Technique for testing the ball indentation of samples

Abstract

A method of testing a sample for ball indentation is provided that includes placing the sample on a stage of a testing instrument and moving a trigger assembly including a tip having a rounded end to the sample such that the end impacts the sample one or more times.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 288,685, filed December 13, 2021, which is incorporated by reference in its entirety herein. [Background technology]

[0002] Ball bearings are commonly utilized in actuator assemblies. For example, camera modules in mobile phones, laptop computers, digital cameras, digital video cameras, and the like often include actuator assemblies for optical image stabilization (OIS) to reduce loss of resolution or blur caused by camera shake. The actuator assemblies function by moving a lens module to a target position in response to a specific signal. To help ensure proper alignment of the lens module during movement, many actuator assemblies also include ball bearings that help guide the lens module in a desired direction. Ball bearings are generally formed from strong materials capable of withstanding the forces exerted thereon by relatively heavy moving components. Other components of the actuator assembly are formed from different materials that may be impacted by interaction with ball bearings, e.g., camera lens modules, housings, guide rods, and the like. Unfortunately, the ball bearings of the actuator assembly may cause damage, e.g., dents, to the surfaces of other such components. This damage may cause noise and affect performance, as well as shorten the useful life of the device. Thus, there is a need for techniques to test the performance characteristics of ball bearings used in actuator assemblies. Summary of the Invention [Means for solving the problem]

[0003] According to one embodiment of the present invention, a ball dent test instrument is disclosed that includes an actuator in communication with a trigger assembly. The trigger assembly includes a tip including a first end defining a rounded termination and an opposite second end. The tip further includes a trigger rod extending from the tip second end to a trigger rod end.

[0004]

[0004] According to another embodiment of the present invention, a method of testing a sample for ball indentation is disclosed that includes the steps of placing a sample on a stage of a testing instrument and moving a trigger assembly including a tip having a rounded end toward the sample so that the end impacts the sample one or more times.

[0005]

[0005] Other features and aspects of the present invention are described in more detail below.

[0006] A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures. [Brief description of the drawings]

[0006] [Figure 1]

[0007] FIG. 1 illustrates one embodiment of the ball indentation test instrument described herein. [Diagram 2]

[0008] FIG. 2 illustrates one embodiment of a trigger assembly of the ball indentation test instrument described herein. [Diagram 3]

[0009] FIG. 3 illustrates the trigger assembly of FIG. 2 in disassembly. [Figure 4]

[0010] FIG. 4 illustrates the tip of the trigger assembly of FIGS. [Diagram 5]

[0011] FIG. 5 illustrates one embodiment of a camera module that includes components formed from materials that can be tested in accordance with the disclosed embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007]

[0012] Those skilled in the art should understand that this discussion is a description of exemplary embodiments only, and is not intended to limit the broader aspects of the invention.

[0013] Generally speaking, the present invention is directed to techniques for determining ball indentation properties of samples to obtain better information regarding the long term expectancy of materials of interest for use in forming devices, such as actuator assemblies. For example, the devices and methods can be utilized to study materials of interest, including cameras found in combination devices, such as cell phones, laptop computers, etc., for use in forming actuator assemblies for cameras, such as digital cameras, lens modules for video cameras. Notably, by use of the techniques of the present invention, materials used in actuator assemblies can be evaluated prior to incorporation into the assembly.

[0008]

[0014] Various embodiments of the invention will now be described in more detail.

[0009] I. Test Equipment

[0015] Referring to FIG. 1, an exemplary embodiment of a testing instrument that can be used with the present invention is illustrated. Briefly, the instrument includes a trigger assembly 10 that includes a tip 12 at one end. The trigger assembly 10 is in communication with an actuator 14. The instrument can also include a stage 18 that can hold a sample to be tested. In use, a control system can be used to control the actuator 14, thereby moving the trigger assembly 10 a predetermined distance away from the stage 18, as indicated by the double-headed arrow, and then causing the trigger assembly 10 to impact the sample carried on the stage 18 with the tip 12 in the reverse direction. For example, the actuator 14 can release the trigger assembly 10, whereupon the trigger assembly 10 falls back to the stage 18 under gravity alone. Thus, the sample held on the stage 18 can be repeatedly impacted by the tip 12 at a predetermined location on a surface as the trigger assembly 10 is repeatedly dropped onto the stage 18. The trigger assembly 10 can also include a weight 16 that can be added or removed from the trigger assembly 10 to change the force of impact of the tip 12 on the sample.

[0010]

[0016] 2-4 illustrate the trigger assembly 10 in both an assembled (FIG. 2) and disassembled (FIG. 3) state. As shown, the trigger assembly 10 can include a tip 12 designed to simulate a ball bearing. That is, the tip 12 can include a rounded first end 21 at the end of a head 20 formed from a material and having a curvature that mimics a ball bearing of interest, e.g., a ball bearing that may be incorporated into an actuator assembly. In some embodiments, the test instrument can be designed to simulate the impact of a relatively small ball bearing, e.g., a ball bearing having a diameter of about 1 millimeter or less. In such embodiments, the rounded end 21 of the tip 12 can define a particular radius of curvature of about 500 micrometers or less, in some embodiments, about 1 to about 400 micrometers, in some embodiments, about 2 to about 300 micrometers, in some embodiments, about 5 to about 200 micrometers, etc. The rounded end 21 and / or head 20 of tip 12 can be formed from the same or different materials, such as, for example, ceramic materials (e.g., silicon nitride, titanium carbide, zirconia, silicon carbide, etc.), metals (e.g., steels, such as high carbon chromium steels, martensitic stainless steels, austenitic stainless steels), etc. In certain embodiments, polymer compositions, such as those described in more detail below, may be used in tip 12 (e.g., rounded end 21). In such embodiments, it may be desirable for tip 12 to include the same type of material as the ball bearings being simulated in the testing protocol.

[0011]

[0017] The head 20 of the tip 12 may be of a size and shape to carry a rounded end 21 that simulates a ball bearing during a testing protocol. For example, the head 20 may be conical in shape, terminating in a rounded end 21 as illustrated in FIG. 4, or may have a different shape, e.g., pyramidal, triangular, cylindrical, etc. In some embodiments, the head 20 may expand in at least one dimension along the length of the head 20 to provide additional strength to the tip 12. For example, the head 20 may be about 2 millimeters to about 20 millimeters in length (from the rounded end 21 to the base of the head 20 as illustrated by line L) and may expand along its length from the diameter of the tip 12 to a thickness that, in some embodiments, may be about 2 to about 5 times the diameter of the rounded end 21. The expansion may be gradual as illustrated, or may be a distinct step, each of which independently includes a taper across the length of the step, or a constant cross-sectional area across the length of the step. Thus, head 20 can define a taper having an angle measured by the included angle of a triangle superimposed on the tapered head of from about 5° to about 120° in some embodiments, from about 10° to about 90° in some embodiments, and from about 20° to about 45° in some embodiments. Although by no means required, head 20 can be unitary and of the same material as tip 12.

[0012]

[0018] In the illustrated embodiment of FIG. 4, the tip 12 includes a body portion 24 that is separate from the head 20. In other embodiments, the separate body portion 24 is not present, and the head extending from the spherical tip can form the body of the tip 12. If included, the body portion 24 can be of unitary construction and of the same material as the head 20, or can be formed from a different material as described above. If present, the separate body portion 24 can be different in shape from the head 20. For example, compared to the head 20, the body portion 24 can have a larger cross-sectional footprint. The overall shape of the body portion 24 can be, but is not limited to, a cube, a cuboid, a cylinder, etc., and the body portion 24 can have any suitable cross-sectional shape (e.g., circular, square, triangular, pentagonal, hexagonal, etc.). If present, the length of the body portion 24 is not particularly limited, and in some embodiments may be from about 2 millimeters to about 20 millimeters in length. Similarly, the maximum cross-sectional dimension of body portion 24 is not particularly limited, and in some embodiments may be from about 1 to about 50 millimeters, in some embodiments, from about 2 to about 40 millimeters, and in some embodiments, from about 3 to about 20 millimeters.

[0013]

[0019] Referring again to FIG. 2, the end of the tip 12 (opposite the first rounded end 21) can be disposed adjacent to the end of the trigger rod 15. In the illustrated embodiment, the tip 12 can be separable from the trigger rod 15 and thus can include a mounting 22 (FIG. 4) that secures the tip 12 to the trigger rod 15. For example, the mounting 22 can include mating threads on the outside of the mounting 22 of the tip 12 and on the inside of the end of the trigger rod 15. Other types of mountings can include, but are not limited to, nuts / bolts, screws, snap fittings, push button snap fittings, threaded couplings, snap couplings, and the like. In other embodiments, the tip 12 can be of unitary construction with the trigger rod 15, in which case a separable mounting need not be present. However, in some embodiments, a separable tip 12 can be incorporated, providing a means for relatively easy modification of the instrument to incorporate a variety of different sizes and / or materials of tip tools. The trigger rod 15 can be formed from the same or different material as the tip. In some embodiments, the trigger rod 15 may be formed from steel. The length of the trigger rod 15 is not particularly limited and may depend on the size of the instrument, the location of the actuator of the instrument, etc. As shown in FIG. 1, the trigger rod 15 can hold the tip tool 12 in communication with the actuator 14 to move the tip tool 12 toward and away from the stage 18. In some embodiments, the trigger rod 15 can have a length of about 5 centimeters to about 20 centimeters, for example, about 6 centimeters to about 15 centimeters.

[0014]

[0020] The trigger assembly 10 may also include one or more weights 16 that may be removably attached to the trigger rod 15, for example, by use of the attachment types described above for the attachment of the tip tool 12 to the trigger rod 15. Such attachment mechanisms may be the same or different than those used for the attachment of the tip tool 12. In the illustrated embodiment, the trigger rod 15 may include a frame 17 that may include a snap joint, internal threads, or the like configured to mate with the weight 16. The presence and size of the frame 17 may generally depend on the style of weight 16, as well as the attachment mechanism used to attach the weight 16 to the trigger rod 17. In some embodiments, the frame 17 may have a larger cross-sectional dimension and may be used to help retain the trigger assembly within the instrument. For example, the frame 17 may have a height of about 1 to about 50 millimeters, in some embodiments about 2 to about 40 millimeters, and in some embodiments about 5 to about 30 millimeters, and may have a maximum cross-sectional dimension of about 1 to about 80 millimeters, in some embodiments about 2 to about 60 millimeters, and in some embodiments about 5 to about 40 millimeters.

