US5077115A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Thermoplastic composite material
Assignee: World Properties Inc
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Filing: 1990-05-08
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Granted: 1991-12-31
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Expires: 2010-05-08
Abstract
Abstract A thermoplastic composite material is presented which comprises a thermoplastic matrix which is highly filled with a coated ceramic filler. In an important feature of the present invention, the ceramic filler has been coated with a rubbery polymer that bonds to the filler. In a preferred embodiment, the thermoplastic matrix comprises a fluoropolymer, preferably a chlorofluoropolymer and the ceramic filler is a fused amorphous silica coated with a rubbery polymeric material. The thermoplastic composite material of this invention exhibits numerous advantages which makes it well suited for use as a bonding film, particularly a bonding film for producing multilayer printed wiring boards.
Inventors
- 👤 David J. Arthur
- 👤 Allen F. Horn, III
- 👤 Kenneth W. Kristal
- 👤 Gwo S. Swei
- 👤 William R. Zdanis
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 03:19
CPC Classifications
H; H05; H05K; H05K3/00; H05K3/46; H05K3/4611; H05K3/4626; C; C08; C08K; C08K3/00; C08K3/34; C08K3/36; C08K9/00; C08K9/10; H05K1/00; H05K1/02; H05K1/03; H05K1/0313; H05K1/0353; H05K1/0373; H10; H10W; H10W70/00; H10W70/60; H10W70/67; H10W70/69; H10W70/695; H05K2201/00; H05K2201/01; H05K2201/0104; H05K2201/0133; H05K2201/0137; H05K2201/015; H05K2201/0158; H05K2201/0183; H05K2201/0195; H05K2201/02; H05K2201/0203; H05K2201/0206; H05K2201/0209; Y; Y10; Y10S; Y10S428/00; Y10S428/901; Y10T; Y10T428/00; Y10T428/24; Y10T428/24273; Y10T428/24322; Y10T428/24802; Y10T428/24917; Y10T428/25; Y10T428/254; Y10T428/256; Y10T428/29; Y10T428/2982; Y10T428/2991
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
65 words
A thermoplastic composite material, comprising: extrudable thermoplastic matrix material, ceramic filler material, said filler material being in an amount of at least about 40 volume percent of the total composite; and an elastomeric polymer coated over said ceramic filler, said elastomeric polymer being bonded to said ceramic filler and comprising from about 2 weight percent to about 10 weight percent of the total ceramic filler.
Claim 2
Dependent Claim
65 words
A thermoplastic composite material, comprising: extrudable thermoplastic matrix material, ceramic filler material, said filler material being in an amount of at least about 40 volume percent of the total composite; and an elastomeric polymer coated over said ceramic filler, said elastomeric polymer being bonded to said ceramic filler and comprising from about 2 weight percent to about 10 weight percent of the total ceramic filler.
Claim 3
Dependent Claim
16 words
The composite of claim 1 wherein: said thermoplastic matrix material comprises a chlorofluoropolymeric or fluoropolymeric material.
Claim 4
Dependent Claim
17 words
The composite of claim 2 wherein said chlorofluoropolymeric material is selected from the group comprising: poly(ethylene-co-chlorotrifluoroethylene, chlorotrifluoroethylene.
Claim 5
Dependent Claim
11 words
The composite of claim 3 wherein said ceramic filler comprises silica.
Claim 6
Dependent Claim
13 words
The composite of claim 4 wherein said silica comprises amorphous fused silica powder.
Claim 7
Dependent Claim
21 words
The composite of claim 1 wherein said elastomeric polymer comprises silicone rubber which forms chemical bonds to said ceramic filler material.
Claim 8
Dependent Claim
11 words
The composite of claim 2 including at least one acid scavenger.
Claim 9
Dependent Claim
13 words
The composite of claim 7 wherein said acid scavenger comprises a metal oxide.
Claim 10
Dependent Claim
24 words
The composite of claim 8 wherein: said metal oxide is selected from group consisting of CaO, ZnO, MgO, or Sb 2 O 3 .
Claim 11
Dependent Claim
21 words
The composite of claim 1 wherein: said thermoplastic matrix material is selected from the group consisting of poly (4-methylpentene) and polyolefins.
Claim 12
Dependent Claim
30 words
The composite of claim 1 wherein said thermoplastic matrix material and said ceramic filler material define a substrate and including: conductive material on at least a portion of said substrate.
Claim 13
Dependent Claim
103 words
In a multilayer circuit including at least a first circuit layer and second circuit layer, the improvement comprising: an adhesive layer sandwiched between the first and second circuit layers, said adhesive layer comprising: extrudable thermoplastic matrix material; ceramic filler material, said filler material being in an amount of at least about 40 volume percent of the total composite; and an elastomeric polymer coated over said ceramic filler, said elastomeric polymer being bonded to said ceramic filler, but not bonded to said thermoplastic matrix and said elastomeric polymer comprising from about 2 weight percent to about 10 weight percent of the total ceramic filler.
