Polyetherimide Composite for Optical Connectors
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Solution Overview
Problem
There is a need for a thermoplastic composition that can maintain optical properties and dimensional stability at elevated temperatures, particularly for optical applications like single mode fiber optic connectors, where existing polymer materials fail to provide sufficient thermal stability and infrared transmission.
Innovation Solution
A composition comprising 50-97 weight percent of polyetherimide or poly(arylene ether sulfone) combined with 3-50 weight percent of an inorganic filler having a refractive index of 1.60-1.68, such as boehmite, calcium carbonate, or wollastonite, which exhibits high infrared transmission and low coefficients of thermal expansion, enabling improved processability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer materials are used for optical lenses, then ease of manufacture and impact resistance are improved, but dimensional stability and infrared transmission at elevated temperatures deteriorate
Solution Approach 1:
The patent employs composite materials by combining polyetherimide or poly(arylene ether sulfone) polymers with specific inorganic fillers (boehmite, calcium carbonate, barium sulfate, or wollastonite) to create a material that maintains dimensional stability at elevated temperatures while retaining optical properties and ease of manufacture. The composite structure allows the polymer matrix to provide toughness and processability while the inorganic filler enhances thermal stability and reduces coefficient of thermal expansion.
2Stability of the object's composition
If glass is used for optical lenses requiring high dimensional stability, then dimensional stability is improved, but impact resistance and ease of manufacture deteriorate
Solution Approach 1:
The composite material combines the dimensional stability characteristics of glass-like inorganic fillers with the impact resistance and toughness of polymer matrices. The inorganic filler particles (particularly boehmite, calcium carbonate, barium sulfate, or wollastonite) provide thermal stability and low coefficient of thermal expansion similar to glass, while the polyetherimide or poly(arylene ether sulfone) matrix provides impact resistance and flexibility that glass lacks.
3Ease of manufacture
If conventional molding processes are used for processing optical materials, then ease of manufacture is improved, but optical properties and dimensional stability at high temperatures deteriorate
Solution Approach 1:
The patent utilizes parameter changes by carefully controlling the refractive index of the inorganic filler (1.60 to 1.68 at 587 nm wavelength) to match the polymer matrix, minimizing optical scattering and maintaining high infrared transmission. The specific refractive index range and particle size distribution are optimized to ensure conventional molding processes can be used while achieving superior optical properties and dimensional stability that exceed traditional material limitations.
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 achieves transmission rates greater than 50% in specific wavelength ranges and thermal expansion coefficients less than 6.5E-5 1/°C, making it suitable for optical applications and maintaining mechanical properties like flexural and impact strength.
Implementation Method 1
an inorganic filler having a refractive index of 1.60 to 1.68 as determined at a wavelength of 587 nanometers
Implementation Method 2
a flow coefficient of thermal expansion, a cross-flow coefficient of thermal expansion, or both of less than 6.5E-5 1/° C. between −40° C. and 85° C.
Data Source
AI summary
A composition including particular amounts of a polyetherimide or a poly(arylene ether sulfone) and an inorganic filler is described herein. Molded samples of the composition can exhibit an advantageous combination of properties, and the composition can be used in various articles. Methods of making the composition are also described.