylation of 2,2′-dibromo-3,3′,5,5′-tetra-t-butyl-4,4′-biphenol to form 2,2′-dibromo-4,4′-biphenol. Suitable catalysts for effecting the reaction between the epoxy resin and the phenolic hydroxyl-containing compound include, for example, those disclosed in US-A-3,306,872; 3,341,580; 3,379,684; 3,477,990; 3,547,881; 3,637,590; 3,843,605; 3,948,855; 3,956,237; 4,048,141; 4,093,650; 4,131,633; 4,132,706; 4,171,420; 4,177,216; 4,302,574; 4,320,222; 4,358,578; 4,366,295; and 4,389,520. Particularly suitable catalysts are those quaternary phosphonium and ammonium compounds such as, for example, ethyltriphenylphosphonium chloride, ethyltriphenylphosphonium bromide, ethyltriphenylphosphonium iodide, ethyltriphenylphosphoniumacetate, ethyltriphenylphosphonium diacetate (ethyltriphenylphosphonium acetate·acetic acid complex), ethyltriphenylphosphonium tetrahaloborate, tetrabutylphosphonium chloride, tetrabutylphosphonium acetate, tetrabutylphosphonium diacetate (tetrabutylphosphonium acetate·acetic acid complex), tetrabutylphosphonium tetrahaloborate, butyltriphenylphosphonium tetrabromobisphenate, butyltriphenylphosphonium bisphenate, butyltriphenylphosphonium bicarbonate, benzyltrimethylammonium chloride, benzyltrimethylammonium hydroxide, benzyltrimethylammonium tetrahaloborate, tetramethylammonium hydroxide, tetrabutylammonium hydroxide, tetrabutylammonium tetrahaloborate, and mixtures thereof. Other suitable catalysts include tertiary amines such as, for example, triethylamine, tripropylamine, tributylamine, 2-methylimidazole, benzyldimethylamine, and mixtures thereof. Other suitable catalysts include ammonium compounds such as, for example, triethylammonium chloride, triethylammonium bromide, triethylammonium iodide, triethylammonium tetrahaloborate, tributylammonium chloride, tributylammonium bromide, tributylammonium iodide, tributylammonium tetrahaloborate, N,N′-dimethyl-1,2-diaminoethane tetrahaloboric acid complex, and mixtures thereof. Other suitable catalysts include quaternary and tertiary ammonium, phosphonium, and arsonium adducts or complexes with suitable non-nucleophilic acids such as, for example, fluoboric, fluoarsenic, fluoantimonic, fluophosphoric, perchloric, perbromic, periodic, and mixtures thereof. The catalysts are suitably employed in any quantity which is sufficient to cause curing of the epoxy resin and the phenolic hydroxyl-containing composition at the temperature employed. Particularly suitable quantities for the catalyst is from about 0.5 to about 5, more suitably from about 0.1 to about 2, most suitably from about 0.2 to about 1, parts of catalyst per 100 parts by weight of epoxy resin contained in the composition. Suitable solvents which can be employed herein include, for example, ketones, alcohols, glycol ethers and amides, such as, for example, acetone, methyl ethyl ketone, methanol, propylene glycol mono methyl ether and dimethyl formamide. The compositions of the present invention may also contain, if desired, stabilizers, pigments, dyes, mold release agents, flow control agents, reinforcing agents, fillers, fire retardant agents, rubber modifiers, surfactants, accelerators, reactive diluents, mixtures thereof and the like. Suitable stabilizers which can be employed herein include, for example, those represented by the formula wherein each R¹ is independently hydrogen, a hydrocarbyl group having from 1 to 10 carbon atoms or a halogen and R² is a hydrocarbyl group having from 1 to 10 carbon atoms. Particularly suitable stabilizers include, for example, methyl p-toluene sulfonate, ethyl p-toluene sulfonate, methyl chlorobenzene sulfonate, and combinations thereof. The stabilizer component, when used, can be employed in any suitable quantity; however, the usual quantity is from 0.001 to 10, suitably from 0.01 to 2 percent by weight based upon the weight of the epoxy resin component. The compositions of the present invention are suitable for such applications as structural or electrical laminates or composites, coatings, adhesives, castings, moldings, electronic encapsulations and in potting compositions. Suitable substrates which can be employed