Claim 14
Dependent Claim
103 words
In a multilayer circuit including at least a first circuit layer and second circuit layer, the improvement comprising: an adhesive layer sandwiched between the first and second circuit layers, said adhesive layer comprising: extrudable thermoplastic matrix material; ceramic filler material, said filler material being in an amount of at least about 40 volume percent of the total composite; and an elastomeric polymer coated over said ceramic filler, said elastomeric polymer being bonded to said ceramic filler, but not bonded to said thermoplastic matrix and said elastomeric polymer comprising from about 2 weight percent to about 10 weight percent of the total ceramic filler.
Claim 15
Dependent Claim
13 words
The multilayer circuit of claim 12 including: at least one plated through hole.
Claim 16
Dependent Claim
17 words
The multilayer circuit of claim 12 wherein: said thermoplastic matrix material comprises a chlorofluoropolymeric or fluoropolymeric material.
Claim 17
Dependent Claim
19 words
The multilayer circuit of claim 14 wherein said chlorofluoropolymeric material is selected from the group comprising; poly(ethylene-co-chlorotrifluoroethylene, or chlorotrifluoroethylene.
Claim 18
Dependent Claim
12 words
The multilayer circuit of claim 15 wherein said ceramic filler comprises silica.
Claim 19
Dependent Claim
14 words
The multilayer circuit of claim 16 wherein said silica comprises amorphous fused silica powder.
Claim 20
Dependent Claim
22 words
The multilayer circuit of claim 12 wherein said elastomeric polymer comprises silicone rubber which forms chemical bonds to said ceramic filler material.
Claim 21
Dependent Claim
12 words
The multilayer circuit of claim 14 including at least one acid scavenger.
Claim 22
Dependent Claim
14 words
The multilayer circuit of claim 19 wherein said acid scavenger comprises a metal oxide.
Claim 23
Dependent Claim
25 words
The multilayer circuit of claim 20 wherein: said metal oxide is selected from group consisting of CaO, ZnO, MgO, or Sb 2 O 3 .
Claim 24
Dependent Claim
21 words
The composite of claim 12 wherein: said thermoplastic matrix material is selected from the group consisting of poly (4-methylpentene) and polyolefins.
Claim 25
Dependent Claim
30 words
The multilayer circuit of claim 12 wherein: said first and second circuit layers comprise a ceramic filled fluoropolymeric substrate wherein said ceramic filler is coated with a silane coating material.
Claim 26
Dependent Claim
78 words
A highly filled thermoplastic matrix composite material, comprising: a matrix, said matrix comprising an extrudable thermoplastic polymer; a ceramic filler distributed throughout said matrix in an amount of at least about 40 volume percent of the composite material; and an elastomeric polymer coated over and bonded to the ceramic filler, said elastomeric polymer being included in an amount effective to increase the ultimate tensile elongation of the composite material to render the composite material handleable in sheet form.
Claim 27
Dependent Claim
78 words
A highly filled thermoplastic matrix composite material, comprising: a matrix, said matrix comprising an extrudable thermoplastic polymer; a ceramic filler distributed throughout said matrix in an amount of at least about 40 volume percent of the composite material; and an elastomeric polymer coated over and bonded to the ceramic filler, said elastomeric polymer being included in an amount effective to increase the ultimate tensile elongation of the composite material to render the composite material handleable in sheet form.
Claim 28
Dependent Claim
31 words
The composite material of claim 24, wherein the elastomeric polymer is included in an amount of about 2 volume percent to about 20 volume percent of the amount of ceramic filler.
Claim 29
Dependent Claim
99 words
A multilayer circuit, comprising: a first circuit layer; a second circuit layer; and a layer of adhesive sandwiched between the first and second circuit layers, said adhesive layer comprising: a matrix, said matrix comprising an extrudable thermoplastic polymer; a ceramic filler distributed throughout said matrix in an amount of at least about 40 volume percent of the composite material; and an elastomeric polymer coated over and bonded to the ceramic filler, said elastomeric polymer being included in an amount effective to increase the ultimate tensile elongation of the composite material to render the composite material handleable in sheet form.
Claim 30
Dependent Claim
99 words
A multilayer circuit, comprising: a first circuit layer; a second circuit layer; and a layer of adhesive sandwiched between the first and second circuit layers, said adhesive layer comprising: a matrix, said matrix comprising an extrudable thermoplastic polymer; a ceramic filler distributed throughout said matrix in an amount of at least about 40 volume percent of the composite material; and an elastomeric polymer coated over and bonded to the ceramic filler, said elastomeric polymer being included in an amount effective to increase the ultimate tensile elongation of the composite material to render the composite material handleable in sheet form.
Claim 31
Dependent Claim
31 words
The multilayer circuit of claim 26, wherein the elastomeric polymer is included in an amount of about 2 volume percent to about 20 volume percent of the amount of ceramic filler.
References Cited (Backward Citations)
CA943387A
Cited
EP0066330A2
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-12-30 | 1995-07-01 | 1995-12-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-12-30 | 1999-07-01 | 1999-12-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-12-30 | 2003-07-01 | 2003-12-31 | $7700.00 | Window Closed / Lapsed |