US4897301A
Expired / Lapsed
US
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Flexible sheet reinforced with poly(aromatic amide) non-woven fabric and use thereof
Assignee: Toyobo Co Ltd
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Filing: 1986-01-22
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Granted: 1990-01-30
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Expires: 2006-01-22
Abstract
Abstract A flexible sheet which comprises a non-woven fabric made predominantly from a poly(aromatic amide) component which is impregnated with a heat- and/or light-curable resin, wherein the non-woven fabric satisfies the following conditions: 5 g/m.sup.2 <weight per unit area<35 g/m.sup.2, and 0.15 g/cm.sup.3 ≦density≦0.8 g/cm.sup.3, which has well balanced properties, such as excellent heat dimensional stability, heat resistance (soldering resistance), water resistance, solvent resistance, electrical insulating properties and mechanical properties and is useful for the preparation of a flexible printed circuit board, and use thereof for a flexible metal-clad laminate and a flexible printed circuit board.
Inventors
- 👤 Keiichi Uno
- 👤 Yoshimi Ishinami
- 👤 Masaaki Nakamura
- 👤 Tomohiko Nakao
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 13:22
CPC Classifications
H; H05; H05K; H05K1/00; H05K1/02; H05K1/03; H05K1/0313; H05K1/032; H05K1/0326; D; D04; D04H; D04H1/00; D04H1/40; D04H1/42; D04H1/4326; D04H1/4334; D04H1/4342; D04H1/4382; D04H1/43835; D04H1/58; D04H1/587; D04H1/64; H05K1/0353; H05K1/0366; H05K2201/00; H05K2201/02; H05K2201/0275; H05K2201/0278; H05K2201/0293; Y; Y10; Y10S; Y10S428/00; Y10S428/901; Y10S428/902; Y10S428/92; Y10T; Y10T428/00; Y10T428/24; Y10T428/24802; Y10T428/24917; Y10T428/249921; Y10T428/249924; Y10T428/24994; Y10T428/24995; Y10T428/249951; Y10T428/27; Y10T428/31504; Y10T428/31678; Y10T428/31681; Y10T428/31725; Y10T428/31736; Y10T442/00; Y10T442/20; Y10T442/2861; Y10T442/60; Y10T442/654; Y10T442/656
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
139 words
A flexible sheet which comprises a non-woven fabric made predominantly from a poly(aromatic amide) component which is impregnated with a heat- and/or light-curable resin, w herein the non-woven fabric satisfies the following conditions: 5 g/m.sup.2 <weight per unit area<35 g/m.sup.2, and 0.15 g/cm.sup.3 ≦density≦0.8 g/cm.sup.3 said non-woven fabric made predominantly from a poly(aromatic amide) component being a poly(aromatic amide) non-woven fabric comprising chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and binder, said chopped fibers of an aromatic polyamide or copolyamide being selected from the groups consisting of (a) chopped fibers of a polymer comprising predominantly an aromatic homopolyamide or copolyamide wherein the bonding chain extends from the aromatic ring in uniaxial or parallel axial direction, (b) chopped fibers of an aromatic homopolyamide or copolyamide other than the polymer of the chopped fibers (a) and mixtures thereof.
Claim 2
Dependent Claim
139 words
A flexible sheet which comprises a non-woven fabric made predominantly from a poly(aromatic amide) component which is impregnated with a heat- and/or light-curable resin, w herein the non-woven fabric satisfies the following conditions: 5 g/m.sup.2 <weight per unit area<35 g/m.sup.2, and 0.15 g/cm.sup.3 ≦density≦0.8 g/cm.sup.3 said non-woven fabric made predominantly from a poly(aromatic amide) component being a poly(aromatic amide) non-woven fabric comprising chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and binder, said chopped fibers of an aromatic polyamide or copolyamide being selected from the groups consisting of (a) chopped fibers of a polymer comprising predominantly an aromatic homopolyamide or copolyamide wherein the bonding chain extends from the aromatic ring in uniaxial or parallel axial direction, (b) chopped fibers of an aromatic homopolyamide or copolyamide other than the polymer of the chopped fibers (a) and mixtures thereof.
Claim 3
Dependent Claim
16 words
The flexible sheet of claim 1 wherein said chopped fibers consist of both (a) and (b).
Claim 4
Dependent Claim
20 words
The flexible sheet according to claim 1, wherein the ratio of (a)/(b) is in the range of 10/90 to 100/0.
Claim 5
Dependent Claim
38 words
The flexible sheet of claim 1 wherein said non-woven fabric is made from 97 to 20% by weight of said chopped fibers consisting predominantly of aromatic polyamide or copolyamide and from 3 to 80% by weight of binder.