herein include, for example, fibers or filaments in woven, matt or non-woven form of glass, carbon, graphite, synthetic fibers, quartz, and combinations thereof. Electrical laminates are usually prepared from one or more plies of a substrate material impregnated with a curable resin composition with an outer ply of an electrical conducting material. Suitable electrical conducting materials include, for example, aluminum, copper, gold, platinum and silver. The following examples are illustrative of the invention but are not to be construed as to limiting the scope thereof in any manner. Fracture Toughness Measurement (G 1C ) The method for measuring G 1C (fracture toughness or "critical strain energy release rate") is an adaptation of ASTM E-399 for plastics materials from the original usage with metals. The compact tension test is now widespread in usage and is described in the J. Mater. Sci. , Vol. 16, 2657, 1981. An individual test piece is cut as an approximate 1" (25.4 mm) square from a flat casting usually of 1/8" (3.175 mm) thickness. A dovetail notch is cut into one edge, centered, about 1/4" (6.25 mm) in depth. Next, a razor blade is inserted into this notch and tapped to produce a precrack. Two holes are then drilled adjacent to the dovetail as indicated in ASTM E-399, allowing the test piece to be pinned into position in the Instron test machine. Extension of the sample now allows the force required to propagate opening of the precrack to be measured, using a test speed of 0.02 inches/minute (0.0085 mm/sec.). This force is used in the equation given in ASTM E-399, along with the required sample dimensions and actual precrack length, to calculate a "stress intensification factor" K Q . This is then combined with the tensile modulus and Poisson's ratio for the material to give the value for G 1C , usually reported in ergs/cm x 106. A scale comparing typical values for G 1C for various plastics and metals is given in reference Lee, L.H., "Physicochemical Aspects of Polymer Surfaces", K.L. Mittal, ed. Plenum Press, New York, N.Y., 1983. The Tg was determined by Differential Scanning Calorimetry using a calibrated DuPont Instrument (Model No. 912 with a 1090 controller). Samples were run under a nitrogen atmosphere with a heat-up rate of 10°C per min. (0.1667°C/sec.). Coefficient of thermal expansion (CTE) was determined using a calibrated DuPont Thermal Mechanical Analyzer (Model No. 943 with a 1090 controller). Decomposition properties were determined using a DuPont Thermal Gravimetric Analyzer (Model No. 951 with a DuPont 1090 controller). Dynamic mechanical properties were measured on a DuPont Dynamic Mechanical Analyzer (Model No. 982 with a DuPont 1090 controller). The following components were employed in the Examples and Comparative Experiments. Epoxy Resin A was a polyglycidyl ether of a phenol-orthohydroxybenzaldehyde condensation product having an EEW of 220 and an average functionality of 3.6. Epoxy Resin B was the reaction product of a diglycidyl ether of bisphenol A having an EEW of 180 and tetrabromobisphenol A wherein the bromine atoms were in the ortho position with respect to the hydroxyl groups. The resultant epoxy resin had an EEW of 430. Epoxy Resin C was a phenol-formaldehyde epoxy novolac resin having an average functionality of 3.6 and an average EEW of 178. Epoxy Resin D was a cresol-formaldehyde epoxy novolac resin having an average functionality of 6 and an average EEW of 211. The epoxy resin melt viscosity at 150°C was 880 cs (880 mm²/s). Epoxy Resin E was a phenol-formaldehyde epoxy novolac resin having an average functionality of 6, containing less then 1 percent two functional monomer and having an average EEW of 185 (the epoxy was made from a water extracted 91°C melt point novolac). Epoxy Resin F was a polyglycidyl ether of a phenol/glyoxal condensation product having an average functionality of 4.2 and an average EEW of 231. Epoxy Resin G was a polyglycidyl ether of a pheno-orthohydroxybenzaldehyde condensation product having an EEW of 204 and an average functionality of 3.5. Dihydric Phenol A was 2,2′,6,6′-tetrabromo-3,3′,5,5′-tetramethyl-4,4′-biphenol. Dihydric