[0015]

[0021] As shown, the device can include weights 16 that can be removably attached to one another, and numerous variations can be made to the weight of the trigger assembly using a minimum number of weights 16. As will be apparent to one skilled in the art, the weights can be formed of any suitable material, such as metals (steel, iron, etc.), polymers, etc., as well as combinations of materials, and can be any suitable weight, such as milligrams to a few grams each. The weights 16 can be any suitable size and shape. For example, they can, in some embodiments, have a generally disk-like shape having approximately the same cross-sectional shape and size as the frame 17 to which they can be attached. In some embodiments, the weights 16 can have a size similar to the size of the frame 17, such as a height of about 1 to about 50 millimeters, in some embodiments about 2 to about 40 millimeters, in some embodiments about 5 to about 30 millimeters, and can have a maximum cross-sectional dimension of about 1 to about 80 millimeters, in some embodiments about 2 to about 60 millimeters, and in some embodiments about 5 to about 40 millimeters.

[0016]

[0022] As shown in FIG. 1, the trigger assembly 10 can be positioned within the instrument in communication with an actuator 14 designed to impart movement of the tip tool toward and away from a stage 18. As shown, the actuator 14 can include a cam 8 that engages a lever 6 connected to a trigger rod 15. As the cam 8 rotates, the lever 6 and attached trigger rod 15 move the trigger assembly 10 a predetermined distance away from the stage 18. The trigger assembly then moves toward or back toward the stage to impact a sample held thereon with the tip tool 12. For example, in some embodiments, the cam 8 can be non-spherical and can detach from the lever at the apex of the travel distance, allowing the trigger assembly 10 to free fall back toward the stage 18, where the tip tool 12 impacts the sample with its spherical tip 21. Of course, other types of reciprocating actuators are encompassed herein, including but not limited to hydraulic and pneumatic piston actuators that can actively move the trigger assembly into the sample with a predetermined impact force, or allow the free fall of the trigger assembly to impart the impact of gravity alone, if desired.

[0017]

[0023] Generally speaking, the actuator 14 can be controlled by a control system (not shown). In one embodiment, the control system may include a computer or other suitable processing unit. Thus, the control system may include suitable computer readable instructions that, when implemented, configure the components of the instrument to perform a variety of different functions, such as, for example, actuating the trigger assembly 10, changing the position of the stage 18 via the stage actuator 17, etc. A computer generally includes one or more processors and a memory. The processor(s) may be any known processing device. The memory stores information available to the processor(s), including instructions that can be executed by the processor(s). As used herein, the term "processor" refers not only to integrated circuits referred to in the art as included in a computer, but also to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application specific integrated circuits, and other programmable circuits.

[0018]

[0024] The memory device(s) of the control system may generally include memory element(s) including, but not limited to, computer readable media (e.g., random access memory (RAM)), computer readable non-volatile media (e.g., flash memory), read only memory (ROM) of any medium, magneto-optical disk (MOD), digital versatile disk (DVD) and / or other suitable memory elements. The memory may be non-transitory. Such memory device(s) may generally be configured to store computer readable instructions that, when executed by the processor(s), configure the instrument to perform various computer-implemented functions, such as facilitating the test protocols described herein. The instructions may be any set of instructions that, when executed by the processor(s), cause the processor(s) to provide a desired functionality. For example, the instructions may be software instructions rendered in a computer readable form. If software is used, any suitable programming, scripting, or other type of language or combination of languages ​​may be used to implement the teachings contained herein. Alternatively, the instructions may be implemented by hard-wired logic or other circuitry, including, but not limited to, application specific circuitry. Memory may also include data that may be retrieved, manipulated, or stored by the processor(s). The computing device may also include a network interface for accessing information over a network. The network may include a combination of networks, such as a Wi-Fi network, a LAN, a WAN, the Internet, a cellular network, and / or other suitable networks, and may include any number of wired or wireless communication connections. For example, the computing device may communicate with the actuator 14 and the stage 18 over a wired or wireless network.

[0019]

[0025] The control system may be electronically coupled to an actuator 14 which actuates a cam 8 in response to input commands to move the trigger assembly 10 between the tip 12 of the trigger assembly 10 and a sample held on the stage 18 a predetermined distance from the sample for a predetermined number of repeated impacts. The control system may also be electronically coupled to a stage actuator 17 which actuates the stage 18 in response to "x", "y" and "z" axis drive signals to move the stage in one or more of the x, y and z planes, as shown in Figure 1. Thus, the stage 18 may be positioned as desired to bring sample material held thereon into contact with the tip 12 of the trigger assembly 10 at a predetermined location during a testing protocol.

[0020]

[0026] The control system and associated memory device(s) may be configured to store data for later execution and / or retrieval. For example, the memory device(s) may be configured to store instructions of a protocol that can be executed by the processor(s) and later executed. For example, in certain embodiments, multiple different test protocols may be executed in succession, and data associated with each protocol may be stored and later retrieved.

[0021]

[0027] The instrument may also be communicatively connected to a display 30 (indicated by a dashed bidirectional arrow) that can provide input / output communication with the control system. For example, the display 30 may include a keyboard 31 or the like that can provide command input, such as impact number, impact speed, stage position, start time, etc. Additionally, the display 30 may include various output readouts 32 that can indicate characteristics of the test protocol, including, but not limited to, the current number of impacts in the protocol, the total number of impacts performed, the force of the impact on the test material, the weight of the trigger assembly, the execution time, the distance traveled by the trigger assembly in a single impact cycle, the start / end time of the test, the stage position, etc. Other control inputs / outputs that may be incorporated into the display include, but are not limited to, a power control, a mode selection (e.g., auto / manual), a start / stop switch, etc.

[0022]

[0028] For carrying out the test protocol, the sample can be held to the stage 18, for example, by use of adhesives, clips, screws or other suitable holders. The size and shape of the material held to the stage is not critical, although in some embodiments the material may be of a size and shape, e.g., thickness, similar to that of the product into which the material is expected to be incorporated. For example, in one embodiment, the sample can simulate a material for incorporation in an actuator assembly of a camera module that includes ball bearings.

[0023]

[0029] The size of the sample is not particularly limited, as embodiments of the instrument can include a movable stage to accommodate a sample of any desired thickness. By way of example, the sample can be from a few micrometers to a few millimeters thick (i.e., in the z direction shown in FIG. 1 on the location of stage 18), such as from about 50 micrometers to about 10 millimeters thick, from about 100 micrometers to about 5 millimeters thick, or in some embodiments, from about 200 micrometers to about 2 millimeters thick.

[0024]

[0030] Following assembly of the sample with the instrument, a test protocol can be performed in which the sample is impacted several times with a predefined force using the tip 12 of the trigger instrument 10. There are no particular limitations on the number of impacts or impact force of the test protocol (e.g., drop distance and weight of the trigger assembly). For example, the number of impacts of the test protocol can range from a single impact to thousands of impacts, e.g., from about 100 impacts to about 100,000 impacts, e.g., from about 500 impacts to about 50,000 impacts, or from about 1,000 impacts to about 25,000 impacts. Similarly, the weight of the trigger assembly (which determines the force of the impact in relation to the velocity of the trigger assembly at the impact) can be the weight of the trigger assembly alone, e.g., a few grams, e.g., about 5 grams, or hundreds of grams, e.g., up to about 200 grams. For example, the weight added to the trigger assembly through the use of one or more weights 16 can be from about 1 gram to about 100 grams, from about 5 grams to about 90 grams, in some embodiments from about 10 grams to about 80 grams, or from about 20 grams to about 75 grams.

[0025]

[0031] In embodiments in which the trigger assembly is configured to free fall to impact the sample, the drop height of the trigger assembly is also not critical, for example, a test protocol may drop the trigger assembly from a height of several hundred micrometers to a few millimeters, such as from about 250 micrometers to about 5 millimeters, or in some embodiments, from about 500 micrometers to about 2 millimeters.

[0026]

[0032] Following the test protocol, the sample can be inspected to determine the depth of the indentation made by tip 12 upon multiple impacts on the specimen surface.

[0027] II. Sample Materials A. Polymer Matrix

[0033] Samples tested using the techniques of the present invention are generally formed from polymer compositions that include a polymer matrix. The polymer matrix may include one or more thermoplastic polymers. Typically, it is desirable for such polymers to have a high degree of heat resistance, as reflected by a deflection temperature under load ("DTUL") of about 40°C or higher, in some embodiments about 50°C or higher, in some embodiments about 60°C or higher, in some embodiments about 80°C to about 250°C, and in some embodiments about 100°C to about 200°C, as determined at 1.8 MPa load according to ISO 75-2:2013. In addition to exhibiting a high degree of heat resistance, thermoplastic polymers also typically have a high glass transition temperature, such as about 10°C or higher, in some embodiments about 20°C or higher, in some embodiments about 30°C or higher, in some embodiments about 40°C or higher, in some embodiments about 50°C or higher, and in some embodiments about 60°C to about 320°C. When semi-crystalline or crystalline polymers are used, the high performance polymers may also have high melting temperatures, such as above about 140° C., in some embodiments from about 150° C. to about 400° C., and in some embodiments from about 200° C. to about 380° C. Glass transition and melting temperatures may be determined using differential scanning calorimetry ("DSC") according to ISO 11357-2:2020 (glass transition) and 11357-3:2018 (melting), as is well known in the art.

[0028]

[0034] Suitable thermoplastic polymers for this purpose may include, for example, polyolefins (e.g., ethylene polymers, propylene polymers, etc.), polyamides (e.g., aliphatic, semi-aromatic or aromatic polyamides), polyesters, polyarylene sulfides, liquid crystal polymers (e.g., wholly aromatic polyesters, polyesteramides, etc.), polycarbonates, polyethers (e.g., polyoxymethylene), etc., as well as blends thereof. The exact selection of the polymer system will depend on a variety of factors, such as the nature of other fillers included within the composition, the manner in which the composition is formed and / or processed, and the particular requirements of the intended application.

