Thermosetting resin compositions, electrical laminates obtained therefrom and process of producing these

Abstract: The present invention relates to thermosetting resin compositions with excellent electrical properties comprising (a) a first vinyl ester resin synthesized from diglycidyl ether of bisphenol A, bisphenol A and glacial methacrylic acid, in about 1% to about 95% by weight of the total composition; (b) a resin selected from the group consisting of (1) a second different vinyl ester synthesized from diglycidyl ether of bisphenol A with glacial methacrylic acid, and (2) an unsaturated polyester, in about 1% to about 69% by weight of the total composition; and electrical laminates made therefrom which further comprise a catalyst in about 0.1% to about 2% by weight of the total composition and which may or may not be clad with an electrical conductive layer on at least one side; and method of producing these.

Description: The present invention relates to thermosetting resin compositions with excellent electrical properties; electrical laminates made therefrom; and methods of producing these. Electrical laminates such as circuit boards are produced by laminating sheets of electrical conducting material onto a base substrate of insulation material (see eg US-A-5 298 314). The performance of the finished circuit board is effected by the electrical characteristics of the base substrate material. Commercially available thermoset resin systems with acceptable electrical performance at high frequencies (> 350 MHz) are restricted in their applications due to high cost. The lower cost alternatives that are available do not perform satisfactorily at high frequencies due to unacceptable electrical properties, such as high dielectric constant (D k ), high dissipation factor (D f ), high variability of D k and D f with frequency, and consistency of D k and D f from lot to lot of production material. Thermoplastic polymers such as polytetrafluoroethylene (PTFE) which have exceptional electrical performance at high frequencies are commercially available. The primary drawbacks associated with these materials are very high raw material costs and special processing considerations that add substantial cost to the final product. Because of the physical properties, very high laminating temperatures and pressures are also required to fabricate an electrical laminate from PTFE. Furthermore, due to the inability to "wet" PTFE, costly and hazardous chemicals are required to modify its surface during fabrication of the circuit. A thermoset material would have much greater mechanical properties over a much broader temperature range. Additionally, since thermoset materials have better mechanical properties, this would allow the circuit board fabricator to use conventional cost effective processes. A need exists for thermosetting resin compositions, and electrical laminates made therefrom, of low to moderate cost with acceptable electrical properties at frequencies up to at least 20 GHz. Such compositions would have great utility as circuit board substrates and the laminates made from these thermosetting resins can be utilized in many applications such as in the rapidly growing wireless communication market, in high speed computers, in high definition televisions, and in various other electrical and related applications. An object of the present invention is to provide a thermosetting resin composition which can be made flame retardant and which can be utilized in existing cost effective technologies to manufacture electrical laminates therefrom. Additionally, the present invention resin compositions can have utility as, for example, electrical insulators, encapsulants, insulating adhesives and in various other electrical and related applications generally known to those skilled in this art. Accordingly the present invention provides a thermosetting resin composition, comprising: (a) 1% to 95% by weight, based on the total weight of the composition, of a first vinyl ester resin obtainable from diglycidyl ether of bisphenol A, bisphenol A and, preferably anhydrous or glacial, methacrylic acid; (b) 1% to 69% by weight, based on the total weight of the composition, of a resin selected from (1) a second vinyl ester obtainable from diglycidyl ether of bisphenol A with, preferably anhydrous or glacial, methacrylic acid, which second vinyl ester is different from component (a), and (2) an unsaturated polyester; and (c) 10% to 70% by weight, based on the total weight of the composition, of a halogenated vinyl functional monomer. The composition resins may also further contain monomers which would, for example, aid in the adhesion of a metal foil to the laminate; increase crosslink density and thermal performance; or provide fire retardation. Catalysts which, for example, induce free-radical cure may also be added. Other components may include moisture scavengers, compounds which increase or reduce the dielectric constant, and/or reduce the dissipation factor, polyethylene fillers, other fillers, organic or inorganic, which modify rheology, surface agents, viscosity and performance modifiers, wetting agents, air release agents, defoaming agents, flame retardant synergists, adhesion promoters, and other additional monomers and conventional additives known in the art. Other objects of the present invention are to provide electrical laminates, and methods for producing these laminates containing the composition resins of the present invention, which have excellent electrical properties and which may be flame retardant or heat resistant. Accordingly, the present invention further provides electrical laminates, preferably from 0.008 to 0.305 cm (0.003 to 0.120 inches) thick, which may or may not be clad with an electrical conducting material on one or both sides. The electrical laminates of the present invention are produced by: (1) impregnating or coating at least one substrate with a thermosetting resin composition comprising a mixture of: (a) 1% to 95% by weight, based on the total weight of the composition, of a first vinyl ester resin, obtainable from diglycidyl ether of bisphenol A, bisphenol A and, preferably anhydrous or glacial, methacrylic acid; (b) 1% to 69% by weight, based on the total weight of the composition, of a resin selected from (1) a second vinyl ester obtainable from diglycidyl ether of bisphenol A with, preferably anhydrous or glacial, methacrylic