POLYBUTADIENE AND POLYISOPRENE BASED THEREMOSETTING COMPOSITIONS AND METHOD OF MANUFACTURE

Abstract: An electrical substrate material is presented comprising a resin matrix which includes a thermosetting polybutadiene or polysoprene resin, and ethylene propylene rubber, and optionally a thermoplastic unsaturated butadiene- or isoprene-containing polymer; a particulate filler, a flame retardant addititive, a curing agent, and a woven or unwoven fabric. The presence of the ethylene propylene rubber enhances the heat age properties of the substrate material, particularly the dielectric strengh and the mechanical properties, while other electrical, chemical, and mechanical properties of the material are not adversely effected.

Description: POLYBUTADIENE AND POLYISOPRENE BASED THERMOSETTI G COMPOSITIONS AND METHOD OF MANUFACTURE Background of the Invention 1. Field of the Invention This invention relates generally to the field of circuit boards. In particular, this invention relates to substrates for circuit boards comprising a thermosetting composition, wherein the thermosetting composition comprises a polybutadiene/polyisoprene resin and a low molecular weight ethylene propylene rubber. 2. Brief Description of the Related Art Circuit boards generally comprise an electrical substrate material laminated to a conductive metal layer, usually copper. Electrical substrate materials used in circuit boards are most commonly composites, comprising a polymeric matrix and an inorganic particulate and/or fibrous filler. Polybutadiene and polyisoprene resins and combinations thereof are particularly useful thermosetting compositions as described in commonly assigned U.S. Pat. No. 5,233,568 to Landi et al. and U.S. Pat. No. 5,571,609 to St. Lawrence et al., both of which are herein incoφorated by reference in their entirety. U.S. Pat. No. 5,233,568 discloses a moldable thermosetting composition which is first formed into a shape, and then cured at a high temperature of greater than about 250 °C. U.S. Pat. No. 5,571,609 discloses a thermosettmg resin comprising a polybutadiene or polyisoprene resin and an unsaturated butadiene- or isoprene-containing polymer in an amount of 25 to 50 volume percent (vol%); a woven glass fabric in an amount of 10 to 40 vol%; and a particulate filler in an amount of 5 to 60 vol%. This filled composite material leads to a prepreg which has very little tackiness and can therefore be easily handled by operators. The material in accordance with this patent has a low dissipation factor, a consistent, low dielectric constant, and a low coefficient of thermal expansion, and is therefor ideal for w ireless communication and high speed, high frequency signal transmission applications Other polymeric matrices and substrates commonly used for circuit boards are disclosed in U S Patent No 5,264,065 to Kohm, which descπbes a base material for printed wiring boards where inert filler is used to control Z axis coefficient of thermal expansion m fiberglass reinforced thermoset resins The Kohm patent discloses a range of 45-65 weight percent (wt%) fiberglass reinforcement and a range of 30 to 100 parts filler per 100 parts of the polymer U S Patent No 4,997,702 to Grant et al discloses a circuit laminate having an epoxy resm system which also includes inorganic fillers or fibers m the range of 20-70 wt% of the total composite The fibers include both glass and polymeric fibers and the fillers include clay or mineral (e g silica) particulate fillers U S Pat No 4,241 ,132 to Pratt et al discloses an insulating board comprising a polymeric matπx such as polybutadiene and a filler consisting of polymeric filler (e g , fibrous polypropylene) In all cases, the dielectric constant or dissipation factor of the resin matπx is matched to the fibrous reinforcement m order to obtain an isotropic composite European Patent No 202 488 A2 discloses a polybutadiene based laminate wherein a high molecular weight, bromine-containmg prepolymer is used to reduce tack and flammabihty of a 1,2-polybutadιene resm Similarly, in Japanese Patent No 04,258,658, a high molecular weight compound is added to a tacky polybutadiene resm to control tack The compound utilized is a halogen-containmg bismaleimide which provides flammabihty resistance as well as good copper bonding and heat resistance There is no mention of the use of fillers and the resulting laminate has a relatively high dissipation factor An article titled "A New Flame Retardant 1 ,2- Polybutadiene Laminate by N Sawatπ et al , IEEE Transactions on Electπcal Insulation, Vol EI-18, No 2, April 1983 uses a high percentage of very high molecular polybutadiene and a low molecular weight, modified polybutadiene as a minor component, but there is no mention of the use of filler of any type The article entitled "1,2 Polybutadiene-High Performance Resms for the Electrical Industry", by R E Drake, ANTEC '84 pp 730-733 (1984), generally discloses con entional polybutadiene resins for use