Polyphenylene Sheets with Polysalicylate for Thermal Aging Resistance

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Poly(phenylene ether) based sheets exhibit unsatisfactory long-term thermal aging resistance, which is a limitation in applications requiring prolonged heat exposure such as photovoltaic modules and solar hot water systems.

Innovation Solution

The development of sheets comprising 60 to 80 weight percent polyphenylene, 0 to 10 weight percent polystyrene, 10 to 20 weight percent hydrogenated block copolymer, 3 to 10 weight percent polysalicylate, and 3 to 20 weight percent phosphorous containing flame retardant additive, with a hydrogenated block copolymer having a weight average molecular weight of 100,000 to 150,000, enhancing thermal aging resistance and maintaining hydrothermal resistance, electrical insulation, and dimensional stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If poly(phenylene ether) based sheets are used in photovoltaic modules and solar hot water systems, then electrical insulation and mechanical properties are maintained, but long-term thermal aging resistance deteriorates under prolonged heat exposure

Engineering Contradiction:

Improvelong-term thermal aging resistanceVSAvoidthermal aging degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses polysalicylate (3-10 wt%) and phosphorous containing flame retardant (3-20 wt%) as intermediary substances that mediate between the poly(phenylene ether) matrix and thermal aging conditions. These intermediaries protect the base polymer from thermal degradation by acting as stabilizers and flame retardants, thereby improving long-term thermal aging resistance while the polymer maintains its electrical insulation and mechanical properties under prolonged heat exposure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If hydrogenated block copolymer with weight average molecular weight of 100,000 to 150,000 is used in the composition, then long-term thermal aging resistance is improved, but processing parameters and manufacturing complexity increase

Engineering Contradiction:

Improvelong-term thermal aging resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by specifying a narrow molecular weight range (100,000 to 150,000) for the hydrogenated block copolymer component. This parameter optimization improves long-term thermal aging resistance while keeping processing manageable. The controlled molecular weight ensures adequate processing flow characteristics while providing sufficient thermal stability enhancement, balancing performance improvement with manufacturing feasibility

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3562887B1Sheets including polyphenylene and an aryl salicylate and methods of making thereof

Publication Date: 2023.03.29 SABIC GLOBAL TECHNOLOGIES BV

Figure 1

AI summary

A sheet includes: a composition comprising about (60) to about (85) weight percent of polyphenylene, about (0) to about (10) weight percent of polystyrene, about (10) to about (20) weight percent of a hydrogenated block copolymer of an alkenyl aromatic compound and a conjugated diene, about (3) to about (10) weight percent of an aryl salicylate, and optionally, a flame retardant additive.