Liquid Crystalline Polymer Resin Molded Article with Low Surface Roughness
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Solution Overview
Problem
Conventional resin molded articles with reinforced fillers used in electric, electronic, and optical components often experience decreased production yield and false operations due to fine particle generation over time, especially when subjected to surface-mounting processes and usage.
Innovation Solution
A resin molded article composed of a liquid crystalline polymer and a fibrous filler, with a surface roughness difference of 0.4 μm or smaller after repeated tape-pasting and peeling tests, is produced by mixing and pelletizing the polymer and filler, melting the composition, and injecting it into a mold at elevated temperatures to achieve high mechanical strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fibrous filler is added to liquid crystalline polymer to improve mechanical strength, then strength is improved, but fine particles are generated causing decreased production yield and false operations
Solution Approach 1:
The invention changes the physical and chemical parameters of the liquid crystalline polymer system by controlling the molecular weight (viscosity) within specific ranges (intrinsic viscosity 0.4-1.2 dL/g for the polymer, and melt viscosity 10-100 Pa·s at processing temperature). This parameter optimization ensures adequate mechanical strength while minimizing fine particle generation during molding and assembly processes
Solution Approach 2:
The invention creates an optimized composite material system by carefully selecting and combining liquid crystalline polymer with specific types and amounts of fibrous fillers. The composite achieves enhanced mechanical strength through the fibrous reinforcement while the controlled polymer matrix prevents filler particle degradation and fine particle generation, thereby maintaining high production yield and operational reliability
2Strength
If fibrous filler is used to enhance rigidity and heat resistance, then rigidity and heat resistance are improved, but surface roughness increases causing assembly difficulties
Solution Approach 1:
The invention optimizes processing parameters including melt temperature, mold temperature, and injection pressure to control the orientation and distribution of fibrous fillers. By maintaining specific temperature ranges and controlling the molding process, the invention achieves high rigidity and heat resistance while minimizing surface roughness and filler exposure on the molded article surface
3Strength
If fibrous filler is added to improve mechanical properties, then mechanical properties are improved, but fine particles are generated during assembly causing false operations
Solution Approach 1:
The invention controls the molecular weight and viscosity parameters of the liquid crystalline polymer to reduce fine particle generation. By optimizing the intrinsic viscosity range and melt viscosity at processing temperature, the polymer matrix maintains cohesive strength that prevents filler particle breakage and fine particle generation during assembly operations
Solution Approach 2:
The liquid crystalline polymer acts as an intermediary matrix that bonds fibrous fillers together, preventing their separation and breakage during handling and assembly. The controlled polymer properties ensure adequate adhesion between filler particles and matrix, eliminating fine particle generation that would otherwise cause assembly yield loss and operational failures
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 resulting resin molded article exhibits improved assembly yield and reduced false operations, maintaining high heat resistance, rigidity, and dimensional stability, making it suitable for components like camera modules and optical mechanisms.
Implementation Method 1
mixing and pelletizing a liquid crystalline polymer and a fibrous filler to obtain a resin composition pellet
Implementation Method 2
melting the resin composition pellet at a temperature of from a temperature higher than the flow starting temperature of the resin composition by 30° C. to a temperature higher than the flow starting temperature by 80° C. to obtain a melted resin composition
Implementation Method 3
a liquid crystalline polymer and a fibrous filler, the article having a surface with difference of 0.4 μm or smaller in a surface roughness expressed by Ra value measured before and after repeating 30 times the operation of pasting and peeling a tape
Data Source
AI summary
The present invention provides for a resin molded article comprising a liquid crystalline polymer and a fibrous filler, the article having a surface with difference of 0.4 μm or smaller in a surface roughness expressed by Ra value measured before and after repeating 30 times the operation of pasting and peeling a tape having an adhesive power of 4.0 N/mm. The resin molded article is excellent in mechanical strength when used in an electric/electronic component or in an optical apparatus.