Liquid crystal polymer particle, manufacturing method thereof and polyimide film using the same
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Solution Overview
Problem
Conventional liquid crystal polymer (LCP) manufacturing methods require high temperatures and multiple labor-intensive steps like crushing, grinding, and sieving to achieve desired particle sizes, leading to equipment damage and increased costs, and fail to produce LCP with high melting points and small particle sizes efficiently.
Innovation Solution
A method involving acetylation and transesterification reactions in solvents with boiling points above 100°C, followed by solid-state polymerization at 200-250°C, produces LCP particles with a cumulative particle size distribution of 1.5 μm or less and a melting point above 300°C, eliminating the need for crushing and grinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional melt polycondensation is used to produce liquid crystal polymer, then the polymer can be manufactured, but high temperatures (200-350°C) are required which cause equipment damage and increase production costs
Solution Approach 1:
The patent changes the reaction temperature parameter from conventional 200-350°C to a lower range of 100-200°C by using a two-stage polymerization process (solution polymerization followed by solid-state polymerization), thereby avoiding equipment damage while still achieving high molecular weight LCP with melting point above 300°C
Solution Approach 2:
The patent performs preliminary solution polymerization to form oligomers before conducting solid-state polymerization. This preliminary action allows the reaction to proceed at lower temperatures initially, avoiding the need for high-temperature equipment while still achieving the desired final polymer properties
2Manufacturing precision
If conventional methods are used to obtain liquid crystal polymer particles of required size, then particle size can be achieved, but multiple labor-intensive steps (crushing, grinding, sieving) are required which increase production time and costs
Solution Approach 1:
The patent enables the polymerization reaction to self-form particles of the desired size range (D50 ≤ 1.5 μm, D99 ≤ 10 μm) directly during the solid-state polymerization process, eliminating the need for external size reduction operations like crushing and grinding. The system serves itself by producing the final particle morphology as an inherent outcome of the polymerization process
Solution Approach 2:
The patent extracts and eliminates the unnecessary intermediate steps of crushing, grinding, and sieving from the conventional manufacturing process. By using solution polymerization followed by solid-state polymerization, the process directly produces particles of the required size, removing the harmful extraction steps that reduce productivity
3Temperature
If higher melting point liquid crystal polymer is desired, then higher reaction temperature is needed, but this exacerbates equipment damage and production cost issues
Solution Approach 1:
The patent performs preliminary solution polymerization to build up the polymer chain structure at low temperatures, then completes the polymerization through solid-state polymerization. This staged approach allows the formation of high melting point LCP (above 300°C) without requiring high reaction temperatures, thus protecting equipment while achieving the desired thermal properties
Solution Approach 2:
The patent changes the polymerization temperature parameters from conventional high temperatures to a lower range (100-200°C for solution polymerization, 200-250°C for solid-state polymerization), while still achieving LCP with melting point above 300°C through the extended reaction time and two-stage process
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 achieves LCP particles with improved thermal stability and smaller particle sizes, reducing production costs and equipment wear, and enables the production of polyimide films with reduced thickness and surface roughness.
Implementation Method 1
adding the compound monomer to a solvent with a boiling point of 100° C. or above, and heating to the boiling point of the solvent for performing an acetylation reaction to obtain a first product
Implementation Method 2
adding a catalyst to the first product to perform a transesterification reaction for obtaining a second product
Implementation Method 3
performing a solid-state polymerization of the second product at a temperature of 200-250° C. to obtain the liquid crystal polymer particle
Data Source
AI summary
Provide a liquid crystal polymer particle, a manufacturing method thereof, and a polyimide film using the particle. The manufacturing method comprises the following steps: providing a compound monomer having a chemical structural formula of COOH—Ar—OH, wherein Ar is at least one conjugated cyclic structure; adding the compound monomer to a solvent with a boiling point of 100° C. or above, and heating to the boiling point of the solvent for performing an acetylation reaction to obtain a first product; adding a catalyst to the first product to perform a transesterification reaction for obtaining a second product; performing a solid-state polymerization of the second product at a temperature of 200-250° C. to obtain the liquid crystal polymer particle, a particle size distribution of which has a cumulative particle size at 50% (D50) of 1.5 um or less and a cumulative particle size at 99% (D99) of 10 um or less.