acid, which second vinyl ester is different from component (a), and (2) an unsaturated polyester; (c) 10% to 70% by weight, based on the total weight of the composition, of a halogenated vinyl functional monomer; and (d) 0.1% to 2% by weight, based on the total weight of the composition, of a catalyst which induces free radical cure, polymerization, or UV initiation; and (2) curing the resin impregnated or coated substrate to produce an electrical laminate. The thermosetting resin composition may also further contain the above mentioned added components and may be cured by electron beam processing, radiation, heat with or without pressure, ultra violet light processing, and other conventional curing methods in conjunction with the appropriate initiators. The electrical laminates may further comprise an electrical conductive cladding on at least one side. In the accompanying drawings: Fig. 1 is an enlarged cross-sectional view of a part of an electrical laminate which comprises an electrically conductive metal layer 1 and a cross linked thin-wall body of the invented composition 2. Fig. 2 is an enlarged cross-sectional view of an electrical laminate which exemplifies a double-sided metal clad electrical laminate, further provided with two metal conductive layers 1, and an electrically insulating thin-wall body of the invented composition 2. Fig. 3 is an enlarged cross-sectional view of an electrical laminate which exemplifies a multilayered electrical laminate, of the structure of a combination of single-sided and double sided metal clad electrical laminates as illustrated in Fig. 1 and Fig. 2. Fig. 4 is an enlarged cross-sectional view of an electrical laminate which comprises an electrically conductive layer 1, a crosslinked thin-wall body of the invented composition 2, and an uniformly dispersed inorganic or organic filler 3. Fig. 5 is an enlarged cross-sectional view of an electrical laminate which comprises an electrically conductive metal layer 1, a crosslinked thin-wall body of invented composition 2, and nonwoven -glass fibers 4. Fig. 6 is an enlarged cross-sectional view of an electrical laminate which comprises an electrically conductive metal layer 1, a crosslinked thin-wall body of invented composition 2, and woven glass cloth 5. Fig. 7 is an enlarged cross-section view of part of an example of a double-sided metal clad electrical laminate of Fig. 6 further provided with an electrically conductive metal layer 1 on the other surface. Fig. 8 is an enlarged cross-sectional view of an electrical laminate which comprises an electrically conductive metal layer 1, a crosslinked thin-wall body of the invented composition 2, and an aramid non-woven sheet 6. The present invention comprises resin compositions of moderate cost with excellent electrical properties up to at least 20 GHz which may be flame retardant and heat resistant. The present compositions have utility as electrical insulators, electrical laminates, electrically insulating encapsulants, electrically insulating adhesives and other electrical and related applications. A primary component of these compositions is a first vinyl ester resin (referred herein as VE1). VE1 is 1% to 95% by weight of the total composition; preferably 10% to 75% by weight of the total composition; more preferably 15% to 60% by weight of the total composition and most preferably 20% to 40% by weight of the total composition. A detailed description of the vinyl ester chemistry involved in the production of these vinyl ester resins can be found in U.S. Patent Nos. 3,221,043 and 3,256,226 to Frank Fekete et al. An embodiment of the present invention utilizes a vinyl ester which is synthesized from 1.0 molar equivalent of diglycidyl ether of bisphenol A, DGEBPA (such as "EPON 828" from Shell Oil Company, Houston, TX); 0.42 molar equivalents of bisphenol A (BPA): and 0.58 molar equivalents of glacial methacrylic acid (MAA). This material is synthesized in a two step process. (1) The DGEBPA and BPA are charged into the reactor with a reaction catalyst (such as triphenyl phosphine) under an inert gas blanket. The reactor is heated to 130°C and held until the weight-per-epoxide (WPE) value is approximately 400. (2) The temperature is dropped to 115°C, and a gas sparge (comprised of nitrogen with about 5% oxygen) is started. At this point, an inhibitor (such as tetrahydroquinone), the MAA, and a reaction catalyst (usually a tertiary amine, such as 2,4,6-tris(dimethylaminomethyl)phenol, also known as "DMP-30") is charged. The reaction conditions are held until the WPE is ≈5000 and the acid number is <10. At the endpoint, the resultant polymer is thinned in styrene at the 70% level (70% polymer). Other VE1 components which may be utilized in the present invention are also commercially available. Vinyl ester resins identified with the trade name "VE 12-70" from Alpha/Owens-Corning and "DEREKANE 411" from Dow Chemical Co. are examples of such commercially available resins. A second component of the compositions of the present invention is a different vinyl ester (referred herein as VE2). VE2 is 1% to 69% by weight of the total composition; preferably 5% to 50% by weight of the total composition; more preferably 7% to 30% by weight of the total composition and most preferably 10% to 20% by weight of the total composition. An embodiment of the present invention utilizes a different second vinyl ester comprised of 1.0 molar equivalent of DGEBPA and 1.1 molar equivalents of glacial methacrylic acid which is synthesized in a one step process. The DGEBPA and MAA are charged into the reactor along with an inhibitor (such as a p-benzoquinone) and a reaction catalyst (DMP-30). A nitrogen with ≈5% oxygen sparge is started and the reactor is heated and held at 120°C until the acid number is <15 and the viscosity is A½ (Gardner-Holt method). At the end-point, the polymer is thinned in styrene at the 70% level (70% polymer). The second component (VE2) can also be an unsaturated polyester. It can be chosen to further improve electrical properties or another aspect of the composition's performance. One example of such an unsaturated polyester would be composed of 1.0 mole of maleic anhydride, 0.75 moles of diethylene glycol, 0.5 moles of isophthalic acid and 0.83 mole of propylene glycol. The unsaturated polyester would be synthesized through traditional esterification techniques well known throughout the