[0029]

[0035] Aromatic polymers, for example, may be suitable for some applications. Aromatic polymers may be substantially amorphous, semi-crystalline or crystalline in nature. One example of a suitable semi-crystalline aromatic polymer is, for example, an aromatic polyester, which may be a condensation product of at least one diol (e.g., aliphatic and / or cycloaliphatic), such as those having 4 to 20 carbon atoms, and in some embodiments 8 to 14 carbon atoms, with at least one aromatic dicarboxylic acid. Suitable diols include, for example, neopentyl glycol, cyclohexanedimethanol, 2,2-dimethyl-1,3-propanediol, and carboxylic acids of the formula HO(CH2). nOH, where n is an integer from 2 to 10. Suitable aromatic dicarboxylic acids may include, for example, isophthalic acid, terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, and the like, as well as combinations thereof. Fused rings may also be present, for example, in 1,4- or 1,5- or 2,6-naphthalene-dicarboxylic acids. Specific examples of such aromatic polyesters may include, for example, poly(ethylene terephthalate) (PET), poly(1,4-butylene terephthalate) (PBT), poly(1,3-propylene terephthalate) (PPT), poly(1,4-butylene 2,6-naphthalate) (PBN), poly(ethylene 2,6-naphthalate) (PEN), poly(1,4-cyclohexylene dimethylene terephthalate) (PCT), as well as mixtures of the foregoing.

[0030]

[0036] Derivatives and / or copolymers of aromatic polyesters (e.g., polyethylene terephthalate) may also be used. In one embodiment, for example, modifying acids and / or modifying diols may be used to form derivatives of such polymers. As used herein, the terms "modifying acid" and "modifying diol" are intended to define compounds that can form part of the acid and diol repeat units of a polyester, respectively, and that can modify the polyester to reduce its crystallinity or make the polyester amorphous. Examples of modifying acid components include, but are not limited to, isophthalic acid, phthalic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, 2,6-naphthaline dicarboxylic acid, succinic acid, glutaric acid, adipic acid, sebacic acid, suberic acid, 1,12-dodecanedioic acid, and the like. In practice, it is often preferred to use their functional acid derivatives, e.g., dimethyl, diethyl, or dipropyl esters of the dicarboxylic acids. Anhydrides or acid halides of these acids may also be used where practical.Examples of diol components to be modified include neopentyl glycol, 1,4-cyclohexanedimethanol, 1,2-propanediol, 1,3-propanediol, 2-methyl-1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, Z,8-bis(hydroxymethyltricyclo-[5.2.1.0]-decane [wherein Z represents 3, 4 or 5]; 1,4-bis(2-hydroxyethoxy)benzene, 4,4'-bis( They may include, but are not limited to, 2-hydroxyethoxydiphenyl ether [bis-hydroxy-ethyl bisphenol A], 4,4'-bis(2-hydroxyethoxy)diphenyl sulfide [bis-hydroxy-ethyl bisphenol S], and diols containing one or more oxygen atoms in the chain, such as diethylene glycol, triethylene glycol, dipropylene glycol, tripropylene glycol, and the like. Generally, these diols contain 2 to 18 carbon atoms, and in some embodiments, 2 to 8 carbon atoms. The alicyclic diols can be used in their cis or trans configuration, or as a mixture of both forms.

[0031]

[0037] For example, the aromatic polyesters described above typically have a DTUL value of about 40°C to about 80°C, about 45°C to about 75°C in some embodiments, and about 50°C to about 70°C in some embodiments, as determined at a load of 1.8 MPa according to ISO 75-2:2013. The aromatic polyesters also typically have a glass transition temperature of about 30°C to about 120°C, about 40°C to about 110°C in some embodiments, and about 50°C to about 100°C in some embodiments, as determined, for example, according to ISO 11357-2:2020, and a melting temperature of about 170°C to about 300°C, about 190°C to about 280°C in some embodiments, and about 210°C to about 260°C in some embodiments, as determined, for example, according to ISO 11357-2:2018. The aromatic polyester may also have an intrinsic viscosity, for example, as determined according to ISO 1628-5:1998, of from about 0.1 dl / g to about 6 dl / g, in some embodiments from about 0.2 to about 5 dl / g, and in some embodiments, from about 0.3 to about 1 dl / g.

[0032]

[0038] Polyarylene sulfide is also a suitable semi-crystalline aromatic polymer. Polyarylene sulfide may be a homopolymer or a copolymer. For example, the selective combination of dihaloaromatic compounds can result in a polyarylene sulfide copolymer containing at least two different units. For example, when p-dichlorobenzene is used in combination with m-dichlorobenzene or 4,4'-dichlorodiphenyl sulfone, a polyarylene sulfide copolymer containing a segment having the structure of the following formula can be formed:

[0033] [ka]

[0034] and a segment having the structure:

[0035] [ka]

[0036] or a segment having the structure:

[0037] [ka]

[0038]

[0039] Polyarylene sulfides may be linear, semi-linear, branched or crosslinked. Linear polyarylene sulfides usually contain 80 mol % or more of the repeating unit -(Ar-S)-. Such linear polymers may also contain a small amount of branching or crosslinking units, but the amount of branching or crosslinking units is usually less than about 1 mol % of the total monomer units of the polyarylene sulfide. Linear polyarylene sulfide polymers may be random or block copolymers containing the aforementioned repeating units. Semi-linear polyarylene sulfides may also have a crosslinked or branched structure in which a small amount of one or more monomers having three or more reactive functional groups are introduced into the polymer. As an example, the monomeric components used to form semi-linear polyarylene sulfides may include an amount of polyhaloaromatic compounds having two or more halogen substituents per molecule that can be utilized in preparing branched polymers. Such monomers are represented by the formula R'X nwhere each X is selected from chlorine, bromine, and iodine, n is an integer from 3 to 6, and R' is a polyvalent aromatic radical of valence n which may have up to about four methyl substituents, and the total number of carbon atoms in R' is in the range of 6 to about 16. Examples of some polyhaloaromatic compounds having more than two substituted halogens per molecule that can be used to form semi-linear polyarylene sulfides include 1,2,3-trichlorobenzene, 1,2,4-trichlorobenzene, 1,3-dichloro-5-bromobenzene, 1,2,4-triiodobenzene, 1,2,3,5-tetrabromobenzene, hexachlorobenzene, 1,3,5-trichloro-2,4,6-trimethylbenzene, 2,2',4,4'-tetrachlorobiphenyl, 2,2',5,5'-tetra-iodobiphenyl, 2,2',6,6'-tetrabromo-3,3',5,5'-tetramethylbiphenyl, 1,2,3,4-tetrachloronaphthalene, 1,2,4-tribromo-6-methylnaphthalene, and the like, and mixtures thereof.

[0039]

[0040] For example, the polyarylene sulfide typically has a DTUL value of about 70°C to about 220°C, about 90°C to about 200°C in some embodiments, and about 120°C to about 180°C in some embodiments, as determined at a load of 1.8 MPa according to ISO 75-2:2013. Similarly, the polyarylene sulfide typically has a glass transition temperature of about 50°C to about 120°C, about 60°C to about 115°C in some embodiments, and about 70°C to about 110°C in some embodiments, as determined, for example, according to ISO 11357-2:2020, and a melting temperature of about 220°C to about 340°C, about 240°C to about 320°C in some embodiments, and about 260°C to about 300°C in some embodiments, as determined, for example, according to ISO 11357-3:2018.

[0040]

[0041] As noted above, amorphous polymers that have substantially no distinct melting point temperature may also be used. Suitable amorphous polymers, for example, typically have the formula -R 1It may also include aromatic polycarbonates containing carbonate units of the repeating structure -OC(O)-O-. 1 At least a portion (e.g., 60% or more) of the total number of groups contains aromatic moieties, the remainder being aliphatic, cycloaliphatic or aromatic, so that the polycarbonate is aromatic in that respect. 1 is C 6~30 It may be an aromatic group, i.e., it contains at least one aromatic moiety. Typically, R 1 is the general formula HO-R 1 -OH dihydroxyaromatic compounds, for example those having the specific formula: H.O.A. 1 -Y 1 -A 2 -OH [In the formula, A 1 and A 2 are independently a monocyclic divalent aromatic group; Y 1 is a single bond, or A 2 From A 1 is a bridging group having one or more atoms separating: In one particular embodiment, the dihydroxy aromatic compound can be derived from the following formula (I):

[0041] [ka]

[0042] [In the formula, R a and R b are each independently a halogen or C 1~12 Alkyl groups, e.g., C arranged meta to the hydroxy group of each arylene group. 1~3 an alkyl group (e.g., methyl); p and q are each independently 0 to 4 (e.g., 1); X arepresents a bridging group connecting two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituents of each C6 arylene group are arranged ortho, meta, or para (especially para) relative to each other on the C6 arylene group.

[0043] In one embodiment, X a is the formula -C(R c )(R d )-[where R c and R d are each independently hydrogen, C 1~12 Alkyl, C 1~12 Cycloalkyl, C 7~12 Arylalkyl, C 7~12 Heteroalkyl or cyclic C 7~12 Heteroarylalkyl, or a group of the formula -C(=R e )-{where, R e is divalent C 1~12 is a hydrocarbon group.} is a group. 3~18 Cycloalkylidene, C 1~25 It may also be alkylidene. Exemplary groups of this type include methylene, cyclohexylmethylene, ethylidene, neopentylidene, and isopropylidene, as well as 2-[2.2.1]-bicycloheptylidene, cyclohexylidene, cyclopentylidene, cyclododecylidene, and adamantylidene. a A specific example where is a substituted cycloalkylidene is a cyclohexylidene bridged alkyl substituted bisphenol of formula (II):

[0044] [ka]

[0045] [In the formula, R a’ and R b’ are each independently 1~12 Alkyl (e.g., C such as methyl) 1~4 alkyl), optionally in the meta configuration relative to the cyclohexylidene bridging group; R g is C 1~12 Alkyl (e.g. C 1~4 alkyl) or halogen; r and s are each independently 1 to 4 (e.g., 1); t is 0 to 10, e.g., 0 to 5.