in laminates and discloses the use of reactive monomers which react w ith the polybutadiene U K Patent Application 2 172 892A, generally discloses laminates composed of styrene-contammg and thermoplastic copolymers \\ ith unsaturated double bonds and polybutadiene Application Serial No 09/132,869, filed August 12, 1998, discloses polybutadiene or polyisoprene-based circuit board substrates comprising liquid ethylene propylene rubbers Such materials undergo a thermal cure at a high temperature (e g , greater than about 250°C), w ithout loss of copper bonding strength Use of the ethylene propylene rubber and a stviene-butadiene block copolymer allows the materials to achιe\ e the required high dielectiic strength Howe\er, such materials generally do not contain flame retardants due to the high temperature cure conditions While the above composites are well-suited for their intended puφoses, the industry is constantly moving to the processing and use of circuit boards under evei more stringent environmental conditions Properties such as dielectric strength should accordingly be well retained at the elevated temperatures which may be encountered during processing oi use Underwriters Laboratories, Inc (UL) has developed protocols for characterizing the temperature limits that circuit boards and circuit board substrate materials can withstand during processing applications and under prolonged use The UL Relative Thermal Index (RTI) identifies the temperature at which a material endures 100,000 hours of use before losing half of its initial dielectπc break down strength or mechanical (tensile or flexural ) strength The RTI is generally thickness dependent, and so UL grants RTFs to circuit board materials at different thicknesses Industry is furthermore requiring that circuit boards meet the UL Flammabihty test Consequently, there is a percen ed need in the art for circuit board substrates which have improved flammabihty resistance, improved time to the loss of initial dielectric and mechanical strength at a gι\ en temperature and at a given thickness, and ιmpro\ ed retention of dielectπc constant and mechanical strength at elevated temperatures, all while maintaining optimal electrical, chemical and processing characteπstics as well as low cost Summary of the Invention The above-discussed and other diawbacks and deficiencies of the prior art aie overcome or alleviated by low temperature cure, flame retardant, electrical substrate material comprising, based on the total composition, about 10 vol% to about 75 vol% of a resm composition which comprises a thermosetting polybutadiene or polyisoprene resm, a low molecular w eight ethylene propylene rubber m an amount of up to about 20 wt% (based on the total resm composition), and optionally a thermoplastic unsaturated butadiene- or lsoprene-containmg polymer capable of participating m cross-lmkmg with the polybutadiene oi polyisoprene resm, about 20 to about 60 parts per hundred parts of the resm composition of a flame retardant. up to about 50 vol% fabric, up to about 65 \ ol% particulate filler, and an effective quantity of a peroxide curing agent The composition possesses improv ed fire retardance over prior art electncal circuit materials, as ell as improv ed stability in dielectπc constant and mechanical properties with thermal aging In a prefeπed embodiment, at least a portion of the substrate is laminated to a conductive metal such as copper These and other features, aspects, and advantages of the present invention will become better understood with reference to the following detailed descπption. drawings, and appended claims Brief Description of the Drawings Referring now to the drawings wherein like elements are numbered alike m the several FIGURES FIGURE 1 is a cross-sectional elevation view of a circuit substrate material m accordance with the present invention. FIGURE 2 is a cross-sectional elevation view of a circuit substrate material in accordance with the present invention FIGURE 3 is a graph showing the percent retention of tensile strength over time for two embodiments of the present invention, and a comparative example FIGURE 4 is a graph showing the percent retention of dielectric strength ov ei time for two embodiments of the present invention, and a comparativ e example Descnption of the Preferred Embodiments The present invention preferably comprises a resm composition, a woven or non-woven fabric, at least one type of particulate filler, a flame retardant, and a peroxide-based curing agent The resm composition comprises a thermosetting polybutadiene or polyisoprene resm, an ethylene propylene rubber and optionally a thermoplastic unsaturated butadiene- or isoprene-contammg polymer The resm system, fabric, fillers, flame retardants, curative agents, and representative constructions together with Examples are discussed in detail below In geneial, the thermosetting compositions are processed as described in U S Patent No 5,571 ,609 to St Lawrence