Liquid Crystal Polymer Film Manufacturing via Solution Coating
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Solution Overview
Problem
Conventional methods for manufacturing liquid crystal polymer films are prone to peeling or cracking due to high orientational order of molecules, and adding additives like polytetrafluoroethylene is difficult to control rheological properties, leading to non-uniform thickness and degraded film quality.
Innovation Solution
A method involving dispersing liquid crystal polymer powder in a solvent with optional additives, coating, and heating to specific temperatures to form a film with controlled molecular orientation, allowing for uniform thickness and improved film properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid crystal polymer films are produced by melting and molding methods, then production efficiency is improved, but molecular arrangement has high orientational order causing peeling or cracking under external stresses
Solution Approach 1:
The patent changes the fundamental processing parameter from melt-state molding to solution-based coating. The liquid crystal polymer is dissolved in a solvent to form a coating solution, which is then applied to a substrate. After coating, the solvent is removed through drying or heating, leaving a film with controlled molecular orientation that reduces peeling and cracking while maintaining production efficiency.
2Ease of manufacture
If additives like polytetrafluoroethylene are added to control rheological properties, then processability is improved, but film thickness uniformity deteriorates and film quality is degraded
Solution Approach 1:
The patent changes the approach to rheological control by selecting solvents with appropriate properties (viscosity, boiling point, solubility parameters) instead of adding polymeric additives. This allows control of the coating solution's flow characteristics and film formation behavior during the coating and drying processes, achieving both ease of manufacture and uniform film thickness without the complications of additive-based rheology modification.
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 method produces films with lower water absorption, dielectric constant, and coefficient of thermal expansion, along with superior dimensional stability and electrical properties, suitable for high-frequency applications.
Implementation Method 1
the second temperature is at least higher than a liquid crystal transition temperature of the liquid crystal polymer powder
Implementation Method 2
heating the coating layer to a first temperature to remove the solvent in the coating layer
Data Source
AI summary
A method of manufacturing a liquid crystal polymer film, which includes the following operations: providing a liquid crystal polymer powder; uniformly dispersing the liquid crystal polymer powder in a solvent to form a mixed solution; coating the mixed solution on a carrier board to form a coating layer; heating the coating layer to a first temperature to remove the solvent in the coating layer; heating the liquid crystal polymer powder to a second temperature after the solvent is removed to form the liquid crystal polymer film.