[0046]

[0043] The cyclohexylidene bridged bisphenol may be the reaction product of two moles of o-cresol with one mole of cyclohexanone. In another embodiment, the cyclohexylidene bridged bisphenol may be the reaction product of two moles of cresol with one mole of hydrogenated isophorone (e.g., 1,1,3-trimethyl-3-cyclohexan-5-one). Such cyclohexane-containing bisphenols, such as the reaction product of two moles of phenol with one mole of hydrogenated isophorone, are useful for producing polycarbonate polymers with high glass transition temperatures and high heat distortion temperatures.

[0047] In another embodiment, X a is C 1~18 Alkylene group, C 3~18 Cycloalkylene group, fused C 6~18 A cycloalkylene group or a group of formula -B 1 -W.B. 2 -[wherein, B 1 and B. 2 is independently C 1~6 An alkylene group, W is C 3~12 Cycloalkylidene group or C 6~16 It may also be a group represented by the formula:

[0048]

[0045] X a Also, the substituent C of the formula (III) 3~18 It may be a cycloalkylidene:

[0049] [ka]

[0050] [In the formula, R r , R p , R q and R t are each independently hydrogen, halogen, oxygen or C 1~12 is an organic group; I is a direct bond, carbon or divalent oxygen, sulfur or -N(Z)-, where Z is hydrogen, halogen, hydroxy, C 1~12 Alkyl, C 1~12 Alkoxy or C 1~12 acyl;}; h is 0 to 2; j is 1 or 2; i is 0 or 1; k is 0 to 3, where R r , R p , R q and R t at least two of the groups taken together are fused alicyclic, aromatic or heteroaromatic rings.

[0051] Other useful aromatic dihydroxyaromatic compounds include those having the formula (IV):

[0052] [ka]

[0053] [In the formula, R h are independently a halogen atom (e.g., bromine), C 1~10 Hydrocarbyl (e.g. C 1~10 Alkyl group), halogen-substituted C 1~10 Alkyl group, C 6~10 Aryl or halogen substituted C 6~10 is an aryl group; n is 0 to 4.

[0054] Specific examples of bisphenol compounds of formula (I) include, for example, 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane (hereinafter "bisphenol A" or "BPA"), 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxy-t-butylphenyl)propane, 3,3-bis(4-hydroxyphenyl)phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP), and 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC). In one particular embodiment, the polycarbonate has formula (I) represented by A 1 and A 2 each of Y is p-phenylene; 1 It may also be a linear homopolymer derived from bisphenol A, in which is isopropylidene.

[0055] Other examples of suitable aromatic dihydroxy compounds may include, but are not limited to, 4,4'-dihydroxybiphenyl, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, 1,3-bis(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, 1,4-bis(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, 1,5-bis(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, 1,6-bis(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, 1,5 ...5-bis(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, 1,5-bis(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, 1,5-bis(4-hydroxyphenyl)-2-(3-hydroxyphenyl)-1,2-diphenylethane, bis(4-hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)isobutene, 1,1-bis(4-hydroxyphenyl)cyclododecane, trans-2,3-bis(4-hydroxyphenyl)-2-butene, 2,2-bis(4-hydroxyphenyl)adamantane, α,α'-bis(4-hydroxyphenyl)toluene Ene, bis(4-hydroxyphenyl)acetonitrile, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane Pan, 2,2-bis(3-allyl-4-hydroxyphenyl)propane, 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)hexafluoropropane, 1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene 4,4'-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone, 1,6-bis(4-hydroxyphenyl)-1,6-hexanedione, ethylene glycol bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxyphenyl)fluorine, 2,7-dihydroxypyrene, 6,6'-dihydroxy-3,3,3',3'-tetramethylspiro(bis)indane ("spirobiindane bisphenol"), 3,3-bis(4-hydroxyphenyl)phthalimide, 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran ... dibenzothiophene, and 2,7-dihydroxycarbazole; resorcinol; substituted resorcinol compounds such as 5-methylresorcinol, 5-ethylresorcinol, 5-propylresorcinol, 5-butylresorcinol, 5-t-butylresorcinol, 5-phenylresorcinol, 5-cumylresorcinol, 2,4,5,6-tetrafluororesorcinol, 2,4,5,6-tetrabromoresorcinol, and the like; catechol; hydroxyl; non; substituted hydroquinones, such as 2-methylhydroquinone, 2-ethylhydroquinone, 2-propylhydroquinone, 2-butylhydroquinone, 2-t-butylhydroquinone, 2-phenylhydroquinone, 2-cumylhydroquinone, 2,3,5,6-tetramethylhydroquinone, 2,3,5,6-tetra-t-butylhydroquinone, 2,3,5,6-tetrafluorohydroquinone, 2,3,5,6-tetrabromohydroquinone, and the like, as well as combinations thereof.

[0056] For example, the aromatic polycarbonate generally has a DTUL value of about 80° C. to about 300° C., in some embodiments, about 100° C. to about 250° C., and in some embodiments, about 140° C. to about 220° C., as determined at a load of 1.8 MPa according to ISO 75-2:2013. The glass transition temperature may also be, for example, about 50° C. to about 250° C., in some embodiments, about 90° C. to about 220° C., and in some embodiments, about 100° C. to about 200° C., as determined according to ISO 11357-2:2020. Such polycarbonates may also have an intrinsic viscosity of about 0.1 dl / g to about 6 dl / g, in some embodiments, about 0.2 to about 5 dl / g, and in some embodiments, about 0.3 to about 1 dl / g, as determined according to ISO 1628-4:1998.

[0057] In addition to the above-referenced polymers, highly crystalline aromatic polymers may also be used in the polymer composition. Particularly suitable examples of such polymers are liquid crystal polymers, which have a high degree of crystallinity that allows them to effectively fill small spaces in the mold. Liquid crystal polymers are generally classified as "thermotropic" insofar as they have a rod-like structure and can exhibit crystalline behavior in the molten state (e.g., in the thermotropic nematic state). The polymers have relatively high melting temperatures, such as from about 280°C to about 400°C, in some embodiments from about 290°C to about 390°C, and in some embodiments from about 300°C to about 380°C. As is known in the art, such polymers may be formed from one or more types of repeating units. Liquid crystal polymers may contain, for example, one or more aromatic ester repeating units, generally represented by the following formula (I):

[0058] [ka]

[0059] wherein ring B is a substituted or unsubstituted six-membered aryl group (e.g., 1,4-phenylene or 1,3-phenylene), a substituted or unsubstituted six-membered aryl group fused to a substituted or unsubstituted five- or six-membered aryl group (e.g., 2,6-naphthalene), or a substituted or unsubstituted six-membered aryl group linked to a substituted or unsubstituted five- or six-membered aryl group (e.g., 4,4-biphenylene); Y1 and Y2 are independently O, C(O), NH, C(O)HN or NHC(O).

[0060]

[0051] Normally, Y 1 and Y 2 At least one of Y is C(O). Examples of such aromatic ester repeat units include, for example, aromatic dicarboxylic acid repeat units (in formula I, Y 1 and Y 2 is C(O)), aromatic hydroxycarboxylic acid repeating units (Y in formula I 1 is O and Y 2 is C(O).) as well as various combinations thereof.

[0061] For example, aromatic hydroxycarboxyl repeat units derived from aromatic hydroxycarboxylic acids such as 4-hydroxybenzoic acid, 4-hydroxy-4'-biphenylcarboxylic acid, 2-hydroxy-6-naphthoic acid, 2-hydroxy-5-naphthoic acid, 3-hydroxy-2-naphthoic acid, 2-hydroxy-3-naphthoic acid, 4'-hydroxyphenyl-4-benzoic acid, 3'-hydroxyphenyl-4-benzoic acid, 4'-hydroxyphenyl-3-benzoic acid, and the like, as well as alkyl, alkoxy, aryl, and halogen substituted versions thereof, and combinations thereof, may be used. Particularly suitable aromatic hydroxycarboxylic acids are 4-hydroxybenzoic acid ("HBA") and 6-hydroxy-2-naphthoic acid ("HNA"). When used, repeat units derived from hydroxycarboxylic acids (e.g., HBA and / or HNA) typically comprise about 50 mol % or more of the polymer, in some embodiments about 60 mol % or more, and in some embodiments about 80 mol % to 100 mol %.

[0062] Aromatic dicarboxylic acid repeat units derived from aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, diphenylether-4,4'-dicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 4,4'-dicarboxybiphenyl, bis(4-carboxyphenyl)ether, bis(4-carboxyphenyl)butane, bis(4-carboxyphenyl)ethane, bis(3-carboxyphenyl)ether, bis(3-carboxyphenyl)ethane, and the like, as well as their alkyl, alkoxy, aryl, and halogen substitutions, and combinations thereof, may also be used. Particularly suitable aromatic dicarboxylic acids may include, for example, terephthalic acid ("TA"), isophthalic acid ("IA"), and 2,6-naphthalenedicarboxylic acid ("NDA"). When used, repeat units derived from aromatic dicarboxylic acids (e.g., IA, TA and / or NDA) typically comprise from about 1 mol % to about 50 mol %, in some embodiments from about 2 mol % to about 40 mol %, and in some embodiments, from about 5 mol % to about 30 mol % of the polymer.