Claim 6
Dependent Claim
16 words
The flexible sheet of claim 1 wherein said chopped fibers consist of poly(m-phenylene isophthalamide) chopped fibers.
Claim 7
Dependent Claim
34 words
The flexible sheet of claim 1, wherein the non-woven fabric has a weight per unit area ranging from 15 to 30 g/m 2 and a density ranging from 0.26 to 0.6 g/cm 3 .
Claim 8
Dependent Claim
24 words
The flexible sheet of claim 6, wherein the non-woven fabric has a weight per unit area ranging from 15 to 26 g/m 2 .
Claim 9
Dependent Claim
75 words
The flexible sheet according to claim 1, wherein the heat- and/or light-curable resin is a resin composition containing a polyester resin comprising 9i) as the acid component 70 to 30 5 by mole of an aliphatic dicarboxylic acid having 4 to 12 carbon atoms and/or an aliphatic hydroxycarboxylic acid having 4 to 12 carbon atoms and/or as an alcoholic component 30 to 100% by mole of an aliphatic glycol having 4 to 10 carbon atoms.
Claim 10
Dependent Claim
107 words
The flexible sheet according to claim 8, wherein the polyester resin comprises as the acid component 70 to 30% by mole of an aliphatic dicarboxylic acid having 4 to 12 carbon atoms and/or an aliphatic hydroxycarboxylic acid having 4 to 12 carbon atoms, 30 to 70% by mole of an aromatic dicarboxylic acid and 0 to 5% by mole of a trifunctional or more polyfunctional carboxylic acid and as an alcoholic component 95 to 100% by mole of an aliphatic glycol having 2 to 10 carbon atoms, an alicyclic glycol and/or an aromatic glycol and 0 to 5% by mole of a trifunctional or more polyfunctional alcohol.
Claim 11
Dependent Claim
113 words
The flexible sheet according to claim 8, wherein the polyester resin comprises as the acid component 30 to 100% by mole of an aromatic dicarboxylic acid, 0 to 70% by mole of an aliphatic dicarboxylic acid having 4 to 12 carbon atoms and/or an aliphatic hydroxycarboxylic acid having 4 to 12 carbon atoms and 0 to 5% by mole of a trifunctional or more polyfunctional carboxylic acid and as an alcoholic component 30 to 100% by mole of an aliphatic glycol having 4 to 10 carbon atoms, 70 to 0% by mole of an alicyclic glycol and/or an aromatic glycol and 0 to 5% by mole of a trifunctional or more polyfunctional alcohol.
Claim 12
Dependent Claim
100 words
The flexible sheet according to claim 8, wherein the polyester resin comprises as the acid component 70 to 30% by mole of an aliphatic dicarboxylic acid having 4 to 12 carbon atoms and/or an aliphatic hydroxycarboxylic acid having 4 to 12 carbon atoms, 30 to 70% by mole of an aromatic dicarboxylic acid and 0 to 5% by mole of a trifunctional or more polyfunctional carboxylic acid and as an alcoholic component 30 to 100% by mole of an aliphatic glycol having 4 to 10 carbon atoms and 0 to 5% by mole of a trifunctional or more polyfunctional alcohol.
Claim 13
Dependent Claim
148 words
A flexible metal-clad laminate which comprises a metal layer and a base sheet, said base sheet comprising a non-woven fabric made predominantly from a poly(aromatic amide) component which is impregnated heat-and/or light-curable resin, wherein the non-woven fabric satisfies the following conditions: 5 g/m.sup.2 <weight per unit area<35 g/m.sup.2, and 0.15 g/cm.sup.3 ≦density≦0.8 g/cm.sup.3 ; said non-woven fabric made predominantly from a poly(aromatic amide) component being a poly(aromatic amide) non-woven fabric comprising chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and binder, said chopped fibers of an aromatic polyamide or copolyamide being selected from the group consisting of (a) chopped fibers of a polymer comprising predominantly an aromatic homopolyamide or copolyamide wherein the bonding chain extends from the aromatic ring in uniaxial or parallel axial direction, (b) chopped fibers of an aromatic homopolyamide or copolyamide other than the polymer of the chopped fibers (a) and mixtures thereof.
