Reinforced laminates produced from crosslinkable thermoplastic olefin polymer material

Claim 2

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet from said molten polymer at a temperature below said decomposition temperature, (c) cooling said continuous sheet to a temperature below said melting temperature to a self-supporting, two-dimensional molecular state, (d) combining said sheet in said self-supporting state with a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate to form a laminate, (e) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (f) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 3

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate under pressure at a temperature above said melting temperature to form a continuous laminate, (d) heating said laminate to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (e) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (f) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 4

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate under pressure at a temperature above said melting temperature to form a continuous laminate, (d) heating said laminate to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (e) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (f) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 5

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate at a temperature above said melting temperature to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (e) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (f) cooling said heated laminate to a temperature below said melting temperature to a self-supporting state, (g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 6

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate at a temperature above said melting temperature to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (e) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (f) cooling said heated laminate to a temperature below said melting temperature to a self-supporting state, (g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 7

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di (t-butylperoxy)hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and about 300° F. to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a laminate, (d) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state, and (e) cooling said heated laminate to a temperature below 270° F. to a self-supporting state, (f) said laminate having a dielectric constant at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 8

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di (t-butylperoxy)hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and about 300° F. to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a laminate, (d) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state, and (e) cooling said heated laminate to a temperature below 270° F. to a self-supporting state, (f) said laminate having a dielectric constant at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 9

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di(t-butylperoxy) hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and 300° F. to form a tube closed at one end thereof, blowing air into said tube from the other end thereof under pressure to expand said tube and form an elongated tube having a predetermined wall thickness, flattening said elongated tube, and slitting said elongated tube along at least one side thereof so as to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a laminate, (d) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state, and (e) cooling said heated laminate to a temperature below 270° F. to a self-supporting state, (f) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 10

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di(t-butylperoxy) hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and 300° F. to form a tube closed at one end thereof, blowing air into said tube from the other end thereof under pressure to expand said tube and form an elongated tube having a predetermined wall thickness, flattening said elongated tube, and slitting said elongated tube along at least one side thereof so as to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a laminate, (d) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state, and (e) cooling said heated laminate to a temperature below 270° F. to a self-supporting state, (f) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 11

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet from said molten polymer at a temperature below said decomposition temperature, (c) cooling said continuous sheet to a temperature below said melting temperature to a self-supporting, two-dimensional molecular state, (d) combining said sheet in said self-supporting state with a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate to form a laminate, (e) combining a sheet of copper foil with said laminate, (f) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three dimensional molecular state, and (g) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (h) said laminate having a dielectric constate in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 12

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet from said molten polymer at a temperature below said decomposition temperature, (c) cooling said continuous sheet to a temperature below said melting temperature to a self-supporting, two-dimensional molecular state, (d) combining said sheet in said self-supporting state with a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate to form a laminate, (e) combining a sheet of copper foil with said laminate, (f) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three dimensional molecular state, and (g) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (h) said laminate having a dielectric constate in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 13

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet from said molten polymer at a temperature below said decomposition temperature, (c) cooling said continuous sheet to a temperature below said melting temperature to a self-supporting, two-dimensional molecular state, (d) combining said sheet in self-supporting state with a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate to form a laminate, (e) cutting and shaping said laminate and superposing a plurality of said laminates, (f) combining a sheet of copper foil with said laminates, (g) heating said superposed laminates under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of superposed laminates, and (h) cooling said superposed laminates to a temperature below said melting temperature to a self-supporting state, (i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 14

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet from said molten polymer at a temperature below said decomposition temperature, (c) cooling said continuous sheet to a temperature below said melting temperature to a self-supporting, two-dimensional molecular state, (d) combining said sheet in self-supporting state with a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate to form a laminate, (e) cutting and shaping said laminate and superposing a plurality of said laminates, (f) combining a sheet of copper foil with said laminates, (g) heating said superposed laminates under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of superposed laminates, and (h) cooling said superposed laminates to a temperature below said melting temperature to a self-supporting state, (i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 15

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate under pressure at a temperature above said melting temperature to form a continuous laminate, (d) applying a sheet of copper foil to at least one surface of said laminate, (e) heating said laminate to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (f) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 16

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and about 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate under pressure at a temperature above said melting temperature to form a continuous laminate, (d) applying a sheet of copper foil to at least one surface of said laminate, (e) heating said laminate to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (f) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 17

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate at a temperature above said melting temperature to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (e) applying a sheet of copper foil to at least one surface of said laminate, (f) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (g) cooling said heated laminate to a temperature below said melting temperature to a self-supporting state, (h) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 18

