Aromatic Hollow Resin Particles for Low-Dielectric Resin Layers

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Solution Overview

Problem

Existing hollow resin particles, such as acrylic and styrene-based particles, fail to effectively reduce dielectricity and dielectric loss tangent due to high relative dielectric constants and difficulties in solvent removal, leading to incomplete hollow portions and high production costs.

Innovation Solution

A hollow resin particle with a shell portion containing an aromatic polymer formed by polymerizing a monomer composition of aromatic crosslinkable, monofunctional, and (meth)acrylic acid ester-based monomers, produced through suspension polymerization with a low-boiling organic solvent, allowing easy solvent removal and complete hollow formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If acrylic hollow resin particles are used, then the hollow structure is formed, but the relative dielectric constant and dielectric loss tangent remain high

Engineering Contradiction:

Improvehollow structureVSAvoidrelative dielectric constant and dielectric loss tangent

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material composition of the hollow particle shell from acrylic resin to a copolymer containing aromatic vinyl monomers (low dielectric constant) and specific functional monomers. This parameter change in material composition directly reduces the relative dielectric constant and dielectric loss tangent while maintaining the hollow structure's volume reduction effect.

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If styrene-based hollow resin particles are produced using saturated hydrocarbon solvents, then the hollow structure is formed, but solvent removal becomes difficult and production cost increases

Engineering Contradiction:

Improvehollow structureVSAvoidsolvent removal and production cost

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent changes the solvent parameter from saturated hydrocarbons (high boiling point, difficult removal) to aromatic hydrocarbons with boiling points of 80-120°C. This parameter change enables easy solvent removal through simple distillation or evaporation, reducing production cost while maintaining the hollow particle structure formation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses aromatic hydrocarbons as temporary solvent objects that are easily removed after serving their purpose in polymerization. These solvents act as disposable medium that facilitates hollow structure formation but is subsequently eliminated through simple heating, avoiding the need for complex solvent removal processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If styrene-based hollow resin particles are produced, then the relative dielectric constant is reduced, but the hollow portion cannot be completely replaced with air due to solvent removal difficulties

Engineering Contradiction:

Improverelative dielectric constantVSAvoidhollow portion completeness

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent changes the solvent boiling point parameter to 80-120°C, which allows complete solvent removal through simple heating processes. This ensures the hollow portion can be fully replaced with air or vacuum, achieving complete hollow structure without residual solvent, while maintaining low dielectric properties.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The hollow resin particle achieves significant reductions in dielectricity and dielectric loss tangent by introducing an empty area, with a simple production method that lowers production costs.

Implementation Method 1

a shell portion and a hollow portion surrounded by the shell portion, wherein the shell portion contains an aromatic polymer (P1) obtained by polymerizing a monomer composition

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

produced through suspension polymerization with a low-boiling organic solvent, allowing easy solvent removal and complete hollow formation

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12534600B2Hollow resin particle and method for producing same

Publication Date: 2026.01.27 SEKISUI PLASTICS CO LTD

AI summary

Provided is a hollow resin particle that can reduce the dielectricity and dielectric loss tangent of a resin layer by introducing an empty area thereinto, and can be obtained by forming a hollow portion in a simple manner. Also provided is a method of producing such hollow resin particle in a simple manner. A hollow resin particle according to an embodiment of the present invention is a hollow resin particle including a shell portion and a hollow portion surrounded by the shell portion, wherein the shell portion contains an aromatic polymer (P1) obtained by polymerizing a monomer composition containing an aromatic crosslinkable monomer (a), an aromatic monofunctional monomer (b), and a (meth)acrylic acid ester-based monomer (c) having a specific structure.