Polycarbonate Resin Container for Precision Members
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Solution Overview
Problem
Conventional polycarbonate resin containers for precision members, such as semiconductor chips and silicon wafers, are prone to damage due to volatilization of chlorine ions and other impurities, leading to contamination and damage, and existing methods to minimize chlorine content are uneconomical and ineffective in maintaining mechanical properties like impact resistance and transparency.
Innovation Solution
A polycarbonate resin container is developed using a solution prepared by immersing polycarbonate resin in water to achieve low concentrations of chloride, fluoride, and sulfate ions, with a weight average molecular weight of 20,000 to 35,000 g/mol, and prepared through melt polymerization of an aromatic dihydroxy compound and diaryl carbonate, ensuring minimal volatile gases and maintaining mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If interfacial polymerized polycarbonate resin is used to make containers, then the containers have good mechanical properties and transparency, but chlorine ions are volatilized causing damage to precision members
Solution Approach 1:
The patent changes the polymerization method from interfacial polymerization to melt polymerization, and adjusts the molecular weight parameters to 20,000-35,000 g/mol. This parameter change eliminates chlorine ion volatilization while maintaining mechanical properties and transparency of the polycarbonate resin containers
Solution Approach 2:
The patent uses a cost-effective melt polymerization process instead of expensive interfacial polymerization methods. The resin is designed for single-use containers where economic efficiency is important, eliminating the need for complex purification processes while achieving low chlorine content
2Object-generated harmful factors
If methods are used to minimize chlorine content in polycarbonate resin, then chlorine volatilization is reduced, but the process becomes uneconomical and mechanical properties deteriorate
Solution Approach 1:
The patent changes the polymerization parameters by using melt polymerization instead of interfacial polymerization, and controls molecular weight at 20,000-35,000 g/mol. This approach minimizes chlorine content while maintaining manufacturing economy and mechanical properties
Solution Approach 2:
The patent extracts chlorine-containing components during the melt polymerization process by controlling reaction conditions and molecular weight, eliminating the need for additional purification steps that would increase manufacturing cost
3Object-generated harmful factors
If interfacial polymerized polycarbonate resin with minimized chlorine is used, then chlorine damage is reduced, but manufacturing cost increases significantly
Solution Approach 1:
The patent uses melt polymerization with molecular weight control at 20,000-35,000 g/mol, which inherently produces resin with low chlorine content. This eliminates the need for expensive post-polymerization purification processes while achieving the desired low chlorine damage effect
4Reliability
If precision members are preserved in conventional containers, then transportation is possible, but impurities and contaminants cause damage to the precision members
Solution Approach 1:
The patent uses polycarbonate resin with controlled molecular weight (20,000-35,000 g/mol) produced by melt polymerization, which generates minimal volatile impurities. This ensures precision members are protected from contamination during transportation and storage
Solution Approach 2:
The patent creates an inert environment inside the container by using resin that volatilizes minimal impurities and contaminants. This inert atmosphere protects precision members from chemical contamination during storage and transportation
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 container effectively minimizes contamination and damage to precision members by reducing volatile impurities, maintaining transparency and impact resistance, and is produced economically through a simple melt polymerization process.
Implementation Method 1
the polycarbonate resin may be prepared by melt polymerization of an aromatic dihydroxy compound and a diaryl carbonate
Implementation Method 2
a polycarbonate resin solution prepared by immersing the polycarbonate resin in water and leaving the solution has chloride ions (Cl−), fluoride ions (F−) and sulfate ions (SO42-) in a concentration of about 2 ppb or less
Data Source
AI summary
A container for precision members is prepared from a polycarbonate resin, wherein a polycarbonate resin solution prepared by immersing the polycarbonate resin in water and leaving the solution has chloride ions (Cl−), fluoride ions (F−) and sulfate ions (SO42−) in a concentration of about 2 ppb or less, independently of each other, as detected by ion chromatography (IC). The container for precision members is capable of preserving and transporting the precision members predisposed to damage by minor amounts of impurities or contaminants without damage.