Aromatic Liquid Crystalline Polyester Resin for Thin-Walled Electronic Parts
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Solution Overview
Problem
Wholly aromatic liquid crystalline polyester resins face challenges in achieving both excellent formability and heat resistance, particularly in the context of manufacturing electronic parts with extremely thin walls, where existing compositions either compromise on mechanical strength or suffer from blistering and curvature issues during reflow processes.
Innovation Solution
A wholly aromatic liquid crystalline polyester resin composition with specific structural units and composition ratios, including structural units (I) to (V), combined with an inorganic filler, which provides enhanced formability, heat resistance, and mechanical strength, while minimizing curvature and blistering in molded articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the molecular amount of the liquid polymer is reduced to attain low viscosity and improve filling properties, then the formability is improved, but the mechanical strength of the molded article decreases and blisters occur on the surface during reflow treatment
Solution Approach 1:
The patent changes the chemical composition parameters of the polyester resin by incorporating specific structural units (I) to (V) in controlled molar ratios. This modifies the molecular structure to achieve optimal balance between viscosity and mechanical strength, allowing thin-walled parts to be filled properly while maintaining strength and preventing blisters during reflow
Solution Approach 2:
The patent creates a composite molecular structure by combining multiple different structural units (I) to (V) in specific proportions. This composite approach allows the resin to exhibit both low viscosity for good filling properties and high mechanical strength to prevent blisters during reflow treatment
2Ease of operation
If the molecular amount of the liquid polymer is reduced to attain low viscosity, then the flowability is improved, but blisters occur on the surface of the molded article during reflow treatment
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating specific structural units (I) to (V) in controlled molar ratios, which changes the viscosity-temperature relationship of the resin. This allows the material to maintain good flowability during injection while resisting blister formation during subsequent reflow treatment
Solution Approach 2:
The patent preemptively addresses the blister problem by designing a resin composition with specific structural units that inherently resist blister formation during reflow. The composition is engineered beforehand to maintain stability and prevent defect formation under high-temperature reflow conditions
3Manufacturing precision
If existing composition ratios are used to improve formability, then the filling property is enhanced, but heat resistance becomes insufficient
Solution Approach 1:
The patent changes the compositional parameters by specifying precise molar ratio ranges for structural units (I) to (V). This optimized composition achieves both improved formability for thin-walled parts and sufficient heat resistance to withstand reflow processing temperatures
Solution Approach 2:
The patent creates a dynamic balance in the resin composition where the specific combination of structural units allows the material to exhibit appropriate flow characteristics during molding while maintaining thermal stability during reflow, adapting its properties to different processing stages
Data Source
AI summary
Provided is a wholly aromatic liquid crystalline polyester resin having excellent heat resistance and formability. The wholly aromatic liquid crystalline polyester resin comprises structural units represented by the following formulae (I) to (V) as essential structural units,wherein the composition ratio (mol %) of the structural units (I) to (V) in the wholly aromatic liquid crystalline polyester satisfies the following conditions: 50 mol %≤structural unit (I)≤75 mol %; 6 mol %≤structural unit (II)≤20 mol %; 1 mol %≤structural unit (III)≤21.5 mol %; 0.5 mol %≤structural unit (IV)≤10.5 mol %; 2.5 mol %≤structural unit (V)≤22 mol %; structural unit (III)>structural unit (IV).