Phenol B was 4,4′-isopropylidene-bis-2,6-dibromophenol, also known as tetrabromobisphenol A. EXAMPLE 1 50 g (0.2273 epoxy equiv.) of Epoxy Resin A was heated to 175°C and degassed. Into the molten resin was stirred 63 g (0.2260 hydroxyl equiv.) of Dihydric Phenol A while maintaining the temperature above 160°C. After 10 minutes, the halogenated phenolic material had dissolved into the resin. The resin system was then degassed and 0.1 g of 2-ethyl-4-methylimidazole was stirred into the mixture. The mixture was then poured into an aluminum mold, which had been sprayed with fluoroglide to prevent sticking, so as to produce cured castings having a thickness of 1/8" (3.175 mm). The mold was placed into an oven for 1 hour at 180°C and 2 hours at 230°C. The results are given in Table I. COMPARATIVE EXPERIMENT A 56.87 g (0.209 hydroxyl equiv.) of Dihydric Phenol B in which all of the bromine atoms were in the ortho position with respect to the hydroxyl groups was stirred into 50 g (0.238 epoxy equiv.) of Epoxy Resin A at 175°C. After heating for 10 minutes, the resin solution was degassed and 0.1 g of 2-ethyl-4-methylimidazole was stirred into the mixture. The resin was then poured into an aluminum mold and cured as in Example 1. The results are given in Table I. COMPARATIVE EXPERIMENT B 50 g (0.116 hydroxyl equiv.) of Epoxy Resin B was heated to 150°C. 5.74 g of methylene dianiline (49.5 amine hydrogen equiv.) was stirred therein and then poured into an aluminium mold. as in Example 1 and cured in an oven at 175°C for 2 hours. The results are given in Table I. Example or Comparative Experiment Tg °C Dynamic Decomposition Temperature °C Ex. 1 220 365 Comp. Expt. A 190 315 Comp. Expt. B 160 310 EXAMPLE 2 A. Varnish Formulation 1434 g (4.889 equiv.) of a 75% solution of Epoxy Resin A in methyl ethyl ketone 2339 g (4.614 equiv.) of a 55% solution of Dihydric Phenol A in methanol 7.532 g of a 5% solution of 2-methylimidazole in dimethylformamide 200 g of acetone The varnish formulation had a viscosity of 19 seconds measured in a No. 2 Zahn cup at 75°F. The formulation also had a gel time of 189 seconds at 171°C. B. Preparation of Preimpregnated Substrate Burlington Style 7628 glass cloth was impregnated with the varnish formulation of Example 2-A in a forced air vertical treater having a total length of 26 feet (7.9 meters) with the first 19.5 feet (5.9 meters) heated to 350°F (176.7°C) at a rate of 12 feet per min. (61 mm/sec.). The resin contained in the impregnated glass cloth had a 136 second gel time at 171°C. The resultant impregnated cloth had a resin content of 39% by weight. C. Preparation of Laminate Both unclad (no copper) and one sided copper clad, 0.062" (1.57 mm) thick laminates were pressed from aforementioned prepreg. Eight 12" x 12" (304.8 cm x 304.8 cm) plies were pressed into laminate form. The copper foil was a 1-ounce (28.35 g) zinc oxide treated material. The laminates were pressed in a preheated Wabash press at 350°F (176.7°C) and 500 psi (3447 kPa) for 1 hour. The unclad laminate had the following properties: 1. Tg = 185°C. 2. Dynamic decomposition temperature was 380°C (run at 3°C/min., 0.05°C/sec.). 3. Decomposition stability at 290°C over a 60 min. period was 100% stable (no weight loss). 4. The relative blister resistance was determined by placing 3 (2" x 4") (5 x 10 cm) unclad laminate coupons in a pressure pot at 15 psi (103 kPa) steam pressure. 5. Tg = 220°C after 1 hour post cure at 225°C for 2 hours. After 2 hours, the coupons were removed, externally dried and dipped in molten solder at 500°F (260°C) for 20 seconds. Each side of the 3 coupons was then inspected for any delamination blisters. The results were reported as number of sides with no blisters divided by total number of sides. This system had a perfect 6/6 or 100% passed. The clad laminate had a copper peel strength of 5.6 to 6.4 lbs./in. (1120.8 N/m). COMPARATIVE EXPERIMENT C 5.140 g (0.0243 equiv.) of Epoxy Resin D was blended with 6.615 g (0.0243 equiv.) of Dihydric Phenol B and 0.100 g of a 10% solution of benzyldimethylamine (BDMA) at 175°C until a complete