Polyetherimide Composite for Optical Lenses
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Solution Overview
Problem
There is a need for a thermoplastic composition that offers low coefficient of thermal expansion, high infrared transmission, and maintains good physical properties such as tensile and flexural strength, particularly suited for optical applications where materials must withstand elevated temperatures without deformation or discoloration.
Innovation Solution
A composition comprising 20-75 weight percent of polyetherimide or poly(arylene ether sulfone), 5-35 weight percent of a polycarbonate-ester copolymer or polyester, and 20-60 weight percent of boehmite, with the boehmite having an average particle diameter of less than 1 micrometer, which is melt-mixed and optionally extruded to provide improved processing and optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional molding processes are used to process polymer materials, then manufacturing efficiency is improved, but dimensional stability deteriorates leading to deformation and discoloration
Solution Approach 1:
The patent employs a composite material system consisting of polyetherimide or poly(arylene ether sulfone) combined with specific inorganic fillers (silica, alumina, titania, zirconia, or boehmite) at controlled weight percentages. This composite structure enables the material to withstand conventional molding processes while maintaining dimensional stability and optical properties, resolving the contradiction between manufacturing efficiency and dimensional stability.
Solution Approach 2:
The patent modifies the material composition parameters by incorporating inorganic fillers within specific weight ranges (5-40% for glass fillers, 5-20% for alumina, 5-15% for titania, 5-10% for zirconia, or 1-10% for boehmite). These parameter changes enable the material to maintain dimensional stability under conventional processing conditions while preserving optical clarity and resistance to deformation.
2Manufacturing precision
If glass materials are used for optical lenses, then dimensional stability is improved, but ease of manufacture deteriorates and cost increases
Solution Approach 1:
The patent changes the material parameter from traditional glass to a specifically formulated polymer composite with inorganic fillers. This parameter change maintains dimensional stability comparable to glass while enabling easier manufacturing through conventional plastic molding processes, reducing production complexity and cost.
Solution Approach 2:
The patent employs thermoplastic polymer matrices (polyetherimide or poly(arylene ether sulfone)) that can be readily processed and molded using standard plastic processing equipment. These materials offer a cost-effective alternative to glass, enabling easier manufacture while maintaining the necessary dimensional stability for optical applications.
3Ease of manufacture
If polymer materials are used for optical applications, then ease of manufacture is improved, but reliability deteriorates under high-temperature conditions
Solution Approach 1:
The patent creates a composite material system where thermoplastic polymers (polyetherimide or poly(arylene ether sulfone)) are reinforced with heat-resistant inorganic fillers. This composite structure enhances the material's ability to withstand high-temperature environments and harsh processing conditions while maintaining optical properties and dimensional stability, thereby improving reliability without sacrificing ease of manufacture.
Solution Approach 2:
The patent modifies the material composition by incorporating inorganic fillers at optimized weight percentages to enhance thermal stability. These parameter changes enable the polymer material to maintain its structural integrity and optical properties under elevated temperatures and conventional processing conditions, resolving the contradiction between ease of manufacture and temperature resistance.
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 exhibits reduced coefficients of thermal expansion, high infrared transmission, and enhanced processability, making it well-suited for various optical applications, including lenses and connectors, while maintaining excellent physical properties.
Implementation Method 1
The composition exhibits reduced coefficients of thermal expansion
Implementation Method 2
high infrared transmission
Implementation Method 3
melt-mixing the components of the composition
Data Source
AI summary
A composition including particular amounts of a polyetherimide or a poly(arylene ether sulfone), a second polymer 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.