industry. An additional example of a suitable unsaturated polyester would be comprised of 1.0 moles of maleic anhydride, 1.62 moles of propylene glycol, 0.33 moles of isophthalic acid, and 0.67 moles of polyethylene terephthalate (PET). The PET would be incorporated into the resin through a transesterification reaction in the presence of an excess of propylene glycol and reaction catalysts and subsequent processing through traditional esterification methods. Other VE2 components which may be utilized in the present invention are also commercially available. Vinyl ester resins such as the resin identified with the trade name "VE 15-70" from Alpha/Owens-Corning is one example of such a commercially available resin. Additionally, VE2 unsaturated polyester resins such as "38-62 Resin" are commercially available from Alpha/Owens-Corning. A third component is a halogenated vinyl functional monomer, preferably dibromostyrene (referred herein as DBS). DBS is 10% to 70% by weight of the total composition; preferably 20% to 60% by weight of the total composition; more preferably 30% to 50% by weight of the total composition and most preferably about 40% by weight of the total composition. Dibromostyrene adds fire retardation to the composition and lowers the dissipation factor and dielectric constant. Alternately, any other halogenated vinyl functional monomer (for example, tribromostyrene or pentabromobenzyl acrylate) may also be used. A fourth component of a composition of the present invention may be glacial methacrylic acid (referred herein as MAA). MAA can be 0.1% to 6% by weight of the total composition; preferably 0.5% to 5% by weight of the total composition; more preferably 1% to 4% by weight of the total composition and most preferably about 3% by weight of the total composition. It is utilized as a monomer as it aids the adhesion of the copper foil to the laminate. A fifth component may be divinyl benzene (referred herein as DVB). DVB can be 0.1% to 10% by weight; preferably 0.5% to 5% by weight of the total composition; more preferably 1% to 4% by weight of the total composition and most preferably about 2.5% by weight of the total composition. Divinyl benzene increases the crosslink density and therefore thermal performance of the composition. Other polyfunctional crosslinking monomers may also be used such as divinyl toluene. The fourth and fifth components contribute to the mechanical and thermal properties of a composition but do not need to be present to obtain the excellent electrical properties. Catalysts and polymerization and U.V. initiators may also be components of the compositions of the present invention. There are many choices available; particularly, catalysts which induce free-radical cure. The preferred catalysts are t-butyl peroctoate at 0.1 to 2% by weight of the total composition (preferably about 0.4% by weight of the total composition); with t-butyl peroxy benzoate at 0.1 to 2% by weight of the total composition (preferably 0.25% by weight of the total composition); and dicumyl peroxide at 0.1 to 2% by weight of the total composition (preferably 0.25% by weight of the total composition). Alternative catalysts include benzoyl peroxide, cummene hydrogen peroxide and others known to those skilled in this art. Combination of catalysts may also be used. Curing mechanisms may be utilized including electron beam processing and ultra-violet light processing in conjunction with UV initiators, radiation, heating with or without pressure, and other conventional curing methods in conjunction with the appropriate initiators. Additional components, such as moisture scavengers may also be added. Free moisture in the composition will negatively affect the dissipation factor. Therefore a component, such as 3-ethyl-2-methyl-2-(3-methylbutyl) -1,3-oxazolidine (available from Angus Chemical Co.) can be added to minimize the free water in the composition. The oxazolidine compound will chemically react with the water to eliminate it. Alternately, a molecular sieve could be utilized. Molecular sieves are well known as moisture reducers throughout the coatings industry. Molecular sieves function by physically trapping the free water. Another additional component may be titanium dioxide which increases the dielectric constant, but reduces the dissipation factor. This combination of electrical properties is desirable for some specific high frequency applications. The titanium dioxide may be in a range of from 1 to 60% by weight of the total composition; preferably 10 to 40% by weight of the total composition; more preferably about 25% by weight of the total composition. Another component which may be added is polyethylene filler, (such as expanded polyethylene compound, available from American Fillers and Abrasives). The polyethylene will lower both the dielectric constant and dissipation factor. The polyethylene may be in a range of from 1 to 60% by weight of the total composition; preferably 5 to 40% by weight of the total composition; more preferably about 10% by weight of the total composition. Other optional additives include organic and/or inorganic fillers, for example, calcined kaolin, to modify rheology; surface active agents, to aid processing; other monomers, such as methyl methacrylate to modify viscosity and possibly performance; epoxies; colorants; fluorescent dyes; U.V. blocking agents; wetting agents; air release agents; defoaming agents; flame retardant synergists (for example, antimony compounds); adhesion promoters (for example, epoxy resin "EPON 828" Shell Chemical Co.); additional monomers including styrene, vinyl toluene, t-butyl styrene, paramethyl styrene, diallyl phthalate, 2,4-ethyl-methyl imidazole, and other conventional additives. The present invention further comprises electrical laminates utilizing the thermosetting resin compositions herein described which have excellent electrical properties and which may be flame retardant and heat resistant. The present thermosetting resin compositions can also be utilized in existing cost effective technologies to manufacture various types of electrical laminates. Examples of these technologies include, but are not limited to, continuous lamination, such as that described in U.S. Patent No. 4,803,022 to Barell et al.; production of printed circuit boards, such as described in U.S. Patents Nos. 4,671,984 and 4,751,146 to Masahiko Maeda et al.; production of electrical