Ceramic and polymer composite, methods of making, and uses thereof

Patent metadata

Field	Value
Publication number	US-2018035538-A1
Application number	US-201715656657-A
Country	US
Kind code	A1
Filing date	Jul 21, 2017
Priority date	Jul 27, 2016
Publication date	Feb 1, 2018
Grant date	—

Abstract

A ceramic and polymer composite including: a first continuous phase comprising a sintered porous ceramic having a solid volume of from 50 to 85 vol % and a porosity or a porous void space of from 50 to 15 vol %, based on the total volume of the composite; and a second continuous polymer phase situated in the porous void space of the sintered porous ceramic. Also disclosed is a composite article, a method of making the composite, and a method of using the composite.

First claim

What is claimed:

1 . A ceramic and polymer composite comprising:
a first continuous phase comprising a sintered porous ceramic having a solid volume of from 50 to 85 vol % and a porosity of from 50 to 15 vol %, based on the total volume of the composite; and a second continuous polymer phase situated in the porosity of the sintered porous ceramic first continuous phase.

2 . The composite of claim 1 wherein the sintered porous ceramic comprises at least one of aluminum oxide, silicon oxide, or mixtures thereof.

3 . The composite of claim 1 wherein the composite is a sheet having a thickness of from 10 to 1000 micrometers.

4 . The composite of claim 1 wherein the composite is a sheet having a thickness of from 10 to 250 micrometers.

5 . The composite of claim 1 wherein the composite is a sheet having a thickness of from 10 to 100 micrometers.

6 . The composite of claim 1 wherein the composite has a strength of from 125 and 250 MPa, and a Young's modulus of from 50 and 250 GPa.

7 . The composite of claim 1 wherein the Young's modulus of the sintered porous ceramic continuous phase is from 50 to 210 GPa

8 . The composite of claim 1 wherein the composite has a stiffness of from 50 to 65 GPa.

9 . The composite of claim 1 wherein the composite has a coefficient of thermal expansion (CTE) of from 11×10 −6 K o-1 to 25×10 −6 K o-1 in each of the x, y, and z axes.

10 . The composite of claim 1 wherein the sintered porous ceramic continuous phase has an overlapping sphere structure comprised of a plurality of partially fused adjacent spherical ceramic particles of at least one of aluminum oxide, silicon oxide, or mixtures thereof.

11 . The composite of claim 1 wherein the sintered porous ceramic continuous phase is non-woven.

12 . A method of making the ceramic and polymer composite of claim 1 comprising:
contacting the surface of a porous ceramic sheet and a curable polymer, where the porous ceramic sheet has a volume percent of open pores of 15 to 50%.

13 . The method of claim 12 further comprising:
forming a porous sintered ceramic sheet having from 15 to 50 volume percent open pores by at least one of tape casting, flame hydrolyzing, firing a green body ceramic having a pore former present in from 15 to 50 vol %, or a combination thereof.

14 . The method of claim 12 wherein the curable polymer comprises a liquid or is in a liquid carrier.

15 . The method of claim 12 wherein the curable polymer comprises a mixture of: a crosslinkable polymer, a polymerizable and crosslinkable monomer, or a mixture thereof, and a crosslinker.

16 . The method of claim 12 wherein the curable polymer comprises at least one of: an epoxy resin, an amine-epoxide resin, a phenolic resin, an isocyanate resin, an alkyd resin, an acrylate, a polystyrene, a polyimide, a polyamine, or a mixture thereof.

17 . An article comprising the ceramic and polymer composite of claim 1 .

18 . The article of claim 17 wherein the article is a printed circuit board.

19 . The article of claim 18 wherein the printed circuit board has a frequency dielectric of from 2.4 to 6.7 at 10 GHz and a frequency dielectric performance of from 0.0016 to 0.012 at 10 GHz.

20 . The article of claim 17 further comprising at least one of:
at least one machined surface;
at least one hole drilled partially into the article;
at least one hole drilled through the article, or combinations thereof.

Assignees

• Corning Inc

Inventors

• Miao Weiguo
• Ocampo Manuela
• Sorensen Michael Lesley
• Zimmermann James William

Classifications

• C04B2111/805

  Transparent material · CPC title

• C04B2111/00844

  for electronic applications · CPC title

• C04B35/111

  Fine ceramics · CPC title

• H05K1/0353

  consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement · CPC title

• C04B41/48

  Macromolecular compounds · CPC title