Thermosetting Resin Compositions For High Performance Laminates
This invention concerns a thermosetting resin system that is useful in the manufacture of high performance prepreg, laminate and composite materials as well as, prepregs, laminates and composites made from the thermosetting resin composition.
1 . A prepreg comprising a substrate impregnated with a thermosetting resin including:
at least one epoxy resin;
at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof; and
at least one styrene-maleic anhydride copolymer.
2 . The prepreg of claim 1 wherein the thermosetting resin includes an accelerator.
3 . The prepreg of claim 1 wherein the thermosetting resin includes a filler.
4 . The prepreg of claim 1 wherein the thermosetting resin includes a toughener.
5 . The prepreg of claim 1 wherein the thermosetting resin includes a flame retardant.
6 . The prepreg of claim 1 wherein the epoxy resin comprises an admixture of Bis-A epoxy resin; brominated bisphenol A diglycidyl ether; and tetrabromobisphenol A.
7 . The prepreg of claim 2 wherein the accelerator is an imidazole.
8 . The prepreg of claim 3 wherein the filler is selected from teflon, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, or mixtures thereof.
9 . The prepreg of claim 4 wherein the toughener is methacrylate butadiene styrene core shell particles.
10 . The prepreg of claim 1 including from about 15 to about 50 wt % of the at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof.
11 . The prepreg of claim 1 wherein the substrate is a woven glass material.
12 . A prepreg comprising a substrate impregnated with a thermosetting resin including:
an epoxy resin;
from about 15-50 weight percent at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof; and
15-23 weight percent of the at least one styrene-maleic anhydride copolymer;
13 . The prepreg of claim 12 wherein the thermosetting resin includes at least one ingredient selected from the group consisting of 2-4 weight percent of methacrylate butadiene core shell particles; 0.2-0.5 weight percent of an accelerator; 25-40 weight percent of a bismaleimidetriazine resin; and 0-10 weight percent of a filler.
14 . The prepreg of claim 12 wherein the at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof is a cyanate ester resin.
15 . The prepreg of claim 12 wherein the substrate is a woven glass material.
16 . The prepreg of claim 12 wherein the thermosetting resin composition is at least partially cured.
17 . A laminate including one or more pregregs of claim 12 .
18 . The laminate of claim 17 including one or more sheets of a conducting foil.
19 . The laminate of claim 18 including at least one prepreg positioned between sheets of conducting foil.
20 . The laminate of claim 17 including at least one sheet of conducting foil positioned between two prepreg sheets.