Conductive Resin Surface Layer Using Filler Alignment and Carbonization
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Solution Overview
Problem
Conventional methods for creating resin members with enhanced electrical and thermal conductivity face challenges such as complex processes, high manufacturing costs, and difficulties in achieving uniform conductivity, particularly in forming complex wiring patterns and preventing carbonized matter from scattering during the carbonization process.
Innovation Solution
A resin member is produced with a surface alignment layer containing filler aligned in the surface direction, which is carbonized to form a graphite-rich layer, using a molding and carbonization process that applies shear stress and heat treatment to enhance electrical and thermal conductivity while preventing carbonized matter detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional carbonization methods are used to enhance electrical and thermal conductivity, then conductivity is improved, but the process becomes complex and manufacturing costs increase
Solution Approach 1:
The patent applies preliminary action by pre-aligning filler particles in the resin material before carbonization. The filler is oriented in the surface direction during molding, creating a pre-prepared structure that facilitates uniform conductivity development during subsequent carbonization. This preliminary arrangement simplifies the overall process by eliminating the need for complex post-processing alignment steps.
Solution Approach 2:
The patent implements local quality by creating an alignment layer specifically in the surface region of the resin member. This alignment layer contains filler particles that are preferentially oriented in the surface direction, concentrating the conductivity-enhancing properties where they are most needed. The localized treatment reduces overall process complexity compared to treating the entire material uniformly.
2Reliability
If conventional carbonization methods are used, then conductivity is enhanced, but manufacturing costs increase
Solution Approach 1:
The alignment layer is formed during the initial molding process through shear stress applied to molten resin, incorporating filler alignment without requiring separate expensive alignment equipment. This preliminary structuring during standard manufacturing reduces overall production costs while maintaining high conductivity performance.
Solution Approach 2:
The patent utilizes parameter changes by controlling the shear stress conditions during molding to achieve filler alignment. By adjusting processing parameters such as injection pressure and mold temperature, the filler orientation is controlled without adding complex process steps, thereby maintaining cost-effectiveness while achieving the desired conductivity enhancement.
3Reliability
If carbonization is performed to improve conductivity, then electrical and thermal performance is enhanced, but carbonized matter scatters and detaches from the base portion
Solution Approach 1:
The patent employs composite materials by combining the carbonized alignment layer with a base polymer and filler particles. The filler particles serve as a reinforcing scaffold that maintains structural integrity during carbonization, preventing the carbonized matter from scattering or detaching. This composite structure ensures both high conductivity and stable composition.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating filler particles into the resin material prior to carbonization. These filler particles act as a protective framework that restrains the carbonized substances during the carbonization process, preventing their scattering. The filler provides mechanical support that cushions against the disruptive forces generated during carbonization.
4Reliability
If filler is added to enhance conductivity, then electrical and thermal performance is improved, but the resin material becomes more complex
Solution Approach 1:
The patent applies local quality by concentrating filler particles in the surface alignment layer rather than uniformly distributing them throughout the entire resin member. This localized filler placement achieves the desired conductivity enhancement at the surface while maintaining simpler material composition in the bulk material, reducing overall complexity.
Solution Approach 2:
The filler alignment is performed preliminarily during the molding process itself, utilizing the flow and shear characteristics of molten resin. This preliminary alignment incorporates filler orientation without requiring additional processing steps or complex material formulations, thereby enhancing conductivity while keeping material composition relatively simple.
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 process effectively enhances the electrical and thermal conductivity of the resin member's surface, achieving high conductivity values and preventing carbonized matter scattering, thus improving the resin member's performance and manufacturing efficiency.
Implementation Method 1
In the carbonization step, the alignment layer is heat-treated, generating the carbonized portion including graphite
Implementation Method 2
molten resin corresponding to an area close to the surface of the resin member is subjected to shear stress and then solidified to form, close to the surface, the alignment layer including the pieces of filler aligned in the surface direction
Data Source
AI summary
A resin member is formed from a resin material containing filler and an insulating base polymer as a main component. The resin member includes an alignment layer close to a surface of the resin member. The alignment layer includes the filler aligned in the surface direction and the base polymer filling the space between pieces of the filler. The alignment layer includes a carbonized portion that is carbonized matter of the base polymer, contains graphite, and provides electrical conductivity and thermal conductivity.