US5223568A — Process for forming hard shaped molded article of…

Claim 1

Independent Claim 107 words

A forming process for producing a hard shaped molded article comprising the steps of (a) providing a moldable thermosetting composition comprising a polybutadiene or polyisoprene resin which is a liquid at room temperature and which has a molecular weight less than 5,000 and pendent vinyl groups available for crosslinking; and an unsaturated butadiene- or isoprene-containing solid polymer capable of participating in crosslinking during cure; (b) forming said composition into a shape: and (c) curing said composition to produce said article by subjecting said composition to a high temperature cure condition at a temperature greater than about 260° C. and less than the decomposition temperature of said composition.

Claim 2

Dependent Claim 107 words

A forming process for producing a hard shaped molded article comprising the steps of (a) providing a moldable thermosetting composition comprising a polybutadiene or polyisoprene resin which is a liquid at room temperature and which has a molecular weight less than 5,000 and pendent vinyl groups available for crosslinking; and an unsaturated butadiene- or isoprene-containing solid polymer capable of participating in crosslinking during cure; (b) forming said composition into a shape: and (c) curing said composition to produce said article by subjecting said composition to a high temperature cure condition at a temperature greater than about 260° C. and less than the decomposition temperature of said composition.

Claim 3

Dependent Claim 17 words

The forming process of claim 1 wherein said solid polymer has pendent vinyl groups available for crosslinking.

Claim 4

Dependent Claim 21 words

The forming process of claim 1 wherein said solid polymer is a copolymer of isoprene or butadiene and a second monomer.

Claim 5

Dependent Claim 15 words

The forming process of claim 3 wherein said second monomer is styrene or α-methyl styrene.

Claim 6

Dependent Claim 67 words

The forming process of claim 3 wherein said copolymer is a thermoplastic elastomer block copolymer having the formula X m --(Y--X) n ##STR3## or the formula where in each formula Y is a block comprising isoprene or butadiene units, X is a thermoplastic block, and m and n represent the average block numbers in said copolymer, m being 0 or 1 and n being at least 1.

Claim 7

Dependent Claim 67 words

The forming process of claim 1 wherein said composition further includes a thermoplastic elastomer block copolymer having the formula W p --(Z--W) q or the formula ##STR4## where in each formula Z is a polyethylene or ethylene-propylene copolymer block, W is a thermoplastic block, and p and q represent the average block numbers in said copolymer, p being 0 or 1 and q being at least 1.

Claim 8

Dependent Claim 21 words

The forming process of claim 5 or 6 wherein said thermoplastic block is a block comprising styrene or α-methyl styrene units.

Claim 9

Dependent Claim 31 words

The forming process of claim 5 wherein the resin which is a liquid at room temperature is polybutadiene and the unsaturated butadiene- or isoprene-containing solid polymer is a styrene-butadiene-styrene triblock copolymer.

Claim 10

Dependent Claim 39 words

The forming process of claim 6 wherein the resin which is a liquid at room temperature is polybutadiene, the unsaturated butadiene- or isoprene-containing solid polymer is a styrene-butadiene-styrene triblock copolymer, and said block copolymer is a styrene-ethylene-propylene-styrene triblock copolymer.

Claim 11

Dependent Claim 16 words

The forming process of claim 1, further comprising adding to said composition one or more fillers.

Claim 12

Dependent Claim 49 words

The forming process of claim 10 adapted to produce a dielectric article wherein the added filler is a quantity of dielectric filler chosen to provide to said article a pre-selected dielectric constant, said unsaturated butadiene- or isoprene-containing solid polymer maintaining said added filler dispersed substantially uniformly throughout said composition.

Claim 13

Dependent Claim 35 words

The forming process of claim 11 wherein a plurality of said fillers having different dielectric constants are employed, the respective quantities of said fillers being selected to provide to said article a pre-selected dielectric constant.

Claim 14

Dependent Claim 20 words

The forming process of claim 12 wherein said composition comprises between 5 and 80% by volume, inclusive, of said filler.

Claim 15

Dependent Claim 60 words

The forming process of claim 11 or 12 further comprising applying to said hard shaped molded article a metal layer having a pre-selected coefficient of thermal expansion and, in the process of forming said article, selecting said filler and the quantity thereof to provide to said article a coefficient of thermal expansion substantially equal to that of said metal layer.

Claim 16

Dependent Claim 16 words

The forming process of claim 1 further comprising adding a crosslinking agent to said thermosetting composition.