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate at a temperature above said melting temperature to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (e) applying a sheet of copper foil to at least one surface of said laminate, (f) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and (g) cooling said heated laminate to a temperature below said melting temperature to a self-supporting state, (h) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 19

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate at a temperature above said melting temperature to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (e) cutting and shaping said laminate and superposing a plurality of said laminates, (f) applying a sheet of copper foil to at least one surface of said laminates, (g) heating said superposed laminates under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of said superposed laminates, and (h) cooling said heated superposed laminates to a temperature below said melting temperature to a self-supporting state, (i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 20

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310° F. and 525° F., to a molten state at a melting temperature between about 270° F. and 300° F., (b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature, (c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate at a temperature above said melting temperature to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, (e) cutting and shaping said laminate and superposing a plurality of said laminates, (f) applying a sheet of copper foil to at least one surface of said laminates, (g) heating said superposed laminates under pressure to a temperature between about 310° F. and about 525° F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of said superposed laminates, and (h) cooling said heated superposed laminates to a temperature below said melting temperature to a self-supporting state, (i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 21

Reinforced laminates of crosslinkable thermoplasic olefin material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di(t-butylperoxy)hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and about 300° F. to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a laminate, (d) applying a sheet of copper foil to at least one side of said laminate, (e) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state, and (f) cooling said heated laminate to a temperature below 270° F. to a self-supporting state, (g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 22

Reinforced laminates of crosslinkable thermoplasic olefin material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di(t-butylperoxy)hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and about 300° F. to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a laminate, (d) applying a sheet of copper foil to at least one side of said laminate, (e) heating said laminate under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state, and (f) cooling said heated laminate to a temperature below 270° F. to a self-supporting state, (g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 23

Reinforced laminates of a crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di(t-butylperoxy)hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and about 300° F. to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, cutting and shaping said laminate and superposing a plurality of said laminates, (f) applying a sheet of copper foil to at least one surface of said laminates, (g) heating said superposed laminates under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of superposed laminates, and (h) cooling said heated superposed laminates to a temperature below 270° F. to a self-supporting state, (i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 24

Reinforced laminates of a crosslinkable thermoplastic olefin polymer material, produced by the process of (a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di(t-butylperoxy)hexyne-3 as a catalyst, to a molten state at a temperature between about 270° F. and 300° F., (b) extruding said molten polymer at a temperature between about 270° F. and about 300° F. to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer, (c) applying said continuous sheet under pressure at a temperature between about 270° F. and about 300° F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a continuous laminate, (d) cooling said laminate to a temperature below said melting temperature to a self-supporting state, cutting and shaping said laminate and superposing a plurality of said laminates, (f) applying a sheet of copper foil to at least one surface of said laminates, (g) heating said superposed laminates under pressure to a temperature between about 310° F. and about 525° F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of superposed laminates, and (h) cooling said heated superposed laminates to a temperature below 270° F. to a self-supporting state, (i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

Claim 25

A reinforced polyethylene and fibrous glass laminate comprising a glass fibrous substrate having cross-linked polyethylene in the interstices of said glass fibrous substrate, wherein said polyethylene is cross-linked with an acetylenic diperoxy cross-linking agent which effects the cross-linking of polyethylene at a temperature of about 310° F. to about 525° F., and said polyethylene when it is in an uncrosslinked state is a normally solid polyethylene having a melt index of at least about 10, and wherein said cross-linked polyethylene is bonded by a glass to polyethylene coupling agent to said glass fibrous substrate, and wherein the dielectric constant of said laminate at 1 MC/Sec. in Condition A is from about 2.40 to about 3.43.

Claim 26

A reinforced polyethylene and fibrous glass laminate comprising a glass fibrous substrate having cross-linked polyethylene in the interstices of said glass fibrous substrate, wherein said polyethylene is cross-linked with an acetylenic diperoxy cross-linking agent which effects the cross-linking of polyethylene at a temperature of about 310° F. to about 525° F., and said polyethylene when it is in an uncrosslinked state is a normally solid polyethylene having a melt index of at least about 10, and wherein said cross-linked polyethylene is bonded by a glass to polyethylene coupling agent to said glass fibrous substrate, and wherein the dielectric constant of said laminate at 1 MC/Sec. in Condition A is from about 2.40 to about 3.43.

