Composite Polymer Structure for High-Temperature Resin Adhesion
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Solution Overview
Problem
The existing polymer materials used in the outer cases of film capacitors exhibit poor adhesion to sealing resins, particularly at high temperatures, which affects the performance of electric powertrains in vehicles.
Innovation Solution
A composite structure is developed comprising a polymer composition with polyarylene sulfide and a bifunctional polymer containing epoxide and (meth)acrylate functional groups, combined with a thermoset resin, enhancing adhesion strength and providing improved mechanical, thermal, and insulative properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional polymer materials are used in the outer case of film capacitors, then the case provides basic protection and structural support, but the adhesion to sealing resin deteriorates at high temperatures
Solution Approach 1:
The patent employs a composite polymer material consisting of polyarylene sulfide as the base polymer combined with a bifunctional polymer containing both epoxide and carboxyl functional groups. This composite structure enables the outer case to simultaneously achieve high-temperature resistance from the polyarylene sulfide and strong adhesion to sealing resin from the reactive functional groups, directly resolving the contradiction between thermal stability and adhesion strength
2Strength
If the polymer composition is optimized for adhesion, then bonding strength improves, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes specific parameter ranges for the bifunctional polymer content (5-50 parts by weight per 100 parts polyarylene sulfide) and molecular weight to achieve the desired balance between adhesion strength and processability. By controlling these parameters within defined ranges, the material delivers superior bonding performance while maintaining manageable manufacturing complexity through standardized formulation specifications
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite structure achieves high adhesion strength, excellent insulative properties, flame retardancy, and good flowability, ensuring reliable performance in electric vehicles by maintaining mechanical integrity and thermal stability.
Implementation Method 1
The polymer composition includes a polyarylene sulfide and a bifunctional polymer that contains an epoxide functional group and a (meth)acrylate functional group. The resinous material includes a thermoset resin.
Data Source
AI summary
A composite structure comprising a first layer positioned adjacent to a second layer is provided. The first layer contains a polymer composition and the second layer contains a resinous material. The polymer composition includes a polyarylene sulfide and a bifunctional polymer that contains an epoxide functional group and a (meth)acrylate functional group. The resinous material includes a thermoset resin.