et al Resm System The resin system used in the electrical substrate material of this invention is a resm composition general]} comprising (1 ) a thermosetting polybutadiene oi polyisoprene resm or mixture thereof, (2) an ethylene propylene rubber (ethylene propylene copolymer (EPM) or ethylene propylene diene teφolymer (EPDM)), and optionally (3) a thermoplastic unsaturated butadiene- or isoprene-contammg polymei capable of participating in crosslmkmg with the polybutadiene or polyisoprene resm during cure The polybutadiene or polyisoprene resm crosslinks during cure and may be liquid or solid at room temperature, with liquid preferred in order to maintain the viscosity of the composition at a manageable level during processing Liquid resins may have a number average molecular weight greater than about 5.000 but preferably have a molecular weight of less than about 5.000 (most preferably betvv een about 1 ,000 and about 3,000) Polybutadiene and polyisoprene resms hav mg at least 90 wt% 1 ,2-addιtιon are prefeπed because they exhibit the greatest crosslink density upon cure due to the large number of pendent vinyl groups available for crosslmkmg High crosslink densities are desirable because such electπcal circuit substrates exhibit superior high temperature properties Possible res s include B3000 resm, a low molecular weight polybutadiene liquid resm having greater than 90 wt% 1 ,2-addιtιon and B1000 a lower molecular weight polybutadiene liquid resm having greater than 90 wt% 1 ,2-addιtιon, commercially available from Nippon Soda, Ltd , Japan, and RICON liquid 1,2-polybutadιenes from Ricon, Grand Junction, Colorado among others In order to improve the stability of the dielectπc strength and mechanical properties of the resulting electrical substrate material over time, a lower molecular weight ethylene propylene rubber is added to the polybutadiene or polyisoprene resms An ethylene propylene rubber as used herein is a copolymer, teφolymer, or other polymer comprising pπmaπly ethylene and propylene Ethylene propylene rubbers may be further classified as EPM copolymers (1 e , copolymers of ethylene and propylene monomers), or EPDM teφolymers (l e , teφolymers of ethylene, propylene, and diene monomers) Ethylene propylene diene teφolymer rubbers, m particular, have saturated mam chains, with unsaturation available off the mam chain for facile cross-linking Liquid ethylene propylene diene teφolymer rubbers in w hich the diene is dicyclopentadiene are preferred Suitable ethylene propylene rubbers include an ethylene propylene rubber having a GPC equivalent molecular weight (MW) of about 40,000, available from Uniroyal under the trade name Tπlene CP80, a liquid ethylene propylene dicyclopentadiene teφolymer rubber having a molecular weight of about 30,000, available from Uniroyal under the trade name Tπlene 54. and Tπlene 67, a liquid ethylene propylene ethyhdene norbornene teφolymer, having a molecular weight of about 40,000, available from Uniroyal Typically, the preferred molecular weights of the ethylene propylene rubbeis are less than 50,000 polystyrene equivalent weight average molecular weight as measured by gel permeation chromatography (GPC) The ethylene propylene rubber is preferably present in an amount effective to maintain the stability of the properties of the substrate material over time, in particular the dielectπc strength and mechanical properties Typically, such amounts are up to about 20 wt% with respect to the total resm system, preferably about 4 wt% to about 20 wt% preferred, and with an amount of about 6 to about 12 wt% most preferred The optional, unsaturated polybutadiene- or polyisoprene-contammg polymer component is preferably a solid, thermoplastic elastomer comprising a linear or graft- type block copolymer having a polybutadiene or polyisoprene block, and a thermoplastic block that preferably is styrene or α-methyl styrene Possible block copolymers, e g , styrene-butadiene-styrene tπ-block copolymers, include Vector 8508M (commercially available from Dexco Polymers, Houston, TX), Sol-T-6302 (commercially available from Emchem Elastomers America, Houston, TX), and Fmaprene 401 (commercially available from Fma Oil and Chemical Compan}. Dallas TX) Preferably, the copolymer is a styrene-butadiene di-block copolymer, such as K-raton Dl 118X (commercially available from Shell Chemical Coφoration Kraton Dl 1 18X is a di-block styrene-butadiene copolymer, containing 30 v ol% styrene The optional unsaturated polybutadiene- or polyisoprene- containing polymer component may further comprise a second block copolymer similar to that described above, except that the polybutadiene or polyisoprene block is hydrogenated, thereby forming a polyethylene block (in the case of polybutadiene) or an ethylene-propylene copolymer (m the case of polyisoprene) When used m conjunction ith the above- described copolymer, materials with greater "toughness" can be produced Where it is desired to use this second