solution occurred. The resulting homogeneous composition was cured at 175°C for 2 hours and 230°C for 90 minutes. Physical properties of the final clear casting is reported in Table II. COMPARATIVE EXPERIMENT D 4.981 g (0.02798 equiv.) of Epoxy Resin C, 7.683 g (0.0282 equiv.) of Dihydric Phenol B and 0.100 g of BDMA were blended and cured as described in Comparative Experiment C. Physical properties of the final clear casting is reported in Table II. EXAMPLE 3 5.838 g (0.0328 equiv.) of Epoxy Resin C, 9.221 g (0.0332 equiv.) of Dihydric Phenol A and 0.100 g of a 10% solution BDMA were blended and cured as described in Comparative Experiment C. Physical properties of the final clear casting is reported in Table II. EXAMPLE 4 5.662 g (0.0278 equiv.) of Epoxy Resin G, 7.716 g (0.0278 equiv.) of Dihydric Phenol A and 0.108 g of a 10% solution BDMA in methanol were blended and cured as described in Comparative Experiment C. Physical properties of the final clear casting is reported in Table II. EXAMPLE 5 4.618 g (0.02496 equiv.) of Epoxy Resin E, 6.958 g (0.0250 equiv.) of Dihydric Phenol A and 0.100 g of a 10% solution BDMA were blended and cured as described in Comparative Experiment C. Physical properties of the final clear casting is reported in Table II. EXAMPLE 6 5.425 g (0.0235 equiv.) of Epoxy Resin F, 6.520 g (0.0235 equiv.) of Dihydric Phenol A and 0.100 g of a 10% solution BDMA were blended and cured as described in Comparative Experiment C.Physical properties of the final clear casting is reported in Table II. Example or Comp. Expt. Tg (DSC) Tg (DMA) Tg (DMA) Elevated Temperature Mechanical Strength Ex.3 157°C 168°C 157°C 165°C Ex.4 208°C 221°C 207°C 217°C Ex.5 209°C 219°C 200°C 210°C Ex.6 214°C 232°C 216°C 220°C Comp. Expt C 159°C 170°C 160°C 170°C Comp. Expt. D 141°C 153°C 140°C 147°C

Claims: Claims for the following Contracting States : BE, CH, DE, FR, GB, IT, LI, NL, SE A composition comprising (A) at least one of (1) at least one epoxy resin represented by the following formulas I, II, III, IV, V or VI wherein each A′ is independently a divalent hydrocarbyl group having from 1 to 12 carbon atoms, -S-, -S-S-, -SO-, -SO₂-, -CO- or -O-; each B is represented by the formula each B′ is represented by the formula each B″ is represented by the formula each R is independently hydrogen or an alkyl group having from 1 to 4 carbon atoms; each Q is independently hydrogen or a hydrocarbyl group having from 1 to 10 carbon atoms; each R′ is independently hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10 carbon atoms or a halogen; m has a value of n-1; m′ has a value of n′-1; m″ has a value of n″-1 whereby each of m, m′ and m″ has at least the value zero; each n, n′ and n″ independently has a value from zero to 3; q has a value from zero to 4; each y independently has an average value from 1 to 5; y′ has an average value of from zero to 3 and each z and z′ independently has a value from zero to 3; (2) the reaction product of (a) at least one epoxy resin as defined in component (A-1) and b) at least one dihydric or polyhydric phenol represented by the following formulas VII, VIII or IX wherein A is a divalent hydrocarbon group having from 1 to 12 carbon atoms, -O-, -S-, -S-S-, -SO-, -SO₂-, or -CO-; each Y is independently hydrogen, a halogen or a hydrocarby or hydrocarbyloxy group having from 1 to 10 carbon atoms; each A″ is independently a divalent hydrocarbon group having from 1 to 6 carbon atoms; each Y′ is independently hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10, preferably from 1 to 4 carbon atoms, a halogen atom or a hydroxyl group; and n has a value of 0 or 1; and wherein components (A-2-a) and (A-2-b) are present in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.01:1 to 0.5:1; or (3) mixtures thereof; and (B) at least one halogenated dihydric phenol represented by the following formulas X, XI or XII wherein A, A″, Y, Y′ and n are as defined above; each X is a halogen; and wherein components (A) and (B) are present in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.7:1 to 1.1:1; characterized by employing as at least a portion of