US4034136A — Flame-retardant resin compositions

Claim 1

Independent Claim 168 words

A copper clad laminate comprising (a) a copper sheet, coated with a thermosetting coating comprising: (1) 10 to 50 parts by weight of a polyunsaturated monomer, (2) 5 to 30 parts by weight of a polychlorinated or polybrominated aromatic hydrocarbon containing at least 50% by weight chlorine or bromine and having a molecular weight of at least 200, (3) 20 to 60 parts by weight of a polyphenylene ether polymer, (4) 0 to 30 parts by weight of a polyunsaturated polymer having carbon to carbon unsaturation, (5) 2 to 10 parts by weight per 100 parts of all of (1) plus (2) plus (3) plus (4) of a peroxide catalyst which has a ten hour half-life in benzene at a temperature in excess of 100° C. the said coated copper being heated for 2 to 30 minutes at 100° to 170° C. prior to being laminated at a temperature of at least 130° C. to (b) a base, whereby said thermosetting coating is converted to the thermoset state.

Claim 2

Dependent Claim 168 words

A copper clad laminate comprising (a) a copper sheet, coated with a thermosetting coating comprising: (1) 10 to 50 parts by weight of a polyunsaturated monomer, (2) 5 to 30 parts by weight of a polychlorinated or polybrominated aromatic hydrocarbon containing at least 50% by weight chlorine or bromine and having a molecular weight of at least 200, (3) 20 to 60 parts by weight of a polyphenylene ether polymer, (4) 0 to 30 parts by weight of a polyunsaturated polymer having carbon to carbon unsaturation, (5) 2 to 10 parts by weight per 100 parts of all of (1) plus (2) plus (3) plus (4) of a peroxide catalyst which has a ten hour half-life in benzene at a temperature in excess of 100° C. the said coated copper being heated for 2 to 30 minutes at 100° to 170° C. prior to being laminated at a temperature of at least 130° C. to (b) a base, whereby said thermosetting coating is converted to the thermoset state.

Claim 3

Dependent Claim 243 words

The copper clad laminate of claim 1 in which the base is a thermoset polymer composition selected from the group consisting of: (a) Thermosetting polyunsaturated polymers with carbon to carbon unsaturation containing 10 to 50% by weight of a polyunsaturated monomer with carbon to carbon unsaturation converted to the thermoset state at an elevated temperature of at least 130° C in the presence of a peroxide catalyst; (b) flame-retardant thermosetting compositions comprising 5-70 parts by weight of a polyunsaturated monomer with carbon to carbon unsaturation, 95-30 parts by weight of a polymer selected from the group consisting of polyunsaturated polymers with carbon to carbon unsaturation and polyphenylene ether polymers, with 5 to 50 parts by weight per 100 parts of monomer and polymer of a polychlorinated or polybrominated aromatic compound containing at least 50% by weight combined chlorine or bromine and whose molecular weight is greater than 200, in which composition there is at least 1 mol of polyunsaturated monomer for each 3 mols of polychlorinated or polybrominated aromatic compound converted to the thermoset state at a temperature of at least 130° C in the presence of a peroxide catalyst; and (c) a thermosetting composition comprising 10-45% by weight of a polyunsaturated monomer, 20-75% by weight of a polyunsaturated polymer containing carbon to carbon unsaturation, 10-35% by weight of said polyphenylene ether resin, converted to the thermoset state at a temperature of at least 130° C. in the presence of a peroxide catalyst.

Claim 4

Dependent Claim 36 words

The copper clad laminate of claim 2 in which the polyunsaturated monomer is selected from the group consisting of diallyl phthalate, diallyl isophthalate, diallyl chlorendate, diallyl maleate, triallyl cyanurate, triallyl isocyanurate, glycol dimethacrylate and divinyl benzene.

Claim 5

Dependent Claim 37 words

The copper clad laminate of claim 2 in which the polychlorinated or polybrominated aromatic hydrocarbon is selected from the group consisting of chlorinated or brominated biphenyls, chlorinated or brominated terphenyls, trichlorobenzene, chlorinated naphthalene, and chlorinated triphenyl phosphate.

Claim 6

Dependent Claim 80 words

The copper clad laminate of claim 2 in which the polyunsaturated polymer with carbon to carbon unsaturation is selected from the group consisting of diallyl orthophthalate prepolymer, diallyl isophthalate prepolymer, diallyl terphthalate prepolymer, and reactive polyester resins in which at least 50% of the dibasic acid portion of the polyester resin is an unsaturated dibasic carboxylic acid and the polyhydric alcohol portion of the polyester resin is a difunctional glycol containing 2-8 carbon atoms which may be cyclic or acyclic.

Claim 7

Dependent Claim 33 words

The copper clad laminates of claim 2 further comprising incorporating a reinforcing material in the base, the reinforcing material being selected from the group consisting of nonwoven fibrous mats, woven fabrics and fibers.

Claim 8

Dependent Claim 27 words

The copper clad laminate of claim 2 further comprising coating a second sheet of copper and laminating a coated copper sheet to each side of said base.