block copolymer, a prefeπed material is Kraton GX1855 (commercially available from Shell Chemical Coφ ) which is behev ed to be a mixtuie of styrene-high 1,2 butadiene-styrene block copolymer and styrene-(ethylene- propylene)-styrene block copolymer Thus, in a preferred embodiment, the optional unsaturated polybutadiene- oi polyisoprene-contammg polymer component comprises a solid thermoplastic elastomer block copolymer having the formula (a graft copolymer) where Y is a polybutadiene or polyisoprene block, X is a thennoplastic block, and m and n represent the average block numbers in the copolymer, m being 0 or 1 and n being at least 1 The composition may further include a second thermoplastic elastomer block copolymer having the formula W — z — W-777- (a linear copolymer) or (a graft copolymer) where Z is a polyethylene or ethylene-propylene copolymer block, W is a thermoplastic block, and p and q represent the average block numbers in the copolymer, p being 0 and 1 and q being at least 1 Particularly preferred compositions are those m which the thermosetting resm is polybutadiene, the ethylene propylene rubber is a liquid, and the unsaturated polybutadiene- or polyisoprene- containing polymer is a diblock polymer wherein the first block is polystyrene and the second block is polybutadiene The volume volume ratio of the polybutadiene or polyisoprene resm to the optional polybutadiene- or polyisoprene- containing polymer preferably is between 1 9 and 9 1, inclusive Typically, the amount of polybutadiene- or polyisoprene- contammg polymer is about 10 to about 50 wt% of the total resm system, with an amount of about 15 to about 30 wt% prefeπed The amount of combined polybutadiene or polyisoprene resm, ethylene propylene rubber, and optional, unsaturated butadiene or isoprene-contammg component is in the range of from about 10 to about 75 vol% of the total electπcal substrate material, with about 10 vol% to about 50 vol% preferred Other free radical curable monomers and polymers which can co-cure vv ith butadiene polymers may be added for specific property or processing modifications Such possible modification puφoses include toughness, adherabihty to copper foil and copper plating, and prepreg handling characteristics These co-curable polymers include random and block copolymers of primarily 1,3-addιtιon butadiene or isoprene with styrene, α-methyl styrene, acrylate or methacrylate, or acrylonitnle monomers, homopolymers or copolymers of ethylene, such as polyethylene, eth lene oxide copolymers, natural rubber, norbornene polymers such as polydιc}clopentadιene, hydrogenated styrene-isoprene-styrene copolymers and butadiene-acrylonitπle copolymers, and others Lev els of these copolymers should be less than 50 vol% of the total polymeric component Particulate Filler As will be discussed hereinafter, the mateπal described herein is preferably used as a dielectric substrate in a circuit laminate having one or more layers of conductive metal, e g copper, laminated thereto Preferably, the filler mateπal and quantity thereof is selected so as to provide the substrate with a coefficient of thermal expansion which is equal or substantially equal to the coefficient of thermal expansion of the metal layer Examples of preferred fillers include titanium dioxide (rutile and anatase), barium titanate, strontium titanate, silica (particles and hollow spheres) including fused amoφhous silica, corundum, wollasto te, ai amide fibers (e g Kevlar), fiberglass, Ba 2 Tι 9 O 20 , glass spheres, quartz, boron nitride, aluminum nitride, silicon carbide, berylha, alumina or magnesia, used alone or in combination Particularly preferred fillers are rutile titanium dioxide and amoφhous silica because these filleis have a high and low dielectπc constant, respectively, thereby permitting a broad range of dielectπc constants combined with a low dissipation factor achiev able in the final cured product by adjusting the respective amounts of the two fillers in the composition. To improve adhesion between the fillers and resm, coupling agents, e g , silanes, are preferably used The volume percent of the filler (based upon the combined v olume of the resm system, fabπc, and particulate filler) can be up to about 65%, with 0 to about 60% preferred, and about 30%o to about 50% especially preferred It is preferred that the particulate filler is present m an amount which is (1) greater than the amount (in volume percent) of thermosetting composition (preferably the ratio of filler to thermosetting composition is 55.45) and (2) greater than the amount (m olume percent) of the fabric. Flame Retardant Additive The present invention includes a flame retardant such as a bromine containing flame retardant m an amount of about 20 PHR (parts per hundred parts of resin) to about 60 PHR, and preferably contains about 30 to about 45 PFIR. Examples of suitable brominated flame retardants include Saytex BT93W (ethylene bistetrabromophthalimide), Saytex 120 (tetradecabromodiphenoxy benzene), or Saytex 102 (decabromodiphenyl oxide). Curing Agent A curing agent is added to the composition to accelerate the curing reaction. When the composition is heated, the curing agent decomposes to form free radicals, which then initiate crosslinking of the polymeric chains. Preferred curing agents are free radical cure initiators such as organic peroxides, e.g. dicumyl peroxide, t- butylperbenzoate, di(2-t-butylperoxyisopropyl) benzene, and t-butylperoxy hexyne-3. all of which are commercially available. The peroxide curing agent is provided m an amount of between 1.5 and 6 PHR. Fabric The fabric comprises woven or non- woven, thermally stable webs or mats of a suitable fiber, preferably glass (E, S, and D glass) or high temperature polyester fibers (e.g., KODEL from Eastman Kodak). The fabric is present in an amount of up to about 50 vol%, with about 10 to 40 vol% preferred, and about 15 to about 25 vol° o especially preferred (with respect to the entire laminate). Such thermally stable fabric provides the laminate a means of controlling shrinkage upon cure within the plane of the laminate. In addition, the use of the fabric produces a dielectric substrate with a relatively high mechanical strength. Examples of the prefeπed fabrics are set forth in Tables 1 and 2 Woven fiberglass fabrics, are set forth m Table 1, and nonw ov en fabric are set forth in Table 2 The method for preparing the laminate is as generally described in U S Patent No. 5,571,609. Accordingly, the polymeric ingredients, peroxide, filler, silane, flame retardant and solvent (if use) are well dissolved or dispersed into a uniform slurry In the next step, the glass web is saturated with sluπ to the coπect thickness, and then solvent is removed to form the prepreg Then, a stack up is made of one or more layers of prepreg with outside layers of conductive foil This stack up is densified and cured via lamination or a combination of lamination and ov en baking The stack up is cured in a conv entional peroxide cuie step, typically betw een 330T (about 165 ° C) and 475 (about 245 ° C) Unlike U S Application Serial No 09/132,869, there is no high temperature cure step where temperatuie is greater than about 250 ° C Referring now to FIGURES 1 and 2, wherein like elements are number alike prefeπed embodiments of the present inv ention are shown FIGURE 1 illustrates a single clad dielectric material 10 having a thermosetting composition m accordance with the present invention 12 and a single layer of copper 14 adhered by means known in the art to the composite 12 Such adhesion is by lamination, use of an adhesiv e, and the like FIGURE 2 illustrates a diclad electrical material 20, wherein the thermosettmg composition in accordance with the present invention 12 is adhered to two layers of a metal, e g , copper 22, 24 The invention is further illustrated by the following non-limiting examples EXAMPLES The following examples employed the components shown in Table 3 The etched laminate was measured for dielectric strength and tensile strength, both unaged and after aging various aging times Samples were aged in air circulating ovens at the designated temperatures within ±3°C, at aging temperatures indicated below After removal from an oven, samples were conditioned at room temperature (1 e about 25 °C) and 50% relative humidity for at least 16 hours before testing As described by the UL Thermal Index method m UL 746B ("Polymeπc Materials - Long Term Property Evaluations"), the point of failure is the time for the measured property to decrease to 50% of its unaged v alue The dielectric strength w as measured using American Society for Testing Materials procedure ASTM D149 Tensile strength was measured using ASTM D638 The dried prepregs were made so as to provide a laminated layer about 3 35 mils thick, according the formulations set forth in Table 4 (all amounts are listed m weight percent) Examples 1 to 6 were prepared on a laboratory scale using two layers of prepreg and 1 -ounce ED copper foil The following temperature cycle was used for lamination ramp-up at 4°F/mmute from room temperature to 375°F, dwell 2 hours at 375°F, cool-down at 3°F/mm to about 100°F Examples 1 and 2 were made using a lamination pressure of 300 psi, Examples 3 to 6 at 1,000 psi Examples 7 to 9 were formed into prepregs and laminated at full production scale Laminating pressure was 1 ,000 psi using a lamination temperature cycle of 6°F/mιnute ramp-up to 475°F, 90 mmute dwell at 475 F, and 6°F/mmute ramp dow n Laminates were made with 6 prepreg layers, or about 0 020 inches EXAMPLE 1 (Comparative) This example is included for comparison puφoses It contains no ethylene propylene rubber, and a tπblock SBS elastomeπc component Unaged dielectπc strength and tensile strength data are shown m Tables 5 and 6 along with the time to 50% of the initial property value on agmg at 170°C, 190 ° C and 210°C The data shown is the average from two separate preparations