US4868059A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Curable composition containing a difunctional epoxy resin, a polyfunctional epoxy resin, a difunctional phenol and a polyfunctional phenol
Assignee: Dow Chemical Co
•
Filing: 1987-11-16
•
Granted: 1989-09-19
•
Expires: 2007-11-16
Abstract
Abstract Electrical laminates are prepared from prepreg materials prepared by impregnating a substrate with a laminating varnish comprising a solvent solution of a curable composition comprising (A) a mixture of at least one epoxy resin having an average of more than 1 but not more than 2 vicinal epoxy groups per molecule and at least one epoxy resin having an average of more than 2 vicinal epoxy groups per molecule; (B) a mixture of at least one phenolic hydroxyl-containing compound having an average of more than 1 but not more than 2 phenolic hydroxyl groups per molecule and at least one phenolic hydroxyl-containing compound having an average of more than 2 phenolic hydroxyl groups per molecule; and (C) at least one catalyst for effecting the reaction between (A) and (B).
Inventors
- 👤 Louis L. Walker
- 👤 Paul A. Larson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 23:01
CPC Classifications
C; C08; C08G; C08G59/00; C08G59/02; C08G59/04; C08G59/06; C08G59/066; C08G59/18; C08G59/20; C08G59/32; C08G59/3218; C08G59/38; C08G59/40; C08G59/62; C08G59/621; C08G59/68; C08J; C08J5/00; C08J5/24; C08J5/241; C08J5/244; C08J5/249; C08J2363/00; H; H05; H05K; H05K1/00; H05K1/02; H05K1/03; H05K1/0313; H05K1/032; H05K1/0326; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31511; Y10T428/31515; Y10T428/31522; Y10T428/31529
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
334 words
A laminate resulting from curing one or more plies of a substrate material which has been impregnated with a laminating varnish composition comprising a substantially unreacted mixture of (A) an epoxy-containing composition consisting essentially of (1) from about 5 to about 95 percent by weight of at least one epoxy resin having an average of not more than 2 vicinal epoxide groups per molecule; and (2) from about 95 to about 5 percent by weight of at least one epoxy resin having an average of more than 2 vicinal epoxide groups per molecule represented by the following formulas III or IV or a combination of such resins ##STR5## wherein each A' is independently a divalent hydrocarbyl group having from 1 to about 4 carbon atoms; each R is independently hydrogen or an alkyl group having from 1 to about 3 carbon atoms; each R' is independently hydrogen or a hydrocarbyl group having from 1 to about 5 carbon atoms; each X is independently hydrogen, an alkyl group having from 1 to about 10 carbon atoms or a halogen; m has a value from about 1 to about 4; and m' has a value from zero to about 1; (B) a phenolic hydroxyl-containing composition consisting essentially of (1) from about 10 to about 70 equivalent percent of at least one phenolic hydroxyl-containing compound having an average of not more than 2 phenolic hydroxyl groups per molecule; and (2) from about 90 to about 30 equivalent percent of at least one phenolic hydroxyl-containing compound having an average of more than 2 phenolic hydroxyl groups per molecule; and wherein components (A) and (B) are present in quantities which provide a ratio of phenolic hydroxyl groups for each epoxy group of from about 0.75:1 to about 1.2:1; (C) a catalytic quantity of at least one catalyst for effecting the reaction between components (A) and (B); and optionally (D) one or more solvents in an amount of from zero to about 75 percent by weight of the total composition.
Claim 2
Dependent Claim
334 words
A laminate resulting from curing one or more plies of a substrate material which has been impregnated with a laminating varnish composition comprising a substantially unreacted mixture of (A) an epoxy-containing composition consisting essentially of (1) from about 5 to about 95 percent by weight of at least one epoxy resin having an average of not more than 2 vicinal epoxide groups per molecule; and (2) from about 95 to about 5 percent by weight of at least one epoxy resin having an average of more than 2 vicinal epoxide groups per molecule represented by the following formulas III or IV or a combination of such resins ##STR5## wherein each A' is independently a divalent hydrocarbyl group having from 1 to about 4 carbon atoms; each R is independently hydrogen or an alkyl group having from 1 to about 3 carbon atoms; each R' is independently hydrogen or a hydrocarbyl group having from 1 to about 5 carbon atoms; each X is independently hydrogen, an alkyl group having from 1 to about 10 carbon atoms or a halogen; m has a value from about 1 to about 4; and m' has a value from zero to about 1; (B) a phenolic hydroxyl-containing composition consisting essentially of (1) from about 10 to about 70 equivalent percent of at least one phenolic hydroxyl-containing compound having an average of not more than 2 phenolic hydroxyl groups per molecule; and (2) from about 90 to about 30 equivalent percent of at least one phenolic hydroxyl-containing compound having an average of more than 2 phenolic hydroxyl groups per molecule; and wherein components (A) and (B) are present in quantities which provide a ratio of phenolic hydroxyl groups for each epoxy group of from about 0.75:1 to about 1.2:1; (C) a catalytic quantity of at least one catalyst for effecting the reaction between components (A) and (B); and optionally (D) one or more solvents in an amount of from zero to about 75 percent by weight of the total composition.