laminates such as described in U.S. Patent No. 4,336,297 to Yasuo Fushiki et al. and U.S. Patent No. 5,009,949 to Kazuyuki Tanaka et al.; continuous belt press lamination, such as the equipment offered by GreCon Corp.; and traditional press or vacuum press lamination. An electrical laminate of the present invention is produced by infiltrating or impregnating at least one substrate, or multiple substrates, with a resin composition of the present invention to prepare resin-infiltrated or resin-impregnated substrates which are laminated by passage between rolls while removing interlaminar gas bubbles. Subsequently, the resulting laminate is heated, with or without pressure, to cure the resin composition whereby the electrical laminate is obtained. Other cure mechanisms can also be utilized. The electrical laminate of this invention can be continuously produced. For curing the resin composition, organic peroxides can be used as curing catalysts. The organic peroxides include, for example, t-butyl perbenzoate, t-butyl peroxide, benzoyl peroxide, t-butyl peroctoate, t-butyl peroxy benzoate, and dicumyl peroxide. If necessary, the curing can be controlled by use of curing accelerators or polymerization inhibitors. Characteristics of the resin composition can be improved by incorporating thereinto, for example, plasticizers, stabilizers, thickeners, fillers, coloring agents, or lubricants. A copper-clad laminate can be obtained by subjecting substrates impregnated with an uncured resin composition and copper foil to laminated molding to unite them in a body, or by inserting an adhesive between substrates impregnated with an uncured resin and copper foil and then subjecting them to laminated molding to unite them in a body. A copper-clad laminate can be obtained by also preparing a laminate by laminate molding and then unite this laminate and a copper foil laminate in a body through an adhesive. Adhesives such as epoxy resins or butyryl-modified epoxy resins can be used. The present electrical laminates may be from 0.0025 to 0.635 cm (0.001 to 0.25 inches) thick and may be metal clad on one or both sides or not clad in metal. A preferred embodiment is 0.005 to 0.508 cm (0.002 to 0.20 inches) thick. A more preferred embodiment is 0.008 to 0.305 cm (0.003 to 0.120 inches) thick. Suitable cladding metals include aluminum, silver, gold, brass and most preferably copper. The metal cladding may be in various forms and weight. The weight may range from 0.08 to 1.53 kg/m 2 (0.25 to 5 oz/ft 2 ). The form can be any conventional type, such as, foil, an electrodeposited layer or rolled annealed metal, such as for example, rolled annealed copper. A preferred embodiment comprises a copper clad electrical laminate suitable for subsequent processing as a circuit board, stripline, microstripline microwave components and other related applications. The preferred embodiment of this composition is an electrical laminate from 0.008 to 0.305 cm (0.003 to 0.120 inches) thick with metal foil clad on one or both sides. Suitable reinforcement components include organic or inorganic fillers, woven fiberglass, glass paper, glass mat, glass cloth, polyimide paper (such as "THERMOUNT" from DuPont), woven polymeric fibers and non-woven polymer fiber reinforcements. The reinforcement components of the laminates of the present invention may be in the range of 25% to 75% by weight of the total laminate, preferably 30% to 40%, and more preferably about 35%. The performance of this composition differs from similar materials mainly in electrical performance. These properties, especially dissipation factor, are very important when considering high frequency applications. Typical electrical properties of a 0.076 cm (0.030") thick laminate of approximate 32% (by weight) of fiberglass reinforcement are: Frequency (GHz 0.5 0.85 1.0 2.5 3.0 Dielectric constant 3.233 3.237 3.204 3.213 3.231 Dissipation factor 0.002 0.003 0.005 0.006 0.010 The electrical properties of the same laminate at 1 MHz are: Dielectric constant 2.98 Dissipation factor 0.010 This embodiment of the present invention is clearly superior in electrical properties over presently available compositions. The invention will be further clarified by a consideration of the following examples which are to be considered as illustrative of the present invention. It should be understood that the invention is not limited to the specific details of the examples. EXAMPLES The first vinyl ester resins used in the following examples can be made in a two step process according to U.S. Patent Nos. 3,221,043 and 3,256,226 to Frank Fekete et al. or are commercially available as, for example, "VE 12-70" from Alpha/Owens-Corning. The second vinyl ester resins can also be synthesized in a one step process or are commercially available, for example, from Alpha/Owens-Corning as "VE 15-70". The unsaturated polyester resin used in the examples is also commercially available from Alpha/Owens Corning as "38-62". The general method of preparing the resin compositions is as follows. 1) The resin components were charged into a mixing vessel in the desired proportions. 2) The monomer(s) and/or halogenated monomers were added to the mixing vessel. 3) The ingredients were mixed with a Cowels blade on an air motor at moderate (≈1,000 rpm) speed for five minutes. 4) With the mixer operating at high speed, (≈2,000 rpm), the filler, if needed, was added, and sheared for 10 minutes. 5. The initiator(s) (peroxides) were added to the composition while the air motor was operating at low speed (≈400 rpm) and mixed for ≈ 5 minutes. Example 1 31.78 weight % of a first vinyl ester resin, "VE12-70" (Alpha/Owens Corning) and 13.02 weight % of a second vinyl ester resin, "VE 15-70" (Alpha/Owens Corning) were charged into a mixing vessel and 2.65 weight % of monomer methacrylic acid was added along with 2.21 weight % divinyl benzene; and 36.18 weight % dibromostyrene (Great Lakes Chemicals) as a fire retardant. The ingredients were mixed with a Cowels blade on an air motor at moderate (≈ 1,000 rpm) speed for five minutes. The mixer operating at high speed, (approximately 2,000 rpm), 13.36 weight percent calcined kaolin ("TRANSLINK-37" Englehard) was then added and sheared for 10 minutes. The speed of the air motor was then reduced to a low speed (approximately 400 rpm) and 0.22 weight % of dicumylperoxide; 0.36 weight % t-butyl peroctoate and 0.22 weight % t-butyl