Claim 27

The laminate according to claim 13 wherein said polyethylene will soften and deform at a temperature of about 250° F. or less, and said polyethylene melts at a temperature above about 250° F., and when it is in an uncrosslinked state said polyethylene has a density of from about 0.910 to about 0.970.

Claim 28

The laminate according to claim 14 comprised of about 30-35% glass and about 65-70% polyethylene.

Claim 29

The laminate according to claim 14 wherein said polyethylene is at least about 80% cross-linked.

Claim 30

The laminate according to claim 14 wherein said laminate has a dielectric strength of about 700 v/mil, a power factor of about 0.008-0.011.

Claim 31

The laminate according to claim 14 wherein said laminate is comprised of about 3 to about 18 plies.

Claim 32

The laminate according to claim 14 wherein said coupling agent is a gamma-methacryloxypropyltrimethoxy silane.

Claim 33

The laminate according to claim 14 wherein said polyethylene portion of said laminate further includes a flame-retardant.

Claim 34

The laminate according to claim 20 wherein said flame retardant is a thiopropionate acid ester.

Claim 35

The laminate according to claim 13 wherein said substrate is comprised of a woven fiberglass.

Claim 36

The laminate according to claim 13 wherein said coupling agent is selected from the group consisting of vinyltrimethoxy silane, an alkylsilane, trimethoxysilylpropylacrylate silane, and gamma-methacryloxypropyltrimethoxy silane.

Claim 37

The laminate according to claim 13 wherein said laminate further includes a layer of copper foil.

Claim 38

A laminate comprises of a reinforced polyethylene and glass fibrous substrate which is chemically bonded by a glass to polyethylene coupling agent to a cross-linked polyethylene polymer which is present in the interstices of said substrate, said laminate having a dielectric constant in Condition A at 1 MC/Sec. within the range of about 2.40 to about 3.43; and said laminate is prepared by: (a) applying a self-supporting continuous sheet of said polyethylene containing a heat activated cross-linking agent to the surface of a glass fibrous substrate which has been treated with a glass to polyethylene coupling agent which bonds said polyethylene to said glass at a temperature above the melting temperature of said polyethylene, and (b) applying heat and pressure to said polyethylene sheet and glass substrate sufficient to cross-link said polyethylene, and to provide a laminate wherein said cross-linked polyethylene is present in the interstices of said glass fibrous substrate and said polyethylene is bonded by said coupling agent to said glass fibrous substrate.

Claim 39

A laminate comprises of a reinforced polyethylene and glass fibrous substrate which is chemically bonded by a glass to polyethylene coupling agent to a cross-linked polyethylene polymer which is present in the interstices of said substrate, said laminate having a dielectric constant in Condition A at 1 MC/Sec. within the range of about 2.40 to about 3.43; and said laminate is prepared by: (a) applying a self-supporting continuous sheet of said polyethylene containing a heat activated cross-linking agent to the surface of a glass fibrous substrate which has been treated with a glass to polyethylene coupling agent which bonds said polyethylene to said glass at a temperature above the melting temperature of said polyethylene, and (b) applying heat and pressure to said polyethylene sheet and glass substrate sufficient to cross-link said polyethylene, and to provide a laminate wherein said cross-linked polyethylene is present in the interstices of said glass fibrous substrate and said polyethylene is bonded by said coupling agent to said glass fibrous substrate.

Claim 40

The laminate according to claim 25 wherein said polyethylene has a melting temperature of from about 270° F. to about 300° F., and said cross-linking agent effectuates the cross-linking of said polymer at a temperature of from about 310° F. to about 525° F., said polyethylene is a normally solid polyethylene which has a melt index of about 10, and a density of from about 0.910 to about 0.970 when it is in an uncrosslinked state, and said polyethylene is applied to at least one surface of said glass fibrous substrate in the form of an uncrosslinked self-supporting sheet containing crosslinking agent and said substrate and polyethylene combination is subjected to pressure and a temperature sufficient to effect at least about 80% cross-linking of said polyethylene.

Claim 41

The laminate according to claim 25 wherein said continuous sheet is prepared by extruding polyethylene in a molten state at a temperature of about 270° F. to about 300° F. in the form of a tube which is closed at one end, blowing air into said tube to expand it to the form of an elongated tube and then flattening and slitting said elongated tube to provide said continuous non-reinforced polyethylene sheet.

Claim 42

The laminate according to claim 25 wherein prior to said application of heat and pressure, said glass fibrous substrate and continuous sheet of polyethylene are combined with a sheet of copper foil.

