Claims
- 1. A thermosetting resin composition comprising:
at least one elastomer; at least one ester; and at least one flame retardant.
- 2. The composition of claim 1 wherein the at least one elastomer comprises from about 20 wt % to about 60 wt %; the at least one ester comprises from about 1 wt % to about 15 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content.
- 3. The composition of claim 1 wherein the at least one elastomer is selected from the group consisting of thermoplastic polymers, butadiene polymers, styrene butadiene polymers, acrylonitrile-butadiene copolymers, isoprene polymers, urethane elastomers, polyamides, a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof.
- 4. The composition of claim 1 wherein the at least one ester is an unsaturated ester.
- 5. The composition of claim 1 further comprising at least one catalyst.
- 6. The composition of claim 5 wherein the at least one catalyst is a peroxide catalyst.
- 7. The composition of claim 5 wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content.
- 8. The composition of claim 1 wherein the at least one flame retardant is decabromodiphenylethane.
- 9. The composition of claim 1 wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof.
- 10. The composition of claim 4 wherein the unsaturated ester is an unsaturated polyester.
- 11. The composition of claim 6 wherein the at least one catalyst is selected from dicumyl peroxide, tert-butyl peroxbenzoate, and mixtures thereof.
- 12. The composition of claim 1 further comprising at least one filler selected from the group consisting of teflon, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof.
- 13. The composition of claim 12 wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content.
- 14. The composition of claim 12 wherein the filler is silane treated fused silica.
- 15. A thermosetting resin composition comprising:
a polybutadiene styrene divinylbenzene graft terpolymer; an unsaturated polyester; decabromodiphenylethane; fused silica; and dicumyl peroxide.
- 16. The composition of claim 15 wherein the terpolymer comprises from about 30 wt % to about 35 wt %; the polyester comprises from about 2 wt % to about 4 wt %; the decabromodiphenylethane comprises from about 20 wt % to about 25 wt %; the fused silica comprises from about 32 wt % to about 38 wt %; and the dicumyl peroxide comprises from about 5 wt % to about 6 wt %, each as a percentage of the composition solids content.
- 17. A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises:
at least one elastomer; at least one ester; and at least one flame retardant.
- 18. The prepreg of claim 17 wherein the at least one elastomer comprises from about 20 wt % to about 60 wt %; the at least one ester comprises from about 1 wt % to about 15 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content.
- 19. The prepreg of claim 17 wherein the at least one elastomer is selected from the group consisting of thermoplastic polymers, butadiene polymers, styrene butadiene polymers, acrylonitrile-butadiene copolymers, isoprene polymers, urethane elastomers, polyamides, a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof.
- 20. The prepreg of claim 17 wherein the at least one ester is an unsaturated ester.
- 21. The prepreg of claim 17 wherein the thermosetting resin composition further comprises at least one catalyst.
- 22. The prepreg of claim 21 wherein the at least one catalyst is a peroxide catalyst.
- 23. The prepreg of claim 21 wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content.
- 24. The prepreg of claim 17 wherein the at least one flame retardant is decabromodiphenylethane.
- 25. The prepreg of claim 17 wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof.
- 26. The prepreg of claim 20 wherein the unsaturated ester is an unsaturated polyester.
- 27. The prepreg of claim 22 wherein the at least one catalyst is selected from dicumyl peroxide, tert-butyl peroxbenzoate, and mixtures thereof.
- 28. The prepreg of claim 17 wherein the thermosetting resin composition further comprises at least one filler selected from the group consisting of teflon, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof.
- 29. The prepreg of claim 28 wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content.
- 30. The prepreg of claim 28 wherein the filler is silane treated fused silica.
- 31. The prepreg of claim 17 wherein the core material comprises a woven glass web.
- 32. A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises:
a polybutadiene styrene divinylbenzene graft terpolymer; an unsaturated polyester; decabromodiphenylethane; fused silica; and dicumyl peroxide.
- 33. The prepreg of claim 32 wherein the core material comprises a woven glass web.
- 34. A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: at least one elastomer; at least one ester; and at least one flame retardant.
- 35. The laminate of claim 34 wherein the one or more prepregs and the one or more sheets of conducting foil are alternately stacked.
- 36. The laminate of claim 34 wherein in the thermosetting resin composition, the at least one elastomer comprises from about 20 wt % to about 60 wt %; the at least one ester comprises from about 1 wt % to about 15 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content.
- 37. The laminate of claim 34 wherein the at least one elastomer is selected from the group consisting of thermoplastic polymers, butadiene polymers, styrene butadiene polymers, acrylonitrile-butadiene copolymers, isoprene polymers, urethane elastomers, polyamides, a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof.
- 38. The laminate of claim 34 wherein the at least one ester is an unsaturated ester.
- 39. The laminate of claim 34 wherein the thermosetting resin composition further comprises at least one catalyst.
- 40. The laminate of claim 39 wherein the at least one catalyst is a peroxide catalyst.
- 41. The laminate of claim 39 wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content.
- 42. The laminate of claim 34 wherein the at least one flame retardant is decabromodiphenylethane.
- 43. The laminate of claim 34 wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof.
- 44. The laminate of claim 38 wherein the unsaturated ester is an unsaturated polyester.
- 45. The laminate of claim 40 wherein the at least one catalyst is selected from dicumyl peroxide, tert-butyl peroxbenzoate, and mixtures thereof.
- 46. The laminate of claim 34 wherein the thermosetting resin composition further comprises at least one filler selected from the group consisting of teflon, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof.
- 47. The laminate of claim 46 wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content.
- 48. The laminate of claim 46 wherein the filler is silane treated fused silica.
- 49. The laminate of claim 34 wherein the one or more sheets of conducting foil are copper foil.
- 50. A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: a polybutadiene styrene divinylbenzene graft terpolymer; an unsaturated polyester; decabromodiphenylethane; fused silica; and dicumyl peroxide.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Serial No. 60/337,362, filed Dec. 5, 2001, which is incorporated herein by reference in its entirety.
Provisional Applications (1)
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Number |
Date |
Country |
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60337362 |
Dec 2001 |
US |