Liquid Crystal Polymer Insulation for High-Voltage Connectors
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Solution Overview
Problem
Conventional polymeric materials lack simultaneous excellence in heat resistance, flowability, moldability, and insulation properties, making them unsuitable for high-voltage electrical and electronic components, particularly in connectors like USB 3.1, where current leakage or part failure can occur due to low comparative tracking index ratings.
Innovation Solution
A composition for liquid crystal polymer synthesis incorporating alicyclic dicarboxylic acid or its derivative, aromatic diol, aromatic monocarboxylic acid with 7-10 carbon atoms, and aromatic monocarboxylic acid with 11-20 carbon atoms, with specific molar ratios and contents, to produce a liquid crystal polymer with enhanced insulation and heat resistance, suitable for high-voltage applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymeric materials are used, then manufacturing cost is low, but insulation properties and heat resistance are insufficient for high-voltage applications
Solution Approach 1:
The patent uses a composite monomer system comprising four specific components: alicyclic dicarboxylic acid (or derivative), aromatic diol, aromatic monocarboxylic acid with 7-10 carbon atoms, and aromatic monocarboxylic acid with 11-20 carbon atoms. This composite approach combines different molecular structures to achieve synergistic effects, providing both excellent insulation properties (CTI class 0-2) and heat resistance while maintaining manufacturability through defined molar ratio ranges
Solution Approach 2:
The patent specifies precise parameter ranges for the monomer composition to optimize performance: alicyclic dicarboxylic acid at 5-40 mol%, aromatic diol at 10-40 mol%, aromatic monocarboxylic acid (7-10C) at 10-60 mol%, and aromatic monocarboxylic acid (11-20C) at 5-30 mol%. These parameter changes enable tuning of the polymer's insulation and thermal properties while ensuring processability
2Temperature
If wholly aromatic liquid crystal polymer is used, then heat resistance is improved, but insulation properties deteriorate with low CTI rating
Solution Approach 1:
The patent introduces alicyclic dicarboxylic acid components (5-40 mol%) with specific local molecular structures that provide superior insulation properties compared to conventional aromatic structures. This local quality modification in specific regions of the polymer chain achieves CTI class 0-2 ratings while maintaining the heat resistance provided by the aromatic diol and aromatic monocarboxylic acid components
3Reliability
If liquid crystal polymer with excellent insulation properties is developed, then reliability for high-voltage parts is improved, but manufacturing complexity increases
Solution Approach 1:
The patent defines specific parameter ranges for each monomer component to achieve the desired insulation properties without excessive complexity. The molar ratios are constrained to practical ranges: alicyclic dicarboxylic acid (5-40 mol%), aromatic diol (10-40 mol%), aromatic monocarboxylic acid 7-10C (10-60 mol%), and aromatic monocarboxylic acid 11-20C (5-30 mol%). These parameter specifications enable reliable insulation performance while maintaining manufacturability through standard polymerization processes
Data Source
AI summary
The present invention is a composition for liquid crystal polymer synthesis comprising an alicyclic dicarboxylic acid or its derivative (e.g., 1,4-cyclohexanedicarboxylic acid (CHDA)); an aromatic diol (e.g., hydroquinone (HQ)); an aromatic monocarboxylic acid having 7 to 10 carbon atoms and containing a hydroxyl group (e.g., 4-hydroxybenzoic acid, (HBA)); and an aromatic monocarboxylic acid having 11 to 20 carbon atoms and containing a hydroxyl group (e.g., 6-hydroxy-2-naphthalenecarboxylic acid (HNA)), and a liquid crystal polymer for electrical/electronic products, a polymer resin composition, and a molded product using the same.