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Article(id=1190369066515796132, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1190365079976640655, articleNumber=null, orderNo=null, doi=10.16790/j.cnki.1009-9239.im.2025.07.010, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1722700800000, receivedDateStr=2024-08-04, revisedDate=1728835200000, revisedDateStr=2024-10-14, acceptedDate=null, acceptedDateStr=null, onlineDate=1761735701445, onlineDateStr=2025-10-29, pubDate=1752940800000, pubDateStr=2025-07-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1761735701445, onlineIssueDateStr=2025-10-29, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1761735701445, creator=13701087609, updateTime=1761735701445, updator=13701087609, issue=Issue{id=1190365079976640655, tenantId=1146029695717560320, journalId=1149653034449285133, year='2025', volume='58', issue='7', pageStart='1', pageEnd='150', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=1, specialIssue=null, createTime=1761734750980, creator=13701087609, updateTime=1761735924323, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1190370001430348320, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1190365079976640655, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1190370001430348321, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1190365079976640655, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=86, endPage=92, ext={EN=ArticleExt(id=1190369066738094247, articleId=1190369066515796132, tenantId=1146029695717560320, journalId=1149653034449285133, language=EN, title=Preparation and performance analysis of polyurethane potting materials for specialized electronic components, columnId=1190369066675179686, journalTitle=Insulating Materials, columnName=Material Research, runingTitle=null, highlight=

In this paper, different types of polyurethane potting materials were developed successfully by taking propylene epoxide-tetrahydrofuran polyether or polytetrahydrofurane glycol as polymer polyols, toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), and 3,3′-dimethyl-4,4′-biphenyl diisocyanate (TODI) as curing agents, and adding an appropriate amount of silica aerogel. The mechanical property, proccessability, low temperature resisitance, high temperature resistance, resistance to high and low temperature shock, and insulting property of the polyurethane potting materials were analyzed systematically. The results show that the polyurethane potting material formulated with propylene oxide-tetrahydrofuran copolymer and TODI as primary components, supplemented with silica aerogel with the mass fraction of 0.5%, exhibits outstanding processability, mechanical strength, and electrical insulation. It also demonstrates exceptional tolerance to extreme temperature fluctuations. This material achieves a glass transition temperature as low as -69.3°C and maintains a compression cold resistance coefficient of 0.54 at -60°C. Its 5% weight loss temperature reaches 302.3°C. After enduring 20 cycles of thermal shock between -65°C and 125°C, the material retains 93.5% of its tensile strength with a dimensional change rate of merely -0.6%, while preserving excellent insulation properties: volume resistivity of 4.2×1012 Ω·cm and dielectric strength of 25 kV/mm.

, articleAbstract=

In this paper, different types of polyurethane potting materials were developed successfully by taking propylene epoxide-tetrahydrofuran polyether or polytetrahydrofurane glycol as polymer polyols, toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), and 3,3′-dimethyl-4,4′-biphenyl diisocyanate (TODI) as curing agents, and adding an appropriate amount of silica aerogel. The mechanical property, proccessability, low temperature resisitance, high temperature resistance, resistance to high and low temperature shock, and insulting property of the polyurethane potting materials were analyzed systematically. The results show that the polyurethane potting material formulated with propylene oxide-tetrahydrofuran copolymer and TODI as primary components, supplemented with silica aerogel with the mass fraction of 0.5%, exhibits outstanding processability, mechanical strength, and electrical insulation. It also demonstrates exceptional tolerance to extreme temperature fluctuations. This material achieves a glass transition temperature as low as -69.3°C and maintains a compression cold resistance coefficient of 0.54 at -60°C. Its 5% weight loss temperature reaches 302.3°C. After enduring 20 cycles of thermal shock between -65°C and 125°C, the material retains 93.5% of its tensile strength with a dimensional change rate of merely -0.6%, while preserving excellent insulation properties: volume resistivity of 4.2×1012 Ω·cm and dielectric strength of 25 kV/mm.

