Plasma-Treated LCP Powders for Low-Temperature Bonding
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Solution Overview
Problem
In press forming of liquid crystal polymer (LCP) powders, low processing temperatures result in insufficient bonding between particles and deformation, leading to undesired flow and low adhesion, while using LCP in varnish form or pulverized form faces issues of high hygroscopicity and gas barrier capability, and solvent handling problems.
Innovation Solution
Surface treatment of LCP powders with plasma or ultra violet rays enhances bonding strength, allowing for improved adhesion without increasing the temperature above the melting point, thus overcoming undesired flow and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If LCP powders are processed at low temperature to avoid deformation, then base material deformation is prevented, but bonding between particles is insufficient
Solution Approach 1:
The LCP powder particles are pre-coated with a binder resin before processing. This preliminary action ensures that when low temperature pressing is applied, the binder resin is already present to facilitate bonding between particles, eliminating the need for high temperatures to achieve adequate bonding strength.
Solution Approach 2:
A binder resin is introduced as an intermediary substance between LCP powder particles. The binder resin mediates the bonding process by adhering to particle surfaces and creating strong bonds between them at lower temperatures, preventing direct reliance on high temperature melting for bonding.
2Strength
If processing temperature is increased to improve bonding strength, then particle bonding is enhanced, but undesired flow and deformation occur
Solution Approach 1:
Particles are pre-coated with binder resin before the bonding process. This preliminary preparation allows bonding to occur at lower temperatures through the binder's adhesive properties, eliminating the need to raise temperature to melting point and thus preventing undesired flow and deformation.
Solution Approach 2:
The invention changes the bonding mechanism parameter from thermal melting-dependent bonding to binder-resin-dependent bonding. By shifting from a temperature-driven bonding process to a chemistry-driven bonding process, the system achieves strong bonding without the harmful effects of high temperature processing.
3Ease of operation
If LCP is dissolved in solvent to form varnish for application, then LCP can be applied to desired regions, but gas barrier capability decreases and hygroscopicity increases
Solution Approach 1:
A binder resin serves as an intermediary that enables the LCP powder to be applied in a dry state without requiring solvents. The binder resin provides the necessary adhesive properties for application and bonding, while the LCP powder itself remains in its intact crystalline form, preserving its excellent gas barrier properties and low hygroscopicity.
Solution Approach 2:
The invention eliminates the use of expensive and problematic solvents by using a dry powder formulation with binder resin. This approach avoids the need for solvent evaporation, drying, and associated environmental and handling issues, while maintaining applicability through the binder resin's adhesive properties.
4Strength
If LCP powder is completely fused to ensure bonding, then adhesion is improved, but melting point is exceeded causing base material deformation
Solution Approach 1:
LCP powder particles are pre-coated with binder resin before the bonding process. This preliminary action ensures that adequate adhesion is achieved through the binder's adhesive properties at lower temperatures, eliminating the need to completely fuse the LCP powder and avoid exceeding its melting point.
Solution Approach 2:
The binder resin acts as an intermediary that provides adhesion between LCP powder particles and the base material without requiring the LCP itself to melt. This intermediary mechanism achieves strong bonding while maintaining LCP powder integrity and avoiding temperature-induced deformation.
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 surface treatment significantly improves bonding strength between particles and between the LCP powders and the base material, enabling effective film formation and molding without weld lines, and enhancing the handling and adhesive properties of LCP powders.
Implementation Method 1
surface treatment with plasma or ultra violet rays
Implementation Method 2
surface treatment with plasma or ultra violet rays
Data Source
AI summary
Treated liquid crystal polymer powders have been subjected to surface treatment with plasma or ultra violet rays, a paste including the treated liquid crystal polymer powders and a dispersion medium, a liquid crystal polymer sheet comprising the treated liquid crystal polymer powders or the paste including the treated liquid crystal polymer powders and a dispersion medium into a sheet, a stack including the liquid crystal polymer sheet as a resin layer, and a method of manufacturing the treated liquid crystal polymer powders are provided by the present disclosure.