Varnishes and Prepregs and Laminates Made Therefrom
Varnishes useful in manufacturing prepregs and laminates including at least one polymer selected from the group consisting of polyphenylene ether, polyphenylene oxide and combinations thereof; at least on reactive monomer; and at least one initiator.
1 . A varnish composition comprising:
a polymer selected from the group consisting of polyphenylene ether, polyphenylene oxide and combinations thereof;
at least on reactive monomer;
at least one initiator.
2 . The varnish composition of claim 1 wherein the polymer is polyphenylene ether having the formula:
wherein R 1 and R 2 can each be hydrogen, methacrylate or acrylate group and n is an integer ranging from 1 to 100.
3 . The varnish composition of claim 1 wherein the polymer is polyphenylene oxide having the following general formula:
Where R 1 , R 2 , R 3 and R 4 may be individually selected from hydrogen and a C 1 to C 4 alkyl group wherein n is an integer ranging from 1 to 100.
4 . The varnish composition of claim 3 wherein the polyphenylene oxide is selected from:
and mixtures thereof wherein n is 1 to 100.
5 . The varnish composition of claim 1 wherein the polymer is present in the varnish in an amount ranging from about 25 to about 75 wt % on a dry weight basis.
6 . The varnish composition of claim 1 wherein the polymer is present in the varnish in an amount ranging from about 30 to about 60 wt % on a dry weight basis.
7 . The varnish composition of claim 1 wherein the reactive monomer is selected from the group of reactive monomers consisting of styrene, bromo-styrene, dibromostyrene, divinylbenzene, pentabromobenzyl acrylate, trivinylcyclohexane, triallyl isocyanurate, triallyl cyanurate, triacrylate isocyanurate and combinations thereof.
8 . The varnish composition of claim 1 wherein the reactive monomer is selected from triallyl isocyanurate, triallyl cyanurate and mixtures thereof.
9 . The varnish composition of claim 1 wherein the reactive monomer is present in the varnish in an amount ranging from about greater than 0 to about 40 wt % on a dry basis.
10 . The varnish composition of claim 1 wherein the reactive monomer is present in the varnish composition in an amount ranging from about 15 to about 35 wt % on a dry basis.
11 . The varnish composition of claim 1 wherein the reactive monomer is a copolymer of dibromostyrene and triallyl cyanurate.
12 . The varnish composition of claim 11 wherein the copolymer is present in the varnish in an amount ranging from about 15 to about 60 wt %.
13 . The varnish composition of claim 1 including one or more flame retardants in an amount ranging from about 5% to about 50 wt % on a dry basis.
14 . The varnish composition of claim 13 wherein the flame retardant is one or more halogen free flame retardants.
15 . The varnish composition of claim 14 wherein the one or more halogen free flame retardants is selected from the group of compounds consisting of:
and mixtures thereof.
16 . The varnish composition of claim 13 wherein the flame retardant is pentabromobenzyl acrylate.
17 . The varnish composition of claim 13 wherein the flame retardant is Decabromodiphenylethane.
18 . The varnish composition of claim 1 wherein the initiator is a peroxide initiator selected from the group consisting of benzoyl peroxide, dicumyl peroxide, 2,5-Dimethyl-2,5-di-t-butylperoxyhexyne, 2,5-Dimethyl-2,5-di-t-butylperoxyhexane and combinations thereof where the initiator is present in the varnish in an amount ranging from about 0.5 to about 3.0 wt %.
19 . A varnish composition comprising:
from about 30 to about 60 wt % of at least one polyphenylene oxide polymer having the following formula:
where R 1 , R 2 , R 3 and R 4 may be individually selected from hydrogen and a C 1 to C 4 alkyl group wherein n is an integer ranging from 1 to 100;
from about 15 to about 35 wt % triallyl cyanurate;
from about 0.5 to about 3 wt % of at least one initiator selected from the group consisting of benzoyl peroxide, dicumyl peroxide, 2,5-Dimethyl-2,5-di-t-butylperoxyhexyne, 2,5-Dimethyl-2,5-di-t-butylperoxyhexane and combinations thereof;
from about 5 to about 50 wt % of at least one flame retardant selected from
and decabromodiphenyl ethane; and
from greater than 0 to about 30 wt % of at least one silica filler.
20 . The varnish composition of claim 19 wherein the polyphenylene oxide is selected from:
and mixtures thereof wherein n is 1 to 100.
21 . The varnish composition of claim 19 wherein the initiator is present in the varnish in an amount ranging from about 1% to 2% based upon 100% of reactive component.
22 . The varnish composition of claim 19 wherein the weight ratio of the polyphenylene oxide polymer to triallyl cyanurate ranges from 1.0 to 3.0.