Claim 3
Dependent Claim
113 words
A laminate of claim 1 wherein component (A) consists essentially of from about 5 to about 60 weight percent of component (1) and from about 95 to about 40 weight percent of component (2); (b) component (B) consisting essentially of from about 10 to about 50 equivalent percent of component (1) and from about 90 to about 50 equivalent percent of component (2); and (c) components (A) and (B) are present in quantities which provide a ratio of phenolic hydroxyl groups for each epoxy group from about 0.85:1 to about 1.1:1 and (d) component (D) is present in an amount of from zero to about 50 percent by weight of the total composition.
Claim 4
Dependent Claim
113 words
A laminate of claim 2 wherein (a) Component (A) consists essentially of 5 to about 40 weight percent of component (1) and from about 95 to about 60 weight percent of component (2); (b) component (B) consists essentially of from about 10 to about 35 equivalent percent of component (1) and from about 90 to about 65 equivalent percent of component (2); and (c) components (A) and (B) are present in quantities which provide a ratio of phenolic hydroxyl groups for each epoxy group from about 0.95:1 to about 1:1 and (d) component (D) is present in an amount of from about 0 to about 25 percent by weight of the total composition.
Claim 5
Dependent Claim
212 words
A laminate of claim 1, 2 or 3 wherein (a) component (A-1) is an epoxy resin represented by the following formulas I or II or a combination of such epoxy resins ##STR6## wherein each A is independently a divalent hydrocarbyl group having suitably from 1 to about 5 carbon atoms, --S--, --S--S--, --SO--, --SO 2 --, --CO--, or --O--; each R is independently hydrogen or an alkyl group having from 1 to about 3 carbon atoms; each X is independently hydrogen, an alkyl group having from 1 to about 5 carbon atoms or a halogen; each n independently has a value of zero or 1; and n, has a value from zero to about 2; (b) component (B-1) is a phenolic hydroxyl-containing compound represented by the following formulas V or VI or a combination of such phenolic hydroxyl-containing compounds ##STR7## wherein A, X and n are as previously defined; (c) component (B-2) is a phenolic hydroxyl-containing compound represented by the following formulas VII or VIII or a combination of such phenolic hydroxyl-containing compounds ##STR8## wherein each A', R', X and m is as previously defined; (d) component (C) is a phosphonium compound, an imidazole or a combination thereof; and (e) component (D) is a ketone, a glycol ether or a combination thereof.
Claim 6
Dependent Claim
98 words
A laminate of claim 4 wherein (a) component (A-1) is a diglycidyl ether represented by formula II wherein n has value of 1 and n' has a value from zero to about 0.5; (b) component (A-2) is a polyglycidyl ether represented by formula III wherein m has a value from about 1 to about 4 (c) component (B-1) is a phenolic hydroxyl-containing compound represented by formula VI wherein n has a value of 1; and (d) component (B-2) is a phenolic hydroxy-containing compound represented by formula VII wherein m has a value from about 0.1 to about 4.
Claim 7
Dependent Claim
98 words
A laminate of claim 5 wherein (a) component (A-1) is a diglycidyl ether of bisphenol A; (b) component (A-2) is a polyglycidyl ether of a phenol-formaldehyde novolac epoxy resin; (c) component (B-1) is bisphenol A or tetrabromo bisphenol A; (d) component (B-2) is a phenol-formaldehyde novolac resin; (e) component (C) is quaternary phosphonium acetate.acetic acid complex and fluoboric acid in a respective molar ratio of from about 1:0.9 to about 1:1.25, 2-methylimidazole 2-methylimidazole or a combination thereof; and (f) component (D), when present, is propylene glycol methyl ether, methyl ethyl ketone, methanol, ethanol, dimethylformamide or a combination thereof.
Claim 8
Dependent Claim
18 words
A laminate of claim 1, 2, or 3 which has an outer layer of an electrical conducting material.
Claim 9
Dependent Claim
12 words
A laminate of claim 7 wherein the electrical conducting material is copper.
Claim 10
Dependent Claim
15 words
A laminate of claim 4 which has an outer layer of an electrical conducting material.
Claim 11
Dependent Claim
12 words
A laminate of claim 9 wherein the electrical conducting material is copper.
Claim 12
Dependent Claim
15 words
A laminate of claim 5 which has an outer layer of an electrical conducting material.
Claim 13
Dependent Claim
12 words
A laminate of claim 11 wherein the electrical conducting material is copper.
Claim 14
Dependent Claim
15 words
A laminate of claim 7 which as an outer layer of an electrical conducting material.
Claim 15
Dependent Claim
12 words
A laminate of claim 13 wherein the electrical conducting material is copper.
References Cited (Backward Citations)
US3493630A
Cited
US3738862A
Cited
US3931109A
Cited
US4322456A
Cited
US4186036A
Cited
JPS5819322A
Cited
US4440914A
Cited
US4549000A
Cited
US4604317A
Cited
JPS61148228A
Cited
JPS61148226A
Cited
JPS61246228A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-09-18 | 1993-03-20 | 1993-09-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-09-18 | 1997-03-20 | 1997-09-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-09-18 | 2001-03-20 | 2001-09-19 | $7700.00 | Window Closed / Lapsed |