Conductive Layer Formation in Composite Resin Particles
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Solution Overview
Problem
Existing conductive resin materials require high concentrations of expensive conductive materials, which increase production costs and can adversely affect the resin's workability and strength, while low concentrations result in insufficient conductivity.
Innovation Solution
A composite resin material particle is created by dispersively mixing conductive nano-materials into the surface of resin material particles using ultrasonic waves in a subcritical or supercritical carbon dioxide environment, forming a conductive layer that maintains continuity during molding, reducing the need for high material concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of conductive material is added to achieve sufficient conductivity, then the conductivity is improved, but the molding property and strength of the resin is lowered
Solution Approach 1:
The conductive material is concentrated in the surface layer of the resin particle rather than being uniformly distributed throughout the bulk. This creates a local conductive network at the surface while preserving the bulk resin properties, thereby achieving sufficient conductivity without compromising overall resin strength and molding properties.
Solution Approach 2:
The invention transitions from three-dimensional uniform distribution of conductive material to a two-dimensional surface-layer distribution. By forming a conductive layer only in the surface region of resin particles, the patent achieves conductivity enhancement with minimal conductive material dosage, avoiding the strength reduction that would result from bulk incorporation of large amounts of conductive filler.
2Quantity of substance
If the dose of expensive conductive material is reduced to lower production cost, then the cost is improved, but the conductivity becomes insufficient
Solution Approach 1:
By concentrating conductive material in the surface layer rather than distributing it uniformly throughout the resin particle, the invention achieves efficient use of conductive material. The surface layer forms effective conductive pathways while minimizing the total amount of expensive conductive material required, thus maintaining conductivity at lower dosages.
Solution Approach 2:
The invention creates a composite structure with distinct functional zones: a conductive surface layer and a non-conductive bulk resin. This composite architecture allows the conductive material to be strategically positioned where it is most needed for electrical performance, optimizing the balance between conductivity and material cost.
3Quantity of substance
If carbon black is used as conductive material to avoid high cost, then the cost is reduced, but the conductivity of the material itself is low requiring large dosage
Solution Approach 1:
The invention concentrates carbon black in the surface layer of resin particles, creating a high-density conductive network at the surface where it is most effective. This localized concentration compensates for the inherently low conductivity of carbon black, achieving sufficient overall conductivity with a smaller total dosage than would be required for uniform distribution.
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
This method allows for the production of highly conductive molding products with reduced conductive material usage, maintaining conductivity and strength while lowering production costs.
Implementation Method 1
dispersively mixing conductive nano-materials into the surface of resin material particles using ultrasonic waves
Implementation Method 2
in a subcritical or supercritical carbon dioxide environment
Implementation Method 3
the conductive material is kept from being freed due to the viscosity of the melted resin material liquid
Implementation Method 4
since carbon nano-materials are hydrophobic, they have a high affinity with resins
Data Source
AI summary
A composite resin material particle of the present invention includes: a resin material particle that is a material for producing a resin molding product; and a conductive nano-material, wherein a dispersion mixing layer, which is obtained by dispersedly mixing the conductive nano-material from the surface to the inside of the resin material particle, is formed over all of the surface or at least a part of the surface of the resin material particle, the conductive nano-material is dispersedly mixed within a resin material of the resin material particle in the dispersion mixing layer, and the whole of the dispersion mixing layer forms a conductive layer.