peroxy benzoate were added and the composition was mixed for about 5 minutes. A composition ready for use was obtained. Example 2 35.68 weight % of a first vinyl ester resin, "VE 12-70" (Alpha/Owens Corning) and 14.62 weight % of a second vinyl ester resin, "VE 15-70" (Alpha/Owens Corning) were charged into a mixing vessel and 2.73 weight % of styrene monomer was added along with 2.97 weight % methacrylic acid; 2.48 weight % divinyl benzene; and 40.62 weight % dibromostyrene (Great Lakes Chemicals) as a fire retardant. The ingredients were mixed with a Cowels blade on an air motor at moderate (≈1,000 rpm) speed for five minutes. Then the speed of the air motor was reduced to operate at a low speed (approximately 400 rpm) and 0.25 weight % of dicumylperoxide; 0.4 weight % t-butyl peroctoate and 0.25 weight % t-butyl peroxy benzoate were added and the composition was mixed for about 5 minutes. A composition ready for use was obtained. Example 3 26.45 weight % of a first vinyl ester resin, "VE 12-70" (Alpha/Owens Corning) and 8.82 weight % of an unsaturated polyester resin, "38-62" (Alpha/Owens Corning) were charged into a mixing vessel and 1.24 weight % of monomer methyl methacrylate was added along with 2.62 weight % "EPON 828" epoxy (Shell Chemical Co.); 0.05 weight % "EMI 24" (2,4-ethyl-methyl imidazole); 4.42 weight % methacrylic acid monomer; and 39.95 weight % dibromostyrene (Great Lakes Chemicals) as a fire retardant. The ingredients were mixed with a Cowels blade on an air motor at moderate (≈1,000 rpm) speed for five minutes. With the mixer operating at high speed, (approximately 2,000 rpm), 15.44 weight percent calcined kaolin ("TRANSLINK-37" Englehard) was added and sheared for 10 minutes. The speed of the air motor was reduced to operate at a low speed (approximately 400 rpm) and 0.36 weight % of dicumylperoxide; 0.26 weight % t-butyl peroctoate and 0.39 weight % t-butyl peroxy benzoate were added and the composition was mixed for about 5 minutes. The prepared composition was ready for use. Example 4 (Comparative) 90.18 weight % of a first vinyl ester resin, "VE 12-70" (Alpha/Owens Corning) and 9.02 weight % dibromostyrene (Great Lakes Chemicals) were charged into a mixing vessel and mixed with a Cowels blade on an air motor at moderate (about 1,000 rpm) speed for five minutes. The speed of the air motor was reduced to operate at a lower speed (about 400 rpm) and 0.22 weight % of dicumyl peroxide, 0.36 weight % t-butyl peroctoate, and 0.22 weight % t-butyl peroxy benzoate were added and the composition was mixed for 5 minutes. A composition ready for use was produced. Example 5 (Comparative) 76.31 weight % of a first vinyl ester resin, "VE 12-70" (Alpha/Owens Corning) and 22.89 weight % dibromostyrene (Great Lakes Chemicals) were charged into a mixing vessel and mixed with a Cowels blade on an air motor at moderate (about 1,000 rpm) speed for five minutes. The speed of the air motor was reduced to operate at a lower speed (about 400 rpm) and 0.22 weight % of dicumyl peroxide, 0.36 weight % t-butyl peroctoate, and 0.22 weight % t-butyl peroxy benzoate were added and the composition was mixed for 5 minutes. A composition ready for use was produced. Example 6 (Comparative) 66.14 weight % of a first vinyl ester resin, "VE 12-70" (Alpha/Owens Corning) and 33.06 weight % dibromostyrene (Great Lakes Chemicals) were changed into a mixing vessel and mixed with a Cowels blade on an air motor at moderate (about 1,000 rpm) speed for five minutes. The speed of the air motor was reduced to operate at a lower speed (about 400 rpm) and 0.22 weight % of dicumyl peroxide, 0.36 weight % t-butyl peroctoate, and 0.22 weight % t-butyl peroxy benzoate were added and the composition was mixed for 5 minutes. A composition ready for use was produced. Example 7 31.78 weight % of a first vinyl ester resin, "VE 12-70" (Alpha/Owens Corning) and 13.02 weight % of a second vinyl ester resin, "VE 15-70" (Alpha/Owens Corning) were charged into a mixing vessel and 36.18 weight % of styrene monomer was added along with 2.65 weight % methacrylic acid; and 2.21 weight % divinyl benzene. The ingredients were mixed with a Cowels blade on an air motor at moderate (≈1,000 rpm) speed. With the mixer operating at high speed, (approximately 2,000 rpm), 13.36 weight percent calcined kaolin ("TRANSLINK-37" Englehard) was added and sheared for 10 minutes. The speed of the air motor was reduced to operate at a low speed (approximately 400 rpm) and 0.22 weight % of dicumylperoxide; 0.36 weight % t-butyl peroctoate and 0.22 weight % t-butyl peroxy benzoate were added and the composition was mixed for about 5 minutes. A composition ready for use was obtained. Examples 8 to 15 The general method of preparing electrical laminates from the resin compositions is as follows. The specific electrical laminates embodied in Examples 8 to 15 were made from the resin compositions of Examples 1 to 3 and were prepared as indicated below and as further indicated in TABLE 2 which follows below. 1) A layer of carrier film, such as polyethylene terephthalate of 0.00361 cm (1.42 mills) thick, was placed on a 0.63 cm (1/4th inch) thick glass plate of 38.1 by 38.1 cm (1.25 by 1.25 ft). The dimensions of the film were large enough to protrude around the edges of the glass plate. 2) A 30.5 cm (one foot) square piece of 305 g/m 2 (1 oz. per sq. foot) weight of copper foil was placed treatment side up on the carrier film. 3) A film of a resin composition, prepared according to the present invention, was metered onto the copper foil by using a wire-wound rod designed to provide a coating of the target thickness of the laminate. Wire-wound rods are well known through the coatings industry. 4) A layer of glass cloth, woven or nonwoven, was laid onto the resin film and allowed to saturate for approximately 2 minutes. If a plurality of layers were used, the layers were placed onto the resin film approximately 2 minutes apart to allow the resin mixture to saturate the glass. 5) An additional layer of copper foil, of the same size and weight as 2), was placed treatment side down on the laminate so as to align the edges with the first sheet of copper foil. 6) Another layer of carrier film, of the same size and dimensions as 1), was placed on top of the copper foil. 7) Two 1.3 cm (1/2 inch) wide by 30.5 cm (12 inches) long shims of the target laminate thickness were placed on opposing sides of the laminate, on top of the carrier film, but still on the glass plate. 