Camera Module Polymer Composition Strength Adhesion
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Solution Overview
Problem
Camera module molded parts face issues with mechanical properties and adhesion strength, particularly the outer skin layer peeling off, leading to poor productivity and adhesion to other components.
Innovation Solution
A polymer composition comprising thermotropic liquid crystalline polymer and inorganic particles with a hardness of 2.5 or more on the Mohs scale, along with mineral fibers, is used to form molded parts, enhancing mechanical and adhesive properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plate-like substances (e.g., talc) and milled glass are added to liquid crystalline polymers to improve mechanical properties, then strength and elastic modulus are improved, but the outer skin layer peels off readily
Solution Approach 1:
The patent changes the particle hardness parameter by selecting inorganic particles with Mohs hardness of 2.5 or more (such as calcium carbonate, calcium sulfate, or barium sulfate), replacing traditional plate-like fillers. This parameter change resolves the contradiction by providing both mechanical strength enhancement and preventing skin layer peeling, as the appropriate hardness level improves strength while maintaining adhesion integrity.
Solution Approach 2:
The patent creates a composite material system combining liquid crystalline polymer with specific inorganic particles (having defined hardness and size characteristics). This composite approach resolves the contradiction by selecting particles with optimal properties: hardness of 2.5 or more for strength, and median width of 0.1-35 micrometers for preventing peeling, achieving both improved mechanical properties and maintained adhesion.
2Strength
If traditional polymer compositions are used to achieve smooth surfaces, then surface quality is good, but mechanical properties are insufficient
Solution Approach 1:
The patent changes the particle size parameter by specifying a median width of 0.1-35 micrometers for inorganic particles. This parameter optimization resolves the contradiction between mechanical strength and surface smoothness: particles within this size range provide sufficient mechanical reinforcement while remaining small enough to maintain surface smoothness and prevent defects in molded parts.
Solution Approach 2:
The patent applies local quality by ensuring uniform distribution of inorganic particles throughout the polymer matrix. This resolves the contradiction by locally reinforcing the material structure to improve mechanical strength while maintaining overall surface smoothness, as properly distributed particles of appropriate size enhance strength without creating surface irregularities.
3Productivity
If the skin layer adhesion is poor, then assembly productivity is reduced, but using stronger adhesives or treatments increases process complexity
Solution Approach 1:
The patent extracts the adhesion problem from the assembly process by addressing it at the material formulation stage. By incorporating inorganic particles with specific hardness (2.5 or more) and size (0.1-35 micrometers) directly into the polymer composition, the material itself gains improved adhesion properties, eliminating the need for additional adhesives or surface treatments and thereby maintaining high productivity without increasing process complexity.
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 polymer composition achieves improved mechanical strength, reduced delamination of the skin layer, and enhanced adhesion, making it suitable for compact camera modules with smooth surfaces and high mechanical properties.
Implementation Method 1
a polymer composition that comprises a thermotropic liquid crystalline polymer and inorganic particles having a hardness value of about 2.5 or more based on the Mohs hardness scale
Data Source
AI summary
A camera module containing a molded part (e.g., generally planar base, lens barrel mounted on the base, etc.) that is formed form a polymer composition is provided. The polymer composition includes a liquid crystalline polymer and inorganic particles that have a hardness value of about 2.5 or more based on the Mohs hardness scale.