[0063]

[0054] Other repeat units may also be used in the polymer. In some embodiments, repeat units derived from aromatic diols, such as hydroquinone, resorcinol, 2,6-dihydroxynaphthalene, 2,7-dihydroxynaphthalene, 1,6-dihydroxynaphthalene, 4,4'-dihydroxybiphenyl (or 4,4'-biphenol), 3,3'-dihydroxybiphenyl, 3,4'-dihydroxybiphenyl, 4,4'-dihydroxybiphenyl ether, bis(4-hydroxyphenyl)ethane, and the like, as well as alkyl, alkoxy, aryl and their halogen-substituted versions, and combinations thereof, may be used. Particularly suitable aromatic diols may include, for example, hydroquinone ("HQ") and 4,4'-biphenol ("BP"). When used, repeat units derived from aromatic diols (e.g., HQ and / or BP) typically comprise from about 1 mol % to about 30 mol %, in some embodiments from about 2 mol % to about 25 mol %, and in some embodiments from about 5 mol % to about 20 mol % of the polymer. Repeat units, such as those derived from aromatic amides (e.g., acetaminophen ("APAP")) and / or aromatic amines (e.g., 4-aminophenol ("AP")), 3-aminophenol, 1,4-phenylenediamine, 1,3-phenylenediamine, and the like, may also be used. When used, repeat units derived from aromatic amides (e.g., APAP) and / or aromatic amines (e.g., AP) typically comprise from about 0.1 mol % to about 20 mol %, in some embodiments from about 0.5 mol % to about 15 mol %, and in some embodiments from about 1 mol % to about 10% of the polymer. It should also be understood that repeat units of various other monomers may be incorporated into the polymer. For example, in certain embodiments, the polymer may include one or more repeat units derived from non-aromatic monomers, such as aliphatic or alicyclic hydroxycarboxylic acids, dicarboxylic acids, diols, amides, amines, and the like. Of course, in other embodiments, the polymer may be "fully aromatic" in that there are no repeat units derived from non-aromatic (e.g., aliphatic or alicyclic) monomers.

[0064]

[0055] Typically, a liquid crystal polymer is a "high naphthene" polymer insofar as it contains a relatively high content of repeat units derived from naphthenic hydroxycarboxylic acids and naphthenic dicarboxylic acids, such as naphthalene-2,6-dicarboxylic acid ("NDA"), 6-hydroxy-2-naphthoic acid ("HNA"), or combinations thereof. That is, the total amount of repeat units derived from naphthenic hydroxycarboxylic acids and / or dicarboxylic acids (e.g., NDA, HNA, or combinations of HNA and NDA) is typically about 10 mol% or more, in some embodiments about 15 mol% or more, and in some embodiments about 20 mol% to about 35 mol% of the polymer. Contrary to many conventional "low naphthene" polymers, the resulting "high naphthene" polymers are believed to be capable of exhibiting good thermal and mechanical properties. In one particular embodiment, for example, the liquid crystal polymer may be formed from repeat units derived from 4-hydroxybenzoic acid ("HBA") and 6-hydroxy-2-naphthoic acid ("HNA"), as well as various other optional components. The repeat units derived from 4-hydroxybenzoic acid ("HBA") may comprise from about 50 mol% to about 90 mol%, in some embodiments from about 60 mol% to about 85 mol%, and in some embodiments from about 65 mol% to about 80% of the polymer. The repeat units derived from 6-hydroxy-2-naphthoic acid ("HNA") may similarly comprise from about 10 mol% to about 50 mol%, in some embodiments from about 15 mol% to about 40 mol%, and in some embodiments from about 20 mol% to about 35% of the polymer.

[0065]

[0056] Of course, besides aromatic polymers, aliphatic polymers may also be suitable for use as high performance thermoplastic polymers in the polymer matrix. In one embodiment, for example, polyamides may be used, which generally have CO-NH linkages in the main chain and are obtained by condensation of aliphatic diamines with aliphatic dicarboxylic acids, by ring-opening polymerization of lactams, or by self-condensation of aminocarboxylic acids. For example, the polyamides may contain aliphatic repeating units derived from aliphatic diamines, usually having 4 to 14 carbon atoms. Examples of such diamines include straight chain aliphatic alkylenediamines such as 1,4-tetramethylenediamine, 1,6-hexanediamine, 1,7-heptanediamine, 1,8-octanediamine, 1,9-nonanediamine, 1,10-decanediamine, 1,11-undecanediamine, 1,12-dodecanediamine, etc.; branched aliphatic alkylenediamines such as 2-methyl-1,5-pentanediamine, 3-methyl-1,5-pentanediamine, 2,2,4-trimethyl-1,6-hexanediamine, 2,4,4-trimethyl-1,6-hexanediamine, 2,4-dimethyl-1,6-hexanediamine, 2-methyl-1,8-octanediamine, 5-methyl-1,9-nonanediamine, etc.; and combinations thereof. Aliphatic dicarboxylic acids may include, for example, adipic acid, sebacic acid, etc. Specific examples of such aliphatic polyamides include, for example, nylon-4 (poly-α-pyrrolidone), nylon-6 (polycaproamide), nylon-11 (polyundecaneamide), nylon-12 (polydodecanamide), nylon-46 (polytetramethylene adipamide), nylon-66 (polyhexamethylene adipamide), nylon-610, and nylon-612. Nylon-6 and nylon-66 are particularly suitable.

[0066] It should also be understood that it is possible to include aromatic monomer units in the polyamide so that it is considered aromatic (containing only aromatic monomer units, or both aliphatic and aromatic monomer units). Examples of aromatic dicarboxylic acids may include, for example, terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 1,4-phenylenedioxydiacetic acid, 1,3-phenylenedioxydiacetic acid, diphenic acid, 4,4'-oxydibenzoic acid, diphenylmethane-4,4'-dicarboxylic acid, diphenylsulfone-4,4'-dicarboxylic acid, 4,4'-biphenyldicarboxylic acid, and the like.Particularly suitable aromatic polyamides are poly(nonamethylene terephthalamide) (PA9T), poly(nonamethylene terephthalamide / nonamethylene decanediamide) (PA9T / 910), poly(nonamethylene terephthalamide / nonamethylene dodecanediamide) (PA9T / 912), poly(nonamethylene terephthalamide / 11-amino undecane amide) (PA9T / 11), poly(nonamethylene terephthalamide / 12-amino dodecane amide) (PA9T / 12), poly(decamethylene terephthalamide / 11-amino undecane amide) (PA10T / 11), poly(decamethylene terephthalamide / 12-amino dodecane amide) (PA10T / 12), poly(decamethylene terephthalamide / 11-amino undecane amide) (PA10T / 11), poly(decamethylene terephthalamide / 12-amino dodecane amide) (PA10T / 12), poly(decamethylene terephthalamide / 11-amino undecane amide) (PA10T / 12), poly(decamethylene terephthalamide / 12-amino do ... poly(decamethylene terephthalamide / hexamethylene hexanediamide) (PA10T / 66), poly(dodecamethylene terephthalamide / dodecamethylene dodecanediamide) (PA10T / 1010), poly(decamethylene terephthalamide / decamethylene dodecanediamide) (PA10T / 1012), poly(decamethylene terephthalamide / tetramethylene hexanediamide) (PA10T / 46), poly(decamethylene terephthalamide / caprolactam) (PA10T / 6), poly(decamethylene terephthalamide / hexamethylene hexanediamide) (PA10T / 66), poly(dodecamethylene terephthalamide / dodecamethylene dodecanediamide) (PA10T / 66) Poly(dodecamethylene terephthalamide / hexamethylene hexanediamide) (PA12T / 66), poly(dodecamethylene terephthalamide / caprolactam) (PA12T / 1212), poly(dodecamethylene terephthalamide / caprolactam) (PA12T / 6), poly(dodecamethylene terephthalamide / hexamethylene hexanediamide) (PA12T / 66), and the like.

[0067]

[0058] Polyamides suitable for the polymer matrix are typically crystalline or semi-crystalline in nature and therefore have a measurable melting temperature. The melting temperature may be relatively high so that the composition can impart a significant degree of heat resistance to the resulting part. For example, the polyamide may have a melting temperature of about 220°C or higher, in some embodiments about 240°C to about 325°C, and in some embodiments about 250°C to about 335°C. The polyamide may also have a relatively high glass transition temperature, such as about 30°C or higher, in some embodiments about 40°C or higher, and in some embodiments about 45°C to about 140°C. Glass transition and melting temperatures may be determined as is well known in the art, such as by ISO Test Nos. 11357-2:2020 (glass transition) and 11357-3:2018 (melting) using differential scanning calorimetry ("DSC").

[0068]

[0059] Propylene polymers may also be suitable aliphatic high performance polymers used in the polymer matrix. In general, any of a variety of propylene polymers or combinations of propylene polymers may be used in the polymer matrix, such as, for example, propylene homopolymers (e.g., syndiotactic, atactic, isotactic, etc.), propylene copolymers, etc. In one embodiment, a propylene polymer may be used that is, for example, an isotactic or syndiotactic homopolymer. In general, the term "syndiotactic" refers to a tacticity in which a significant portion (if not all) of the methyl groups are alternately on opposite sides along the polymer chain. On the other hand, the term "isotactic" generally refers to a tacticity in which a significant portion (if not all) of the methyl groups are on the same side along the polymer chain. In yet other embodiments, copolymers of propylene with α-olefin monomers may be used. Specific examples of suitable α-olefin monomers may include ethylene, 1-butene, 3-methyl-1-butene, 3,3-dimethyl-1-butene, 1-pentene, 1-pentene with one or more methyl, ethyl or propyl substituents, 1-hexene with one or more methyl, ethyl or propyl substituents, 1-heptene with one or more methyl, ethyl or propyl substituents, 1-octene with one or more methyl, ethyl or propyl substituents, 1-nonene with one or more methyl, ethyl or propyl substituents, ethyl, methyl or dimethyl substituted 1-decene, 1-dodecene, and styrene. The propylene content of such copolymers may be from about 60 mol% to about 99 mol%, in some embodiments from about 80 mol% to about 98.5 mol%, and in some embodiments from about 87 mol% to about 97.5 mol%. The α-olefin content may similarly range from about 1 mol % to about 40 mol %, in some embodiments from about 1.5 mol % to about 15 mol %, and in some embodiments, from about 2.5 mol % to about 13 mol %.

[0069] Suitable propylene polymers typically have a DTUL value of about 80° C. to about 250° C., in some embodiments about 100° C. to about 220° C., and in some embodiments about 110° C. to about 200° C., as determined according to ISO 75-2:2013 at a load of 1.8 MPa. The glass transition temperature of such polymers may also be, for example, about 10° C. to about 80° C., in some embodiments about 15° C. to about 70° C., and in some embodiments about 20° C. to about 60° C., as determined according to ISO 11357-2:2020. Furthermore, the melting temperature of such polymers may be, for example, about 50° C. to about 250° C., in some embodiments about 90° C. to about 220° C., and in some embodiments about 100° C. to about 200° C., as determined according to ISO 11357-3:2018.