8) A rod of 1.3 cm (1/2 inch) thick steel was placed on the shims at one edge of the laminate and gently pulled to the opposing edge while being forced by hand to ride on the shims. As the rod moved across the laminate, excess resin composition was allowed to drain out of the laminate. 9) Another plate of glass of equivalent dimensions as 1), was placed on top of the laminate. 10) The laminate was placed in a forced air convection oven at 150°C for one hour. 11) The laminate, still between the glass plates, was removed from the oven and allowed to cool to room temperature. At this time, the two glass plates and two layers of carrier film were removed. TABLE 2 indicates the particular laminate construction and resin compositions used in Examples 8 to 15. The resins A, B and C correspond to those of Examples 1, 2 and 3 respectively. The test method used to determine the electrical properties above 1MHz was a 70 ohm transmission line test method. It is analogous to ASTM D 3380-90 from the American Society for Testing Materials, Philadelphia, PA. Properties of Neat (unreinforced) Composition Electrical Properties @ 1 MHZ Example Sample Dielectric Constant Dissipation Factor 1 A 2.93 0.010 2 B 3.06 0.010 3 C 3.18 0.011 4 D 2.97 0.014 5 E 2.99 0.012 6 F 2.95 0.009 7 G 2.73 0.007 Properties of 30% Glass Reinforced Laminate Example Flame Test Foil Adhesion Tg 1 Pass 6.8 155 2 Pass 7.2 155 3 Pass 7.5 145 High Frequency Electrical Properties of Glass Reinforced Laminates Which Are Double Sided Cladded With 153 g/m 2 (1/2oz/square foot) of Copper. The laminates measure 0.076 cm (0.030") thick without copper cladding. Electrical properties of the glass reinforced laminates are determined via a "Microstripline" Method. NOTE: Dk = Dielectric Constant Df = Dissipation Factor Examples Resin Composition Laminate Construction 0.5 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.233 0.0022 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.134 0.0028 10 C (Example 3) 4 plies 7624 woven glass 2.977 0.0064 11 A (Example 1) 4 plies 7624 woven glass 3.031 0.0062 12 A (Example 1) 3 plies 7624 woven glass 2.941 0.0085 13 B (Example 2) 3 plies 7624 woven glass 3.066 0.0057 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.231 0.0022 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.167 0.0057 Examples Resin Composition Laminate Construction 0.85 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.237 0.0033 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.105 0.0048 10 C (Example 3) 4 plies 7624 woven glass 2.993 0.0061 11 A (Example 1) 4 plies 7624 woven glass 2.967 0.0064 12 A (Example 1) 3 plies 7624 woven glass 3.008 0.0098 13 B (Example 2) 3 plies 7624 woven glass 3.065 0.0078 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.234 0.0038 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.134 0.0069 Examples Resin Composition Laminate Construction 1.0 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.204 0.0056 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.048 0.0121 10 C (Example 3) 4 plies 7624 woven glass 2.968 0.155 11 A (Example 1) 4 plies 7624 woven glass 2.908 0.0197 12 A (Example 1) 3 plies 7624 woven glass 2.962 0.0172 13 B (Example 2) 3 plies 7624 woven glass 3.048 0.0122 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.196 0.0068 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.156 0.0085 Examples Resin Composition Laminate Construction 2.5 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.213 0.0062 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.113 0.0112 10 C (Example 3) 4 plies 7624 woven glass 3.034 0.016 11 A (Example 1) 4 plies 7624 woven glass 3.034 0.0182 12 A (Example 1) 3 plies 7624 woven glass 2.981 0.0162 13 B (Example 2) 3 plies 7624 woven glass 2.957 0.0127 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.163 0.0062 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 2.987 0.0097 Examples Resin Composition Laminate Construction 3.0 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.231 0.0105 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.202 0.0169 10 C (Example 3) 4 plies 7624 woven glass 3.022 0.027 11 A (Example 1) 4 plies 7624 woven glass 3.034 0.024 12 A (Example 1) 3 plies 7624 woven glass 3.081 0.0311 13 B (Example 2) 3 plies 7624 woven glass 3.065 0.0216 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.227 0.011 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 3.013 0.0180 Examples Resin Composition Laminate Construction 5.0 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.245 0.0011 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.200 0.0011 10 C (Example 3) 4 plies 7624 woven glass 11 A (Example 1) 4 plies 7624 woven glass 12 A (Example 1) 3 plies 7624 woven glass 13 B (Example 2) 3 plies 7624 woven glass 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 15 A (Example 1) 2 plies 7625 woven glass with 0.038 cm (15 mil) veil glass core Examples Resin Composition Laminate Construction 10.0 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.289 0.0017 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.235 0.0018 10 C (Example 3) 4 plies 7624 woven glass 11 A (Example 1) 4 plies 7624 woven glass 12 A (Example 1) 3 plies 7624 woven glass 13 B (Example 2) 3 plies 7624 woven glass 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core Examples Resin Composition Laminate Construction 15.0 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.295 0.0026 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.256 0.0034 10 C (Example 3) 4 plies 7624 woven glass 11 A (Example 1) 4 plies 7624 woven glass 12 A (Example 1) 3 plies 7624 woven glass 13 B (Example 2) 3 plies 7624 woven glass 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core Examples Resin Composition Laminate Construction 20.0 GHz Dk Df 8 A (Example 1) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.222 0.0056 9 B (Example 2) 2 plies 2116 woven glass with 0.038 cm (15 mil) veil glass core 3.201 0.0058 10 C (Example 3) 4 plies 7624 woven glass 11 A (Example 1) 4 plies 7624 woven glass 12 A (Example 1) 3 plies 7624 woven glass 13 B (Example 2) 3 plies 7624 woven glass 14 B (Example 2) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core 15 A (Example 1) 2 plies 7624 woven glass with 0.038 cm (15 mil) veil glass core Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description.