component (B) a halogenated dihydric phenol wherein at least 5 weight percent of the halogen atoms present in component (B) are in the meta position with respect to the hydroxyl groups. A composition of Claim 1 wherein components (A) and (B) are present in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.85:1 to 1:1; and a stabilizing quantity of a stabilizer represented by the formula wherein each R¹ is independently hydrogen, a hydrocarbyl group having from 1 to 10 carbon atoms or a halogen, and R² is a hydrocarbyl group having from 1 to 10 carbon atoms is present; characterized in that;at least 30 weight percent of the halogen atoms present in component (B) are in the meta position with respect to the hydroxyl groups. A composition of Claim 2 wherein components (A) and (B) are present in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.9:1 to 0.95:1; and said stabilizer is present in an amount of from 0.001 to 10 percent by weight of the weight of component (A); characterized in that at least 50 weight percent of the halogen atoms present in component (B) are in the meta position with respect to the hydroxyl groups. A composition of Claim 1 or Claim 2 wherein component (A) is component (A-1) represented by formula I or II wherein Q, R and R′ are hydrogen; q has an average value of from 0.1 to 2 and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from 1 to 6 carbon atoms, and each X is bromine. A composition of Claim 1 or Claim 2 wherein component (A) is component (A-1) represented by formula III wherein A′ has from 1 to 4 carbon atoms and each R and R′ is hydrogen and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from 1 to 6 carbon atoms and each X is bromine. A composition of Claim 1 or Claim 2 wherein component (A) is component (A-1) represented by formulas IV or V wherein each Q, R and R′ is hydrogen and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from1 to 6 carbon atoms and each X is bromine. A composition of Claim 1 or Claim 2 wherein component (A) is component (A-1) represented by formula VI wherein each Q and R′ is hydrogen and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from 1 to 6 carbon atoms and each X is bromine. A composition of anyone of Claims 4-7 wherein component (B) is 2,2′,6,6′-tetrabromo-3,3′,5,5′-tetramethyl-4,4′-biphenol or 2,2′,6-tribromo-3,3′,5,5′-tetra-methyl-4,4′-biphenol or 4,4′-methylene-bis-3,5-dibromo- -2,6-dimethylphenol, or mixture thereof and said stabilizer is methyl p-toluene sulfonate. A composition which comprises (I) a composition of any one of Claims 1-8 and (II) a catalytic quantity of at least one catalyst for effecting the reaction between components (I-A) and (I-B). An electrical laminate prepared from one or more layers of a substrate impregnated with a composition of Claim 9. Claims for the following Contracting States : AT, ES A method for preparing a composition said composition comprising (A) at least one of (1) at least one epoxy resin represented by the following formulas I, II, III, IV, V or VI wherein each A′ is independently a divalent hydrocarbyl group having from 1 to 12 carbon atoms, -S-, -S-S-, -SO-, -SO₂-, -CO- or -O-; each B is represented by the formula each B′ is represented by the formula each B″ is represented by the formula each R is independently hydrogen or an alkyl group having from 1 to 4 carbon atoms; each Q is independently hydrogen or a hydrocarbyl group having from 1 to 10 carbon atoms; each R′ is independently hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10 carbon atoms or a halogen; m has a value of n-1; m′ has a value of n′-1; m″ has a value of n″-1 whereby each of m, m′ and m″ has at least the value zero; each n, n′ and n″ independently has a value from zero to 3; q has a value from zero to 4; each y independently has an average value from 1 to 5; y′ has an average value of from zero to 3 and each z and z′ independently has a value from zero to 3; (2) the reaction product of (a) at least one epoxy resin as defined in component (A-1) and b) at least one dihydric or polyhydric phenol represented by the following formulas VII, VIII or IX wherein A is a divalent