Liquid Crystal Polymer Composites for Anti-Dent Camera Parts
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Solution Overview
Problem
Liquid crystalline polymers (LCPs) face challenges with inadequate melt strength, poor processability, narrow processing windows, and poor tear strength in machine direction, limiting their use in compact camera modules, particularly in components like ball guide actuators that are susceptible to denting and particle generation during impact.
Innovation Solution
A composition comprising 50-85 wt% liquid crystal polymer resin, 0.1-15 wt% polyetherimide polymer, 0.05-8 wt% compatibilizer, and 2-25 wt% mineral filler, which improves anti-dent performance and reduces particulate release, characterized by a dent depth of 30-40 micrometers and reduced particle generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid crystalline polymer is used for high heat resistance applications, then heat resistance is improved, but anti-dent performance deteriorates
Solution Approach 1:
The patent applies composite materials by combining liquid crystalline polymer with polyetherimide polymer, compatibilizer, and mineral filler to create a multi-component composition. This composite structure allows the material to simultaneously achieve high heat resistance from the LCP and improved anti-dent performance from the synergistic combination of components, particularly the polyetherimide and mineral filler which enhance mechanical strength and impact resistance.
Solution Approach 2:
The patent utilizes parameter changes by carefully controlling the weight percentages of each component in the composition. The LCP content is optimized at 50-85 wt% to maintain heat resistance, while polyetherimide is included at 5-20 wt% and mineral filler at 10-40 wt% to enhance anti-dent properties. This precise parameter optimization allows the material to achieve both high heat resistance and improved anti-dent performance.
2Reliability
If liquid crystalline polymer is used, then dielectric and barrier properties are improved, but processability deteriorates
Solution Approach 1:
The patent employs an intermediary approach by introducing a compatibilizer component that mediates between the liquid crystalline polymer and other constituents. The compatibilizer improves interfacial adhesion and compatibility between components, enabling better processability and manufacturing performance while preserving the excellent dielectric and barrier properties of the LCP matrix. This intermediary component facilitates easier processing without sacrificing the functional advantages of LCP.
3Temperature
If liquid crystalline polymer is used, then heat resistance is improved, but tear strength deteriorates
Solution Approach 1:
The patent applies composite materials by combining liquid crystalline polymer with polyetherimide polymer, compatibilizer, and mineral filler to create a multi-component composition. This composite structure allows the material to simultaneously achieve high heat resistance from the LCP and improved anti-dent performance from the synergistic combination of components, particularly the polyetherimide and mineral filler which enhance mechanical strength and impact resistance.
4Temperature
If liquid crystalline polymer is used, then high heat resistance is achieved, but melt strength deteriorates
Solution Approach 1:
The patent utilizes parameter changes by carefully controlling the weight percentages of each component in the composition. The LCP content is optimized at 50-85 wt% to maintain heat resistance, while polyetherimide is included at 5-20 wt% and mineral filler at 10-40 wt% to enhance anti-dent properties. This precise parameter optimization allows the material to achieve both high heat resistance and improved anti-dent performance.
Data Source
AI summary
Compositions include from about 50 wt % to about 85 wt % of a liquid crystal polymer resin, from about 0.1 wt % to about 15 wt % of a polyetherimide polymer, from about 0.05 wt % to about 8 wt % of a compatibilizer, and from about 2 wt % to about 25 wt % of a mineral filler. A 50 mm×60 mm sample having a thickness of 0.6 mm molded from the composition exhibits an anti-dent performance characterized by a dent depth from 30-40 micrometers as measured using a three dimensional surface profiler; the sample is tested using a drop tester with a 1.6 mm diameter steel ball having a weight of 50 grams dropped from a height of 50 mm. Articles including the composition, including components of a mobile compact camera module, are also described.