Polyolefin Resin Composition for High-Temperature Laminates
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Solution Overview
Problem
Conventional resin materials face challenges in achieving high resin filling uniformity, low dissipation factor variation under heat, high glass transition temperature, low Z-axis ratio of thermal expansion, high peeling strength, and high thermal resistance after moisture absorption, which are essential for high-performance laminates in high-temperature environments.
Innovation Solution
A resin composition comprising 100 parts by weight of polyolefin and 10 to 50 parts by weight of a compound of Formula (1) with a pH value of 10 or less, where n is an integer of 3 to 6, and each Y and Z are independently selected from o-vinylphenoxy and phenoxy groups, undergoing a prepolymerization reaction to form a prepolymer with a conversion rate of 10% to 99%, and optionally including additional compounds and unsaturated C═C double bond-containing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional resin materials are used, then the laminate can be manufactured with standard materials, but the dissipation factor variation under heat is high and glass transition temperature is insufficient
Solution Approach 1:
The patent uses a composite resin system combining polyolefin (component A) with a specific compound of Formula (1) having pH≤10, creating a multi-component composition that achieves both high glass transition temperature (≥225°C) and low dissipation factor variation (≤30%) under heat. This composite approach allows synergistic effects between components to simultaneously satisfy multiple performance requirements.
Solution Approach 2:
The patent specifies precise parameter ranges: pH value of 10 or less for the compound, n=3 to 6 in the formula structure, and specific weight ratios (10-50 parts by weight of compound B per 100 parts of polyolefin). These parameter controls ensure the resin achieves the required glass transition temperature while maintaining low dissipation factor variation under thermal conditions.
2Manufacturing precision
If high resin filling uniformity is achieved, then laminate quality is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent controls resin viscosity and flow characteristics by specifying the pH value (≤10) and molecular structure (n=3 to 6) of the compound, which inherently promotes uniform resin filling during manufacturing. The controlled parameters ensure proper wetting and impregnation of reinforcement materials without requiring overly complex processing equipment or procedures.
3Stability of the object's composition
If low Z-axis ratio of thermal expansion is achieved, then dimensional stability is improved, but material formulation complexity increases
Solution Approach 1:
The patent employs a composite resin formulation combining polyolefin with the specific low-pH compound of Formula (1), where the compound's molecular structure (with o-vinylphenoxy and phenoxy groups) and pH characteristics contribute to reduced Z-axis thermal expansion. This composite system achieves dimensional stability through the synergistic interaction between components rather than requiring complex multi-phase formulations.
4Strength
If high peeling strength is achieved, then laminate bonding is improved, but resin composition complexity increases
Solution Approach 1:
The patent uses a two-component composite resin system where polyolefin provides baseline adhesion and the compound of Formula (1) with pH≤10 enhances bonding through its specific molecular structure containing o-vinylphenoxy and phenoxy groups. This composite formulation achieves high peeling strength through the synergistic effect of the two components rather than requiring complex multi-component or multi-stage resin systems.
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 resin composition achieves improved resin filling uniformity, reduced dissipation factor variation under heat, elevated glass transition temperature, controlled thermal expansion, enhanced peeling strength, and maintained thermal resistance after moisture absorption, meeting the requirements for high-performance laminates.
Implementation Method 1
the prepolymer is prepared by subjecting a mixture to a prepolymerization reaction, and the mixture at least comprises the component (A) and the component (B)
Data Source
AI summary
A resin composition includes the following components or a prepolymer thereof: (A) 100 parts by weight of a polyolefin; and (B) 10 parts by weight to 50 parts by weight of a compound of Formula (1) having a pH value of 10 or less. In Formula (1), n is an integer of 3 to 6, each Y and Z are independently selected from o-vinylphenoxy group and phenoxy group, and each Y and Z are not phenoxy group at the same time. The prepolymer is prepared by subjecting a mixture to a prepolymerization reaction, and the mixture at least comprises the component (A) and the component (B). An article is made from the resin composition. The article includes a prepreg, a resin film, a laminate or a printed circuit board and achieves improvements in one or more properties including resin filling uniformity, dissipation factor variation rate under heat, glass transition temperature, Z-axis ratio of thermal expansion, peeling strength and thermal resistance after moisture absorption.