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本文分别选用环氧丙烷-四氢呋喃共聚醚或聚四氢呋喃醚二醇作为聚合物多元醇，甲苯二异氰酸酯（TDI）、二苯基甲烷二异氰酸酯（MDI）以及3,3′-二甲基-4,4′-联苯二异氰酸酯（TODI）作为固化剂，并添加适量二氧化硅气凝胶，成功研发出不同类型聚氨酯灌封材料。对各类聚氨酯灌封材料的力学、工艺、耐低温、耐高温、耐高低温冲击以及绝缘性能等进行系统性分析。结果表明：以环氧丙烷-四氢呋喃共聚醚与TODI为主要成分，并添加质量分数为0.5%的二氧化硅气凝胶所制备的聚氨酯灌封材料，展现出卓越的工艺性能、力学性能以及绝缘性能，同时对高低温冲击展现出极高的耐受性。该材料的玻璃化转变温度低至-69.3℃，在-60℃下的压缩耐寒系数可达0.54；其5%热失重温度高达302.3℃；经历-65～125℃的循环冲击20次后，材料拉伸强度保持率高达93.5%，尺寸变化率仅为-0.6%，并且仍然保持着良好的绝缘性能，体积电阻率达到4.2×1012 Ω·cm，电气强度为25 kV/mm。

, articleAbstract=

本文分别选用环氧丙烷-四氢呋喃共聚醚或聚四氢呋喃醚二醇作为聚合物多元醇，甲苯二异氰酸酯（TDI）、二苯基甲烷二异氰酸酯（MDI）以及3,3′-二甲基-4,4′-联苯二异氰酸酯（TODI）作为固化剂，并添加适量二氧化硅气凝胶，成功研发出不同类型聚氨酯灌封材料。对各类聚氨酯灌封材料的力学、工艺、耐低温、耐高温、耐高低温冲击以及绝缘性能等进行系统性分析。结果表明：以环氧丙烷-四氢呋喃共聚醚与TODI为主要成分，并添加质量分数为0.5%的二氧化硅气凝胶所制备的聚氨酯灌封材料，展现出卓越的工艺性能、力学性能以及绝缘性能，同时对高低温冲击展现出极高的耐受性。该材料的玻璃化转变温度低至-69.3℃，在-60℃下的压缩耐寒系数可达0.54；其5%热失重温度高达302.3℃；经历-65～125℃的循环冲击20次后，材料拉伸强度保持率高达93.5%，尺寸变化率仅为-0.6%，并且仍然保持着良好的绝缘性能，体积电阻率达到4.2×1012 Ω·cm，电气强度为25 kV/mm。

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张文新（1986-），男（汉族），山西文水人，高级工程师，主要从事功能材料的研发和应用研究。

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张文新（1986-），男（汉族），山西文水人，高级工程师，主要从事功能材料的研发和应用研究。

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张文新（1986-），男（汉族），山西文水人，高级工程师，主要从事功能材料的研发和应用研究。

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Study on preparation and properties of silica aerogel modified thermoplastic polyurethane elastomers[J]. Plastics Science and Technology,2019,47(3):21-25., articleTitle=Study on preparation and properties of silica aerogel modified thermoplastic polyurethane elastomers, refAbstract=null)], funds=[Fund(id=1190979646536692601, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1190369066515796132, awardId=202104010911021, language=CN, fundingSource=山西省技术创新中心项目(202104010911021), fundOrder=null, country=null)], companyList=[AuthorCompany(id=1190979643810394954, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1190369066515796132, xref=null, ext=[AuthorCompanyExt(id=1190979643818783563, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1190369066515796132, companyId=1190979643810394954, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=1. 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试样编号 硬段类型 软段类型 扩链剂类型 NCO含量设定值 气凝胶添加量
PU1-0 TDI PTMG-1000+PTMG-2000 PTMG-650 4.3 —
PU2-0 MDI PTMG-1000+PTMG-2000 PTMG-650 4.0 —
PU3-0 TODI PTMG-1000+PTMG-2000 PTMG-650 4.0 —
PU4-0 TDI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.3 —
PU5-0 MDI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.0 —
PU6-0 TODI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.0 —
PU4-1 TDI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.3 总量的0.5%
PU6-1 TODI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.0 总量的0.5%
), ArticleFig(id=1190979646041764722, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1190369066515796132, language=CN, label=表1, caption=

