Adhesive-filler film composite

• US 5,879,794 A
• Filed: 11/08/1996
• Issued: 03/09/1999
• Est. Priority Date: 08/25/1994
• Status: Expired due to Term

• Current Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Original Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Inventors: Korleski, Joseph E. Jr.
• Primary Examiner(s): Chen, Vivian
• Application Number:
  US08/745,396
• Time in Patent Office: 851 Days
• Field of Search: 428/355 EN, 428/355 BL, 428/304.4, 428/306.6, 428/308.4, 428/311.1, 428/314.2, 428/315.5, 428/316.6, 428/317.1, 428/317.7, 428/317.9 , 428/318.4, 428/323, 428/328, 428/329, 428/330, 428/331, 428/413, 428/421, 428/422, 428/319.1, 428/319.3, 428/319.7, 428/319.9, 428/457, 428/461, 428/463 , 428/522, 428/523, 428/901, 442/324, 442/325, 442/322, 442/164, 442/170, 442/171, 442/173, 442/285, 442/172, 442/175, 442/178, 442/179, 442/180, 442/417
• US Class Current: 428/317.1
• CPC Class Codes: B32B 5/28 impregnated with or embedded in a plastic substance not used
• CPC Class Codes: C08L 27/18 Homopolymers or copolymers or tetrafluoroethene
• CPC Class Codes: C09J 2400/263 in the substrate
• CPC Class Codes: C09J 7/21 Paper; Textile fabrics
• CPC Class Codes: H05K 1/0353 consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
• CPC Class Codes: H05K 1/0366 reinforced, e.g. by fibres, fabrics H05K1/036 takes precedence
• CPC Class Codes: H05K 2201/0116 Porous, e.g. foam
• CPC Class Codes: H05K 2201/015 Fluoropolymer, e.g. polytetrafluoroethylene [PTFE]
• CPC Class Codes: H05K 2201/0158 Polyalkene or polyolefin, e.g. polyethylene [PE], polypropylene [PP]
• CPC Class Codes: H05K 2201/0209 Inorganic, non-metallic particles
• CPC Class Codes: H05K 2201/0278 Polymeric fibers
• CPC Class Codes: H05K 2201/0293 Non-woven fibrous reinforcement
• CPC Class Codes: Y10S 428/901 Printed circuit
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249978 Voids specified as micro
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249985 Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/249986 Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/24999 Inorganic
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic
• CPC Class Codes: Y10T 428/249993 : Hydrocarbon polymer
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/256 : Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/257 : Iron oxide or aluminum oxide
• CPC Class Codes: Y10T 428/259 : Silicic material
• CPC Class Codes: Y10T 428/2878 : including addition polymer from unsaturated monomer
• CPC Class Codes: Y10T 428/2883 : including addition polymer of diene monomer [e.g., SBR, SIS, etc.]
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/3154 : Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31544 : Addition polymer is perhalogenated
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31699 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon
• CPC Class Codes: Y10T 442/2861 : Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/291 : Coated or impregnated polyolefin fiber fabric
• CPC Class Codes: Y10T 442/2918 : Polypropylene fiber fabric
• CPC Class Codes: Y10T 442/2926 : Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/2934 : Coating or impregnation contains vinyl polymer or copolymer
• CPC Class Codes: Y10T 442/2951 : Coating or impregnation contains epoxy polymer or copolymer or polyether
• CPC Class Codes: Y10T 442/2975 : Coated or impregnated ceramic fiber fabric
• CPC Class Codes: Y10T 442/2984 : Coated or impregnated carbon or carbonaceous fiber fabric
• CPC Class Codes: Y10T 442/2992 : Coated or impregnated glass fiber fabric
• CPC Class Codes: Y10T 442/56 : From synthetic organic fiber
• CPC Class Codes: Y10T 442/57 : Including particulate material other than fiber
• CPC Class Codes: Y10T 442/699 : Including particulate material other than strand or fiber material

Abstract

A method of preparing an adhesive composite is provided where a fluoropolymer having nodes and interconnected fibrils with a void volume formed from the node and interconnected fibril structure is at least partially filled with a paste formed from a thermoset or thermoplastic adhesive and a particulate vapor phase formed inorganic filler having uniform surface curvature, sufficient adhesive and filler are present to provide a composite having between about 5 to about 40 volume percent polymeric substrate, 10-95 volume percent adhesive and filler imbibed within the voids of said substrate and 5 to 85 volume percent inorganic filler is contained within the composite. In the composite, the ratio of mean flow pore size to largest particle size is at least above 0.7; or the ratio of mean flow pore size to average particle size is greater than 1.5; or the ratio of minimum pore size to average particle size is at least above 0.8; or the ratio of minimum pore size to largest particle size is at least above 0.4.

Claims

1. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 1.0 to about 1000;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

18. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is comprised of a fluoropolymer material.

19. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is comprised of polytetrafluoroethylene.

20. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is comprised of expanded polytetrafluoroethylene.

21. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is comprised of a porous olefin.

22. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is comprised of polyethylene or polypropylene.

23. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein said filler is formed from the vapor combustion of molten silicon, titanium or aluminum.

24. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein said adhesive resin is a thermosetting or thermoplastic compound.

25. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein said adhesive resin is at least one of epoxy resin, cyanate ester resin or polybutadiene resin.

26. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is formed from an inorganic or organic batting.

27. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is formed from short inorganic or organic fibers.

28. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is formed from an inorganic or organic felt.

29. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is formed from an organic, open cellular material.

30. The composite adhesive material of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, or 17, wherein the non-woven substrate is bonded to at least one metal material layer to form a multilayer circuit assembly.

2. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 1.0 to about 500;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

3. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 1.0 to about 100;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

4. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 10 to about 32;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

5. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from at least above 0.7 to about 32;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

6. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 1000;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

7. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 500;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

8. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 100;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

9. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 38;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

10. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 1000;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

11. A composite adhesive material comprising:

a non-woven substrate having an Initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 500;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

12. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 100;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

13. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 28;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

14. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from at least above 0.4 to about 1000;

wherein said mixture Is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

15. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from at least above 0.4 to about 500;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

16. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from at least above 0.4 to about 100;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

17. A composite adhesive material comprising:

a non-woven substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from at least above 0.4 to about 18;

wherein said mixture is substantially evenly distributed throughout said initial void volume of said non-woven substrate.

31. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a mean flow pore size and having an initial void volume of at least about 30 percent;

said initial void volume containing a mixture of adhesive and particulate filler evenly distributed throughout, said mixture being present in said film layer such that the volume of said film layer is about 5 to about 40 volume percent of said composite adhesive material;

said particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particulate size is greater than 1.0.

36. The composite adhesive material according to claims 31, 32, 33, 34, or 35, wherein said porous polymer film layer is a fluoropolymer material.

37. The composite adhesive material according to claims 31, 32, 33, 34, or 35, wherein said porous polymer film layer is comprised at least in part of polytetrafluoroethylene.

38. The composite adhesive material according to claims 31, 32, 33, 34, or 35, wherein said porous polymer film layer is comprised at least in part of expanded polytetrafluoroethylene.

39. The composite adhesive material according to claims 31, 32, 33, 34, or 35, wherein said porous polymer film layer is comprised at least in part of a porous olefin.

40. The composite adhesive material according to claims 31, 32, 33, 34, or 35, wherein said porous polymer film layer is comprised at least in part of polyethylene or polypropylene.

41. The composite adhesive material according to claims 31, 32, 33, 34, or 35, wherein said filler is formed from the vapor combustion of molten aluminum, silicon or titanium.

42. The composite adhesive material of claims 31, 32, 33, 34, or 35 wherein the porous polymer film layer Is bonded to at least one metal material layer to form a multilayer circuit assembly.

32. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a mean flow pore size and having an initial void volume of at least about 30 percent;

said initial void volume containing a mixture of adhesive and particulate filler evenly distributed throughout, said mixture being present in said film layer such that the volume of said film layer is about 5 to about 40 volume percent of said composite adhesive material;

said particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particulate size is greater than 0.7.

33. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a mean flow pore size and having an initial void volume of at least about 30 percent;

said initial void volume containing a mixture of adhesive and particulate filler evenly distributed throughout, said mixture being present in said film layer such that the volume of said film layer is about 5 to about 40 volume percent of said composite adhesive material;

said particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is greater than 1.5.

34. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a minimum pore size and having an initial void volume of at least about 30 percent;

said initial void volume containing a mixture of adhesive and particulate filler evenly distributed throughout, said mixture being present in said film layer such that the volume of said film layer is about 5 to about 40 volume percent of said composite adhesive material;

said particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is at least above 0.8.

35. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a minimum pore size and having an initial void volume of at least about 30 percent;

said initial void volume containing a mixture of adhesive and particulate filler evenly distributed throughout, said mixture being present in said film layer such that the volume of said film layer is about 5 to about 40 volume percent of said composite adhesive material;

said particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particulate size is at least above 0.4.

43. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 1.0 to about 1000;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

65. The composite adhesive material of claims 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, or 64, wherein said filler is formed from the vapor combustion of molten aluminum, silicon or titanium.

66. The composite adhesive material of claims 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, or 59, wherein the porous fluoropolymer substrate is bonded to at least one metal material layer to form a multilayer circuit assembly.

44. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 1.0 to about 500;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

45. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 1.0 to about 100;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

46. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from about 1.0 to about 32;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

47. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is in a range from at least above 0.7 to about 32;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

48. A composite adhesive material comprising:

a porous fluoro polymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 1000;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

49. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 500;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

50. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 100;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

51. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is in a range from greater than 1.5 to about 38;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

52. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 1000;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

53. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 500;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

54. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 100;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

55. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is in a range from at least above 0.8 to about 28;

wherein said mixture is distributed throughout said initial void volume of said porous fluoropolymer substrate.

56. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from greater than 0.4 to about 1000;

wherein said mixture is distributed throughout said initial void volume of said a porous fluoropolymer substrate.

57. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from greater than 0.4 to about 500;

wherein said mixture is distributed throughout said initial void volume of said a porous fluoropolymer substrate.

58. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from greater than 0.4 to about 100;

wherein said mixture is distributed throughout said initial void volume of said a porous fluoropolymer substrate.

59. A composite adhesive material comprising:

a porous fluoropolymer substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is in a range from greater than 0.4 to about 18;

wherein said mixture is distributed throughout said initial void volume of said a porous fluoropolymer substrate.

60. A composite adhesive material comprising:

an expanded polytetrafluoroethylene substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is at least 1.0;

wherein said mixture is distributed throughout said initial void volume of said expanded polytetrafluoroethylene substrate.

67. The composite adhesive material of claims 60, 61, 62, 63, or 64, wherein the expanded polytetrafluoroethylene substrate is bonded to at least one metal material layer to form a multilayer circuit assembly.

61. A composite adhesive material comprising:

an expanded polytetrafluoroethylene substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is above at least above 0.7;

wherein said mixture is distributed throughout said initial void volume of said expanded polytetrafluoroethylene substrate.

62. A composite adhesive material comprising:

an expanded polytetrafluoroethylene substrate having an initial void volume and a mean flow pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is greater than 1.5;

wherein said mixture is distributed throughout said initial void volume of said expanded polytetrafluoroethylene substrate.

63. A composite adhesive material comprising:

an expanded polytetrafluoroethylene substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is at least above 0.8;

wherein said mixture is distributed throughout said initial void volume of said expanded polytetrafluoroethylene substrate.

64. A composite adhesive material comprising:

an expanded polytetrafluoroethylene substrate having an initial void volume and a minimum pore size; and

a mixture containing particulate filler and an adhesive resin, the particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is at least above 0.4;

wherein said mixture is distributed throughout said initial void volume of said expanded polytetrafluoroethylene substrate.

68. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a mean flow pore size and having an initial void volume;

said initial void volume containing a mixture of an adhesive and a particulate filler evenly distributed throughout;

said particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is greater than 1.0.

73. The composite adhesive material according to claims 68, 69, 70, 71, or 72, wherein said porous polymer film layer is a fluoropolymer material.

74. The composite adhesive material according to claims 68, 69, 70, 71, or 72, wherein said porous polymer film layer is comprised at least in part of polytetrafluoroethylene.

75. The composite adhesive material according to claims 68, 69, 70, 71, or 72, wherein said porous polymer film layer is comprised at least in part of expanded polytetrafluoroethylene.

76. The composite adhesive material according to claims 68, 69, 70, 71, or 72, wherein said porous polymer film layer is comprised at least in part of a porous olefin.

77. The composite adhesive material according to claims 68, 69, 70, 71, or 72, wherein said porous polymer film layer is comprised at least in part of polyethylene or polypropylene.

78. The composite adhesive material according to claims 68, 69, 70, 71, or 72, wherein said filler is formed from the vapor combustion of molten aluminum, silicon or titanium.

79. The composite adhesive material of claims 68, 69, 70, 71, or 72, wherein the porous polymer film layer is bonded to at least one metal material layer to form a multilayer circuit assembly.

69. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a mean flow pore size and having an initial void volume;

said initial void volume containing a mixture of an adhesive and a particulate filler evenly distributed throughout;

said particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is greater than 0.7.

70. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a mean flow pore size and having an initial void volume;

said initial void volume containing a mixture of an adhesive and a particulate filler evenly distributed throughout;

said particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said mean flow pore size to the average particle size is greater than 1.5.

71. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a minimum pore size and having an initial void volume;

said initial void volume containing a mixture of an adhesive and a particulate filler evenly distributed throughout;

said particulate filler being a collection of individual particles having an average particle size, wherein a ratio of said minimum pore size to the average particle size is at least above 0.8.

72. A composite adhesive material comprising:

at least one porous polymer film layer having nodes, fibrils, and pores, said film layer having a minimum pore size and having an initial void volume;

said initial void volume containing a mixture of an adhesive and a particulate filler evenly distributed throughout;

said particulate filler being a collection of individual particles, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said minimum pore size to the largest particle size is at least above 0.4.

80. A multilayer circuit device comprising:

at least two metal layers; and

a dielectric material having a porous polymer substrate layer having a microstructure defined by nodes and fibrils;

the porous polymer substrate layer having a mean flow pore size, a minimum pore size and an initial void volume;

wherein a mixture containing particulate filler and an adhesive is evenly distributed throughout said initial void volume, the particulate filler being a collection of individual particles having an average particle size, said collection containing a particle having a largest particle size which is the largest detectable particle in the collection, wherein a ratio of said mean flow pore size to the largest particle size is at least above 1.0, or a ratio of said mean flow pore size to the average particle size is at least above 1.5, or a ratio of minimum pore size to the average particle size or the largest particle size is respectively at least above 0.8 and 0.4.