Aromatic Polyetherketone Molded Body: Electron-Beam Surface Crystallization
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Solution Overview
Problem
Rapid cooling of molds in resin molded bodies, necessary for shortening tact time, reduces surface strength due to hindered crystallization, leading to increased production costs and dimensional changes, while heat treatment to enhance crystallization prolongs the process and causes further issues.
Innovation Solution
An aromatic polyetherketone molded body with a surface layer portion having a higher degree of crystallization than the body portion, achieved through electron beam application, ensuring increased mechanical strength in the surface layer and maintaining shock absorption in the body portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid cooling of mold is applied to shorten tact time, then productivity is improved, but surface strength is reduced due to hindered crystallization
Solution Approach 1:
The patent applies electron beam irradiation to the molded body after molding to promote crystallization in the surface layer. This preliminary action of inducing crystallization through electron beam energy input resolves the contradiction by restoring surface strength that was compromised by rapid mold cooling, without requiring additional heat treatment steps that would extend tact time.
2Strength
If heat treatment such as annealing is applied to enhance crystallization, then surface strength is improved, but tact time becomes longer and production cost increases
Solution Approach 1:
The patent replaces the conventional thermal field (heat treatment) with an electron beam field to induce crystallization. This substitution allows crystallization to occur rapidly in the surface layer without requiring prolonged heat treatment, thereby improving surface strength while avoiding the time loss and cost increase associated with traditional annealing processes.
3Strength
If heat treatment is applied to progress crystallization, then surface strength is improved, but dimensional changes occur due to overall shrinkage
Solution Approach 1:
The patent applies electron beam irradiation specifically to the surface layer of the molded body, creating a localized crystallization effect. This local quality approach ensures that only the surface region undergoes crystallization and associated shrinkage, while the bulk material maintains its original dimensions, thereby improving surface strength without causing significant dimensional 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 solution enhances surface mechanical strength, suppresses wear and chipping, and maintains impact absorption, while minimizing dimensional changes and production costs.
Implementation Method 1
applying an electron beam to a surface of the molded body
Implementation Method 2
the degree of crystallization is made higher in the surface layer portion forming the surface than in the body portion inside the surface layer portion
Data Source
AI summary
[Object] To provide a technology capable of further improving the performance of an aromatic polyetherketone molded body.[Solving Means] An aromatic polyetherketone molded body includes: a body portion; and a surface layer portion covering the body portion. An infrared absorption spectrum is obtained by measurement using an infrared spectrophotometer for both the body portion and the surface layer portion, the infrared absorption spectrum including a peak A and a peak B, the peak A appearing in a wavenumber range of 1295 to 1340 cm−1, the peak B appearing in a wavenumber range of 1265 to 1295 cm−1. A ratio A′/B′ of strength A′ of the peak A to strength B′ of the peak B is higher in the surface layer portion than in the body portion.