of this formulation EXAMPLE 2 In Example 2, a portion of the polybutadiene resm, B-3000, was replaced by an equal portion of Trilene 54 liquid EPDM rubber, at a level of 2 4 vvt% of the total coating composition (resm system, particulate filler, and cure agent) Testing at 170°C (Tables 5 and 6) showed an increase of about 79% in agmg time to failure in dielectric strength, and of about 57% in tensile strength compared to Example 1 (Examples 1 and 2, which were laminated at 300 psi, were lower in initial tensile strength and dielectric constant than the following examples laminated at 1 ,000 psi ) EXAMPLES 3 and 4 In Examples 3 and 4, Trilene 54 at the level of 1 2 wt% based upon the total coating formulation was used m place of an equal amount of B-3000 resm A change was furthermore made m the type of polybutadiene block copolymer from Vector 8508D to Kraton KX 410CS m Example 3, or Kraton Dl 118X in Example 4 The Vector 8508D is a tπblock SBS polymer, while Kraton KX 410CS is essentially a diblock (about 67% diblock, 33% tπlblock), and Kraton Dl 118X is all diblock copolymer Example 3 agmg results at 170°C, 190°C and 210°C were compared to those of Example 1 (Tables 5 and 6) At all three temperatures there was significant improvement in agmg time in Example 3 The improvement appeared greater in tensile strength than dielectric strength, and greater at the higher two temperatures In Example 4, the comparison was made at 190 ° C and 210°C, and again there was a substantial improvement over Example 1. EXAMPLE 5 In Example 5, Trilene 54 was added in an amount of 2.4 wt% in lieu of an equal amount of B-3000 resin, as in Example 2. In Example 5 however, there was also replacement of the triblock SBS polymer, Vector 8508D, by a predominantly diblock SB polymer, Kraton KX 410CS. The aging results (Tables 5 and 6) were much improved for Example 5 over Example 1. Results for Example 5 were also improved over Example 3. which is similar, except it contains half as much Trilene 54. The magnitude of the improvement over Example 1, as shown in Table 4, is a 3- fold or greater increase in time to failure in the data at 190 ° C and 210°C. At 170°C, the rate of degradation was so slow that testing was discontinued before failure, after 49 days in the case of dielectric strength and 88 days for tensile strength. EXAMPLE 6 Example 6 is similar to Example 5 except a small amount of an antioxidant, Naugard XL-1, was added. Example 6 was tested at 210°C, and no improvement was found over Example 5 (Table 5). This Example is included in connection with scaled-up Examples 8 and 9, which contain the same amount of antioxidant added to improve viscosity stability in processing operations. The improvements in dielectric strength and tensile strength shown in Examples 8 and 9 are therefore not associated with the antioxidant which they contain and which is absent in the Example 7. EXAMPLE 7 (Comparative) Comparative Example 7 was prepared in large production equipment using the same formulation as used in Example 1. It is used to compare with Examples 8 and 9 which were similarly prepared. Test samples were made nominally 0.020 inches thick in production. Comparisons were made at similar thickness, because time to aging failure is greater in thicker samples. Four test temperatures were used in this comparison: 170°C, 190°C, 210°C and 230°C. *Test discontinued without reaching a failure point. NT = Not tested under this condition *Test discontinued without reaching a failure point. NT = Not tested under this condition EXAMPLES 8 and 9 In Examples 8 and 9, the formulation of comparative Example 7 was changed by adding 2 4 wt% Trilene 54 m lieu of B-3000 resin, and replacing Vector 8508D b} Kraton 410CS in Example 8, and Kraton Dl 118X m Example 9 Agmg results are shown in Tables 7 and 8 for retention of dielectric strength and tensile strength at elevated temperatures In Examples 8 and 9. no failures occurred over the agmg times observed Ev en though these tests ere discontinued without failure, they endured times that ere many multiples of the failure times of Example 7 The magnitude of the improvements are indicated graphically in Figures 3 and 4, showing dielectric strength and tensile strength with aging at 230°C Test discontinued without reaching a failure point FIGURES 3 and 4 further demonstrate that the addition of an ethylene propylene rubber improves the retention of circuit board properties hi accordance with the UL RTI test, the failure point of the substrate material is defined as the time it takes to reach 50% of the initial property value at a given thickness and temperature As shown in each of these Figures, each embodiment readily outperforms circuit boards without an ethylene propylene rubber Through inclusion of an ethylene propylene rubber in the thermosetting matrix, and substitution of a tπblock copolymer with a diblock copolymer, retention of the dielectric strength and mechanical properties of the resulting