Liquid crystal polymer composite, liquid crystal polymer composite film, and metal-clad laminate including same
OwnerJohn Henry Welch, III, Kwong Yiu Hauinventors
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Abstract
A liquid crystal polymer composite film is formed from a resin composite including one or more liquid crystal polymers and one or more fillers. The liquid crystal polymer composite film has a thickness in the range of 10 μm-200 μm and a ratio of the in-plane dielectric permittivity in the machine direction to the transverse direction in the range of 1.0-1.4 over a frequency range of 1 Ghz to 10 Ghz. A metal-clad laminate includes the liquid crystal polymer composite film and a metal clad layer laminated to a major surface of the liquid crystal polymer composite film. The metal-clad laminate may be included as part of an antenna.
Claims21
-20. (canceled)
A method of manufacturing a metal-clad laminate comprising:
- wherein the metal-clad laminate comprises a liquid crystal polymer composite film and a metal layer laminated to a major surface of the liquid crystal polymer composite film;
- wherein the composite film has a relative permittivity less than 3.1;
- positioning the metal layer adjacent a calender which comprises a first and second roll which are positioned in a parallel configuration creating a nip region bounded by the surfaces of the first and second roll;
- positioning an extruder in alignment with the calender so that an outlet orifice of the extruder is positioned over said nip region;
- heating the metal layer, and moving the heated metal layer into the nip region;
- extruding a liquid crystal composite film wherein a melt curtain exits the outlet orifice and enters the nip region;
- and
- laminating the liquid crystal composite film and the metal layer in the nip region to create the metal clad laminate.
A method of manufacturing a metal-clad laminate, the method comprising:
- heating a metal foil on a heated roll of a calender having first and second rolls that define a nip region;
- extruding a liquid crystal polymer (LCP) composite to form a melt curtain positioned above the nip region;
- advancing the heated metal foil into the nip region;
- passing the melt curtain and the heated metal foil through the nip region while applying a nip force effective to calender a melt pool formed from the melt curtain;
- and
- solidifying the calendered melt pool to form a metal-clad laminate comprising an LCP composite film having a relative permittivity less than 3.1.
A method of forming a dual-sided metal-clad laminate, the method comprising:
- forming a first metal-clad intermediate by calendering a first metal foil with an LCP composite melt curtain in a first nip region of a calender;
- heating the first metal-clad intermediate or a second metal foil to 225° C. to 300° C.;
- pressing the first metal-clad intermediate and the second metal foil to laminate the second metal foil to an exposed surface of the LCP composite;
- and
- cooling to form a dual-sided metal-clad laminate in which the LCP composite film has a loss tangent less than 0.003 and a dielectric permittivity ratio between the machine direction relative to the transverse direction of 1.0 to 1.1 at 1-10 GHz.
Dependencies are inferred from the claim text.