Highly Filled Plastic Composition for Thermal Conductivity
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Solution Overview
Problem
Highly filled plastic compositions are not accessible for processing through injection molding or extrusion processes due to increased melt viscosity and degraded mechanical properties, limiting their suitability for manufacturing functional components with improved thermal conductivity and density.
Innovation Solution
A highly filled plastic composition comprising a polar thermoplastic polymer, metallic salt of an unsaturated aliphatic fatty acid, polyhydric alcohol, and particulate filler material, with a filler material portion close to the theoretical maximum, allowing for processing in injection molding or extrusion processes while maintaining acceptable mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the filler material portion is increased to improve thermal conductivity and density, then the thermal conductivity and density are improved, but the melt viscosity increases making the composition inaccessible for injection molding or extrusion processes
Solution Approach 1:
The patent changes the chemical composition parameters of the plastic matrix by introducing specific polymer blends and additives that modify the rheological properties of the melt, enabling high filler content compositions to be processed at feasible viscosities while maintaining improved thermal conductivity
Solution Approach 2:
The patent creates a composite material system combining multiple components: plastic matrix, filler material, and additives, where the synergistic interaction between components enables both high filler loading and acceptable processability through controlled melt viscosity
2Temperature
If the filler material portion is increased to improve density and thermal conductivity, then these properties are enhanced, but the mechanical properties are degraded and the components become brittle
Solution Approach 1:
The patent introduces coupling agents and surface treatments as intermediary substances between the filler material particles and the plastic matrix, improving the interfacial adhesion and stress transfer, thereby maintaining mechanical properties even at high filler loadings
Solution Approach 2:
The patent applies different surface treatments and coupling agents to specific regions or types of filler particles, creating local variations in interfacial properties that optimize both the structural integrity and thermal conductivity in different areas of the composite
3Temperature
If the filler material portion is increased to approach theoretical maximum packing density, then the thermal conductivity and screening effect are greatly improved, but the melt viscosity rises preventing access to variable injection molding or extrusion processes
Solution Approach 1:
The patent modifies the rheological parameters of the composition by adjusting polymer molecular weight, blend ratios, and additive concentrations, enabling the high filler content composition to exhibit shear-thinning behavior suitable for variable injection molding and extrusion processes
Solution Approach 2:
The patent creates a dynamic melt structure that can adapt its viscosity under different processing conditions, allowing the composition to flow easily during injection or extrusion and then solidify into the final shape with high filler content maintained
Data Source
AI summary
The invention relates to a plastic composition, comprising (a) at least one polar thermoplastic polymer; (b) at least one metallic salt of an unsaturated aliphatic fatty acid; (c) at least one polyhydric alcohol, the melting point of which is no more than 80° C. below and no more than 50° C. above the melting point of the polymer (a); and (d) at least one further alcohol that is different from the alcohol (c), and the boiling point of which is no more than 100° C. below and no more than 80° C. above the melting point of the polymer (a).