Claim 14
Dependent Claim
148 words
A flexible metal-clad laminate which comprises a metal layer and a base sheet, said base sheet comprising a non-woven fabric made predominantly from a poly(aromatic amide) component which is impregnated heat-and/or light-curable resin, wherein the non-woven fabric satisfies the following conditions: 5 g/m.sup.2 <weight per unit area<35 g/m.sup.2, and 0.15 g/cm.sup.3 ≦density≦0.8 g/cm.sup.3 ; said non-woven fabric made predominantly from a poly(aromatic amide) component being a poly(aromatic amide) non-woven fabric comprising chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and binder, said chopped fibers of an aromatic polyamide or copolyamide being selected from the group consisting of (a) chopped fibers of a polymer comprising predominantly an aromatic homopolyamide or copolyamide wherein the bonding chain extends from the aromatic ring in uniaxial or parallel axial direction, (b) chopped fibers of an aromatic homopolyamide or copolyamide other than the polymer of the chopped fibers (a) and mixtures thereof.
Claim 15
Dependent Claim
39 words
The flexible metal-clad laminate of claim 12 wherein said non-woven fabric is made from 97 to 20% by weight of said chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and from 3 to 80% by weight binder.
Claim 16
Dependent Claim
36 words
The flexible metal clad laminate of claim 12, wherein the non-woven fabric has a weight per unit area ranging from 15 to 30 g/m 2 and a density ranging from 0.26 to 0.6 g/cm 3 .
Claim 17
Dependent Claim
26 words
The flexible metal clad laminate of claim 14, wherein the non-woven fabric has a weight per unit area ranging from 15 to 26 g/m 2 .
Claim 18
Dependent Claim
16 words
The flexible metal-clad laminate according to claim 12, wherein the metal layer is a copper foil.
Claim 19
Dependent Claim
163 words
In a flexible printed circuit board wherein a flexible sheet is used as a base sheet and/or a covering layer, the improvement which comprises that the flexible sheet comprises a non-woven fabric made predominantly from a poly(aromatic amide) component which is impregnated with a heat- and/or light-curable resin, wherein the non-woven fabric satisfies the following conditions: 5 g/m.sup.2 <weight per unit area<35 g/m.sup.2, and 0.15 g/cm.sup.3 ≦density≦0.8 g/cm.sup.3 ; said non-woven fabric made predominantly from a poly(aromatic amide) component being a poly(aromatic amide) non-woven fabric comprising chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and binder, said chopped fibers of an aromatic polyamide or copolyamide being selected from the group consisting of (a) chopped fibers of a polymer comprising predominantly an aromatic homopolyamide or copolyamide wherein the bonding chain extends from the aromatic ring in uniaxial or parallel axial direction, (b) chopped fibers of an aromatic homopolyamide or copolyamide other than the polymer of the chopped fibers (a) and mixtures thereof.
Claim 20
Dependent Claim
163 words
In a flexible printed circuit board wherein a flexible sheet is used as a base sheet and/or a covering layer, the improvement which comprises that the flexible sheet comprises a non-woven fabric made predominantly from a poly(aromatic amide) component which is impregnated with a heat- and/or light-curable resin, wherein the non-woven fabric satisfies the following conditions: 5 g/m.sup.2 <weight per unit area<35 g/m.sup.2, and 0.15 g/cm.sup.3 ≦density≦0.8 g/cm.sup.3 ; said non-woven fabric made predominantly from a poly(aromatic amide) component being a poly(aromatic amide) non-woven fabric comprising chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and binder, said chopped fibers of an aromatic polyamide or copolyamide being selected from the group consisting of (a) chopped fibers of a polymer comprising predominantly an aromatic homopolyamide or copolyamide wherein the bonding chain extends from the aromatic ring in uniaxial or parallel axial direction, (b) chopped fibers of an aromatic homopolyamide or copolyamide other than the polymer of the chopped fibers (a) and mixtures thereof.
Claim 21
Dependent Claim
40 words
The flexible printed circuit board of claim 17 wherein said non-woven fabric is made from 97 to 20% by weight of said chopped fibers consisting predominantly of an aromatic polyamide or copolyamide and from 3 to 80% by weight binder.
Claim 22
Dependent Claim
36 words
The flexible printed circuit board of claim 17, wherein the non-woven fabric has a weight per unit area ranging from 15 to 30 g/m 2 and a density ranging from 0.26 to 0.6 g/cm 3 .
Claim 23
Dependent Claim
26 words
The flexible printed circuit board of claim 19, wherein the non-woven fabric has a weight per unit area ranging from 15 to 26 g/m 2 .
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-01-29 | 1993-07-31 | 1994-01-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-01-29 | 1997-07-31 | 1998-01-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-01-29 | 2001-07-31 | 2002-01-30 | $7700.00 | Window Closed / Lapsed |