[0070]

[0061] Oxymethylene polymers may also be suitable aliphatic high performance polymers used in the polymer matrix. The oxymethylene polymer may be one or more homopolymers, copolymers, or mixtures thereof. Homopolymers are prepared by polymerization of formaldehyde or formaldehyde equivalents, such as cyclic oligomers of formaldehyde. Copolymers may contain one or more comonomers that are generally used to prepare polyoxymethylene compositions. Typically, the comonomers used include alkylene oxides of 2-12 carbon atoms. If a copolymer is selected, the amount of comonomer is usually 20 weight percent or less, in some embodiments 15 weight percent or less, and in some embodiments about 2 weight percent or less. Comonomers may include ethylene oxide and butylene oxide. Homo- and copolymers are: 1) end-capped by chemical reaction of their terminal hydroxy groups to form ester or ether groups; or 2) copolymers that are not fully end-capped but have some free hydroxy ends from the comonomer units. Typical end groups in each case are acetate and methoxy.

[0071] B. Optional Ingredients In some cases, one or more other optional components may be used in the polymer composition. In such embodiments, the polymer matrix typically comprises from about 20% to about 90% by weight, in some embodiments from about 25% to about 80% by weight, and in some embodiments from about 30% to about 70% by weight of the polymer composition, and the optional components similarly typically comprise from about 10% to about 80% by weight, in some embodiments from about 20% to about 75% by weight, and in some embodiments from about 30% to about 70% by weight of the polymer composition.

[0072] In one embodiment, for example, the polymeric composition may contain inorganic filler particles distributed within the polymeric matrix. Such particles typically comprise from about 60 to about 300 parts by weight, in some embodiments from about 80 to about 250 parts by weight, in some embodiments from about 90 to about 225 parts by weight, and in some embodiments from about 100 to about 200 parts by weight per 100 parts by weight of the polymeric matrix. The inorganic filler particles may comprise, for example, from about 30% to about 70% by weight, in some embodiments from about 35% to about 65% by weight, and in some embodiments from about 40% to about 60% by weight of the polymeric composition. In certain embodiments, the particles may be formed from natural and / or synthetic minerals, such as talc, mica, halloysite, kaolinite, illite, montmorillonite, vermiculite, palygorskite, pyrophyllite, calcium silicate, aluminum silicate, wollastonite, and the like. Talc is particularly suitable for use in the polymeric composition. Other suitable inorganic filler particles may include, for example, silica, alumina, calcium carbonate, and the like.

[0073]

[0064] The particles may have a variety of different morphologies and shapes depending on the desired results. For example, the particles may be in the shape of spheres, crystals, rods, disks, tubes, strings, and the like. In one embodiment, for example, the particles may generally be spherical, with an aspect ratio (ratio of median diameter to thickness) of about 0.7 to about 1.3, in some embodiments about 0.8 to about 1.2, and in some embodiments about 0.9 to about 1.1 (e.g., 1). Regardless of their particular shape, however, the particles are generally selectively controlled to have a particular median (D50) diameter, for example, about 4 micrometers or less, in some embodiments about 0.01 to about 3 micrometers, in some embodiments about 0.05 to about 2 micrometers, and in some embodiments about 0.1 to about 1.5 micrometers, as determined, for example, by a laser diffraction particle size analyzer (e.g., Mastersizer 3000). The particles may also have a narrow particle size distribution. That is, at least about 70% by volume of the particles, in some embodiments at least about 80% by volume of the particles, and in some embodiments at least about 90% by volume of the particles may have a size within the ranges noted above. Furthermore, within the general size ranges noted above, it may sometimes be desirable to use a blend of particles having different sizes to achieve target properties. For example, fine particles may be used in combination with coarse particles having a median diameter larger than the fine particles. The fine particles may have a median diameter of, for example, about 1.5 micrometers or less, in some embodiments about 0.1 to about 1.2 micrometers, and in some embodiments about 0.2 to about 1 micrometer, while the coarse particles may have a median diameter of about 1.5 micrometers to about 4 micrometers, in some embodiments about 1.8 to about 3.5 micrometers, and in some embodiments about 2 to about 3 micrometers.

[0074]

[0065] The particles may also have a density of, for example, about 1 to about 50 square meters (m) per gram. 2 / g), in some embodiments from about 2 to about 20 m 2 / g, in some embodiments from about 4 to about 12 m 2The specific surface area may be controlled to be 0.1 to 1.0 μm / g. In general, the term "specific surface area" refers to the surface area as determined by the physical gas adsorption (BET) method of Bruanauer, Emmet and Teller, Journal of American Chemical Society, Vol. 60, 1938, p. 309, using nitrogen as the adsorption gas.

[0075] In one particular embodiment, silica particles may be used. Silica particles may be formed using a variety of different processes, such as fumed processes, precipitation, etc. Fumed particles are particularly suitable due to their high surface area and small particle size. For example, fumed silica is amorphous SiO2 that can be produced by gas phase hydrolysis of silicon tetrachloride in a hydrogen-oxygen flame. Three-dimensional branched chain aggregates are produced from the melting of primary particles in the flame. During cooling, these aggregates coalesce into a fine powder with particle size within the range noted above. Fumed silica has silanol groups that can react under acidic conditions to form a crosslinked network. The resulting siloxane bridges are compounds of silicon and oxygen in which each atom of silicon is bonded to four oxygen atoms to form a tetrahedral structure in a manner similar to the bond of carbon to hydrogen in methane, with the bonds being approximately the same strength in each case. This structure is commonly found in dioxides and silicates, where the SiO4 groups appear in chains or rings. By creating siloxane cross-links, a gel is formed which traps the liquid phase of the electrolyte.

[0076]

[0067] Various other types of additives may also be used in the polymer composition. In one embodiment, for example, mineral fibers (or "whiskers") may be used, such as those derived from silicates, such as neosilicates, sorosilicates, inosilicates (e.g., calcium inosilicates, e.g., wollastonite; calcium magnesium inosilicates, e.g., tremolite; calcium magnesium iron inosilicates, e.g., actinolite; magnesium iron inosilicates, e.g., anthophyllite; etc.), phyllosilicates (e.g., aluminum phyllosilicates, e.g., palygorskite), tectosilicates, etc.; sulfates, such as calcium sulfate (e.g., dehydrated or anhydrous gypsum); mineral wool (e.g., rock or slag wool); etc. Particularly suitable are fibers having the desired hardness values, including fibers derived from inosilicates, such as wollastonite (Mohs hardness of 4.5 to 5.0), commercially available from Nyco Minerals under the trade name Nyglos® (e.g., Nyglos® 4W or Nyglos® 8). The mineral fibers may have a median width (e.g., diameter) of about 1 to about 35 micrometers, in some embodiments about 2 to about 20 micrometers, in some embodiments about 3 to about 15 micrometers, and in some embodiments about 7 to about 12 micrometers. In addition to having the size characteristics noted above, the mineral fibers may also have a relatively high aspect ratio (average length divided by median width) to help further improve the mechanical and surface properties of the resulting polymeric composition. For example, the mineral fibers may have an aspect ratio of about 2 to about 100, in some embodiments about 2 to about 50, in some embodiments about 3 to about 20, and in some embodiments about 4 to about 15. The volume average length of such mineral fibers may range, for example, from about 1 to about 200 micrometers, in some embodiments from about 2 to about 150 micrometers, in some embodiments, from about 5 to about 100 micrometers, and in some embodiments, from about 10 to about 50 micrometers.

[0077] The impact modifier may also be a polymer containing olefinic monomer units derived, for example, from one or more α-olefins. Examples of such monomers include linear and / or branched α-olefins having, for example, from 2 to 20 carbon atoms, typically from 2 to 8 carbon atoms. Specific examples include ethylene, propylene, 1-butene; 3-methyl-1-butene; 3,3-dimethyl-1-butene; 1-pentene; 1-pentene with one or more methyl, ethyl or propyl substituents; 1-hexene with one or more methyl, ethyl or propyl substituents; 1-heptene with one or more methyl, ethyl or propyl substituents; 1-octene with one or more methyl, ethyl or propyl substituents; 1-nonene with one or more methyl, ethyl or propyl substituents; ethyl, methyl or dimethyl substituted 1-decene; 1-dodecene; and styrene. Particularly desirable α-olefin monomers are ethylene and propylene. The olefin polymer may also be in the form of a copolymer containing other monomer units known in the art. For example, other suitable monomers may include "(meth)acrylic" monomers, which include acrylic and methacrylic monomers, as well as their salts or esters, such as acrylate and methacrylate monomers.Examples of such (meth)acrylic monomers are methyl acrylate, ethyl acrylate, n-propyl acrylate, i-propyl acrylate, n-butyl acrylate, s-butyl acrylate, i-butyl acrylate, t-butyl acrylate, n-amyl acrylate, i-amyl acrylate, isobornyl acrylate, n-hexyl acrylate, 2-ethylbutyl acrylate, 2-ethylhexyl acrylate, n-octyl acrylate, n-decyl acrylate, methylcyclohexyl acrylate, cyclopentyl acrylate, cyclohexyl acrylate, methyl methacrylate, ethyl methacrylate, and the like. The impact modifier may include ethylene, 2-hydroxyethyl methacrylate, n-propyl methacrylate, n-butyl methacrylate, i-propyl methacrylate, i-butyl methacrylate, n-amyl methacrylate, n-hexyl methacrylate, i-amyl methacrylate, s-butyl methacrylate, t-butyl methacrylate, 2-ethylbutyl methacrylate, methylcyclohexyl methacrylate, cinnamyl methacrylate, crotyl methacrylate, cyclohexyl methacrylate, cyclopentyl methacrylate, 2-ethoxyethyl methacrylate, isobornyl methacrylate, and the like, as well as combinations thereof. In one embodiment, for example, the impact modifier may be an ethylene methacrylic acid copolymer ("EMAC"). When used, the relative proportions of the monomeric components may be selectively controlled. The α-olefin monomer(s) may, for example, comprise from about 55% to about 95% by weight of the copolymer, in some embodiments from about 60% to about 90% by weight, and in some embodiments from about 65% to about 85% by weight. Other monomeric components (e.g., (meth)acrylic monomers) may comprise from about 5% to about 35% by weight of the copolymer, in some embodiments from about 10% to about 32% by weight, and in some embodiments from about 15% to about 30% by weight.

