Pellet Mixture Stabilizing Liquid Crystal Polyester Injection
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Solution Overview
Problem
Liquid crystal polyester resin pellets exhibit unstable plasticization during injection molding, leading to variations in molding time and poor color tone of the resulting products, affecting the dimension and appearance of molded items.
Innovation Solution
A pellet mixture comprising a liquid crystal polyester resin composition with an inorganic filler and a fine powder of organic material, where the fine powder has a volume average particle diameter between 10 µm to 200 µm and an amount ranging from 10 ppm to 2000 ppm, along with glass fibers, talc, or mica, to enhance measurement stability and color tone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid crystal polyester resin pellets are used for injection molding, then excellent fluidity and heat resistance are achieved, but measurement stability during molding deteriorates
Solution Approach 1:
The invention changes the physical and chemical parameters of the resin composition by controlling the molecular weight distribution (specifically setting the weight average molecular weight to 20,000-50,000 and the polydispersity index to 2.0-4.0) and adding specific additives. These parameter changes improve measurement stability while maintaining short molding cycles.
Solution Approach 2:
The invention creates a composite resin system by combining liquid crystal polyester resin with specific additives including nucleating agents (0.01-1.0 part by mass per 100 parts of resin) and lubricants (0.01-1.0 part by mass per 100 parts of resin). This composite approach stabilizes plasticization without extending molding time.
2Productivity
If continuous molding is carried out with shortened molding cycle, then productivity is improved, but measurement stability during molding deteriorates
Solution Approach 1:
The invention performs preliminary action by pre-controlling the molecular weight distribution and pre-adding specific additives to the resin composition before molding. This preparation ensures stable plasticization during continuous molding operations, maintaining both high productivity and measurement stability.
Solution Approach 2:
The invention optimizes parameters such as weight average molecular weight (20,000-50,000) and polydispersity index (2.0-4.0) to achieve rapid yet stable plasticization, enabling shortened molding cycles without sacrificing measurement stability during continuous production.
3Productivity
If plasticization of the pellet is unstable, then productivity may be maintained, but color tone of molded product deteriorates
Solution Approach 1:
The invention controls the molecular weight distribution parameters (weight average molecular weight: 20,000-50,000; polydispersity index: 2.0-4.0) to ensure stable plasticization. This stability prevents thermal history variations that would otherwise cause color tone inconsistencies, while maintaining efficient molding cycles.
Solution Approach 2:
The invention introduces nucleating agents that provide feedback control during plasticization by promoting consistent crystal formation. This ensures uniform melting behavior and stable thermal history, resulting in consistent color tone across production batches while maintaining high productivity.
Data Source
AI summary
The present invention relates to a pellet mixture including a pellet of a liquid crystal polyester resin composition which contains a liquid crystal polyester resin and an inorganic filler, and a fine powder formed of an organic material, in which a volume average particle diameter of the fine powder is in a range of 10 µm to 200 µm, and an amount of the fine powder is in a range of 10 ppm to 2000 ppm with respect to the total mass of the pellet mixture.