不同聚氨酯灌封材料的配方组成

, figureFileSmall=null, figureFileBig=null, tableContent=
试样编号 硬段类型 软段类型 扩链剂类型 NCO含量设定值 气凝胶添加量
PU1-0 TDI PTMG-1000+PTMG-2000 PTMG-650 4.3 —
PU2-0 MDI PTMG-1000+PTMG-2000 PTMG-650 4.0 —
PU3-0 TODI PTMG-1000+PTMG-2000 PTMG-650 4.0 —
PU4-0 TDI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.3 —
PU5-0 MDI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.0 —
PU6-0 TODI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.0 —
PU4-1 TDI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.3 总量的0.5%
PU6-1 TODI 环氧丙烷-四氢呋喃共聚醚 PTMG-650 4.0 总量的0.5%
), ArticleFig(id=1190979646100484979, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1190369066515796132, language=EN, label=Table 2, caption=Process properties of different polyurethane potting materials, figureFileSmall=null, figureFileBig=null, tableContent=
试样 初始混合黏度/(mPa·s) 凝胶时间/min
PU1-0 610 40
PU2-0 800 25
PU3-0 1 000 32
PU4-0 550 45
PU5-0 740 28
PU6-0 910 34
PU4-1 630 43
PU6-1 1050 33
), ArticleFig(id=1190979646163399540, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1190369066515796132, language=CN, label=表2, caption=

不同聚氨酯灌封材料的工艺性能

, figureFileSmall=null, figureFileBig=null, tableContent=
试样 初始混合黏度/(mPa·s) 凝胶时间/min
PU1-0 610 40
PU2-0 800 25
PU3-0 1 000 32
PU4-0 550 45
PU5-0 740 28
PU6-0 910 34
PU4-1 630 43
PU6-1 1050 33
), ArticleFig(id=1190979646230508405, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1190369066515796132, language=EN, label=Table 3, caption=Mechanical properties of different polyurethane potting materials, figureFileSmall=null, figureFileBig=null, tableContent=
试样 Shore A硬度 拉伸强度/MPa 断裂伸长率/% 撕裂强度/(kN/m)
PU1-0 60 15.4 608 31.8
PU2-0 61 16.5 620 32.5
PU3-0 61 16.7 615 32.8
PU4-0 58 12.3 650 25.4
PU5-0 58 13.5 660 26.6
PU6-0 59 14.8 656 26.7
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PU4-0 61.4 -2.4
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特种电子元器件聚氨酯灌封材料的制备及性能研究
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张文新 1 , 郝亚暾 2 , 朱宇荣 2
绝缘材料 | 材料研究 2025,58(7): 86-92
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绝缘材料 | 材料研究 2025, 58(7): 86-92
特种电子元器件聚氨酯灌封材料的制备及性能研究
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张文新1, 郝亚暾2, 朱宇荣2
作者信息
  • 1.山西应用科技学院，山西 太原 030000
  • 2.山西省化工研究所（有限公司），山西 晋中 030600

    • 张文新（1986-），男（汉族），山西文水人，高级工程师，主要从事功能材料的研发和应用研究。

Preparation and performance analysis of polyurethane potting materials for specialized electronic components
Wenxin ZHANG1, Yatun HAO2, Yurong ZHU2
Affiliations
  • 1. Shanxi College of Applied Science and Technology, Taiyuan 030000, China
  • 2. Shanxi Institute of Chemical Engineering (Co., Ltd.), Jinzhong 030600, China
出版时间: 2025-07-20 doi: 10.16790/j.cnki.1009-9239.im.2025.07.010
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摘要
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本文分别选用环氧丙烷-四氢呋喃共聚醚或聚四氢呋喃醚二醇作为聚合物多元醇，甲苯二异氰酸酯（TDI）、二苯基甲烷二异氰酸酯（MDI）以及3,3′-二甲基-4,4′-联苯二异氰酸酯（TODI）作为固化剂，并添加适量二氧化硅气凝胶，成功研发出不同类型聚氨酯灌封材料。对各类聚氨酯灌封材料的力学、工艺、耐低温、耐高温、耐高低温冲击以及绝缘性能等进行系统性分析。结果表明：以环氧丙烷-四氢呋喃共聚醚与TODI为主要成分，并添加质量分数为0.5%的二氧化硅气凝胶所制备的聚氨酯灌封材料，展现出卓越的工艺性能、力学性能以及绝缘性能，同时对高低温冲击展现出极高的耐受性。该材料的玻璃化转变温度低至-69.3℃，在-60℃下的压缩耐寒系数可达0.54；其5%热失重温度高达302.3℃；经历-65～125℃的循环冲击20次后，材料拉伸强度保持率高达93.5%，尺寸变化率仅为-0.6%，并且仍然保持着良好的绝缘性能，体积电阻率达到4.2×1012 Ω·cm，电气强度为25 kV/mm。

