Polyarylene Sulfide Resin Optical Ferrule Toughness
Solution Overview
Problem
The increasing number of cores in optical ferrules for information communication terminals leads to insufficient mechanical strength and toughness, particularly during processing and coupling to adapters, necessitating an improvement in polyarylene sulfide resin compositions used in molding these components.
Innovation Solution
A polyarylene sulfide resin composition comprising a polyarylene sulfide resin with a melt viscosity of 35 to 80 Pa·s and specific amounts of silica particles, including smaller and larger particle sizes, is used to enhance the mechanical strength and toughness of molded articles and optical ferrules, with the silica particles having a controlled content of coarse powders to improve processing and coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of cores in optical ferrules is increased to address increasing information communication needs, then the information communication capacity is improved, but the mechanical strength and toughness of the optical ferrules become insufficient
Solution Approach 1:
The patent changes the physical and chemical parameters of the polyarylene sulfide resin by controlling its melt viscosity (35-80 Pas at 310°C) and molecular weight, which directly improves the mechanical strength and toughness of the optical ferrule while accommodating increased core numbers
Solution Approach 2:
The patent creates a composite material system by combining polyarylene sulfide resin with specific amounts of silica particles (35-120 parts by mass based on 100 parts of resin), where the composite structure enhances both the mechanical strength and toughness required for high-core optical ferrules
2Reliability
If polyarylene sulfide resin composition is used to maintain dimensional stability and flame retardance, then the reliability of optical ferrules is improved, but the mechanical toughness becomes insufficient for processing and coupling
Solution Approach 1:
The patent adjusts the molecular weight and melt viscosity parameters of the polyarylene sulfide resin to achieve optimal balance between reliability (dimensional stability, flame retardance) and mechanical toughness, specifically setting melt viscosity between 35-80 Pas at 310°C
Solution Approach 2:
The patent develops a composite resin composition incorporating polyarylene sulfide resin with controlled molecular weight and silica particles, where the composite structure provides both the required reliability properties and enhanced mechanical toughness for processing and coupling operations
Data Source
AI summary
A polyarylene sulfide resin composition which yields a molded article with excellent toughness, as well as a molded article and an optical ferrule, which are produced using the polyarylene sulfide resin composition. In a polyarylene sulfide resin composition containing a polyarylene sulfide resin and silica particles, a specific amount of a polyarylene sulfide resin having a melt viscosity of 35 to 80 Pa·s, and a specific amount of silica particles having a lower content of coarse powders with a particle size of 45 μm or more are employed.