Liquid Crystal Polyester Resin Composition for Camera Modules
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Solution Overview
Problem
Conventional liquid crystal polymer resin compositions used in camera modules suffer from low surface hardness, leading to operation failures and particle exfoliation issues, which cannot be simultaneously addressed while maintaining stiffness, heat resistance, and thin-wall processability.
Innovation Solution
A liquid crystal polyester resin composition is developed by adding a specific amount of powder with Mohs hardness of 5 or more and primary particle diameter of 5 μm or less, along with carbon black, to achieve high surface hardness and reduce particle exfoliation during assembly and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional liquid crystal polymer resin composition is used, then heat resistance and thin-wall moldability are maintained, but surface hardness is low causing particle exfoliation and operation failures
Solution Approach 1:
The patent applies composite materials by combining liquid crystal polyester resin with specific inorganic fillers (silica, aluminum oxide, or titanium oxide) having controlled particle sizes (0.1-5 μm). This composite approach increases surface hardness while maintaining the base resin's heat resistance and moldability, preventing particle exfoliation and operation failures through the synergistic properties of the composite structure.
Solution Approach 2:
The patent applies parameter changes by carefully controlling the particle size (0.1-5 μm) and composition ratios of the inorganic fillers within the resin matrix. By optimizing these parameters, the resin achieves enhanced surface hardness without compromising the underlying heat resistance and thin-wall moldability characteristics of the liquid crystal polyester base material.
2Reliability
If surface hardness is increased to prevent particle exfoliation, then operation stability improves, but stiffness and heat resistance may be compromised
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution (0.1-5 μm) and composition ratios of inorganic fillers. This optimization ensures surface hardness improvement for operational stability while the controlled particle dimensions prevent excessive stiffness increase that would compromise the resin's inherent flexibility and heat resistance properties.
3Strength
If inorganic powder is added to increase surface hardness, then particle exfoliation is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by defining specific ranges for inorganic filler particle size (0.1-5 μm) and composition ratios. These controlled parameters enable standard injection molding processes to produce consistent, high-quality parts with enhanced surface hardness, avoiding the need for complex multi-step manufacturing procedures while achieving the desired performance improvement.
Data Source
AI summary
A liquid crystal polyester resin composition for camera modules is used, the composition including, based on 100 parts by mass of the composition as a whole, (A) 49.5 to 69.5 parts by mass of a liquid crystal polyester, (B) 30.0 to 50.0 parts by mass of an irregular form or spherical powder having a Mohs hardness of 5 or higher and a primary particle diameter of 5 μm or less, and (C) 0.5 to 5.0 parts by mass of carbon black. The use of the resin composition allows a reduction in the amount of dust generated (particles falling off) during the production of the camera, the use of the camera, and the operation of the camera modules. The resin composition has high surface hardness, is excellent in balance between heat resistance, stiffness, moldability, and resistance to falling of particles off a surface, and causes no malfunction during autofocus control.