聚氨酯  /  高低温冲击  /  气凝胶  /  灌封材料

In this paper, different types of polyurethane potting materials were developed successfully by taking propylene epoxide-tetrahydrofuran polyether or polytetrahydrofurane glycol as polymer polyols, toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), and 3,3′-dimethyl-4,4′-biphenyl diisocyanate (TODI) as curing agents, and adding an appropriate amount of silica aerogel. The mechanical property, proccessability, low temperature resisitance, high temperature resistance, resistance to high and low temperature shock, and insulting property of the polyurethane potting materials were analyzed systematically. The results show that the polyurethane potting material formulated with propylene oxide-tetrahydrofuran copolymer and TODI as primary components, supplemented with silica aerogel with the mass fraction of 0.5%, exhibits outstanding processability, mechanical strength, and electrical insulation. It also demonstrates exceptional tolerance to extreme temperature fluctuations. This material achieves a glass transition temperature as low as -69.3°C and maintains a compression cold resistance coefficient of 0.54 at -60°C. Its 5% weight loss temperature reaches 302.3°C. After enduring 20 cycles of thermal shock between -65°C and 125°C, the material retains 93.5% of its tensile strength with a dimensional change rate of merely -0.6%, while preserving excellent insulation properties: volume resistivity of 4.2×1012 Ω·cm and dielectric strength of 25 kV/mm.

