Polyurethane composite antioxidant: the "behind the scenes" that improves the reliability of electronic components

In today's era of rapid technological development, electronic components have become an indispensable part of our lives. From smartphones to smart homes, from driverless cars to medical devices, these high-tech products are inseparable from the support of precision electronic components. However, have you ever wondered why these components can operate stably for a long time in extreme environments? One of the answers is polyurethane composite antioxidants.

What is polyurethane composite antioxidant?

Definition and Function

Polyurethane composite antioxidant is a special chemical additive that delays the aging process of materials by inhibiting oxidation reactions. Just as the body needs antioxidants (such as vitamins C and E) to resist the damage caused by free radicals to cells, electronic components also need this "chemical shield" to protect their internal structure from the external environment.

parameter name	Description
Chemical Components	Mainly consist of phenols, amines and sulfide compounds
Appearance shape	White or light yellow powder/granules
Melting point range	100°C – 150°C
Solution	Insoluble in water, easy to soluble in organic solvents

Working Principle

When the electronic components are exposed to harsh conditions such as high temperature, high humidity or ultraviolet rays, the internal polymer materials are prone to oxidation and degradation, resulting in reduced performance or even failure. Polyurethane composite antioxidants can effectively capture these harmful free radicals, prevent chain reactions, and thus extend the service life of the component.

How to improve the reliability of electronic components

Enhanced anti-aging ability

Improved thermal stability

In many application scenarios, electronic components often need to withstand higher operating temperatures. For example, in the power system of an electric vehicle, the battery management unit may be in an environment above 80°C for a long time. At this time, if effective antioxidant measures are lacking, the plastic shell or insulation layer in the component may crack or deform.

The thermal stability of these materials can be significantly improved by adding an appropriate amount of polyurethane composite antioxidant. According to standard test results from the American Society of Materials Testing (ASTM), the treated samples remain original even after continuous heating for 200 hours.More than 90% of the mechanical strength.

Improving light stability

In addition to heat, ultraviolet radiation is also one of the important factors that cause the aging of electronic components. This situation is particularly obvious, especially on communication base stations or solar panel controllers used outdoors.

To this end, scientists have developed a new antioxidant formula with light shielding. Not only can they absorb ultraviolet energy and convert it into harmless heat energy to release it, they can also repair molecular damage caused by light, forming a dual protection mechanism.

Test conditions	No antioxidant	Add common antioxidants	Use composite antioxidants
UV irradiation time (h)	500	1000	2000
Color change level	Level 4	Level 3	Level 1
Mechanical performance retention rate (%)	60%	75%	95%

Electrical Performance Optimization

Insulation performance maintenance

For high-voltage switch cabinets, transformers and other power equipment, good insulation performance is the basis for ensuring safe operation. However, over time, conventional insulating materials may cause changes in dielectric constant due to oxidation, which in turn affects overall efficiency.

Study shows that this negative effect can be greatly inhibited after the introduction of a specific proportion of composite antioxidants into the polyurethane matrix. Specifically, after accelerating aging experiment, the improved material has a breakdown voltage of about 98% of the initial value after 1,000 charge and discharge cycles.

Conductive stability guarantee

On the other hand, the stability of conductive materials is equally important for some microelectronic devices that require precise control of the current transmission path. For example, in the manufacturing process of integrated circuits, copper interconnects, as a key component, are extremely susceptible to oxygen diffusing from surrounding medium, forming copper oxide films and increasing resistance value.

In response to this problem, the researchers proposed an innovative solution: using nano-size dispersion technology to evenly distribute composite antioxidants on the metal surface to build a dense protective barrier. This will not affect the original conductive characteristics, but will also effectively delay the corrosion process.

Material Type	Original State	Single Protection	Composite Protection
Copper Wire	2.5Ω/cm	2.7Ω/cm	2.6Ω/cm
Aluminum Foil	3.0Ω/cm	3.3Ω/cm	3.1Ω/cm

Structural Integrity Guarantee

Stress cracking resistance

As electronic products develop towards miniaturization, more and more components are designed into complex geometric shapes. Although this improves space utilization, it also brings new challenges - local stress concentration areas are more likely to cause cracks to appear and expand.

Luckily, polyurethane composite antioxidants also show unique advantages in this regard. It can reduce the glass transition temperature by adjusting the movement of the molecular chain segments, so that the material has better flexibility and ductility. In this way, even under repeated bending or vibration conditions, fracture accidents can be effectively prevented.

Dimensional accuracy maintain

In addition, for optical sensors or MEMS devices that require extremely high dimensions, any minor changes may lead to functional failure. Therefore, it is particularly important to use packaging glues containing highly effective antioxidant components.

Experimentally, the thickness deviation of the chips packaged with this type of product can still be controlled within ±0.01mm after up to 500 cycles of hot and cold shock (-40°C to +125°C), fully meeting the requirements of industry specifications.

Analysis of the current status of domestic and foreign research

Domestic progress

In recent years, my country has made great progress in the field of polyurethane composite antioxidants. Taking the Department of Chemical Engineering of Tsinghua University as an example, they successfully developed a high-performance product based on bisphenol A-type epoxy resin modification and applied for a number of national patents. This achievement has been widely used in many high-end manufacturing fields such as aerospace and rail transit, and has received unanimous praise from users.

At the same time, in order to further promote the development of the industry, the Ministry of Industry and Information Technology also issued the "Guiding Opinions on Promoting the High-Quality Development of the New Materials Industry", which clearly proposed to increase investment in R&D of functional additives and strive to achieve independent and controllable key technologies within the next five years.

International News

Looking at the world, developed countries in Europe and the United States still occupy the commanding heights of technology. With its strong R&D strength, BASF Germany was the first to launch the fourth generation ultra-low volatile antioxidant series, which completely solved the problem of the industry for many years.migration pollution problem. Japan's Mitsubishi Chemical focuses on the direction of green and environmental protection, launching a series of biodegradable products, making positive contributions to sustainable development.

It is worth noting that due to the differences in the standard systems of different countries, enterprises often face many obstacles when conducting international trade. In this regard, the ISO organization is taking the lead in formulating unified testing methods and evaluation indicators, which are expected to be officially released next year.

Applied case sharing

New Energy Vehicle Battery Pack Protection

A well-known new energy vehicle brand uses battery housing materials containing polyurethane composite antioxidants in its new model. The results show that compared with the previous version, the new design's weather resistance has been nearly doubled, greatly reducing after-sales maintenance costs.

Medical Device Micro Motor Package

A medical device manufacturer upgraded the micro-syringe pumps it produced by introducing the technology. The upgraded equipment not only operates normally within a wider operating range, but also extends its service life by about 30%, greatly improving patient satisfaction.

Looking forward

With the continuous emergence of emerging technologies such as 5G communication and artificial intelligence, the requirements for the reliability of electronic components will only become higher and higher. As a key link, polyurethane composite antioxidants will surely usher in a broader development prospect.

We can foresee that in the near future, more intelligent and customized solutions may emerge, allowing every small electronic component to realize its great potential and jointly build a smarter and better world. As the old saying goes, "Details determine success or failure", let us look forward to this technological revolution initiated by the micro field!

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