Thermosetting Resin Compositions For High Performance Laminates

Abstract

This invention concerns a thermosetting resin system that is useful in the manufacture of high performance prepreg, laminate and composite materials as well as, prepregs, laminates and composites made from the thermosetting resin composition.

1 . A prepreg comprising a substrate impregnated with a thermosetting resin including:
 at least one epoxy resin;   at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof; and   at least one styrene-maleic anhydride copolymer.   
     
     
         2 . The prepreg of  claim 1  wherein the thermosetting resin includes an accelerator. 
     
     
         3 . The prepreg of  claim 1  wherein the thermosetting resin includes a filler. 
     
     
         4 . The prepreg of  claim 1  wherein the thermosetting resin includes a toughener. 
     
     
         5 . The prepreg of  claim 1  wherein the thermosetting resin includes a flame retardant. 
     
     
         6 . The prepreg of  claim 1  wherein the epoxy resin comprises an admixture of Bis-A epoxy resin; brominated bisphenol A diglycidyl ether; and tetrabromobisphenol A. 
     
     
         7 . The prepreg of  claim 2  wherein the accelerator is an imidazole. 
     
     
         8 . The prepreg of  claim 3  wherein the filler is selected from teflon, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, or mixtures thereof. 
     
     
         9 . The prepreg of  claim 4  wherein the toughener is methacrylate butadiene styrene core shell particles. 
     
     
         10 . The prepreg of  claim 1  including from about 15 to about 50 wt % of the at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof. 
     
     
         11 . The prepreg of  claim 1  wherein the substrate is a woven glass material. 
     
     
         12 . A prepreg comprising a substrate impregnated with a thermosetting resin including:
 an epoxy resin;   from about 15-50 weight percent at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof; and   15-23 weight percent of the at least one styrene-maleic anhydride copolymer;   
     
     
         13 . The prepreg of  claim 12  wherein the thermosetting resin includes at least one ingredient selected from the group consisting of 2-4 weight percent of methacrylate butadiene core shell particles; 0.2-0.5 weight percent of an accelerator; 25-40 weight percent of a bismaleimidetriazine resin; and 0-10 weight percent of a filler. 
     
     
         14 . The prepreg of  claim 12  wherein the at least one ingredient selected from the group consisting of bismaleimide resin, cyanate ester resin, bismaleimide triazine or combinations thereof is a cyanate ester resin. 
     
     
         15 . The prepreg of  claim 12  wherein the substrate is a woven glass material. 
     
     
         16 . The prepreg of  claim 12  wherein the thermosetting resin composition is at least partially cured. 
     
     
         17 . A laminate including one or more pregregs of  claim 12 . 
     
     
         18 . The laminate of  claim 17  including one or more sheets of a conducting foil. 
     
     
         19 . The laminate of  claim 18  including at least one prepreg positioned between sheets of conducting foil. 
     
     
         20 . The laminate of  claim 17  including at least one sheet of conducting foil positioned between two prepreg sheets.