polyurethane  /  high and low temperature shock  /  aerogel  /  potting material
张文新, 郝亚暾, 朱宇荣. 特种电子元器件聚氨酯灌封材料的制备及性能研究. 绝缘材料, 2025 , 58 (7) : 86 -92 . DOI: 10.16790/j.cnki.1009-9239.im.2025.07.010
Wenxin ZHANG, Yatun HAO, Yurong ZHU. Preparation and performance analysis of polyurethane potting materials for specialized electronic components[J]. Insulating Materials, 2025 , 58 (7) : 86 -92 . DOI: 10.16790/j.cnki.1009-9239.im.2025.07.010
正文
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0 引言
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随着航空航天、船舶以及电子工业的迅猛发展，灌封材料在这些领域中的应用日益广泛。它不仅为电子元器件提供了防腐、防尘、防潮以及防震的功能，有效提升了电子产品的性能与稳定性，同时也促进了电子元器件向小型化、轻量化、智能化方向的迈进[1]。在极端温度环境下，电子元器件的使用性能已成为衡量产品核心竞争力的关键因素之一。若灌封材料无法适应这些极端条件，无法为电子元器件提供有效保护，其存在的价值也将大打折扣。
温度冲击试验是一种评估产品在极端温度变化环境下性能稳定性的重要方法。该试验通过模拟产品可能遭遇的实际极端温度条件，将产品置于高温与低温环境中进行循环处理，从而评估产品在相应条件下的可靠性与耐久性，为改进产品的设计及制造工艺、提升产品的品质与性能提供了重要依据。
目前，市场上主流的灌封材料包括聚氨酯灌封胶、环氧灌封胶和有机硅灌封胶。有机硅灌封胶虽具有卓越的耐高低温冲击性能，但强度较低、附着力差，其应用范围受到限制。环氧灌封胶在耐高温和电气绝缘性能方面表现优异，操作简便，固化前后性能稳定，且对多种金属及多孔底材具有良好附着力。然而，在遭受高低温冲击后，环氧灌封胶易出现收缩开裂，导致污染物渗入电子元器件。尽管已有研究人员通过改性环氧树脂研制出一系列耐高低温冲击的灌封材料，但其低温极限受限于环氧树脂的分子结构，仅能达到-50℃[2]。聚氨酯灌封胶则因其适中的粘结强度、高弹性、良好的抗冲击性和耐低温性能而受到青睐，尤其是其性能可通过调节聚氨酯的分子结构或复合功能材料得以优化[3-6]。然而，目前对聚氨酯灌封材料的相关研究主要集中在导热性能与透声性能提升方面[7-8]，对其耐高低温冲击性能方面的探究和应用鲜有详细报道。
为解决聚氨酯灌封材料在高低温冲击下的性能局限，本研究选用低结晶性的环氧丙烷-四氢呋喃共聚醚为聚合物多元醇，以优化聚氨酯灌封材料的耐低温特性；选用3,3′-二甲基-4,4′-联苯二异氰酸酯作为固化剂，以期增强其耐高温性能及工艺性能。此外，引入二氧化硅气凝胶，以进一步改进该灌封材料对高低温冲击的耐受性。期待通过这些措施，开发出能够抵御-65℃至125℃循环冲击的灌封胶，进而拓宽灌封材料在极端温度条件下的应用领域。
1 实验
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1.1 主要原材料及仪器设备
环氧丙烷-四氢呋喃共聚醚（数均相对分子量$\bar{M}_{\mathrm{n}}=1600$），工业级，山西省化工研究所（有限公司）；聚四氢呋喃醚二醇PTMG-650（$\bar{M}_{\mathrm{n}}$=650）、PTMG-1000（$\bar{M}_{\mathrm{n}}$=1 000）、PTMG-2000（$\bar{M}_{\mathrm{n}}$=2 000），均为工业级，巴斯夫股份公司；甲苯二异氰酸酯（TDI）、二苯基甲烷二异氰酸酯（MDI），工业级，万华化学集团股份有限公司；3,3′-二甲基-4,4′-联苯二异氰酸酯（TODI），工业级，湖北方德新材料有限公司；二氧化硅气凝胶，工业级，深圳中凝科技有限公司。
XHS-A型邵氏A硬度计，营口市新兴实验机械厂；CMT型电子万能试验机，深圳新三思计量技术有限公司；NDJ-8S型旋转黏度计，上海精密仪器仪表有限公司；DSC 1型差示扫描量热仪、TGA 2型热重分析仪，梅特勒托利多科技（中国）有限公司；RL-I-42C型三箱式冷热冲击试验箱，东莞市瑞力检测设备有限公司；BEST-121型体积表面电阻率测试仪，上海众路实业有限公司；JZC-50 kV型电压击穿试验仪，北京中航时代仪器设备有限公司。
