Melt Flowable Polyamide Composition for Thin Wall Connectors
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Solution Overview
Problem
Melt flowable polyamide compositions require high injection pressure for processing, leading to increased cycle time, tool wear, and reduced productivity, and often result in larger press sizes and star-shaped polymer configurations due to conventional polymerization techniques.
Innovation Solution
A polyamide composition comprising a matrix obtained by melt-blending polyamides with specific repeating units and a multifunctional compound, such as 1,2,4,5-benzenetetracarboxylic acid, combined with a fibrous filler material, which reduces injection pressure and prevents star-shaped configurations, allowing for lower melt temperatures and improved processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high injection pressure is used to process melt flowable polyamide compositions, then the composition can be molded, but cycle time increases and productivity decreases
Solution Approach 1:
The patent changes the molecular architecture parameter from conventional linear/star-shaped polymers to polymers with controlled branching degree (0.01 to 0.5 branches per 100 carbon atoms). This parameter change enables the polyamide to achieve both melt flowability for easy molding and reduced injection pressure requirements, thereby decreasing cycle time and increasing productivity without sacrificing moldability
2Ease of manufacture
If high injection pressure is used to process melt flowable polyamide compositions, then the composition can be molded, but tool wear increases
Solution Approach 1:
The patent modifies the molecular structure parameter by controlling the branching degree to 0.01 to 0.5 branches per 100 carbon atoms. This structural modification reduces the injection pressure needed for molding while maintaining melt flowability, thereby significantly reducing tool wear and extending tool life without compromising the ability to mold the composition
3Productivity
If conventional polymerization technique is used, then polyamide can be produced, but star-shaped configuration results which increases residence time
Solution Approach 1:
The patent changes the polymerization method parameter from conventional techniques that produce star-shaped configurations to a controlled polymerization process that limits branching degree to 0.01 to 0.5 branches per 100 carbon atoms. This parameter change reduces polymer residence time in the reactor while maintaining production capability, thereby improving productivity and reducing degradation risks
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 solution enables reduced cycle time, lower tool wear, increased productivity, and the production of thin wall connectors with improved mechanical properties and reduced cooling temperatures, while avoiding star-shaped polymer configurations.
Implementation Method 1
a polyamide matrix obtained by melt-blending (a) a polyamide containing repeating units of formula (I) and/or (b) a polyamide containing repeating units of formula (II) with (c) a multifunctional compound comprising four identical reactive functions selected from carboxylic acid and derivatives thereof
Data Source
AI summary
Described herein is a melt flowable polyamide composition for shaped articles, which may include thin wall connectors such as electrical connectors.