Claims: A thermosetting resin composition, comprising: (a) 1% to 95% by weight, based on the total weight of the composition, of a first vinyl ester resin obtainable from diglycidyl ether of bisphenol A, bisphenol A and methacrylic acid; (b) 1% to 69% by weight, based on the total weight of the composition, of a resin selected from (1) a second vinyl ester obtainable from diglycidyl ether of bisphenol A with methacrylic acid, which second vinyl ester is different from component (a), and (2) an unsaturated polyester; and (c) 10% to 70% by weight, based on the total weight of the composition, of a halogenated vinyl functional monomer. A composition according to claim 1 which comprises 20% to 60% by weight, preferably 30% to 50% by weight, based on the total weight of the composition, of the halogenated vinyl functional monomer. A composition according to claim 1 or 2 wherein the halogenated vinyl functional monomer is selected from dibromostyrene, tribromostyrene and pentabromobenzyl acrylate. A composition according to any preceding claim further comprising 0.1% to 2% by weight, based on the total weight of the composition, of a catalyst. A flame retardant thermosetting resin composition, comprising: (a) 1% to 95% by weight, based on the total weight of the composition, of a vinyl ester resin, obtainable from diglycidyl ether of bisphenol A, bisphenol A and methacrylic acid; (b) 1% to 69% by weight, based on the total weight of the composition, of a resin selected from (1) a vinyl ester obtainable from diglycidyl ether of bisphenol A with methacrylic acid, which vinyl ester is different from compound (a), and (2) an unsaturated polyester; (c) 10% to 70% by weight, based on the total weight of the composition, of a halogenated vinyl functional monomer; and (d) 0.1% to 2% by weight, based on the total weight of the composition, of a catalyst. A composition according to claim 4 or 5 wherein the catalyst is capable of inducing free radical cure, polymerization, or UV initiation. A composition according to any of claims 4 to 6 wherein the catalyst is selected from t-butyl peroctoate, t-butyl peroxy benzoate, dicumyl peroxide, benzoyl peroxide, cumene hydrogen peroxide, t-butyl perbenzoate, t-butyl peroxide and combinations thereof. A composition according to claim 7 which contains, as catalyst, about 0.4% by weight t-butyl peroctoate, about 0.25% by weight t-butyl peroxy benzoate, or about 0.25% by weight dicumyl peroxide, based on the total weight of the composition. A composition according to any preceding claim wherein in component (a) and/or component (b) anhydrous or glacial methacrylic acid is used. A composition according to any preceding claim further comprising 0.1% to 6% by weight, preferably 0.5% to 5% by weight, more preferably 1% to 4% by weight, based on the total weight of the composition, of, preferably anhydrous or glacial, methacrylic acid. A composition according to any preceding claim further comprising 0.1% to 10% by weight, preferably 0.5% to 5% by weight, more preferably 1% to 4% by weight, based on the total weight of the composition, of divinyl benzene. A composition according to any preceding claim further comprising one or more additives selected from moisture scavengers, molecular sieves, organic fillers, inorganic fillers, oxides affecting dielectric constant or dissipation factor, polyethylene fillers, rheology modification fillers, surface active agents, monomers which modify viscosity and performance, colorants, fluorescent dyes, U.V. blockers, wetting agents, air release agents, defoamers, adhesion promoters, flame retardant synergists, styrene, vinyl toluene, t-butyl-styrene, paramethyl styrene, diallyl phthalate, 2,4-ethyl-methylimidazole, 3-ethy-2-is methyl-2-(3-methylbutyl)-1,3-oxazolidine and combinations thereof. A composition according to claim 12 wherein the oxide affecting dielectric constant or dissipation factor comprises titanium dioxide, or an expanded polyethylene compound. A composition according to claim 12 or 13 wherein the filler which modifies rheology is calcined kaolin. A composition according to any of claims 12 to 14 wherein the monomer which modifies viscosity and performance comprises methyl methacrylate. A composition according to any preceding claim wherein the unsaturated polyester is obtainable from a mixture comprising an anhydride, glycol and an organic acid. A composition according to claim 16 wherein the unsaturated polyester is obtainable from a mixture further comprising polyalkylene terephthalate. A composition according to any preceding claim which comprises 10% to 75% by weight, preferably 15% to 60% by weight, more preferably 20% to 40% by weight, based on the total weight of the composition, of the first vinyl ester. A composition according to any preceding claim which comprises 5% to 50% by weight, preferably 7% to 30% by weight, more preferably 10% to 20% by weight, based on the total weight of the composition, of the second vinyl ester. Use of a composition as defined in any preceding claim in the production of an electrical insulator, electrical laminate, electrically insulating encapsulant or electrically insulating adhesive. A method of producing an electrical laminate comprising the steps of: (1) impregnating with or applying to at least one substrate a thermosetting resin composition as defined in any of claims 1 to 19; and (2) curing the resin impregnated or