1.2 试验制备
将聚合物多元醇在100～110℃下真空脱水2 h，冷却至50℃备用。将一定量的异氰酸酯置于装有搅拌器和温度计的玻璃反应容器中，升温至50℃，然后将上述备用的聚合物多元醇按计算比例分3次加入到该玻璃反应容器中，每次间隔0.5 h，然后升温至80℃，反应2～3 h。当体系的异氰酸酯基（NCO）含量达到设定值时停止反应，得到聚氨酯灌封材料的A组分。
将PTMG-650在100～110℃下真空脱水2 h，然后加入一定比例的气凝胶、消泡剂，高速分散1 h，得到聚氨酯灌封材料的B组分。
将A、B组分同时升温至80℃，按比例称量混合，快速搅拌1 min至混合均匀，真空脱泡1 min，浇注至80℃的模具中，待2 h左右脱模后，再放置于80℃的烘箱中后硫化22 h，即得到聚氨酯灌封材料。
本研究制备了不同类型的聚氨酯灌封材料，具体编号和配方如表1所示。
1.3 测试方法
Shore A硬度按GB/T 531.1－2008测试；拉伸性能按GB/T 528－2009测试；撕裂强度按GB/T 529－2008测试；体积电阻率按GB/T 1692－2008测试；电气强度按GB/T 1695－2005测试。
凝胶时间测试：将A、B组分同时升温至80℃，按比例称量混合，快速搅拌1 min至混合均匀，真空脱泡1 min，然后倒入提前预热至80℃的涂有脱模剂的模具中，用玻璃棒不断探测其表面黏度变化，直到出现拉丝现象，此时视为该试样已凝胶化，记录从A、B两组分开始混合到出现拉丝现象的时间即为凝胶时间。
初始混合黏度按照GB/T 2794－2013测试：将A、B组分同时升温至80℃，按比例称量混合，开始计时，快速搅拌1 min至混合均匀，真空脱泡1 min，然后用旋转黏度计测试第3 min时的黏度。
压缩耐寒系数按照HG/T 3866－2008在-60℃的试验温度下进行测试。
差示扫描量热分析（DSC）：使用差示扫描量热仪进行测试，N2气氛，气流速度为40 mL/min，称取5～10 mg样品置于坩埚中，测试温度为-80～0℃，升温速率为10℃/min。
热重分析（TGA）：使用热重分析仪进行测试，N2气氛，气流速度为40.0 mL/min，称取5～10 mg样品置于坩埚中，测试温度为25～600℃，升温速率为10℃/min。
耐高低温冲击按照GB/T 2423.22－2012进行测试，低温为-65℃，高温为125℃，暴露持续时间为2 h，循环次数为20次。
尺寸保持率测试：将聚氨酯灌封材料制备成直径为（29.0±0.5）mm、高度为（12.5±0.5）mm的圆柱体，在实验室温度（23±2）℃下，用厚度仪测量每个试样中心部位的高度，精确至0.01 mm，然后放入冷热冲击试验箱中，完成低温为-65℃、高温为125℃、暴露持续时间为2 h的20次循环。试验结束后，将试样在上述实验室温度下恢复（30±3）min，再次测量温度冲击后试样中心的高度。尺寸保持率（c）按式（1）计算。
c = h 0 - h 1 h 0 × 100 %
式（1）中：h0为试样初始高度，mm；h1为试样恢复后的高度，mm。
2 结果与讨论
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2.1 工艺性能分析
聚氨酯灌封材料的工艺性能对其电子灌封产品的质量与稳定性具有重要影响，其中黏度与可操作时间成为衡量工艺性能的关键技术指标。本研究对不同类型聚氨酯灌封材料的初始混合黏度和凝胶时间进行了测试，结果如表2所示。
从表2可以看出，采用环氧丙烷-四氢呋喃共聚醚制备的同类异氰酸酯灌封胶，呈现出较低的初始混合黏度及更长的凝胶时间。当聚合物多元醇为聚四氢呋喃醚二醇时，灌封胶初始混合黏度从大到小顺序为PU3-0、PU2-0、PU1-0，凝胶时间从大到小顺序为PU1-0、PU3-0、PU2-0；当聚合物多元醇为环氧丙烷-四氢呋喃共聚醚时，灌封胶初始混合黏度从大到小顺序为PU6-0、PU5-0、PU4-0，凝胶时间从大到小顺序为PU4-0、PU6-0、PU5-0。因此，在聚合物多元醇保持一致的前提下，灌封胶初始混合黏度以TODI型为最高，MDI型次之，TDI型最低；而凝胶时间则呈现TDI型长于TODI型，MDI型最短的趋势。此外，在灌封材料制备过程中观察到，MDI型灌封材料极易产生气泡，推测这可能是MDI的高活性所致，尤其在湿度较大的环境下，MDI更易与空气中的水分反应生成二氧化碳。TODI因邻位侧甲基的位阻效应和电子效应，活性较低，不易受环境中水分的影响，因而相较MDI而言，更适宜用作灌封材料的异氰酸酯。