electrical substrate material substantially improves, while other electrical, chemical, and mechanical properties of the material are not adversely effected Additionally, the foregoing component ratios leads to a prepreg which has very little tackiness and can therefore be easily handled by operators This low tackiness feature allows for the use of conventional automated layup processing, including foil cladding, using one or more known roll lammators While the prepreg of this invention is tack- free enough to be tacked by itself using a roll lammator (e g , nip roller) at room temperature While preferred embodiments have been shown and described, v arious modifications and substitutions may be made thereto without departing from the spnit and scope of the invention Accordingly, it is understood that the present invention has been described by way of illustrations and not limitation What is claimed is

Claims: CLAIM 1 An electrical circuit material, comprising a substrate, which comprises based on the total substrate, about 10 vol% to about 75 vol% ot a resm composition, the resm composition comprising a polybutadiene or polyisoprene resin, and based on the total resm composition, up to about 20 wt% of an ethylene propylene rubber having a weight av erage molecular weight of less than about 50,000 measured by gel permeation chromatography, between about 20 and about 60 PHR flame retardant, based on the total substrate, up to about 50 v ol% fabric, based on the total substrate, up to about 65 vol% particulate filler, and an effective quantity of a peroxide cuπng agent, and a layer of conductive metal laminated to at least a portion of the substrate CLAIM 2 The electrical circuit of Claim 1 , wheiein the circuit substrate mateπal comprises, based on the total resm composition, from about 6 wt% to about 12 wt% ethylene propylene rubber CLAPM 3 The electrical circuit of Claim 1, wherein the circuit substrate material comprises, based on the total substrate, about 10 vol% to about 50 vol% of the resm composition, and based on the total resm composition from about 4 wt% to about 20 wt% ethylene propylene rubber CLAIM 4 The electrical circuit of Claim 1, wherein the circuit substrate material comprises, based on the total substrate, about 10 vol% to about 50 ol% of the resm composition, and based on the total resm composition from about 6 wt% to about 12 wt% ethylene propylene rubber CLAIM 5 The electrical circuit of Claim 1 , wherein the ethylene propylene containing rubber is an ethylene propylene copolymer, an ethylene propylene diene teφolymer, or a combination thereof CLAIM 6 The electrical circuit of Claim 5, wherein the diene is dicyclopentadiene or ethyhdene norbornene CLAIM 7 The electrical circuit of Claim 1, wherein the resm composition further comprises an unsaturated butadiene- or isoprene-contammg polymer capable of participating in cross-lmkmg with the polv butadiene or polyisoprene resm, and furthei wherein the volume to volume ratio of the polybutadiene or polyisoprene resm to the unsaturated butadiene- or isoprene-contammg polymer is between 1 9 and 9 1 , inclusive CLAIM 8 The electrical circuit of Claim 7, wherein the unsaturated butadiene- or isoprene-contammg polymer is a copolvmer of isoprene or butadiene and a second monomer CLAIM 9 The electrical circuit of Claim 8, wherein the unsatuiated butadiene- oi isoprene-contammg polymer is a di-block copolymer CLAIM 10 The electπcal circuit of Claim 9, wherein the unsaturated butadiene- oi isoprene-contammg polymer is a styrene-butadiene or α-methyl styrene-butadiene di-block copolymer CLAIM 1 1 The electπcal circuit of Claim 7, wherein the unsaturated butadiene- or isoprene-contammg polymer is a thermoplastic elastomer block copolymer having one of the formula where in each formula Y is a block comprising isoprene or butadiene units, X is a thermoplastic block, and m and n represent the average block numbers m said copolymer, m being 0 or 1 and n being at least 1 , and Z is a polyethylene or ethylene-propylene copolymer block, W is a thermoplastic block, and p and q represent the average block numbers in said copolymer, p being 0 or 1 and q being at least 1 CLAIM 12 The electrical circuit of Claim 1 , further comprising up to about 60 vol% filler and up to about 40 vol% fabric. CLAIM 13 The electrical circuit of Claim 12, wherein the filler is titanium dioxide, barium titanate, strontium titanate, silica, fused amoφhous silica, corundum, wollastonite, polytetrafluoroethylene, aramide fibers, fiberglass, Ba 2 Tι 9 O 20 , glass spheres, quartz, boron nitride, aluminum nitride, silicon carbide, beryl a, alumina or magnesia CLAIM 14 The electrical circuit of Claim 1, wherein the flame retardant is a brominated flame retardant CLAIM 15 The electrical circuit of Claim 1 , herein the flame retardant is selected from the group consistmg of ethylene bistetrabromophthahmide, tetradecabromodiphenoxy benzene, and decabromodiphenoxy oxide CLAIM 16 The