[0078] Other suitable olefin copolymers may be "epoxy-functionalized" containing, on average, two or more epoxy functional groups per molecule. The copolymer may also contain epoxy-functional monomer units. One example of such a unit is an epoxy-functional (meth)acrylic monomer component. For example, suitable epoxy-functional (meth)acrylic monomers may include those containing 1,2-epoxy groups, such as, but not limited to, glycidyl acrylate and glycidyl methacrylate. Other suitable epoxy-functional monomers include allyl glycidyl ether, glycidyl ethyl acrylate, and glycidyl itaconate. Other suitable monomers may also be used to help achieve the desired molecular weight. In a particular embodiment, for example, the copolymer may be a terpolymer formed from an epoxy-functional (meth)acrylic monomer component, an α-olefin monomer component, and a non-epoxy-functional (meth)acrylic monomer component. The copolymer may be, for example, poly(ethylene-co-butyl acrylate-co-glycidyl methacrylate). If used, the epoxy-functional (meth)acrylic monomer(s) typically comprise from about 1% to about 20% by weight of the copolymer, in some embodiments from about 2% to about 15% by weight, and in some embodiments, from about 3% to about 10% by weight.

[0079] A wide variety of additional additives may also be included in the polymer composition, such as lubricants, thermally conductive fillers, pigments, antioxidants, stabilizers, surfactants, waxes, flame retardants, anti-dripping additives, nucleating agents (e.g., boron nitride), fibrous fillers (e.g., glass fiber), antistatic agents, abrasive compounds, and other materials added to enhance properties and processability. For example, lubricants capable of withstanding the processing conditions of the polymer without substantial decomposition may be used in the polymer composition. Examples of such lubricants include fatty acid esters, their salts, esters, fatty acid amides, organophosphate esters, and hydrocarbon waxes of the type commonly used as lubricants in the processing of engineering plastic materials, including mixtures thereof. Suitable fatty acids typically have a backbone carbon chain of about 12 to about 60 carbon atoms, such as myristic acid, palmitic acid, stearic acid, arachidic acid, montanic acid, octadecanoic acid, parinaric acid, and the like. Suitable esters include fatty acid esters, fatty alcohol esters, wax esters, glycerin esters, glycol esters, and complex esters. Fatty acid amides include aliphatic primary amides, aliphatic secondary amides, bisamides and alkanolamides of methylene and ethylene, such as palmitic acid amide, stearic acid amide, oleic acid amide, N,N'-ethylene bisstearamide, and the like. Metal salts of fatty acids, such as calcium stearate, zinc stearate, magnesium stearate, and the like; hydrocarbon waxes, including paraffin wax, polyolefin and oxidized polyolefin waxes, and microcrystalline waxes, are also suitable. Particularly suitable lubricants are stearic acid, salts or amides, such as pentaerythritol tetrastearate, calcium stearate, or N,N'-ethylene bisstearamide. When used, the lubricant(s) typically comprise from about 0.05% to about 1.5% by weight of the polymer composition, and in some embodiments, from about 0.1% to about 0.5% by weight (by weight).

[0080] Regardless of the components used, they may be melt processed or blended together. The components may be fed, separately or in combination, into an extruder that includes at least one screw rotatably mounted and housed within a barrel (e.g., a cylindrical barrel) and may define a feed section and a melt section located downstream from the feed section along the length of the screw. The extruder may be a single screw or a twin screw extruder. The speed of the screw may be selected to achieve the desired residence time, shear rate, melt processing temperature, and the like. For example, the screw speed may range from about 50 to about 800 revolutions per minute ("rpm"), in some embodiments from about 70 to about 150 rpm, and in some embodiments from about 80 to about 120 rpm. The apparent shear rate during melt blending may also be in the range of about 100 s -1 ~about 10,000 seconds -1 , in some embodiments, about 500 seconds -1 ~about 5000 seconds -1 , in some embodiments, about 800 seconds -1 ~about 1200 seconds -1 The apparent shear rate may be in the range of 4Q / πR 3 where Q is the volumetric flow rate of the polymer melt (m 3 / s") and R is the radius ("m") of the capillary (e.g., extrusion die) through which the molten polymer flows.

[0081] The polymeric composition can exhibit certain beneficial properties that enable its use in ball bearings. For example, when subjected to the tests described herein, the polymeric composition can exhibit an indentation of no more than about 15 micrometers, in some embodiments no more than about 12 micrometers, in some embodiments from about 1 to about 10 micrometers, and in some embodiments from about 2 to about 11 micrometers, as determined, for example, by dropping a tip described herein 4,000 times from a height of 1 mm with a 20 gram load or 20,000 times from a height of 0.5 mm with a 70 gram load.

[0082] The polymer composition can also exhibit excellent mechanical properties. For example, the composition can have a mechanical strength of about 10 kJ / m2 as measured at 23° C. according to ISO Test No. 179-1:2010. 2 In some embodiments, from about 15 to about 60 kJ / m 2 In some embodiments, from about 20 to about 50 kJ / m 2 The composition may also exhibit a Charpy unnotched impact strength of about 150 to about 500 MPa, in some embodiments about 160 to about 400 MPa, and in some embodiments about 170 to about 350 MPa; a tensile strength of about 0.5% or more, in some embodiments about 0.8% to about 15%, and in some embodiments about 1% to about 10%; and / or a tensile modulus of about 11,000 MPa or more, in some embodiments about 12,000 MPa to about 30,000 MPa, in some embodiments about 13,000 MPa to about 25,000 MPa, and in some embodiments about 14,000 MPa to about 22,000 MPa, as determined at 23° C., for example, according to ISO Test No. 527:2019. The polymeric composition may also exhibit a flexural modulus of about 11,000 MPa or greater, in some embodiments from about 12,000 MPa to about 30,000 MPa, and in some embodiments from about 13,000 MPa to about 25,000 MPa; a flexural strength of about 40 to about 500 MPa, in some embodiments from about 100 to about 400 MPa, and in some embodiments from about 150 to about 350 MPa; and / or a flexural strain at break of about 0.5% or greater, in some embodiments from about 1% to about 15%, and in some embodiments from about 2% to about 10%, as determined at 23° C. according to, for example, ISO Test No. 178:2019. The composition may also exhibit a flexural modulus of about 45 kJ / m2 as determined at 23° C. according to ISO Test No. 179-1:2010. 2 In some embodiments, the range is about 45 to about 100 kJ / m 2 In some embodiments, from about 50 to about 80 kJ / m 2In addition, the compositions may also exhibit a deflection temperature under load (DTUL) of greater than or equal to about 180° C., and in some embodiments, from about 190° C. to about 280° C., as measured at a specified load of 1.8 MPa in accordance with ASTM D648-18.

[0083] The polymeric composition may also exhibit a Rockwell surface hardness of about 65 or less, and in some embodiments, about 60 or less, and in some embodiments, from about 40 to about 55, as determined according to ASTM D785-08(2015) (scale M). Further, the polymeric composition may also exhibit a Rockwell surface hardness of about 65 or less, and in some embodiments, about 60 or less, and in some embodiments, from about 40 to about 55, as determined according to ASTM D785-08(2015) (scale M). -1 The composition may have a melt viscosity of about 200 Pa·s or less, in some embodiments about 150 Pa·s or less, in some embodiments about 10 to about 100 Pa·s, and in some embodiments about 20 to about 90 Pa·s, measured at a shear rate of 100° C. The melt viscosity may be measured at 15° C. above the melting temperature of the composition (e.g., about 305° C.) according to ISO Test No. 11443:2014.

[0084] III. Product Use

[0075] Once tested according to the present invention, the samples may be used in a wide variety of possible product applications, such as in camera modules, lighting devices, etc. In one embodiment, for example, the samples may be used in a camera module that includes a housing in which is disposed a lens module that includes one or more lenses. However, as known to those skilled in the art, the particular configuration of the camera module may vary.

[0085]

[0076] Referring to FIG. 5, for example, an embodiment of the camera module 100 is shown including a lens module 120 contained in a housing, where the lens module 120 includes a lens barrel 121 coupled to a lens holder 123. The lens barrel 121 may have a hollow cylindrical shape such that a plurality of lenses for imaging an object can be stored therein in an optical axis direction 1. The lens barrel 121 may be inserted into a hollow cavity provided in the lens holder 123, and the lens barrel 121 and the lens holder 123 may be coupled to each other by fasteners (e.g., screws), adhesives, and the like. The lens module 120 including the lens barrel 121 may be movable in the optical axis direction 1 by an actuator assembly 150 (e.g., for autofocus). For example, in the illustrated embodiment, the actuator assembly 150 may include a magnetic body 151 and a coil 153 configured to move the lens module 120 in the optical axis direction 1. The magnetic body 151 may be mounted on one side of the lens holder 123, and the coil 153 may be arranged to face the magnetic body 151. The coil 153 may be mounted on a substrate 155, which may then be mounted on the housing 130 so that the coil 153 faces the magnetic body 151. The actuator assembly 150 may include a driver 160 mounted on the substrate 155 and outputting a signal (e.g., a current) for driving the actuator assembly 150 in response to a control input signal. The actuator assembly 150 may receive the signal and generate a driving force to move the lens module 120 in the optical axis direction 1. If desired, a stopper 140 may be mounted on the housing 130 to limit the moving distance of the lens module 120 in the optical axis direction 1. Furthermore, a shield case 110 (e.g., metal) may be coupled to the housing 130 and encapsulate the outer surface of the housing 130, thereby blocking electromagnetic waves generated during the operation of the camera module 100.

[0086]

[0077] The actuator assembly may also include a guide unit disposed between the housing and the lens module to help guide the movement of the lens module. Any of a variety of guide units known in the art may be used, such as spring(s), ball bearing(s), electrostatic force generator, water pressure generator, etc. For example, a spring may be used that generates a preload that acts on the lens module and guides it in the desired optical axis direction. Alternatively, as illustrated in the embodiment shown in FIG. 1, a ball bearing 170 may act as the guide unit of the actuator assembly 150. More specifically, the ball bearing 170 may be in contact with an outer surface of the lens holder 123 and an inner surface of the housing 130 to guide the movement of the lens module 120 in the optical axis direction 1. That is, the ball bearing 170 may be disposed between the lens holder 123 and the housing 130 and may guide the movement of the lens module 120 in the optical axis direction by rolling. For this purpose, any number of ball bearings 170 may be used, generally 2 or more, in some embodiments 3-20, in some embodiments 4-12, etc. The ball bearings 170 may be spaced apart or in contact with one another, and may be stacked in a direction perpendicular to the optical axis direction 1. The size of the ball bearings 170 may vary as known to one of ordinary skill in the art. For example, the ball bearings may have an average size (e.g., diameter) of about 800 micrometers or less, in some embodiments about 600 micrometers or less, in some embodiments about 400 micrometers or less, and in some embodiments about 50 to about 200 micrometers.

[0087]

[0078] In particular, the samples tested according to the present invention may be used for any of the various components of a camera module. Referring again to FIG. 5, for example, the test samples may be used to form all or part of the guide unit (e.g., ball bearing 170), the housing 130, the lens barrel 121, the lens holder 123, the substrate 155, the stopper 140, the shielding case 110, and / or other parts of the camera module. Regardless, the desired component(s) may be formed using a variety of different techniques. Suitable techniques may include, for example, injection molding, low pressure injection molding, extrusion compression molding, gas injection molding, foam injection molding, low pressure gas injection molding, low pressure foam injection molding, gas extrusion compression molding, foam extrusion compression molding, extrusion molding, foam extrusion molding, compression molding, foam compression molding, gas compression molding, and the like. For example, an injection molding system may be used that includes a mold into which the polymer composition can be injected. The time in the injector can be controlled and optimized to prevent the polymer matrix from solidifying prematurely. When the cycle time is reached and the barrel is full to discharge, a piston can act to inject the composition into the mold cavity. Compression molding systems can also be used. Similar to injection molding, molding of the polymer composition into the desired article also occurs in the mold. The composition can be placed into the compression mold using any known technique, for example by being picked up by an automated robotic arm. The temperature of the mold can be maintained above the solidification temperature of the polymer matrix for a desired period of time to allow solidification. The molded object can then be solidified by lowering it below its melting temperature. The resulting product can be demolded. The cycle time for each molding process can be adjusted to match the polymer matrix, achieve sufficient bonding, and enhance the productivity of the overall process.

[0088] As is known in the art, the resulting camera modules may be used in a wide variety of electronic devices, such as portable electronic devices (e.g., cell phones, handheld computers, tablets, watches, etc.), computers, televisions, automotive parts, etc. In a particular embodiment, the polymer composition may be used in camera modules, such as those commonly used in wireless communication devices (e.g., cell phones).

[0089] The following test methods may be used to determine the above referenced properties.

[0090] Test Method Melt Viscosity: Melt viscosity (Pa·s) was measured over 1,000 s using a Dynisco LCR7001 capillary rheometer according to ISO Test No. 11443:2014. -1 and 15°C above the melt temperature. The rheometer orifice (die) had a diameter of 1 mm, a length of 20 mm, an L / D ratio of 20.1, and an entrance angle of 180°. The barrel diameter was 9.55 mm + 0.005 mm and the rod length was 233.4 mm.

[0091] Melting Temperature: As known in the art, melting temperature ("Tm") may be determined by differential scanning calorimetry ("DSC"). Melting temperature is the Differential Scanning Calorimetry (DSC) peak melting temperature as determined by ISO Test No. 11357-2:2020. Under the DSC procedure, as specified in ISO Standard 10350, samples were heated and cooled at 20°C per minute using DSC measurements performed on a TA Q2000 Instrument.

[0092]

[0083] Deflection Temperature Under Load ("DTUL"): Deflection temperature under load may be determined according to ISO Test No. 75-2:2013 (technically equivalent to ASTM D648-18). In particular, a test specimen sample having a length of 80 mm, a thickness of 10 mm, and a width of 4 mm may be subjected to an edgewise three-point bend test with a prescribed load (maximum outer fiber stress) of 1.8 megapascals. The test specimen may be lowered into a silicone oil bath in which the temperature is increased at 2°C / min until it is deflected 0.25 mm (0.32 mm as per ISO Test No. 75-2:2013).

[0093] Tensile modulus, tensile stress, and tensile elongation: Tensile properties may be tested according to ISO Test No. 527:2019 (technically equivalent to ASTM-D638-14). Modulus and strength measurements may be performed on the same test specimen sample having a length of 80 mm, a thickness of 10 mm, and a width of 4 mm. The test temperature may be 23°C, and the test speed may be 1 or 5 mm / min.

[0094] Flexural Modulus, Flexural Stress and Flexural Elongation: Flexural properties may be tested according to ISO Test No. 178:2019 (technically equivalent to ASTM D790-10). The test may be performed with a support span of 64 mm. The test may be performed on the center section of an uncut ISO-3167 multipurpose bar. The test temperature may be 23° C. and the test speed may be 2 mm / min.

[0095] Charpy Impact Strength: Charpy properties may be tested according to ISO Test No. ISO 179-1:2010 (technically equivalent to ASTM D256-10, Method B). This test may be performed using a Type 1 specimen size (80 mm length, 10 mm width and 4 mm thickness). When testing notched impact strength, the notch may be a Type A notch (0.25 mm bottom radius). The specimen may be cut from the central portion of the general purpose bar using a single tooth milling machine. The test temperature may be 23°C.

[0096] Rockwell Hardness: Rockwell hardness is a measure of the indentation resistance of a material and may be determined according to ASTM D785-08 (scale M). The test is performed by first pressing a steel ball indenter into the surface of the material with a small, specified load. The load is then increased to a large, specified load and decreased back to the original small load. Rockwell hardness is a measure of the net increase in indenter depth and is calculated by subtracting the amount of penetration divided by the scale divisions from 130.

[0097]

[0088] The invention can be better understood with reference to the following examples.

[0098] Examples 1-7 The device illustrated in FIG. 1 was assembled. The trigger assembly included a tip formed from a ceramic material. The tip defined a rounded end hemisphere having a diameter of 835 micrometers. The head was cone-shaped with a length of 5,985 micrometers from the distal end of the ball end to the base of the head where the head meets the body portion. At this junction, the diameter of the head was 3,981 micrometers. The body portion of the tip was cylindrical with a length of 6,062 micrometers. The tip also included a threaded attachment as illustrated. The total length of the tip from the end of the ball to the end of the attachment was 17 millimeters. The tip was threaded onto the end of a trigger rod that was 82 millimeters long and included an 18 millimeter long frame to which a weight could be attached via a threaded attachment. The sample was held on a stage. Samples were formed from a variety of different liquid crystal polymer compositions as noted below, each having a thickness of 0.23 millimeters. The protocol was run with either a 20 gram or 70 gram weight attached to the trigger assembly. The drop height of the trigger assembly was set to either 1.0 mm or 0.5 mm. The number of impacts was either 4,000 or 20,000 impacts. The table below shows the average depth of the indentation formed on the samples (in micrometers).

[0099] [Table 1]

[0100]

[0090] These and other modifications and variations of the present invention can be implemented by those skilled in the art without departing from the spirit and scope of the present invention. Furthermore, it should be understood that aspects of the various embodiments can be interchanged in whole or in part. Furthermore, those skilled in the art will recognize that the above description is for illustrative purposes only and is not intended to limit the invention as further described in the appended claims.

Claims

1. 1. A ball dent test instrument comprising an actuator in communication with a trigger assembly, the trigger assembly including a tip including a first end and an opposite second end defining a rounded terminus, the tip further including a trigger rod extending from the tip second end to a trigger rod end.

2. 10. The ball dent test instrument of claim 1 further comprising one or more weights removably attachable to said trigger rod end.

3. The ball dent test instrument of claim 1 , wherein the rounded end defines a radius of curvature of about 5 millimeters or less.

4. The ball dent test instrument of claim 1 , wherein the rounded end defines a radius of curvature of about 500 micrometers or less.

5. The ball dent test instrument of claim 1 , wherein the rounded end comprises a metal, a ceramic, a glass, a polymeric composition, or a combination thereof.

6. The ball dent test instrument of claim 1 , wherein the tip includes a head extending from the rounded end.

7. The ball dent test instrument of claim 6 , wherein the head has a conical shape.

8. The ball dent test instrument of claim 6 further comprising a body portion extending from said head portion.

9. 2. The ball dent test instrument of claim 1, wherein said tip is removably attachable to said trigger rod.

10. The ball dent test instrument of claim 1 , wherein a control system is configured to initiate movement of the trigger assembly by the actuator.

11. The ball dent test instrument of claim 1 , wherein the actuator is configured to move the trigger assembly a predetermined distance from a stage.

12. The ball dent testing instrument of claim 11 , wherein the actuator is further configured to release the trigger assembly following the movement, thereby releasing the trigger assembly.

13. The ball dent test instrument of claim 1 , further comprising a stage actuator configured to move the stage in one or more directions.

14. 1. A method of testing a sample for ball indentation comprising: placing the sample on a stage of a testing instrument; and moving a trigger assembly including a tip having a rounded end toward the sample such that the end impacts the sample one or more times.

15. 15. The method of claim 14, further comprising inspecting a surface of the sample following the impact to determine characteristics of any indentations in the surface caused by the impact.

16. The method of claim 14 , wherein movement of the trigger assembly towards the stage is initiated by release of the trigger assembly such that the trigger assembly free falls towards the stage under gravity alone.

17. The method of claim 14 , further comprising the step of removably attaching one or more weights to the trigger assembly.

18. The method of claim 14 , wherein the tip impacts the sample multiple times.

19. The method of claim 14 , wherein the sample comprises a polymer composition.

20. 20. The method of claim 19, wherein the polymer composition comprises a polymer matrix comprising a thermotropic liquid crystalline polymer.

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