Aromatic Polycarbonate Resin Composition with Graphite and Sulfonate Compounds
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Solution Overview
Problem
Current resin compositions fail to achieve a balance between electrical conductivity, stiffness, and outgas reduction while maintaining heat stability during melt molding, particularly in the production of electronic components where size reduction and heat generation are concerns.
Innovation Solution
A resin composition comprising 65-85 parts by weight of aromatic polycarbonate resin, 15-35 parts by weight of graphite with a specific particle diameter and shape, and 0.1-5 parts by weight of a polyether ester or polyester having a sulfonate group, which enhances electrical conductivity, stiffness, and outgas reduction properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon black is added to provide electrical conductivity, then electrical conductivity is improved, but stiffness deteriorates
Solution Approach 1:
The patent changes the type of conductive filler from carbon black to graphite, and specifically controls the particle size parameters (D10, D50, D90) and aspect ratio of graphite particles to achieve both electrical conductivity and stiffness. This parameter optimization resolves the contradiction between conductivity and mechanical strength
Solution Approach 2:
The patent creates a composite material system combining aromatic polycarbonate resin with specifically sized graphite particles (5-60 μm) and sulfonate-containing compounds. This composite approach allows simultaneous achievement of electrical conductivity from graphite and stiffness from the resin-graphite composite structure
2Strength
If graphite is added to provide stiffness and electrical conductivity, then stiffness and conductivity are improved, but outgassing increases
Solution Approach 1:
The patent introduces sulfonate-containing compounds as intermediary substances that interact with graphite particles. These compounds appear to suppress outgassing from the graphite-resin composite while maintaining the stiffness and conductivity benefits of graphite, thus resolving the contradiction between mechanical properties and outgassing reduction
3Ease of manufacture
If conventional resin compositions are used, then manufacturing is simple, but heat stability during melt molding deteriorates
Solution Approach 1:
The patent optimizes the particle size distribution parameters of graphite (D10: 2-10 μm, D50: 5-60 μm, D90: 10-200 μm) and aspect ratio (3:1 to 50:1) to achieve both good processability during melt molding and high heat stability. This parameter control allows the material to maintain stability at processing temperatures while remaining easy to manufacture
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 composition achieves high electrical conductivity, stiffness, and excellent melt heat stability, reducing outgassing and ensuring the stability of electronic components by effectively using graphite and sulfonate-containing compounds.
Implementation Method 1
The addition of graphite is known as means of providing stiffness and electrical conductivity to a thermoplastic resin
Implementation Method 2
The addition of graphite is known as means of providing stiffness and electrical conductivity to a thermoplastic resin
Implementation Method 3
a resin composition which has excellent electrical conductivity and stiffness and is suppressed in outgassing caused by a temperature rise
Implementation Method 4
exhibiting excellent heat stability during melt molding in the production process
Data Source
AI summary
A resin composition which has high electrical conductivity and high stiffness, is suppressed in outgassing caused by a temperature rise and is excellent in heat stability during melt molding in the production process and a molded article thereof.The resin composition comprises (A) 65 to 85 parts by weight of an aromatic polycarbonate resin (component A), (B) 15 to 35 parts by weight of graphite having an average particle diameter of 5 to 60 μm (component B), and (C) 0.1 to 5 parts by weight of at least one compound (component C) selected from the group consisting of a polyester having a sulfonate group (component C-1) and a polyether ester having a sulfonate group (component C-2) based on 100 parts by weight of the total of the components A and B.