Claim 43

The laminate according to claim 25 wherein prior to said application of heat and pressure a plurality of layers comprised of said glass fibrous substrate to which said polyethylene sheet has been applied in accordance with step (a) of claim 25, are superposed, and said plurality of superposed layers are combined with a sheet of copper foil.

Claim 44

Reinforced polyethylene and fiberglass laminates comprising a glass fibrous substrate chemically bonded by a glass to polyethylene coupling agent to a crosslinked polyethylene polymer which is present in the interstices of said substrate, said laminate having a dielectric constant in Condition A at 1 MC/Sec. within the range of about 2.40 to about 3.43, wherein said laminate is prepared by: (a) forming a continuous sheet of polyethylene containing a crosslinking agent by extruding a mixture of said polyethylene and crosslinking agent in the form of an uncrosslinked and non-reinforced sheet of polyethylene, and said continuous sheet is applied under pressure and in a molten state to a glass fibrous substrate which has been treated with a glass to polyethylene coupling agent, wherein said coupling agent reacts with said polyethylene and glass fibrous substrate and effects bonding of said polyethylene to said substrate to provide a continuous laminate; and (b) said laminate is subjected to conditions sufficient to crosslink said polyethylene.

Claim 45

Reinforced polyethylene and fiberglass laminates comprising a glass fibrous substrate chemically bonded by a glass to polyethylene coupling agent to a crosslinked polyethylene polymer which is present in the interstices of said substrate, said laminate having a dielectric constant in Condition A at 1 MC/Sec. within the range of about 2.40 to about 3.43, wherein said laminate is prepared by: (a) forming a continuous sheet of polyethylene containing a crosslinking agent by extruding a mixture of said polyethylene and crosslinking agent in the form of an uncrosslinked and non-reinforced sheet of polyethylene, and said continuous sheet is applied under pressure and in a molten state to a glass fibrous substrate which has been treated with a glass to polyethylene coupling agent, wherein said coupling agent reacts with said polyethylene and glass fibrous substrate and effects bonding of said polyethylene to said substrate to provide a continuous laminate; and (b) said laminate is subjected to conditions sufficient to crosslink said polyethylene.

Claim 46

The laminate according to claim 30 wherein (a) said polyethylene is a normally solid polyethylene which has a melt index of about 10 and a density of about 0.910 to about 0.970 when it is in an uncrosslinked state, and said sheet of polyethylene is applied to said substate under pressure and in a molten state at a temperature of about 270° F. to about 300° F.; and (b) said laminate product of step (a) of claim 30 is heated under pressure to a temperature of about 310° F. to about 525° F. to effect at least about 95% cross-linking of said polyethylene.

Claim 47

The laminate according to claim 25 or 30 wherein said polyethylene sheet includes a flame retardant, and a peroxide cross-linkiing agent.

Claim 48

The laminate according to claim 13, 25 or 30 wherein the flexural strength of said laminate is from about 7,000 to about 25,000 psi dry, and about 7,000 to 28,000 psi wet.

Claim 49

A laminate having a dielectric constant in Condition A at 1 MC/Sec. within the range of about 2.40 to about 3.43, of crosslinkable thermoplastic olefin polymer material comprising a glass fibrous substrate which is bonded by a glass to polyethylene coupling agent to a crosslinked ethylenic polymer which is present in the interstices of said glass fibrous substrate, wherein said polymer is a crosslinkable thermoplastic olefinic polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acrylic mono-1 olefin hydrocarbon having about 2 to 8 carbon atoms per molecule, and mixtures thereof; and wherein said impregnated substrate is combined with a layer of metallic foil.

Claim 50

A laminate having a dielectric constant in Condition A at 1 MC/Sec. within the range of about 2.40 to about 3.43, of crosslinkable thermoplastic olefin polymer material comprising a glass fibrous substrate which is bonded by a glass to polyethylene coupling agent to a crosslinked ethylenic polymer which is present in the interstices of said glass fibrous substrate, wherein said polymer is a crosslinkable thermoplastic olefinic polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acrylic mono-1 olefin hydrocarbon having about 2 to 8 carbon atoms per molecule, and mixtures thereof; and wherein said impregnated substrate is combined with a layer of metallic foil.

Claim 51

The laminate according to claim 34 wherein said metallic foil comprises copper, and wherein said polymer is polyethylene.

Claim 52

The laminate according to claim 35 wherein said polyethylene has a melt index of about 10 and a density of about 0.910 to about 0.970.

Claim 53

A printed circuit board comprised of the laminate of claim 13 or claim 25 or claim 30 or claim 34.