Composite dielectric material, composite dielectric substrate, prepreg, coated metal foil, molded sheet, composite magnetic substrate, substrate, double side metal foil-clad substrate, flame retardant substrate, polyvinylbenzyl ether resin composition, thermosetting polyvinylbenzyl ether resin composition, and method for preparing thermosetting polyvinylbenzyl ether resin composition

Abstract

A composite dielectric material comprising a resin resulting from a polyvinylbenzyl ether compound and a dielectric, ceramic powder dispersed therein is useful in the high-frequency region. A composite magnetic material comprising a polyvinylbenzyl ether compound and a magnetic powder is also provided as well as a flame retardant material comprising a polyvinylbenzyl ether compound and a flame retardant. These materials may be used in the fabrication of substrates, prepreg sheets, coated metal foils, molded items, and metal foil-clad substrates.

1 - 86 . (canceled)  
     
     
         87 . A composite dielectric material, comprising a resin and a ceramic powder dispersed therein, and wherein 
 said resin results from a polyvinylbenzyl ether compound,    the content of the ceramic powder is from 10 vol % to less than 70 vol %, based on the ceramic powder and the polyvinylbenzyl ether compound combined, and    said composite dielectric material has a Q of at least 250 and a dielectric constant of at least 3 at a frequency of at least 500 MHz.    
     
     
         88 . The composite dielectric material of  claim 87 , prepared by curing a mixture comprising the polyvinylbenzyl ether compound and the ceramic powder.  
     
     
         89 . The composite dielectric material of  claim 87 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
         wherein R 1  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl from 60:40 to 0:100, and n is a number of 2 to 4.  
       
     
     
         90 . The composite dielectric material of  claim 87 , wherein the ceramic powder to be dispersed, has a Q of 250 to 50,000 and a dielectric constant of 2.5 to 300 at a frequency of 1 to 15 GHz.  
     
     
         91 . The composite dielectric material of  claim 87 , wherein the ceramic powder is at least one ceramic, based on a composition selected from the group consisting of TiO 2 , CaTiO 3 , SrTiO 3 , BaO—Nd 2 O 3 —TiO 2 , Bi 2 O 3 —BaO—Nd 2 O 3 —TiO 2 , BaTi 4 O 9 , Ba 2 Ti 9 O 20 , Ba 2 (Ti,Sn) 9 O 20 , MgO—TiO 2 , ZnO—TiO 2 , MgO—SiO 2 , and Al 2 O 3  base compositions.  
     
     
         92 . A composite dielectric material, comprising a resin and a ceramic powder dispersed therein, and wherein 
 said resin results from a polyvinylbenzyl ether compound,    said ceramic powder is at least one ceramic, based on a composition selected from the group consisting of BaTiO 3 , (Ba,Pb)TiO 3 , Ba(Ti,Zr)O 3 , and (Ba,Sr)TiO 3  base compositions,    the content of the ceramic powder is from 30 vol % to less than 70 vol %, based on the ceramic powder and the polyvinylbenzyl ether compound combined, and    said composite dielectric material has a dielectric constant of at least 10 in a high-frequency band of at least 10 MHz.    
     
     
         93 . The composite dielectric material of  claim 92 , prepared by curing a mixture comprising the polyvinylbenzyl ether compound and the ceramic powder.  
     
     
         94 . The composite dielectric material of  claim 92 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
         wherein R 1  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl from 60:40 to 0:100, and n is a number of 2 to 4.  
       
     
     
         95 . The composite dielectric material of  claim 92 , wherein the ceramic powder to be dispersed, has a dielectric constant of 90 to 100,000 at a frequency of 100 kHz to 10 MHz.  
     
     
         96 . A composite dielectric substrate, comprising a resin and a dielectric ceramic powder dispersed therein, and wherein 
 said resin results from a polyvinylbenzyl ether compound,    the content of the dielectric ceramic powder is from 10 to 65 vol %, based on the dielectric ceramic powder and the polyvinylbenzyl ether compound combined, and    said composite dielectric substrate is used in a high-frequency region of at least 100 MHz.    
     
     
         97 . The composite dielectric substrate of  claim 96 , prepared by molding and curing a mixture comprising the polyvinylbenzyl ether compound and the ceramic powder.  
     
     
         98 . The composite dielectric substrate of  claim 96 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
         wherein R 3  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl of from 60:40 to 0:100, and n is a number of 2 to 4.  
       
     
     
         99 . The composite dielectric substrate of  claim 96 , wherein the dielectric ceramic powder has a mean particle size of 0.5 to 100 μm.  
     
     
         100 . A composite dielectric substrate, prepared by dispersing a polyvinylbenzyl ether compound and a dielectric ceramic powder in a solvent to form a slurry, followed by drying and compression, and wherein 
 the content of the dielectric ceramic powder is from 10 to 65 vol %, based on the dielectric ceramic powder and the polyvinylbenzyl ether compound combined, and wherein    the composite dielectric substrate is used in a high-frequency region of at least 100 MHz.    
     