Claim 17

Dependent Claim 30 words

The forming process of claim 15 wherein said crosslinking agent is selected from the group consisting of triallyl cyanurate, diallyl phthalate, divinylbenzene, a multifunctional acrylate monomer, and a combination thereof.

Claim 18

Dependent Claim 46 words

The forming process of claim 1 wherein curing said composition further includes a step of adding catalyst to said composition and subjecting said composition, prior to said high temperature cure, to a catalyzed cure at a temperature less than the temperature of said high temperature cure.

Claim 19

Dependent Claim 186 words

A forming process for producing a hard shaped molded article comprising the steps of (a) providing a moldable thermosetting composition comprising a polybutadiene or polyisoprene resin which is a liquid at room temperature and which has a molecular weight less than 5,000; a thermoplastic elastomer capable of participating in crosslinking during cure comprising a block copolymer having the formula X m --(Y--X) n or the formula ##STR5## where in each formula Y is a polybutadiene or polyisoprene block, X is a thermoplastic block, and m and n represent the average block numbers in said copolymer, m being 0 or 1 and n being at least 1, both the resin which is a liquid at room temperature and said polybutadiene or polyisoprene block of said thermoplastic elastomer having 1,2 addition in an amount such that together they provide pendent vinyl groups available for crosslinking; (b) forming said composition into a shape; and (c) curing said composition to produce said article by subjecting said composition to a high temperature cure condition at a temperature greater than about 250° C. and less than the decomposition temperature of said composition.

Claim 20

Dependent Claim 186 words

A forming process for producing a hard shaped molded article comprising the steps of (a) providing a moldable thermosetting composition comprising a polybutadiene or polyisoprene resin which is a liquid at room temperature and which has a molecular weight less than 5,000; a thermoplastic elastomer capable of participating in crosslinking during cure comprising a block copolymer having the formula X m --(Y--X) n or the formula ##STR5## where in each formula Y is a polybutadiene or polyisoprene block, X is a thermoplastic block, and m and n represent the average block numbers in said copolymer, m being 0 or 1 and n being at least 1, both the resin which is a liquid at room temperature and said polybutadiene or polyisoprene block of said thermoplastic elastomer having 1,2 addition in an amount such that together they provide pendent vinyl groups available for crosslinking; (b) forming said composition into a shape; and (c) curing said composition to produce said article by subjecting said composition to a high temperature cure condition at a temperature greater than about 250° C. and less than the decomposition temperature of said composition.

Claim 21

Dependent Claim 24 words

The forming process of claim 18 wherein said polybutadiene or polyisoprene block of said thermoplastic elastomer has at least 50% by weight 1,2 addition.

Claim 22

Dependent Claim 13 words

An article prepared according to the process of claim 1, 11, or 18.

Claim 23

Dependent Claim 12 words

The article of claim 20 wherein said article comprises a microwave lens.

Claim 24

Dependent Claim 12 words

The article of claim 20 wherein said article comprises a microwave window.

Claim 25

Dependent Claim 14 words

The article of claim 20 wherein said article comprises a filled wave guide cavity.

Claim 26

Dependent Claim 15 words

The article of claim 20 wherein said article comprises the substrate for a microwave circuit.

Claim 27

Dependent Claim 13 words

The article of claim 24 wherein said microwave circuit comprises a microstrip circuit.

Claim 28

Dependent Claim 13 words

The article of claim 24 wherein said microwave circuit comprises a microstrip circuit.

Claim 29

Dependent Claim 13 words

The article of claim 24 wherein said microwave circuit comprises a microstrip antenna.

Claim 30

Dependent Claim 13 words

The article of claim 24 wherein said microwave circuit comprises a stripline circuit.

Claim 31

Dependent Claim 12 words

The article of claim 20 wherein said article comprises a rod antenna.

Claim 32

Dependent Claim 17 words

The article of claim 20 wherein said article comprises a substrate for a high speed digital circuit.

Claim 33

Dependent Claim 21 words

The article of claim 30 wherein the dielectric constant of said article is substantially the same as that of Gallium Arsenide.

Claim 34

Dependent Claim 12 words

The article of claim 20 wherein said article comprises a chip carrier.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1996-06-28	1996-12-28	1997-06-29	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2000-06-28	2000-12-28	2001-06-29	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2004-06-28	2004-12-28	2005-06-29	$7700.00	Window Closed / Lapsed

Process for forming hard shaped molded article of a cross-linked liquid polybutadiene or polyisoprene resin and a butadiene or isoprene containing solid polymer and resulting articles

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag