Component tray

Abstract

A component carrier tray includes a tray body. The tray body has an upper surface with grooves. The component carrier tray is composed of a thermoplastic composition comprising: (a) a biodegradable plastic; and (b) a biomass-derived solid wax. The biodegradable plastic is present in 100 parts by weight, and the biomass-derived solid wax is present in 0.3 to 1.3 parts by weight.

Description

Component carrier disk COMPONENT TRAY Technical Field

[0001] This case relates to a component carrier containing biodegradable plastic. Prior Technology

[0002] Component carrier trays are used to support and position electronic components (such as integrated circuits, chips, resistors, capacitors, etc.) during manufacturing, testing, assembly, handling, or packaging. To ensure portability and avoid damage to the supported components, component carrier trays are generally made of plastic. Summary of the Invention

[0003] However, the recent surge in plastic usage has led to increasingly serious pollution problems. Therefore, the creators are aware that some component carriers are being repurposed from biodegradable plastics.

[0004] However, biodegradable plastics cure at a significantly slower rate than conventional plastics during injection molding, resulting in a longer curing time. In other words, when using biodegradable plastics to form corresponding plastic products, a longer injection molding cycle is required to ensure the plastic is fully cured. However, an excessively long injection molding cycle reduces the number of parts that can be produced per unit time, leading to low production capacity. Conversely, forcibly shortening the injection molding cycle to increase production capacity can result in product deformation, burrs, or even plastic parts sticking to the mold and failing to demold smoothly, ultimately leading to poor quality of the component carrier.

[0005] In view of the aforementioned problems, one embodiment of this invention provides a component carrier tray, which includes a tray body and a groove. The tray body has an upper surface, and the groove is formed by recessing from the upper surface. The component carrier tray is composed of a thermoplastic composition, which includes a biodegradable plastic and a biomass-derived solid wax. The biodegradable plastic is 100 parts by weight, and the biomass-derived solid wax is 0.3 to 1.3 parts by weight.

[0006] The creators discovered that biomass-derived solid wax can act as a nucleating agent for biodegradable plastics. Therefore, by incorporating biomass-derived solid wax into the aforementioned thermoplastic composition, the overall crystallization rate of the thermoplastic composition can be increased. Consequently, compared to simple biodegradable plastics, the thermoplastic composition of one or more embodiments of this invention has a shorter curing time. Accordingly, even with shorter injection molding cycles, the component carrier plate formed from this thermoplastic composition can still have a smooth surface and the desired shape. Simple Explanation of the Diagram

[0007] Figure 1 is a perspective view of an embodiment of the component carrier disk of this case. Figure 2 is a perspective view of another embodiment of the component carrier disk of this case. Implementation

[0008] The following provides a detailed description of the component carrier disk described in this case. The following description provides many different embodiments, which are merely illustrative and not intended to limit the scope of this case. Furthermore, the phrases "in one embodiment" or "in one embodiment" appearing in different places in the specification do not necessarily refer to the same embodiment. Unless otherwise stated herein or in obvious conflict, the features and structures described herein can be combined in one or more embodiments by any suitable method.

[0009] In this specification, the phrase "from one value to another" is a general representation to avoid listing all values ​​within that range in the specification. Therefore, unless otherwise stated or clearly contrary to reasonable ordinary knowledge in the art to which this application pertains, a specific range of values ​​described in this specification is equivalent to disclosing any value within that range and the smaller range of values ​​defined by that value (including its significant digits and the next significant digit), as if the arbitrary value and the smaller range were explicitly stated in the specification. For example, when the specification states "1 to 10," it is equivalent to disclosing the ranges of "3 to 5" and "2.5 to 6.8," regardless of whether other values ​​are listed in the specification.

[0010] Unless otherwise specified, the terms "contains" and "includes" used in this article are open-ended terms and should be interpreted as "containing but not limited to...".

[0011] In this document, unless otherwise indicated, the term "or" is used to refer to a non-exclusive "or", such that "A or B" includes "A but not B (or A exists but B does not exist)", "B but not A (or B exists but A does not exist)" and "A and B (both A and B exist)".

[0012] Please refer to Figures 1 and 2. Figure 1 is a perspective view of one embodiment of the component carrier 1 of this invention. Figure 2 is a perspective view of another embodiment of the component carrier 1 of this invention. The component carrier 1 includes a body 11 and a recess 13. The body 11 may be solid or hollow. The body 11 has an upper surface 111, and the recess 13 is formed by recessing downward from the upper surface 111. The recess 13 can be used to accommodate or position components. There are no particular limitations on the shape of the body 11, the number of recesses 13, and their shape. For example, in the component carrier 1 shown in Figure 1, the body 11 is generally rectangular in top view, and the component carrier 1 has a single recess 13. In the component carrier 1 shown in Figure 2, the body 11 is generally square in top view, and the component carrier 1 has two recesses 13.

[0013] The component carrier 1 of one or more embodiments of this invention is composed of a thermoplastic composition comprising (a) a biodegradable plastic and (b) a biomass-derived solid wax.

[0014] [(a) Biodegradable plastics]

[0015] Biodegradable plastics are plastics that can be broken down into water, carbon dioxide, and / or methane by living organisms (usually microorganisms). In some embodiments, biodegradable plastics may be polylactic acid (PLA), poly(butylene adipate-co-terephthalate) copolymer (PBAT), polybutylene succinate (PBS), polypropylene carbonate (PPC), polyhydroxyalkanoates (PHA), polycaprolactone (PCL), polyvinyl alcohol (PVA), polyglycolic acid (PGA), polyglycerol sebacate (PGS), polyhydroxybutyrate (PHB), copolymers formed from the above polymer monomers, and mixtures thereof, but are not limited thereto.

[0016] In some embodiments, the thermoplastic composition does not contain biodegradable plastics. For example, in some embodiments, the thermoplastic composition does not contain polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyethylene terephthalate, polyurethane, polyamide, or polyimide. By eliminating biodegradable plastics from the thermoplastic composition, the long-term environmental burden of the component carrier 1 can be further reduced.

[0017] In some embodiments, the only biodegradable plastic in the thermoplastic composition is polybutylene succinate. Because polybutylene succinate has better tensile strength, flexural modulus, and impact resistance compared to other biodegradable plastics, the component carrier 1 can maintain better mechanical properties while retaining low environmental impact.

[0018] [(b) Biomass-derived solid waxes]

[0019] In this case, "biomass-derived solid wax" refers to natural or processed waxes derived from plant, animal, or other biological resources, with a weight-average molecular weight (Mw) of less than 20,000, and being a solid oily component at 25°C. The weight-average molecular weight can be determined using gel permeation chromatography (GPC) with a calibration curve established using polystyrene standards.

[0020] In some embodiments, the biomass-derived solid wax is selected from at least one of the following groups: rice bran wax, soybean wax, sunflower seed wax, carnauba wax, and candelilla wax.

[0021] As a supplementary explanation, compared to biomass-derived solid waxes, non-biomass-derived solid waxes can be listed as hydrocarbon waxes such as ethylene wax, paraffin wax, ceresin wax, microcrystalline wax, hydrogenated microcrystalline wax, Fischer-Tropsch wax, (ethylene / propylene) copolymer, and synthetic wax.

[0022] The creators discovered that biomass-derived solid waxes can act as nucleating agents for biodegradable plastics, increasing their crystallization rate. Furthermore, because biomass-derived solid waxes are derived from biological rather than petrochemical sources, compared to using non-biomass-derived solid waxes, the thermoplastic plastic compositions of one or more embodiments of this invention exhibit faster crystallization rates while also having relatively lower overall carbon footprints.

[0023] In some embodiments, since biomass-derived solid wax is already used as a nucleating agent, the thermoplastic composition does not contain any additional organic or inorganic nucleating agents other than biomass-derived solid wax.

[0024] Inorganic nucleating agents include: calcium silicate, talc, kaolin, montmorillonite, synthetic mica, calcium sulfide, boron nitride, barium sulfate, aluminum oxide, and neodymium oxide.

[0025] Regarding organic nucleating agents, the following can be listed: (1) Sodium benzoate, potassium benzoate, lithium benzoate, calcium benzoate, magnesium benzoate, barium benzoate, lithium terephthalate, sodium terephthalate, potassium terephthalate, calcium oxalate, sodium laurate, potassium laurate, sodium myristate, potassium myristate, calcium myristate, sodium octadecanoate, calcium octadecanoate, sodium stearate, potassium stearate, lithium stearate, calcium stearate, magnesium stearate, barium stearate, sodium lignite, calcium lignite, sodium toluene, sodium salicylate, potassium salicylate, zinc salicylate, diphenyl (1) Metal salts of organic carboxylic acids such as aluminum formate, potassium dibenzoate, lithium dibenzoate, sodium β-naphthenate, and sodium cyclohexaneformate; (2) Organic sulfonates such as sodium p-toluenesulfonate and sodium sulfoisophthalate; (3) Carboxylic acid amides such as stearic acid amide, ethyl dilaurate amide, palmitic acid amide, hydroxystearic acid amide, erucic acid amide, and tris(tert-butyl amide) pyromellitic acid; (4) Benzyl sorbitol and its derivatives; and (5) Metal salts of phenyl phosphonates (e.g., sodium 2,2-methylene bis(4,6-di-tert-butylphenyl) phosphate).

[0026] In some embodiments, the only biomass-derived solid wax in the thermoplastic composition is rice bran wax. The creators found that, compared to other biomass-derived solid waxes, rice bran wax is more effective in shortening curing time at the same addition amount.

[0027] In one or more embodiments of this invention, the amount of biomass-derived solid wax added relative to 100 parts by weight of biodegradable plastic is 0.3 to 1.3 parts by weight. When the amount added is less than 0.3 parts by weight, the effect of reducing curing time is not significant; when the amount added exceeds 1.3 parts by weight, it will affect the mechanical properties or processability of the thermoplastic composition. In some embodiments, the amount of biomass-derived solid wax added is 0.5 to 1.0 parts by weight. When the amount of biomass-derived solid wax added is 0.5 to 1.0 parts by weight, the thermoplastic composition can have a significantly shorter curing time.

[0028] In some embodiments, the thermoplastic composition may also contain other processing aids such as lubricants, antistatic agents, plasticizers, antioxidants, and light stabilizers. Examples of lubricants may include, but are not limited to, ethylene bis-stearamide, erucamide, dioctyl phthalate, or organosilicone oils. Examples of plasticizers may include, but are not limited to, epoxidized soybean oil or naphthenic rubber oils. Antioxidants may include, but are not limited to, hindered phenolic, thioester, or phosphite antioxidants. Light stabilizers may include, but are not limited to, benzotriazoles and hindered amines. The above-mentioned aids may be used alone or in combination of two or more.

[0029] In some embodiments, if 100 parts by weight of biodegradable plastic is taken as the weight of the thermoplastic composition, the thermoplastic composition may contain 0.1 to 1.0 parts by weight of processing aids. In some embodiments, if 100 parts by weight of biodegradable plastic is taken as the weight of the thermoplastic composition, the content of processing aids in the thermoplastic composition may be in the range of 0.1 to 0.5 parts by weight or 0.1 to 0.3 parts by weight.

[0030] In some embodiments, the thermoplastic composition consists solely of biodegradable plastic and biomass-derived solid wax. Therefore, the thermoplastic composition is entirely composed of biorenewable resources, with no petrochemical-derived components, minimizing the environmental impact of the component carrier 1 manufactured from it. Further, in some embodiments, the thermoplastic composition consists of polybutylene succinate and rice bran wax. The inventors have found that, compared to other biomass-derived solid waxes, the combination of polybutylene succinate and rice bran wax has a significantly better curing time reduction effect. Thus, the thermoplastic composition can maintain low environmental impact while having the shortest possible curing time.

[0031] [Manufacturing Method of Component Carrier Disk 1]

[0032] The component carrier 1 of one or more embodiments of this invention can be manufactured by, for example, the following steps: (1) forming a thermoplastic composition; (2) melt-blending the thermoplastic composition; and (3) molding.

[0033] Regarding the step "(1) forming a thermoplastic composition", the required amounts of (a) biodegradable plastic, (b) biomass-derived solid wax, and processing aids (if any) can be directly mixed to form the thermoplastic composition. The mixing step can be performed using a high-speed mixer, a V-type mixer, or a drum mixer, etc.

[0034] Regarding the step "(2) Melt-mixing of the thermoplastic composition", this can be performed by introducing the thermoplastic composition into a heated extruder containing a screw. The extruder can be any of a single-screw extruder, a twin-screw extruder, or a planetary mixing extruder. The applied temperature should be sufficient to melt the thermoplastic composition without causing thermal degradation. In some cases, the melt-mixing step can be performed at a temperature of approximately 150–300°C and a screw speed of approximately 100–300 rpm. In some cases, to facilitate subsequent processing, the melt-mixed thermoplastic composition can be granulated into pellets using a granulator before proceeding to the subsequent step "(3) Molding".

[0035] Regarding the "(3) Molding process" step, the thermoplastic plastic component particles after melting, mixing and granulation can be put into the hopper of the injection molding machine, heated and plasticized, and injected into the mold cavity under the set injection pressure. After holding pressure, cooling and solidifying, the mold is opened and demolded to obtain the component carrier plate 1.

[0036] [Preparation and Property Testing of Thermoplastic Compositions]

[0037] The features and advantages of one or more embodiments of the thermoplastic composition of this application will be described more specifically below through examples of the preparation of thermoplastic compositions and comparative examples. Furthermore, although the following examples of composition preparation are described herein, some details may be appropriately modified without departing from the scope claimed in this application. That is, the examples of composition preparation described below should not be interpreted restrictively on this application.

[0038] <Examples 1 to 3 of the preparation of thermoplastic plastic compositions>

[0039] According to Table 1, the biodegradable plastic and the biomass-derived solid wax of each thermoplastic composition preparation example were fed into a twin-screw extruder (model ZSK25, L / D=40) and mixed at a temperature of 160~220℃ and a screw speed of 200rpm. The mixture was then granulated by a granulator (model GZML-110L-150) to obtain the corresponding thermoplastic composition preparation example granules.

[0040] Table 1 Biodegradable plastics Biomass-derived solid wax Biodegradable plastics weight Biomass-derived solid wax weight Preparation Example 1 Polybutylene succinate Rice bran wax 99.50 (100) 0.50 (0.50) Preparation Example 2 Polybutylene succinate Rice bran wax 99.25 (100) 0.75 (0.76) Preparation Example 3 Polybutylene succinate Soy wax 99.50 (100) 0.5 (0.50)

[0041] The polybutylene succinate (PBS) mentioned above was purchased from Huali Enterprise Co., Ltd., model TH803S; rice bran wax was purchased from Liuhe Chemical Co., Ltd., model LICOCARE RBW 102; and soybean wax was purchased from Shunyi Chemical Raw Materials Co., Ltd., model Cargill C3 soybean wax.

[0042] <Comparative Examples 1 and 2>

[0043] According to Table 2, the components corresponding to each comparative example were fed into a twin-screw extruder (model ZSK25, L / D=40) according to the weight proportions recorded in the table. The mixture was kneaded at a temperature of 160~220℃ and a screw speed of 200rpm, and then granulated by a granulator (model GZML-110L-150) to obtain the corresponding comparative example granules.

[0044] Table 2 Component 1 Component 2 Component 1 weight Component 2 weight Comparative Example 1 Polybutylene succinate No additions - - Comparative Example 2 Polybutylene succinate NA-11 99.50 (100) 0.50 (0.50)

[0045] The aforementioned "NA-11" was purchased from Yu-Di Technology Co., Ltd., and its composition is "sodium 2,2-methylene bis(4,6-di-tert-butylphenyl) phosphate" (its structure is shown in the following method (I)) organic nucleating agent, CAS NO: 85209-91-2. Formula (I)

[0046] <Curing Time / Curing Effect Test>

[0047] To evaluate the curing time / curing effect of each component, the particles of each component were fed into an injection molding machine. Under the same conditions (injection weight, equipment temperature, holding pressure, etc.), the mold was opened at different cooling times, and the shape and appearance of the formed plastic body were observed.

[0048] Specifically, the granules from the aforementioned thermoplastic composition preparation examples 1 to 4 and comparative examples 1 and 2 were fed into an injection molding machine (model: FS-90). The injection molding conditions were set as follows: heating temperature set to 200°C, injection weight to 43g, injection speed to 50mm / s, mold temperature set to 50°C, injection pressure set to 100MPa, holding pressure to 80MPa, and holding time to 20 seconds. The cooling stage began after the holding time ended. After the cooling stage, the mold was opened, and the formed plastic body was removed. The cooling time and the corresponding state of the formed plastic body are shown in Tables 3 and 4.

[0049] Table 3 Preparation Example 1 Preparation Example 2 Preparation Example 3 Cooling time 5 seconds, resulting in a plastic body state Cooling time 10 seconds, resulting in a plastic body state. - -

[0050] Table 4 Comparative Example 1 Comparative Example 2 Cooling time 5 seconds, resulting in a plastic body state Cooling time 10 seconds, resulting in a plastic body state. - Cooling time 30 seconds, resulting in a plastic body state. -

[0051] The results of each preparation example and comparative example were classified according to the following criteria, and the results are summarized in Table 5: Shape completeness: "○" indicates that it can form a complete long column with an overall length of A cm; "X" indicates that the overall length is less than A cm. Rough edge condition: "○" indicates no rough edge or rough edge length less than 0.5 cm; "△" indicates rough edge length more than 0.5 cm but less than 1 cm; "X" indicates rough edge length more than 1 cm.

[0052] Table 5 Cooldown time (seconds) Shape integrity Rough edges Preparation Example 1 5 ○ ○ Preparation Example 2 5 ○ ○ Preparation Example 3 5 X X Preparation Example 3 10 ○ △ Comparative Example 1 5 X (Unable to determine) Comparative Example 1 30 ○ △ Comparative Example 2 5 ○ X Comparative Example 2 10 ○ X

[0053] Please refer to Table 4 first. As shown in the results of Comparative Example 1 in Table 4, when only biodegradable plastic is used for injection molding, if the cooling time is only 5 seconds, the formed plastic body will be severely deformed and unable to form a complete long column (less than 1 cm in length), indicating that the plastic body has not been fully cured during this period. It is necessary to extend the cooling time to 30 seconds to make the plastic body formed in Comparative Example 1 have a long column shape, but some burrs can still be seen at the tip of the plastic body. It can be seen that when only biodegradable plastic is used to form plastic bodies, due to the slow curing speed of biodegradable plastic, a longer injection molding cycle is required to form a plastic body with the desired shape, which will lead to low production efficiency or uneven surface of the article formed in a short curing time.

[0054] Please refer to Table 3 next. In contrast, the thermoplastic compositions of one or more embodiments of this invention, such as Preparation Examples 1 to 3 which added biomass-derived solid wax, all formed a complete, elongated columnar plastic body within a cooling time of less than 10 seconds. That is, after adding biomass-derived solid wax, the curing time of the composition can be significantly reduced to approximately 30% of the original time. Therefore, it can be seen that adding biomass-derived solid wax can significantly increase the curing speed of biodegradable plastics, thereby shortening the product injection molding cycle and improving production efficiency. Furthermore, the articles formed from the thermoplastic compositions of one or more embodiments of this invention within a short curing time can also have a relatively smooth surface.

[0055] Furthermore, please refer to Preparation Examples 1 to 3 in Table 3. As can be seen from Table 3, in Preparation Example 3 using soybean wax as the biomass-derived solid wax, after only 5 seconds of cooling, the resulting plastic body still exhibits slight deformation and fails to form a complete elongated column, with some burrs at the tip. In contrast, Preparation Examples 1 to 2 using rice bran wax as the biomass-derived solid wax, even with only 5 seconds of cooling, successfully formed elongated columnar plastic bodies with almost no burrs at the tip. In other words, compared to other biomass-derived solid waxes, rice bran wax is more effective in shortening curing time at the same dosage. This demonstrates that using rice bran wax as a nucleating agent significantly accelerates the curing of the composition.

[0056] On the other hand, please refer to Preparation Example 1 and Preparation Example 3 in Table 3 and Comparative Example 2 in Table 4. As can be seen from the aforementioned test results, for Comparative Example 2 using a general inorganic nucleating agent, even with a cooling time set to 10 seconds, noticeable burrs still appeared at the tip of the formed plastic body. Looking back at Preparation Example 1 and Preparation Example 3, with cooling times of 10 seconds or less, the burrs at the tip of the formed plastic bodies were significantly reduced. Therefore, it can be concluded that using biomass-derived solid wax as a nucleating agent is significantly more effective than using a commercially available inorganic nucleating agent in accelerating curing.

[0057] The results of the above experiments show that using biomass-derived solid wax as a nucleating agent can significantly increase the crystallization rate of biodegradable plastics and shorten the injection molding cycle. Therefore, even with a shorter injection molding cycle, the component carriers formed from the thermoplastic composition of this invention can still have a smooth surface and the desired shape, thus achieving component carriers of better quality while maintaining high production capacity. Furthermore, since the main components of the thermoplastic composition of this invention are biodegradable plastics and biomass-derived solid wax, the long-term environmental burden of the component carriers 1 of this invention can be further reduced compared to component carriers formed using general plastics.

[0058] 1: Component carrier tray 11: Disc Body 111: Upper surface 13: Groove

Claims

1. A component carrier tray comprising: a tray body having an upper surface, wherein the upper surface has a groove; wherein the component carrier tray is composed of a thermoplastic composition comprising: (a) a biodegradable plastic; and (b) a biomass-derived solid wax; wherein, The biodegradable plastic is 100 parts by weight, and the biomass-derived solid wax is 0.3 to 1.3 parts by weight.

2. The element carrier as claimed in claim 1, wherein the biodegradable plastic is selected from at least one of the following groups: polylactic acid (PLA), poly(butylene adipate-co-terephthalate) copolymer (PBAT), polybutylene succinate (PBS), polypropylene carbonate (PPC), polyhydroxyalkanoates (PHA), polycaprolactone (PCL), polyvinyl alcohol (PVA), polyglycolic acid (PGA), polyglycerol sebacate (PGS), polyhydroxybutyrate (PHB), and copolymers formed from the above polymer monomers.

3. The component carrier as claimed in claim 2, wherein the thermoplastic composition does not contain polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyethylene terephthalate, polyurethane, polyamide, or polyimide.

4. The component carrier as claimed in claim 3, wherein the biodegradable plastic in the thermoplastic composition is only polybutylene succinate.

5. The element carrier as described in claim 1, wherein the biomass-derived solid wax is selected from at least one of the following groups: rice bran wax, soybean wax, sunflower seed wax, carnauba wax, and candelilla wax.

6. The component carrier as claimed in claim 5, wherein the thermoplastic composition does not contain any additional organic nucleating agents or inorganic nucleating agents other than the biomass-derived solid wax.

7. The component carrier as described in claim 6, wherein in the thermoplastic composition, the biomass-derived solid wax is only rice bran wax.

8. The component carrier as claimed in claim 1, wherein in the thermoplastic composition, the biodegradable plastic is only polybutylene succinate and the biomass-derived solid wax is only rice bran wax.

9. The component carrier disk as described in claim 8, wherein polybutylene succinate is 100 parts by weight and rice bran wax is 0.5 to 1.0 parts by weight.

10. The component carrier as claimed in claim 9, wherein the thermoplastic composition is composed of polybutylene succinate and rice bran wax.

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