     
         101 . The substrate of  claim 100 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
       
       wherein R 1  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl from 60:40 to 0:100, and n is a number of 2 to 4.  
     
     
         102 . The substrate of  claim 100 , wherein the dielectric ceramic powder has a mean particle size of 0.5 to 100 μm.  
     
     
         103 . The composite dielectric substrate of  claim 100 , wherein the dried slurry is molded into a molded sheet.  
     
     
         104 . A composite magnetic substrate, comprising a magnetic powder dispersed in a polyvinylbenzyl ether compound.  
     
     
         105 . The composite magnetic substrate of  claim 104 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
       
       wherein R 1  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl from 60:40 to 0:100, and n is a number of 2 to 4.  
     
     
         106 . The composite magnetic substrate of  claim 104 , wherein the magnetic powder is of a ferromagnetic metal or ferrite.  
     
     
         107 . The composite magnetic substrate of  claim 104 , wherein the magnetic powder has a mean particle size of 0.01 to 100 μm.  
     
     
         108 . The composite magnetic substrate of  claim 104 , wherein the content of the magnetic powder is 50 to 90 wt %, based on the magnetic powder and the polyvinylbenzyl ether compound combined.  
     
     
         109 . A prepreg, prepared by mixing a polyvinylbenzyl ether compound and a magnetic powder, at a temperature not lower than the melting point of the polyvinylbenzyl ether compound, and molding the resulting solid mixture under pressure.  
     
     
         110 . A flame retardant substrate, comprising a polyvinylbenzyl ether compound and a flame retardant dispersed therein.  
     
     
         111 . The flame retardant substrate of  claim 110 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
       
       wherein R 1  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl from 60:40 to 0:100, and n is a number of 2 to 4.  
     
     
         112 . The flame retardant substrate of  claim 110 , wherein said flame retardant is a halogenated phosphate.  
     
     
         113 . The flame retardant substrate of  claim 110 , wherein the content of the flame retardant is 40 to 60 wt %, based on the flame retardant and the polyvinylbenzyl ether compound combined.  
     
     
         114 . A flame retardant polyvinylbenzyl ether resin composition, comprising a polyvinylbenzyl ether compound and an additive type flame retardant or a mixture of an additive type flame retardant and a flame retardant adjuvant.  
     
     
         115 . The composition of  claim 114 , wherein the additive type flame retardant is a brominated aromatic flame retardant, which is present in an amount of 5 to 70% by weight, based on the polyvinylbenzyl ether compound.  
     
     
         116 . The composition of  claim 114 , wherein the composition comprises the mixture of an additive type flame retardant and a flame retardant adjuvant, and wherein the flame retardant adjuvant is an inorganic flame retardant, and a mixture of a brominated aromatic flame retardant and the inorganic flame retardant is present in an amount of 5 to 70% by weight, based on the polyvinylbenzyl ether compound.  
     
     
         117 . The composition of  claim 114 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
       
       wherein R 1  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl from 60:40 to 0:100, and n is a number of 2 to 4.  
     
     
         118 . The composition of  claim 114 , wherein the composition comprises a mixture of an additive type flame retardant and a flame retardant adjuvant, and wherein the flame retardant adjuvant is an inorganic flame retardant which has been surface treated with a coupling agent.  
     
     
         119 . A thermosetting polyvinylbenzyl ether resin composition, comprising a polyvinylbenzyl ether compound and a dielectric powder, which has been surface treated with a coupling agent.  
     
     
         120 . The composition of  claim 119 , wherein the coupling agent is an alkoxysilane or organic functional silane having a pyrolysis initiation temperature of at least 250° C.  
     
     
         121 . The composition of  claim 119 , wherein the polyvinylbenzyl ether compound has the following formula (1):  
       
         
           
           
               
               
           
         
       
       wherein R 1  denotes methyl or ethyl, R 2  denotes hydrogen or a hydrocarbon group of 1 to 10 carbon atoms, R 3  denotes hydrogen or a vinylbenzyl group in a molar ratio of hydrogen to vinylbenzyl from 60:40 to 0:100, and n is a number of 2 to 4.  
     
     
         122 . The composition of  claim 119 , wherein the dielectric powder has been surface treated with 0.1 to 6% by weight of the coupling agent, based on the weight of the dielectric powder.  
     
     
         123 . The composition of  claim 119 , further comprising a flame retardant.  
     
     
         124 . A composite dielectric material, obtained by curing the composition of  claim 119 , and wherein the dielectric powder is dispersed in the resin resulting from the polyvinylbenzyl ether compound.  
     
     
         125 . A composite dielectric material, obtained by curing the composition of  claim 123 , and wherein the dielectric powder is dispersed in the resin resulting from the polyvinylbenzyl ether compound, and the composite dielectric material is flame retarded.