Claim 9

Dependent Claim 121 words

A thermoset laminate comprising a fibrous sheet saturated with a thermosetting composition comprising: (1) 10 to 50 parts by weight of a polyunsaturated monomer, (2) 5 to 30 parts by weight of a polychlorinated or polybrominated aromatic hydrocarbon containing at least 50% by weight chlorine or bromine and having a molecular weight of at least 200, (3) 20-60 parts by weight of a polyphenylene ether polymer, (4) 0-30 parts by weight of a polyunsaturated polymer having carbon to carbon unsaturation; converted to the thermoset state in the presence of a peroxide catalyst which has a 10 hour half-life in benzene at a temperature in excess of 100° C. at a temperature of at least 130° C. for 2 to 30 minutes.

Claim 10

Dependent Claim 121 words

A thermoset laminate comprising a fibrous sheet saturated with a thermosetting composition comprising: (1) 10 to 50 parts by weight of a polyunsaturated monomer, (2) 5 to 30 parts by weight of a polychlorinated or polybrominated aromatic hydrocarbon containing at least 50% by weight chlorine or bromine and having a molecular weight of at least 200, (3) 20-60 parts by weight of a polyphenylene ether polymer, (4) 0-30 parts by weight of a polyunsaturated polymer having carbon to carbon unsaturation; converted to the thermoset state in the presence of a peroxide catalyst which has a 10 hour half-life in benzene at a temperature in excess of 100° C. at a temperature of at least 130° C. for 2 to 30 minutes.

Claim 11

Dependent Claim 32 words

The laminate of claim 8 in which the polychlorinated or polybrominated aromatic hydrocarbon is selected from the group consisting of chlorinated or brominated biphenyls, chlorinated or brominated terphenyls, trichlorobenzene, and chlorinated naphthalenes.

Claim 12

Dependent Claim 25 words

The laminate of claim 9 further comprising a copper foil sheet on one or both surfaces of said laminate to form a copper clad laminate.

Claim 13

Dependent Claim 24 words

The laminate of claim 9 in which the fibrous sheet is selected from the group consisting of fibrous mats, woven fabrics and nonwoven fabrics.

Claim 14

Dependent Claim 35 words

The laminate of claim 8 in which the polyunsaturated monomer is selected from the group consisting of diallyl phthalate, diallyl isophthalate, diallyl chlorendate, diallyl maleate, triallyl cyanurate, triallyl isocyanurate, glycol dimethacrylate, and a divinyl benzene.

Claim 15

Dependent Claim 49 words

The copper clad laminate of claim 12 in which a plurality of fibrous sheets are saturated with the thermosetting composition and a plurality of the saturated sheets are laid up to form a multiple ply base carrying a copper foil sheet on one or both surfaces of the laminate.

Claim 16

Dependent Claim 31 words

The laminate of claim 8 in which the free radical initiator is a peroxide catalyst which has a 10 hour half-life in benzene at a temperature in excess of 100° C.

Claim 17

Dependent Claim 32 words

The laminate of claim 8 in which the peroxide catalyst is selected from the group consisting of dicumyl peroxide, tertiary butyl perbenzoate, 2,5-dimethyl-2,5-di(tertiary butylperoxy) hexyne-3,2,5-dimethyl-2,5-di(tertiary butylperoxy) hexane and mixtures with benzoyl peroxide.

Claim 18

Dependent Claim 185 words

A mold encapsulated electrical device with a plurality of leads projecting from the device, said device being coated with a thermosetting coating composition comprising: (1) 10 to 50 parts by weight of a polyunsaturated monomer; (2) 5 to 30 parts by weight of a polychlorinated or polybrominated aromatic hydrocarbon containing at least 50% by weight chlorine or bromine and having a molecular weight of at least 200; (3) 20-60 parts by weight of a polyphenylene ether polymer; (4) 0-30 parts by weight of a polyunsaturated polymer having carbon to carbon unsaturation; and (5) 2-10 parts by weight per 100 parts of all of (1) plus (2) plus (3) plus (4) of a peroxide catalyst which has a 10 hour half-life in benzene at a temperature in excess of 100° C., and said coated device being heated for 2 to 30 minutes at 100° to 170° C. prior to being mold encapsulated with a thermosetting mold encapsulation composition said mold encapsulation being done at a temperature of at least 130° C. whereby the mold encapsulation composition and the thermosetting composition are converted to the thermoset state.

Claim 19

Dependent Claim 185 words

A mold encapsulated electrical device with a plurality of leads projecting from the device, said device being coated with a thermosetting coating composition comprising: (1) 10 to 50 parts by weight of a polyunsaturated monomer; (2) 5 to 30 parts by weight of a polychlorinated or polybrominated aromatic hydrocarbon containing at least 50% by weight chlorine or bromine and having a molecular weight of at least 200; (3) 20-60 parts by weight of a polyphenylene ether polymer; (4) 0-30 parts by weight of a polyunsaturated polymer having carbon to carbon unsaturation; and (5) 2-10 parts by weight per 100 parts of all of (1) plus (2) plus (3) plus (4) of a peroxide catalyst which has a 10 hour half-life in benzene at a temperature in excess of 100° C., and said coated device being heated for 2 to 30 minutes at 100° to 170° C. prior to being mold encapsulated with a thermosetting mold encapsulation composition said mold encapsulation being done at a temperature of at least 130° C. whereby the mold encapsulation composition and the thermosetting composition are converted to the thermoset state.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1980-07-04	1981-01-03	1981-07-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1984-07-04	1985-01-03	1985-07-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1988-07-04	1989-01-03	1989-07-05	$7700.00	Window Closed / Lapsed

Flame-retardant resin compositions

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