High-Metal Epoxy Compound With Wax for Mold Fillability
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Solution Overview
Problem
The flowability and fillability of compounds containing 96 mass % or more metal powder are significantly reduced, making it difficult to fill narrow flow paths and fine cavities in molds, which is a challenge in manufacturing smaller electronic devices.
Innovation Solution
Incorporating metal salts of lauric acid, stearic acid, and saponified montanic acid esters as waxes in the compound, which improve flowability and fillability by reducing friction between metal particles and enhancing the compound's ability to flow through narrow paths and uniformly fill fine cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the content of metal powder in the compound is increased to 96 mass % or more, then the density and electromagnetic properties are improved, but the flowability of the compound is significantly reduced
Solution Approach 1:
A wax component is introduced as an intermediary substance between the metal powder particles and the resin matrix. The wax reduces friction and interparticle adhesion, enabling high metal powder content (96 mass % or more) to maintain adequate flowability through narrow flow paths and fine cavities during molding processes.
Solution Approach 2:
The surface properties of metal powder particles are modified by controlling particle size distribution (D10: 3-10 μm, D50: 15-30 μm, D90: 45-80 μm) and adding wax components. These parameter changes reduce interparticle friction and improve flow characteristics while maintaining high metal powder content.
2Quantity of substance
If the content of metal powder in the compound is increased to 96 mass % or more, then the electromagnetic shielding effectiveness is improved, but the fillability of fine cavities is significantly reduced
Solution Approach 1:
The wax component acts as a lubricant and flow facilitator, enabling the high metal powder content compound to uniformly fill fine cavities (millimeter scale or smaller) without aggregation or incomplete filling defects.
Solution Approach 2:
The compound is formulated as a composite material system consisting of metal powder (96-99.5 mass %), resin (0.5-4 mass %), and wax (0.5-5 mass %). This composite structure combines the electromagnetic benefits of high metal content with the flow and filling benefits provided by the resin-wax matrix system.
3Volume of moving object
If the height of the flow path is reduced to 1 mm or less to accommodate smaller devices, then the device size is reduced, but the flowability of high metal powder content compound is significantly reduced
Solution Approach 1:
The wax component serves as a flow facilitator that enables the compound to navigate through extremely narrow flow paths (height ≤ 1 mm) by reducing interparticle friction and preventing particle jamming, thus maintaining flowability in miniaturized device applications.
Solution Approach 2:
The compound's flow parameters are optimized by controlling metal powder particle size distribution and adding wax, enabling adequate flow through narrow paths while maintaining high metal powder content for electromagnetic performance.
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 compound exhibits excellent flowability and fillability, enabling it to easily fill narrow flow paths and fine cavities, resulting in uniformly filled molded articles with improved mechanical strength and reduced mold release issues.
Implementation Method 1
the wax contains at least one selected from a group consisting of metal salts of lauric acid, metal salts of stearic acid, and saponified montanic acid esters... improve flowability and fillability by reducing friction between metal particles
Data Source
AI summary
A compound includes metal powder, an epoxy resin, and a wax. The content of the metal powder is from 96 mass % to less than 100 mass %. The wax includes at least one selected from the group consisting of metal salts of lauric acid, metal salts of stearic acid, and saponified montanic acid esters.