与PU4-0和PU6-0相比，PU4-1与PU6-1灌封材料中分别添加了总量0.5%的二氧化硅气凝胶，结果发现，初始混合黏度略有上升，而对凝胶时间的影响微乎其微。进一步测试了不同添加量的二氧化硅气凝胶对PU6-0工艺性能的影响，结果如图1所示。从图1可以看出，在一定添加量范围内，随着二氧化硅气凝胶的增加，聚氨酯灌封材料的凝胶时间大体保持恒定，但其初始混合黏度则显著增大。因此，二氧化硅气凝胶在该聚氨酯灌封材料体系中应根据工艺要求适度添加。
2.2 力学性能分析
力学性能在提升灌封材料的密封效果、增强其耐用性与稳定性、适应多变的复杂环境以及提高安全性与可靠性等多个方面扮演着至关重要的角色。本研究对不同类型聚氨酯灌封材料进行了力学性能测定，结果如表3所示。从表3可以看出，不同类型聚氨酯灌封材料均展现出适宜的力学特性，在邵氏A硬度为（60±3）的条件下，其拉伸强度都大于12 MPa，断裂伸长率不低于600%，撕裂强度亦不低于25 kN/m，能够为电子元器件提供卓越的密封与保护效能。
2.3 耐低温性能分析
在低温条件下，灌封材料容易失去弹性，导致其对电子元器件的外力冲击保护能力大幅降低；同时，还可能发生收缩与开裂现象，严重影响其密封效能，进而无法有效阻隔外界环境因素。
图2为不同类型聚氨酯灌封材料在-60℃下的压缩耐寒系数测试结果。
从图2可以看出，PU1-0、PU2-0、PU3-0的压缩耐寒系数分别为0.34、0.36、0.35，组内最大差值仅0.02；PU4-0、PU5-0、PU6-0的压缩耐寒系数分别为0.48、0.49、0.47，组内最大差值也仅为0.02。然而，两组间的平均压缩耐寒系数差值达到0.13，差异显著。这表明中低硬度聚氨酯材料的压缩耐寒系数主要受软段聚合物多元醇的影响，而异氰酸酯种类的影响则相对微弱。由四氢呋喃与环氧丙烷开环聚合生成的共聚醚，通过侧甲基的引入，破坏了分子链的规整性，降低了分子旋转所需的势垒，同时阻碍了氢键的有序形成，进而有效阻止了聚氨酯材料在低温下的结晶[9-10]，因此PU4-0、PU5-0、PU6-0具备较高的压缩耐寒系数。通过对比PU6-1与PU6-0、PU4-1与PU4-0的压缩耐寒系数发现，在聚氨酯灌封材料中添加二氧化硅气凝胶，能显著减缓甚至抵抗低温环境对材料结晶性能的负面影响。这可能是因为二氧化硅气凝胶具有丰富的纳米级孔隙结构，对热传导、热对流及热辐射3种热量传递方式均具有抑制作用，拥有极低的导热系数[11-13]。这种独特的热阻隔特性，有效降低了低温环境对材料内部结晶过程的干扰，从而提升了材料在低温条件下的性能稳定性。
玻璃化转变温度（Tg）是反映材料低温性能的重要指标，通过DSC测试得到不同聚氨酯灌封材料的Tg，结果如图3所示。从图3可以看出，PU1-0、PU2-0、PU3-0的Tg较为接近，PU4-0、PU5-0、PU6-0的Tg亦趋于一致，而PU6-1的Tg最低。根据图3可以得出与图2相同的结论：以环氧丙烷-四氢呋喃共聚醚作为聚合物多元醇，并掺入适量的二氧化硅气凝胶所制备的聚氨酯灌封材料，展现出卓越的耐低温特性。
2.4 耐高温性能分析
在高温环境下，灌封材料可能会经历热膨胀现象，导致其体积增大，进而引起封装内部应力累积，严重时可能导致封装体开裂或变形。此外，高温将加速材料微观结构的改变，例如分子链断裂和交联度下降等，这些变化直接影响材料的机械强度、硬度和耐磨性，使其更易受损于外部冲击或振动。同时，在高温作用下，材料的绝缘电阻率可能会显著降低，增加电流泄漏的风险，对电子设备的稳定运行构成潜在威胁。因此，在选取和设计电子灌封材料时，必须重点考虑其耐高温特性，保障电子设备在极端环境下的可靠性与长期使用寿命。本研究通过热重分析法对所制备的不同聚氨酯灌封材料的耐高温性能进行了考察，结果如图4所示。
从图4可以看出，聚合物多元醇与异氰酸酯的种类以及二氧化硅气凝胶的添加对聚氨酯灌封材料的耐热性都具有显著影响。在110～140℃温度区间内，以环氧丙烷-四氢呋喃共聚醚和TODI为基材，并添加适量二氧化硅气凝胶的聚氨酯灌封材料PU6-1热失重最小。当热失重率达到5%时，PU1-0～PU6-1的分解温度分别为254.7、274.0、284.7、224.2、243.0、278.1、269.8、302.3℃。可以看出，PU1-0耐热性优于PU4-0，PU2-0耐热性优于PU5-0，PU3-0耐热性优于PU6-0，可见在异氰酸酯相同的情况下，PTMG型聚氨酯灌封材料的耐热性优于环氧丙烷-四氢呋喃共聚醚型；同时，PU3-0耐热性优于PU2-0和PU1-0，PU6-0耐热性优于PU5-0和PU4-0，说明在聚合物多元醇相同的情况下，TODI型聚氨酯灌封材料的耐热性优于MDI型及TDI型。二氧化硅气凝胶的引入显著提升了聚氨酯灌封材料的耐热性，这是因为二氧化硅气凝胶表面富含羟基，可与异氰酸酯反应，一方面增加了材料中硬段的含量，另一方面引入了高能的Si-O键。此外，得益于气凝胶卓越的隔热性能，其能够有效阻止或延缓热量向材料内部传递，从而进一步提高了材料的耐热性[14]。