hydrocarbon group having from 1 to 12 carbon atoms, -O-, -S-, -S-S-, -SO-, -SO₂-, or -CO-; each Y is independently hydrogen, a halogen or a hydrocarbyl or hydrocarbyloxy group having from 1 to 10 carbon atoms; each A″ is independently a divalent hydrocarbon group having from 1 to 6 carbon atoms; each Y′ is independently hydrogen, a hydrocarbyl or hydrocarbyloxy group having from 1 to 10, preferably from 1 to 4 carbon atoms, a halogen atom or a hydroxyl group; and n has a value of 0 or 1; and wherein components (A-2-a) and (A-2-b) are present in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.01:1 to 0.5:1; or (3) mixtures thereof; and (B) at least one halogenated dihydric phenol represented by the following formulas X, XI or XII wherein A, A″, Y, Y′ and n are as defined above; each X is a halogen; by mixing components (A) and (B) in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.7:1 to 1.1 :1 said method being characterized by employing as at least a portion of component (B) a halogenated dihydric phenol wherein at least 5 weight percent of the halogen atoms present in component (B) are in the meta position with respect to the hydroxyl groups. A composition of Claim 1 wherein components (A) and (B) are mixed in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.85:1 to 1:1; and a stabilizing quantity of a stabilizer represented by the formula wherein each R¹ is independently hydrogen, a hydrocarbyl group having from 1 to 10 carbon atoms or a halogen, and R² is a hydrocarbyl group having from 1 to 10 carbon atoms is present; characterized in that at least 30 weight percent of the halogen atoms present in component (B) are in the meta position with respect to the hydroxyl groups. A method according to Claim 2 wherein components (A) and (B) are mixed in quantities such that the ratio of phenolic hydroxyl groups to epoxide groups is from 0.9:1 to 0.95:1; and said stabilizer is present in an amount of from 0.001 to 10 percent by weight of the weight of component (A); characterized in that at least 50 weight percent of the halogen atoms present in component (B) are in the meta position with respect to the hydroxyl groups. A method according to anyone of Claims 1 to 3 wherein component (A) is component (A-1) represented by formula I or II wherein Q, R and R′ are hydrogen; q has an average value of from 0.1 to 2 and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from 1 to 6 carbon atoms, and each X is bromine. A method according to anyone of Claims 1 to 3 wherein component (A) is component (A-1) represented by formula III wherein A′ has from 1 to 4 carbon atoms and each R and R′ is hydrogen and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from 1 to 6 carbon atoms and each X is bromine. A method according to anyone of Claims 1 to 3 wherein component (A) is component (A-1) represented by formulas IV or V wherein each Q, R and R′ is hydrogen and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from 1 to 6 carbon atoms and each X is bromine. A method according to anyone of Claims 1 to 3 wherein component (A) is component (A-1) represented by formula VI wherein each Q and R′ is hydrogen and component (B) is represented by formula XI wherein A is a divalent hydrocarbyl group having from 1 to 6 carbon atoms and each X is bromine. A method according to anyone of Claims 4-7 wherein component (B) is 2,2′,6,6′-tetrabromo-3,3′,5,5′-tetramethyl-4,4′-biphenol or 2,2′,6-tribromo-3,3′,5,5′-tetra-methyl-4,4′-biphenol or 4,4′-methylene-bis-3,5-dibromo- -2,6-dimethylphenol, or mixture thereof and said stabilizer is methyl p-toluene sulfonate. A method for preparing a composition which method comprises mixing (I) a composition of any one of Claims 1-8 and (II) a catalytic quantity of at least one catalyst for effecting the reaction between components (I-A) and (I-B). An method for preparing an electrical laminate the method comprising impregnating on or more layers of a substrate with a composition of Claim 9.

Inventors: BERMAN, JODY R., MENDOZA, ABEL
Applicants: THE DOW CHEMICAL COMPANY
Application year: 1987
Main classification: C08G59
IPC codes: C08G59, C08L63, H05K1