Thermosetting resin composition 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.

What we claim is:  
     
         1 . A thermosetting resin composition comprising: 
 (1) at least one epoxy resin;    (2) at least one SMA copolymer; and    (3) at least one bis-maleimidetriazine resin.    
     
     
         2 . The thermosetting resin composition of  claim 1  including an accelerator.  
     
     
         3 . The thermosetting resin composition of  claim 1  including a filler.  
     
     
         4 . The thermosetting resin composition of  claim 1  including a toughener.  
     
     
         5 . The thermosetting resin composition of  claim 1  including a flame retardant.  
     
     
         6 . The thermosetting resin composition 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 thermosetting resin composition of  claim 2  wherein the accelerator is an imidazole.  
     
     
         8 . The thermosetting resin composition 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 thermosetting resin composition of  claim 4  wherein the toughener is methacrylate butadiene styrene core shell particles.  
     
     
         10 . The thermosetting resin composition of  claim 1  including a fluorescent dye.  
     
     
         11 . A thermosetting resin composition comprising: 
 an epoxy resin system including an admixture of Bis-A epoxy resin; brominated bisphenol A diglycidyl ether; and tetrabromobisphenol A;    SMA;    Bis-maleimidetriazine resin;    methacrylate butadiene core shell particles; and    at least one accelerator.    
     
     
         12 . A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises: at least one epoxy resin; at least one SMA copolymer; and at least one bis-maleimidetriazine resin.  
     
     
         13 . The prepreg of  claim 12  wherein the thermosetting resin composition includes an accelerator.  
     
     
         14 . The prepreg of  claim 12  wherein the thermosetting resin composition includes a filler.  
     
     
         15 . The prepreg of  claim 12  wherein the thermosetting resin composition includes a toughener.  
     
     
         16 . The prepreg of  claim 12  wherein the thermosetting resin composition includes a flame retardant.  
     
     
         17 . The prepreg of  claim 12  wherein the epoxy resin comprises an admixture of Bis-A epoxy resin; brominated bisphenol A diglycidyl ether; and tetrabromobisphenol A.  
     
     
         18 . The prepreg of  claim 13  wherein the accelerator is an imidazole.  
     
     
         19 . The prepreg of  claim 14  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.  
     
     
         20 . The prepreg of  claim 15  wherein the toughener is methacrylate butadiene styrene core shell particles.  
     
     
         21 . The prepreg of  claim 12  wherein the thermosetting composition includes a fluorescent dye.  
     
     
         22 . A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises: an epoxy resin system including an admixture of Bis-A epoxy resin, brominated bisphenol A diglycidyl ether, and tetrabromobisphenol A; SMA; Bis-maleimidetriazine; methacrylate butadiene core shell particles; and at least one accelerator.  
     
     
         23 . A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: at least one epoxy resin; at least one SMA copolymer; and at least one bis-maleimidetriazine resin.  
     
     
         24 . The laminate of  claim 23  wherein the thermosetting resin composition includes an accelerator.  
     
     
         25 . The laminate of  claim 23  wherein the thermosetting resin composition includes a filler.  
     
     
         26 . The laminate of  claim 23  wherein the thermosetting resin composition includes a toughener.  
     
     
         27 . The laminate of  claim 23  wherein the thermosetting resin composition includes a flame retardant.  
     
     
         28 . The laminate of  claim 23  wherein the epoxy resin comprises an admixture of Bis-A epoxy resin; brominated bisphenol A diglycidyl ether; and tetrabromobisphenol A.  
     
     
         29 . The laminate of  claim 24  wherein the accelerator is an imidazole.  
     
     
         30 . The laminate of  claim 25  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.  
     
     
         31 . The laminate of  claim 26  wherein the toughener is methacrylate butadiene styrene core shell particles.  
     
     
         21 . The laminate of  claim 23  wherein the thermosetting resin composition includes a fluorescent dye.  
     
     
         33 . A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: an epoxy resin system including an admixture of Bis-A epoxy resin, brominated bisphenol A diglycidyl ether, and tetrabromobisphenol A; SMA; Bis-maleimidetriazine; methacrylate butadiene core shell particles; and at least one accelerator.