Polycarbonate Resin Composition with Boride Particles for Heat Ray Shielding
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Solution Overview
Problem
Existing heat ray shielding materials for windows and vehicles face challenges such as high haze, insufficient transparency, and high costs due to the need for large amounts of phthalocyanine compounds or complex lamination processes, which affect their practicality and effectiveness in reducing solar transmittance and providing thermal stability.
Innovation Solution
A polycarbonate resin composition is developed by blending a small amount of boride particles into an aromatic polycarbonate resin with specific end hydroxyl group concentrations, resulting in a material with low haze, excellent transparency, and sufficient heat ray shielding properties, suitable for windows and vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of phthalocyanine compound is blended into polycarbonate resin to provide sufficient heat ray shielding property, then heat ray shielding performance is improved, but haze increases and transparency deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by replacing phthalocyanine compounds with boron oxide particles having specific properties (particle size 0.01-1 μm, oxide content 90-99 wt%). This parameter change enables achieving heat ray shielding performance with minimal impact on transparency, as boron oxide particles provide infrared absorption while maintaining optical clarity in the visible range.
Solution Approach 2:
The patent creates a composite material system combining polycarbonate resin with boron oxide particles. This composite structure leverages the transparent properties of polycarbonate and the infrared absorbing properties of boron oxide particles to achieve both high transparency and effective heat ray shielding simultaneously.
2Reliability
If a transparent resin plate is laminated with heat ray reflective film to achieve heat ray shielding, then heat ray shielding property is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the heat ray shielding function directly into the resin composition itself by incorporating boron oxide particles during the molding process. This eliminates the need for separate heat ray reflective films and complex lamination processes, achieving both heat ray shielding and manufacturing simplicity in a single integrated material system.
Solution Approach 2:
The patent extracts the heat ray shielding function from separate reflective films and integrates it directly into the resin composition through boron oxide particle incorporation. This extraction and integration simplifies the overall structure by removing unnecessary intermediate layers and processes.
3Reliability
If hexaboride is blended into thermoplastic resin to achieve heat ray shielding, then heat ray shielding property is improved, but haze increases and transparency becomes insufficient
Solution Approach 1:
The patent optimizes critical parameters including particle size (0.01-1 μm), oxide content (90-99 wt%), and concentration (0.01-5 wt%) to achieve the optimal balance between heat ray shielding and transparency. These precise parameter controls ensure that boron oxide particles provide effective infrared absorption while maintaining optical clarity.
Solution Approach 2:
The patent applies local quality by using boron oxide particles with specific local properties (high oxide content, controlled particle size distribution) that are optimally suited for their dual function of absorbing infrared radiation while maintaining optical transparency in the visible spectrum.
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 achieves low solar transmittance, high transparency, and mechanical strength while maintaining thermal stability, making it suitable for various applications including windows, arcades, and optical materials.
Implementation Method 1
have low solar transmittance and sufficient heat ray shielding property (especially, have a function of transparency for visible light and selectively shielding property for infrared ray)
Data Source
AI summary
Polycarbonate resin compositions containing 100 parts by weight of aromatic polycarbonate resin having a concentration of end hydroxyl group of 100 to 1800 ppm and 0.0001 to 5 parts by weight of fine particles of a boride of La, Ce, Pr, Nd, Tb, Dy, Ho, Y, Sm, Eu, Re, Tm, Yb, Lu, Sr or Ca. Heat ray shielding molded products molded from this polycarbonate resin composition have low haze, excellent transparency, low solar transmittance and sufficient heat ray shielding properties, especially for visible light and selective shielding for infrared rays, and are excellent in mechanical strength and thermal stability at melting. These molded products may be used for windows for buildings or vehicles or as optical materials such as infrared ray cut filters or films for agricultural use.