coated substrate to produce an electrical laminate. A method of producing an electrical laminate comprising the steps of: (1) impregnating or coating at least one substrate with a thermosetting resin composition comprising a mixture of: (a) 1% to 95% by weight, based on the total weight of the composition, of a first vinyl ester resin, obtainable from diglycidyl ether of bisphenol A, bisphenol A and methacrylic acid; (b) 1% to 69% by weight, based on the total weight of the composition, of a resin selected from (1) a second vinyl ester obtainable from diglycidyl ether of bisphenol A with methacrylic acid, which second vinyl ester is different from component (a), and (2) an unsaturated polyester; (c) 10% to 70% by weight, based on the total weight of the composition, of a halogenated vinyl functional monomer; and (d) 0.1% to 2% by weight, based on the total weight of the composition, of a catalyst which induces free radical cure, polymerization, or UV initiation; and (2) curing the resin impregnated or coated substrate to produce an electrical laminate. A method according to claim 22 wherein in component (a) and/or component (b) anhydrous or glacial methacrylic acid is used. A method according to any of claims 21 to 23 wherein the curing mechanism is selected from heating without pressure, heating with pressure, electron beam processing, and ultra-violet light processing in conjunction with an U.V. initiator. A method according to any of claims 21 to 24 wherein the substrate is selected from organic or inorganic fillers, woven fiberglass, glass paper, glass cloth, glass mat, polyimide paper, woven polymeric fibers and non-woven polymer fiber reinforcements. A method according to any of claims 21 to 25 which further comprises cladding an electrically conductive layer on at least one side of the substrate before curing. A method according to claim 26 wherein the electrically conductive layer is a metal selected from aluminum, silver, gold, brass and copper. A method according to any of claims 21 to 27 wherein the impregnating step involves more than one substrate and the method further comprises laminating the substrates before the curing step. An electrical laminate, comprising: at least one substrate and a crossed linked, thermosetting resin composition comprising a mixture of (a) 1% to 95% by weight, based on the total weight of the composition, of a first vinyl ester resin, obtainable from diglycidyl ether of bisphenol A, bisphenol A and methacrylic acid; (b) 1% to 69% by weight, based on the total weight of the composition, of a resin selected from (1) a second vinyl ester obtainable from diglycidyl ether of bisphenol A with methacrylic acid, which second vinyl ester is different from component (a), and (2) an unsaturated polyester; (c) 10% to 70% by weight, based on the total weight of the composition, of a halogenated vinyl functional monomer; and (d) 0.1% to 2% by weight, based on the total weight of the composition, of a catalyst which induces free radical cure, polymerization, or UV initiation. A laminate according to claim 29 wherein the composition further comprises, preferably anhydrous or glacial, methacrylic acid. A laminate according to claim 29 or 30 wherein the composition further comprises divinyl benzene. A laminate according to any of claims 29 to 31 wherein the composition further comprises one or more additional components selected from moisture scavengers, molecular sieves, organic fillers, inorganic fillers, monomers to increase or decrease the dielectric constant, monomer to reduce the dissipation factor, polyethylene fillers, monomers to modify rheology, surface active agents, monomers to modify viscosity and performance, colorants, fluorescent dye, U.V. blockers, wetting agents, air release agents, defoaming agents, flame retardant synergists, adhesion promoters, epoxies, styrene, vinyl toluene, t-butyl styrene, paramethyl styrene, diallyl phthalate, and 2,4-ethyl-methyl imidazole, 3-ethyl-2-methyl-2,3-(3-methylbutyl)-1,3-oxazolidine, methyl methacrylate and combinations thereof. A laminate according to any of claims 29 to 32 wherein the substrate is selected from organic or inorganic fillers, woven fiberglass, glass paper, glass cloth, glass mat, polyimide paper, woven polymeric fibers and non-woven polymer fiber reinforcements. A laminate according to any of claims 29 to 33 further comprising an electrically conductive layer clad on at least one side of the cured substrate. A laminate according to claim 34 wherein the electrically conductive layer is a metal selected from aluminum, silver, gold, brass and copper. A laminate according to any of claims 29 to 35 wherein in component (a) and/or component (b) anhydrous or glacial methacrylic acid is used. A multilayer electrical laminate comprising a combination of single sided and double sided laminates according to any of claims 29 to 35. A laminate according to any of claims 29 to 35 which is from 0.008 to 0.305 cm (0.003 to 0.120 inches) thick.

Inventors: AUSTILL TIMOTHY WAYNE, EVEN THOMAS EDWARD, JOHNSON PHILIP ANDREW, LANE SCOTT ALAN, AUSTILL, TIMOTHY WAYNE, EVEN, THOMAS EDWARD, JOHNSON, PHILIP ANDREW, LANE, SCOTT ALAN
Applicants: ALPHA CORP OF TENNESSEE, THE ALPHA CORPORATION OF TENNESSEE
Application year: 1996
Main classification: C08F283
IPC codes: B32B27, B32B15, C08F290, C08F299, C08F20, C09J163, C08L67, H05K1, C08L63, C08J5, B05D7, C08F283, H01B3, C08F220