Composites for high-frequency printed circuit boards and methods of making
A composite includes at least one thermoplastic polymer; and at least one PTFE-based polymer, such that the composite has a dielectric loss tangent of less than 10 −3 . Moreover, a method for preparing a composite includes mixing at least one thermoplastic polymer with at least one PTFE-based polymer to form a homogenous mixture; melting the mixture to form a composite material; and hot pressing the composite material to form a composite sheet.
1. A composite, comprising:
at least one thermoplastic polymer; and
at least one PTFE-based polymer,
wherein the composite has a dielectric loss tangent of less than 10 −3 at a frequency of 10 GigaHertz, and
wherein the at least one thermoplastic polymer comprises at least one of:
2. The composite of claim 1 , wherein the at least one thermoplastic polymer comprises at least one of cyclic olefin copolymers, polystyrene polymers, fluoropolymers, polyetheretherketone polymers, polyetherimide polymers, liquid crystal polymers, polypropylene polymers, cyclic olefins, linear olefins, bi-cyclic olefin norbornene and ethylene, or combinations thereof.
3. The composite of claim 1 , wherein:
the at least one thermoplastic polymer comprises a first thermoplastic polymer and a second thermoplastic polymer,
the first thermoplastic polymer comprises a fluoropolymer, and
the second thermoplastic polymer comprises the at least one thermoplastic polymer comprising at least one of:
4. The composite of claim 1 , wherein a ratio of a total weight of the at least one thermoplastic polymer to a total weight of the at least one PTFE-based polymer is in a range of 1:99 to 99:1 on a wt. % basis relative to a sum of the total weight of the at least one thermoplastic polymer and the total weight of the at least one PTFE-based polymer.
5. The composite of claim 4 , wherein the ratio of the at least one thermoplastic polymer to the at least one PTFE-based polymer is in a range of 40:60 to 60:40 on a wt. % basis, respective to the weight of the composite.
6. The composite of claim 1 , wherein the at least one thermoplastic polymer is present in a range of 20 wt. % to 80 wt. %, respective to the weight of the composite.
7. The composite of claim 1 , wherein the at least one PTFE-based polymer is present in a range of 20 wt. % to 80 wt. %, respective to the weight of the composite.
8. The composite of claim 1 , further comprising:
at least one reinforcing material,
wherein the at least one reinforcing material is at least one of a pellet, a particle, a liquid, a powder, a fiber, a tape, a weave, a filament, a yarn, a sheet, or a combination thereof.
9. The composite of claim 8 , wherein the at least one reinforcing material comprises at least one of silica, alumina, alumina trihydrate, antimony oxide, barium sulfate, calcium carbonate, kaolinite, magnesium hydroxide, talc, titanium dioxide, or combinations thereof.
10. The composite of claim 8 , wherein the at least one reinforcing material comprises silica present in an amount of at least 50 wt. %, respective to the weight of the composite.
11. The composite of claim 8 , wherein at least one of the thermoplastic polymer, PTFE-based polymer, or reinforcing material has a dielectric loss tangent of less than 10 −3 at a frequency of 10 GigaHertz.
12. The composite of claim 8 , wherein the at least one reinforcing material is present in a range of 0.01 wt. % to 50.0 wt. %, respective to the weight of the composite.
13. The composite of claim 1 , further comprising:
at least one inorganic powder.
14. The composite of claim 13 , wherein the at least one inorganic powder comprises at least one of silica (SiO 2 ), alumina (Al 2 O 3 ), alumina trihydrate (Al 2 O 3 ·3H 2 O), antimony oxide (Sb 2 O 3 , Sb 2 O 5 , Sb 2 O 4 ), barium sulfate (BaSO 4 ), calcium carbonate (CaCO 3 ), kaolinite (Al 2 Si 2 O 5 (OH) 4 ), magnesium hydroxide (Mg(OH) 2 ), talc (Mg 3 Si 4 O 10 (OH) 2 ), titanium dioxide (TiO 2 ), or combinations thereof.
15. The composite of claim 13 , wherein the at least one inorganic powder is present in a range of 0.01 wt. % to 20.0 wt. %, respective to the weight of the composite.
16. The composite of claim 13 , further comprising:
at least one reinforcing material.
17. A method for preparing a composite, comprising:
mixing at least one thermoplastic polymer with at least one PTFE-based polymer to form a homogenous mixture;
melting the mixture to form a composite material; and
hot pressing the composite material to form a composite sheet,
wherein the at least one thermoplastic polymer comprises at least one of: