US 4,395,459 A · Reinforced laminates produced from crosslinkable thermoplastic olefin polymer material

Abstract

A process of producing reinforced laminates from crosslinkable thermoplastic olefin polymer material. In the process, a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer containing a catalyst which reacts with and effects crosslinking of the polymer and which has a decomposition temperature above the melting temperature of the polymer, is heated to a molten state at a temperature above the polymer melting temperature but below the catalyst decomposition temperature. A continuous nonreinforced sheet is then formed from the molten polymer at a temperature below the decomposition temperature and is applied to at least one surface of a substrate to form a laminate. The laminate is then heated under pressure to a temperature above the decomposition temperature of the catalyst to effect substantially complete crosslinking of the polymer and is cooled to a temperature below the polymer melting temperature to a self-supporting state to fix the shape of the laminate.

Claims37

Dependent claims

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of

(a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310.degree. F. and about 525.degree. F., to a molten state at a melting temperature between about 270.degree. F. and 300.degree. F.,
(b) forming a continuous non-reinforced sheet from said molten polymer at a temperature below said decomposition temperature,
(c) cooling said continuous sheet to a temperature below said melting temperature to a self-supporting, two-dimensional molecular state,
(d) combining said sheet in said self-supporting state with a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate to form a laminate,
(e) heating said laminate under pressure to a temperature between about 310.degree. F. and about 525.degree. F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state, and
(f) cooling said laminate to a temperature below said melting temperature to a self-supporting state,
(g) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

4 more elements

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of

(a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310.degree. F. and about 525.degree. F., to a molten state at a melting temperature between about 270.degree. F. and 300.degree. F.,
(b) forming a continuous non-reinforced sheet from said molten polymer at a temperature below said decomposition temperature,
(c) cooling said continuous sheet to a temperature below said melting temperature to a self-supporting, two-dimensional molecular state,
(d) combining said sheet in self-supporting state with a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate to form a laminate,
(e) cutting and shaping said laminate and superposing a plurality of said laminates,
(f) combining a sheet of copper foil with said laminates,
(g) heating said superposed laminates under pressure to a temperature between about 310.degree. F. and about 525.degree. F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of superposed laminates, and
(h) cooling said superposed laminates to a temperature below said melting temperature to a self-supporting state,
(i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

6 more elements

Reinforced laminates of crosslinkable thermoplastic olefin polymer material, produced by the process of

(a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970 and containing an acetylenic diperoxy catalyst which reacts with and effects crosslinking of said polymer and which has a decomposition temperature between about 310.degree. F. and 525.degree. F., to a molten state at a melting temperature between about 270.degree. F. and 300.degree. F.,
(b) forming a continuous non-reinforced sheet in a two-dimensional molecular state from said molten polymer at a temperature below said decomposition temperature,
(c) applying said continuous sheet to a glass fibrous substrate treated with an unsaturated organosilanol coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said polymer to said substrate at a temperature above said melting temperature to form a continuous laminate,
(d) cooling said laminate to a temperature below said melting temperature to a self-supporting state,
(e) cutting and shaping said laminate and superposing a plurality of said laminates,
(f) applying a sheet of copper foil to at least one surface of said laminates,
(g) heating said superposed laminates under pressure to a temperature between about 310.degree. F. and about 525.degree. F. to react said catalyst with said polymer and effect at least 80% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of said superposed laminates, and
(h) cooling said heated superposed laminates to a temperature below said melting temperature to a self-supporting state,
(i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

6 more elements

Reinforced laminates of a crosslinkable thermoplastic olefin polymer material, produced by the process of

(a) heating a normally solid, high molecular weight crosslinkable thermoplastic olefin polymer selected from the group consisting of ethylene homopolymers, copolymers of ethylene and at least one acyclic mono-1 olefin hydrocarbon having 2 to 8 carbon atoms per molecule, and mixtures thereof, having a melt index of at least about 10, and a density in the range of 0.910 to 0.970, and containing dilaurylthiodipropionate as a flame-retardant and 2,5 dimethyl 2,5-di(t-butylperoxy)hexyne-3 as a catalyst, to a molten state at a temperature between about 270.degree. F. and 300.degree. F.,
(b) extruding said molten polymer at a temperature between about 270.degree. F. and about 300.degree. F. to form a continuous non-reinforced sheet in a two-dimensional molecular state from said polymer,
(c) applying said continuous sheet under pressure at a temperature between about 270.degree. F. and about 300.degree. F. to a glass fibrous substrate treated with a gamma-methacryloxypropyltrimethoxy silane coupling agent which reacts with said polymer and said glass fibrous substrate and effects bonding of said sheet to said substrate to form a continuous laminate,
(d) cooling said laminate to a temperature below said melting temperature to a self-supporting state,
cutting and shaping said laminate and superposing a plurality of said laminates,
(f) applying a sheet of copper foil to at least one surface of said laminates,
(g) heating said superposed laminates under pressure to a temperature between about 310.degree. F. and about 525.degree. F. to effect about 95% crosslinking of said polymer to a three-dimensional molecular state and combine said plurality of superposed laminates, and
(h) cooling said heated superposed laminates to a temperature below 270.degree. F. to a self-supporting state,
(i) said laminate having a dielectric constant in Condition A at 1 MC/Sec. of about 2.40 to about 3.43.

6 more elements

A laminate comprises of a reinforced polyethylene and glass fibrous substrate which is chemically bonded by a glass to polyethylene coupling agent to a cross-linked polyethylene polymer which is present in the interstices of said substrate, said laminate having a dielectric constant in Condition A at 1 MC/Sec. within the range of about 2.40 to about 3.43;

and said laminate is prepared by:
(a) applying a self-supporting continuous sheet of said polyethylene containing a heat activated cross-linking agent to the surface of a glass fibrous substrate which has been treated with a glass to polyethylene coupling agent which bonds said polyethylene to said glass at a temperature above the melting temperature of said polyethylene, and
(b) applying heat and pressure to said polyethylene sheet and glass substrate sufficient to cross-link said polyethylene, and to provide a laminate wherein said cross-linked polyethylene is present in the interstices of said glass fibrous substrate and said polyethylene is bonded by said coupling agent to said glass fibrous substrate.

Dependencies are inferred from the claim text.

Reinforced laminates produced from crosslinkable thermoplastic olefin polymer material

Life of this patent

Reinforced laminates produced from crosslinkable thermoplastic olefin polymer material

Life of this patent

Abstract

Claims37