Polycarbonate Resin Composition for LED Lens Color and Durability
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Solution Overview
Problem
Existing polycarbonate resin compositions fail to provide a molded body with excellent color tone and high durability, particularly in short optical path lengths, and insufficient LED irradiation resistance, especially with the increasing output of LEDs.
Innovation Solution
A polycarbonate resin composition comprising an aromatic polycarbonate resin blended with specific amounts of a pentaerythritol diphosphite compound, a phenol-based antioxidant, an alicyclic epoxy compound, and a UV absorber, excluding certain components like bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite and triphenylphosphine, to enhance LED irradiation resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If polycarbonate resin composition is used in LED lighting lens with short optical path length, then color tone is improved, but LED irradiation resistance is insufficient
Solution Approach 1:
The patent uses a composite resin composition containing aromatic polycarbonate resin (A), pentaerythritol diphosphite compound (B1), phenol-based antioxidant (C), alicyclic epoxy compound (D), and UV absorber (E). This composite formulation combines multiple materials with complementary properties to achieve both excellent color tone and high LED irradiation resistance, resolving the contradiction between optical performance and durability.
Solution Approach 2:
The patent specifies precise content ranges for each component: component (B1) at 0.01-0.08 parts by mass, component (C) at 0.005-0.15 parts by mass, component (D) at 0.005-0.2 parts by mass, and component (E) at 0.1-0.4 parts by mass per 100 parts by mass of component (A). These controlled parameter changes optimize the balance between color tone and LED irradiation resistance.
2Illumination intensity
If polycarbonate resin composition emphasizes color tone for long optical path length applications, then color tone is improved, but performance in short optical path length LED lighting is insufficient
Solution Approach 1:
The patent introduces a UV absorber (component E) with specific content range of 0.1-0.4 parts by mass per 100 parts by mass of component (A). This parameter change addresses the specific requirements of short optical path length LED lighting applications while maintaining excellent color tone, making the composition adaptable to modern LED lighting standards.
Solution Approach 2:
The composite formulation combines UV absorber (E) with alicyclic epoxy compound (D) and phenol-based antioxidant (C) to create a resin composition that simultaneously achieves excellent color tone and high durability for short optical path length applications, expanding the versatility of the material.
3Power
If LED output is increased, then lighting performance is improved, but resin durability and resistance to deformation are reduced
Solution Approach 1:
The patent incorporates phenol-based antioxidant (C) at 0.005-0.15 parts by mass and alicyclic epoxy compound (D) at 0.005-0.2 parts by mass per 100 parts by mass of component (A) as preventive measures. These additives act as cushioning agents that protect the resin from degradation caused by high LED output before damage occurs, maintaining resin durability under increased power conditions.
Solution Approach 2:
The composite resin composition combines aromatic polycarbonate resin (A) with multiple protective additives including pentaerythritol diphosphite compound (B1), phenol-based antioxidant (C), alicyclic epoxy compound (D), and UV absorber (E). This composite structure provides enhanced resistance to high LED output, preventing resin degradation and deformation while allowing increased LED power.
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 composition produces a molded body with excellent color tone, high moist heat resistance, light fastness, and LED irradiation resistance, suitable for LED lighting applications, maintaining optical characteristics and preventing deformation even under high LED output.
Implementation Method 1
a phenol-based antioxidant (C)
Implementation Method 2
a UV absorber (E)
Implementation Method 3
excellent in long-term moist heat resistance
Data Source
AI summary
Provided is a polycarbonate resin composition, including: an aromatic polycarbonate resin (A); a predetermined antioxidant (B1); a phenol-based antioxidant (C); an alicyclic epoxy compound (D); and a UV absorber (E), wherein a content of the component (B1) is 0.01 to 0.08 part by mass, a content of the component (C) is 0.005 to 0.15 part by mass, a content of the component (D) is 0.005 to 0.2 part by mass, and a content of the component (E) is 0.1 to 0.4 part by mass with respect to 100 parts by mass of the component (A), and wherein the polycarbonate resin composition is substantially free of bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite (Z1) and triphenylphosphine (Z2).