Flexible prepreg and uses thereof

Patent metadata

Field	Value
Publication number	US-11312829-B2
Application number	US-201916380833-A
Country	US
Kind code	B2
Filing date	Apr 10, 2019
Priority date	Jan 4, 2019
Publication date	Apr 26, 2022
Grant date	Apr 26, 2022

Abstract

A prepreg is provided. The prepreg is prepared by impregnating a liquid crystal polymer non-woven fabric with a thermal-curable resin composition or by coating a thermal-curable resin composition onto a liquid crystal polymer non-woven fabric and drying the impregnated or coated liquid crystal polymer non-woven fabric, wherein the thermal-curable resin composition includes:(A) an unsaturated monomer; and(B) a cyclic olefin copolymer including the following repeating units:(B-1) a repeating unit of formula (I),(B-2) a repeating unit of formula (II),and(B-3) a repeating unit of formula (III),R1 to R22, m, n, o, and p in formulas (I) to (III) are as defined in the specification,wherein based on the total moles of the repeating units (B-1) to (B-3), the content of the repeating unit (B-2) is 19 mol % to 36 mol %, andwherein the weight ratio of the cyclic olefin copolymer (B) to the unsaturated monomer (A) is 0.5 to 7.

First claim

What is claimed is:

1. A prepreg, which is prepared by impregnating a liquid crystal polymer non-woven fabric with a thermal-curable resin composition or by coating a thermal-curable resin composition onto a liquid crystal polymer non-woven fabric and drying the impregnated or coated liquid crystal polymer non-woven fabric, wherein the thermal-curable resin composition comprises:
(A) an unsaturated monomer; and
(B) a cyclic olefin copolymer comprising the following repeating units:
(B-1) a repeating unit of formula (I),

(B-2) a repeating unit of formula (II),

and
(B-3) a repeating unit of formula (III),

wherein, in formulas (I) to (III),
R 1 is H or a C 1 to C 29 linear or branched hydrocarbon group;
R 2 to R 21 are independently H, a halogen, a C 1 to C 20 alkyl, a C 1 to C 20 halogenated alkyl, a C 3 to C 15 cycloalkyl, or a C 6 to C 20 aromatic hydrocarbyl;
R 18 to R 21 may bind to each other to form a monocyclic ring or polycyclic ring;
R 22 is H or a C 1 to C 10 alkyl;
m and n are independently 0 or 1;
o is 0 or a positive integer;
p is an integer from 0 to 10; and
in formula (III), when both m and n are 0, at least one of R 10 to R 13 and R 18 to R 21 is not H,
wherein, based on the total moles of the repeating units (B-1), (B-2) and (B-3), the content of the repeating unit (B-2) is 19 mol % to 36 mol %;
wherein the weight ratio of the cyclic olefin copolymer (B) to the unsaturated monomer (A) is 0.6 to 2.4; and
wherein the unsaturated monomer (A) is selected from the group consisting of an alkenyl-containing aromatic monomer, an allyl-containing monomer, an acryoyl-containing monomer, a vinyl ether, a maleimide, and combinations thereof.

2. The prepreg of claim 1 , wherein the allyl-containing monomer is an organic compound comprising at least one allyl.

3. The prepreg of claim 2 , wherein the allyl-containing monomer is selected from the group consisting of diallyl phthalate, diallyl isophthalate, triallyl mellitate, triallyl mesate, triallyl benzene, triallyl cyanurate, triallyl isocyanurate, triallyl amine, and combinations thereof.

4. The prepreg of claim 1 , wherein IV is H 1 or a C1 to C6 alkyl.

5. The prepreg of claim 1 , wherein the repeating unit (B-2) is formed by the addition copolymerization of cyclic non-conjugated diene monomers, wherein the cyclic non-conjugated diene monomer is selected from the group consisting of

and combinations thereof.

6. The prepreg of claim 1 , wherein, based on the total moles of the repeating units (B-1), (B-2) and (B-3), the content of the repeating unit (B-2) is 20 mol % to 33 mol %.

7. The prepreg of claim 1 , wherein the thermal-curable resin composition further comprises a flame retardant, a catalyst, a filler, a curing accelerator, a dispersing agent, a toughener, a viscosity modifier, a thixotropic agent, a defoamer, a leveling agent, a surface treatment agent, a stabilizing agent, an antioxidant, or combinations thereof.

8. The prepreg of claim 7 , wherein the flame retardant is selected from the group consisting of a phosphorus-containing flame retardant, a bromine-containing flame retardant, and combinations thereof.

9. The prepreg of claim 7 , wherein the catalyst is selected from the group consisting of dicumyl peroxide, α,α′-bis(t-butylperoxy)diisopropyl benzene, benzoyl peroxide, and combinations thereof.

10. The prepreg of claim 1 , wherein the liquid crystal polymer non-woven fabric comprises a liquid crystal polyester fiber having an average diameter ranging from 0.6 μm to 20 μm and elongations in the machine direction (MD) and the cross direction (CD) independently ranging from 1% to 8%.

11. The prepreg of claim 10 , wherein the liquid crystal polyester fiber has one or more of the following repeating units (1) to (11):

wherein X, X′, Y and Y′ are independently H, Cl, Br or methyl, and Z is

12. The prepreg of claim 10 , wherein the liquid crystal polyester fiber has repeating units of the following formulas (IV) and (V), and based on 100 mol % of the total amount of repeating units in the liquid crystal polyester, the total amount of the repeating units of formulas (IV) and (V) is at least 65 mol %,

13. A metal-clad laminate, which is prepared by laminating the prepreg of claim 1 and a metal foil.

14. A printed circuit board, which is prepared from the metal-clad laminate of claim 13 .

Assignees

• Taiwan Union Technology Corp

Inventors

• Liu Shur-Fen
• Hung Chin-Hsien

Classifications

• C08L45/00 Primary

  Compositions of homopolymers or copolymers of compounds having no unsaturated aliphatic radicals in side chain, and having one or more carbon-to-carbon double bonds in a carbocyclic or in a heterocyclic ring system; Compositions of derivatives of such polymers (of cyclic anhydrides or imides C08L35/00; of cyclic esters of polyfunctional acids C08L31/00) · CPC title

• C08J5/249

  characterised by the additives used in the prepolymer mixture · CPC title

• C08J5/246

  using polymer based synthetic fibres · CPC title

• C08J5/046 Primary

  with synthetic macromolecular fibrous material · CPC title

• C08L2203/20

  use in electrical or conductive gadgets · CPC title