2.5 耐高低温冲击性能分析
耐高低温冲击实验旨在模拟极端温度环境变化，以验证材料在特定温度条件下是否能保持正常的使用与运行性能。本研究对所制备的不同聚氨酯灌封材料进行了耐高低温冲击测试，结果如表4所示。从表4可以看出，不同聚氨酯灌封材料在经历高低温冲击后，其强度与尺寸稳定性表现出不同程度的变化。其中，PU6-1展现出卓越的耐高低温冲击性能，这可能归因于环氧丙烷-四氢呋喃共聚醚赋予其出色的耐低温特性，而TODI则为其提供了优异的耐高温能力。此外，二氧化硅气凝胶以其极低的导热系数，有效减缓了外部温度变化对材料内部结构的影响。
2.6 绝缘性能分析
绝缘性能对于电子灌封材料的正常使用至关重要。卓越的绝缘性能可显著减少电流泄漏与短路的风险，为电子元器件构筑一道坚固的防护屏障，从而避免其受损。本研究针对高低温冲击实验前后的PU6-0和PU6-1试样进行了体积电阻率与电气强度测试，结果如图5所示。
从图5可以看出，PU6-0与PU6-1在温度冲击实验前后均展现出较高的体积电阻率（大于1011 Ω·cm）和电气强度（大于23 kV/mm），证实两者均具备良好的电绝缘性能。特别是PU6-1在经历温度冲击实验后，体积电阻率仍达到4.2×1012 Ω·cm，电气强度为25 kV/mm，其绝缘性能相较于PU6-0得以更显著的保持，这一现象主要得益于二氧化硅气凝胶的两大作用：一是有效减缓了聚氨酯分子结构中部分基团的分解速率；二是其表面丰富的羟基能够与聚氨酯材料形成氢键及化学键等强力的相互作用，从而提高材料的交联程度，并有效限制载流子的迁移。
3 结论
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（1）聚氨酯灌封材料的耐低温性能主要受聚合物多元醇的影响。以四氢呋喃与环氧丙烷开环聚合生成的共聚醚为聚合物多元醇时，通过引入侧甲基破坏了分子链的规整性，降低了分子转动的势垒，同时减少了氢键的有序排列，从而显著提高了聚氨酯灌封材料在低温环境下的耐受性能。
（2）聚氨酯灌封材料的耐高温性能则受到异氰酸酯与聚合物多元醇的共同作用。相较于环氧丙烷-四氢呋喃共聚醚型聚氨酯灌封材料，PTMG型聚氨酯灌封材料展现出更佳的耐热性。在多种异氰酸酯中，以TODI型聚氨酯灌封材料的耐热性能最为优异。
（3）二氧化硅气凝胶以其极低的导热系数，可以有效抵御外部温度对材料的影响，同步提升材料的耐低温与耐高温性能。
（4）以环氧丙烷-四氢呋喃共聚醚及TODI为主要成分，辅以适量二氧化硅气凝胶制备的聚氨酯灌封材料，展现出卓越的力学性能、工艺性能、耐高低温冲击性能以及绝缘性能，满足在-65℃至125℃循环冲击条件下的使用需求。
基金
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  • 山西省技术创新中心项目(202104010911021)
文献
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2025年第58卷第7期
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doi: 10.16790/j.cnki.1009-9239.im.2025.07.010
  • 接收时间：2024-08-04
  • 首发时间：2025-10-29
  • 出版时间：2025-07-20
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  • 收稿日期：2024-08-04
  • 修回日期：2024-10-14
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山西省技术创新中心项目(202104010911021)
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    1.山西应用科技学院，山西 太原 030000
    2.山西省化工研究所（有限公司），山西 晋中 030600
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2种不同金属材料的力学参数
科
Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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