23 . A copper sheet having a first surface and second surface wherein the first surface includes a b-staged layer of the varnish of claim 1 .
24 . A prepreg comprising a core material that is impregnated with an at least partially cured varnish wherein the varnish is an admixture of: a polymer selected from the group consisting of polyphenylene ether, polyphenylene oxide and combinations thereof;
at least on reactive monomer;
at least one initiator.
25 . The prepreg of claim 24 wherein the polymer is polyphenylene ether having the formula:
wherein R 1 and R 2 can each be hydrogen, methacrylate or acrylate group and n is an integer ranging from 1 to 100.
26 . The prepreg of claim 24 wherein the polymer is polyphenylene oxide having the following general formula:
Where R 1 , R 2 , R 3 and R 4 may be individually selected from hydrogen and a C 1 to C 4 alkyl group wherein n is an integer ranging from 1 to 100.
27 . The prepreg of claim 26 wherein the polyphenylene oxide is selected from:
and mixtures thereof wherein n is 1 to 100.
28 . The prepreg of claim 24 wherein the polymer is present in the varnish in an amount ranging from about 25 to about 75 wt % on a dry weight basis.
29 . The prepreg of claim 24 wherein the polymer is present in the varnish in an amount ranging from about 30 to about 60 wt % on a dry weight basis.
30 . The prepreg of claim 24 wherein the reactive monomer is selected from the group of reactive monomers consisting of styrene, bromo-styrene, dibromostyrene, divinylbenzene, pentabromobenzyl acrylate, trivinylcyclohexane, triallyl isocyanurate, triallyl cyanurate, triacrylate isocyanurate and combinations thereof.
31 . The prepreg of claim 24 wherein the reactive monomer is selected from triallyl isocyanurate, triallyl cyanurate and mixtures thereof.
32 . The prepreg of claim 24 wherein the reactive monomer is present in the varnish in an amount ranging from about greater than 0 to about 40 wt % on a dry basis.
33 . The prepreg of claim 23 wherein the reactive monomer is present in the varnish composition in an amount ranging from about 15 to about 35 wt % on a dry basis.
34 . The prepreg of claim 24 wherein the reactive monomer is a copolymer of dibromostyrene and triallyl cyanurate.
35 . The prepreg of claim 34 wherein the copolymer is present in the varnish in an amount ranging from about 15 to about 60 wt %.
36 . The prepreg of claim 24 including one or more flame retardants in an amount ranging from about 5% to about 50 wt % on a dry basis.
37 . The prepreg of claim 36 wherein the flame retardant is one or more halogen free flame retardants.
38 . The prepreg of claim 37 wherein the one or more halogen free flame retardants is selected from the group of compounds consisting of:
and mixtures thereof.
39 . The prepreg of claim 36 wherein the flame retardant is pentabromobenzyl acrylate.
40 . The prepreg of claim 36 wherein the flame retardant is Decabromodiphenylethane.
41 . The prepreg of claim 24 wherein the initiator is a peroxide initiator selected from the group consisting of benzoyl peroxide, dicumyl peroxide, 2,5-Dimethyl-2,5-d i-t-butylperoxyhexyne, 2,5-Dimethyl-2,5-di-t-butylperoxyhexane and combinations thereof where the initiator is present in the varnish in an amount ranging from about 0.5 to about 3.0 wt %.
42 . A prepreg comprising a core material that is impregnated with an at least partially cured varnish wherein the varnish is an admixture of:
from about 30 to about 60 wt % of at least one polyphenylene oxide polymer having the following formula:
where R 1 , R 2 , R 3 and R 4 may be individually selected from hydrogen and a C 1 to C 4 alkyl group wherein n is an integer ranging from 1 to 100;
from about 15 to about 35 wt % triallyl cyanurate;
from about 0.5 to about 3 wt % of at least one initiator selected from the group consisting of benzoyl peroxide, dicumyl peroxide, 2,5-Dimethyl-2,5-di-t-butylperoxyhexyne, 2,5-Dimethyl-2,5-di-t-butylperoxyhexane and combinations thereof;
from about 5 to about 50 wt % of at least one flame retardant selected from
and decabromodiphenyl ethane; and
from greater than 0 to about 30 wt % of at least one silica filler.
43 . The prepreg of claim 42 wherein the polyphenylene oxide is selected from:
and mixtures thereof wherein n is 1 to 100.
44 . The prepreg of claim 42 wherein the initiator is present in the varnish in an amount ranging from about 1% to 2% based upon 100% of reactive component.
45 . The prepreg of claim 42 wherein the weight ratio of the polyphenylene oxide polymer to triallyl cyanurate ranges from 1.0 to 3.0.
46 . The prepreg of claim 24 or 42 wherein the varnish is c-staged.
47 . A laminate including one or more prepregs of claim 24 or 42 .