electrical circuit of Claim 1 , herein the cuπng agent is an organic peroxide CLAIM 17 The electrical circuit of Claim 16. wherein the curing agent is selected from the group consisting of dicumyl peroxide, dι(2-tert-butylperoxyιsopropyl) benzene, t-butylperbenzoate, t-butylperoxy hexyne-3, and combinations thereof CLAIM 18 The electrical circuit material of Claim 1, wherein the substrate further comprises about 30 volume% to about 50 volume% filler CLAIM 19 The electπcal circuit material of Claim 1, wherein the substrate further comprises about 15 vol% to about 25 vol% fabric CLAIM 20 The electrical circuit material of Claim 1, wherein the metal is copper CLAIM 21. An electrical circuit material, comprising: a substrate, which comprises based on the total substrate, about 10 vol% to about 75 vol% of a resin composition, the resin composition comprising a polybutadiene or polyisoprene resin, an unsaturated butadiene- or isoprene-contammg di-block copolymer, and based on the total resin composition, about 4 to about 20 wt% of an ethylene propylene rubber having a weight average molecular weight of less than about 50,000 measured by gel permeation chromatography; between about 20 and about 60 PHR flame retardant; based on the total substrate, up to about 50 vol% fabric; based on the total substrate, up to about 65 vol% particulate filler; and an effective quantity of a peroxide curing agent; and a layer of conductive metal laminated to at least a portion of the substrate. CLAIM 22. The electrical circuit of Claim 21 , wherein the circuit substrate mateπal comprises, based on the total resin composition, from about 6 wt% to about 12 wt° o ethylene propylene rubber. CLAIM 23. The electrical circuit of Claim 21, wherein the circuit substrate mateπal comprises, based on the total substrate, about 10 vol% to about 50 vol% of the resm composition, and based on the total resin composition from about 4 wt% to about 20 wt% ethylene propylene rubber. CLAIM 24. The electrical circuit of Claim 21 , wherein the circuit substrate mateπal comprises, based on the total substrate, about 10 vol% to about 50 vol% of the resm composition, and based on the total resin composition from about 6 wt% to about 12 wt% ethylene propylene rubber. CLAIM 25 The electncal circuit of Claim 21, wherein the ethylene propylene containing rubber is an ethylene prop} lene copolymer, an ethylene propylene diene teφolymer, or a combination thereof CLAIM 26 The electrical circuit of Claim 25, wherein the diene is dicyclopentadiene or ethyhdene norbornene CLAIM 27 The electrical circuit of Claim 21, wherein the unsaturated butadiene- or isoprene-contammg polymer is a st}τene-butadιene or α-methyl styrene-butadiene di-block copolymer CLAIM 28 The electrical circuit of Claim 28, wherein the unsaturated butadiene- or isoprene-contammg polymer is a thermoplastic elastomer block copolymer having one of the formula X m — (Y— X-7- w p — (-Z— w or wherein each formula Y is a block comprising isoprene or butadiene units, X is a thermoplastic block, and m and n represent the average block numbers m said copolymer, m being 0 or 1 and n being at least 1 , and Z is a polyethylene or ethylene-propylene copolymer block. W is a thermoplastic block, and p and q represent the average block numbers said copolymer, p being 0 or 1 and q being at least 1 CLAIM 29 The electrical circuit of Claim 21, further comprising up to about 60 vol% filler and up to about 40 vol% fabric CLAIM 30 The electrical circuit of Claim 21 , wherein the filler is titanium dioxide, barium titanate, strontium titanate, silica, fused amoφhous silica, corundum, wollastomte, polytetrafluoroethylene, aramide fibers, fiberglass, Ba 2 Tι 9 O 20 , glass spheres, quartz, boron nitride, aluminum nitride, silicon carbide, bervllia, alumina or magnesia CLAIM 31 The electrical circuit of Claim 21 , wherein the flame retardant is selected from the group consisting of a brommated flame retardant ethylene bistetrabromophthahmide, tetradecabromodiphenoxy benzene, decabromodiphenoxy oxide, and combinations thereof CLAIM 32 The electrical circuit of Claim 21 , wherein the cuπng agent is an organic peroxide selected from the group consisting of dicumyl peroxide, dι(2-tert- butylperoxyisopropyl) benzene, t-butylperbenzoate, t-butylperox} hexyne-3, and combinations thereof CLAIM 33 The electπcal circuit material of Claim 21, wherein the substrate further comprises about 30 volume% to about 50 volume% filler CLAIM 34 The electπcal circuit material of Claim 21, wherein the substrate further comprises about 15 vol% to about 25 vol% fabric CLAIM 35 The electπcal circuit material of Claim 21, wherein the electπcal circuit substrate material has a dielectric strength of equal to or greater than 500

Inventors: LANDI VINCENT R, LANDI, VINCENT, R.
Applicants: WORLD PROPERTIES INC, WORLD PROPERTIES, INC.
Application year: 2001
Main classification: H05K1
IPC codes: B32B15, C08J5, C08K3, C08K5, C08L27, C08L47, C08L53, C08L77, H05K1