Polyphenylene Ether Resin Composition with Carbon Nanotubes

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Solution Overview

Problem

Polyphenylene ether resin compositions face challenges in achieving a balance of electrical conductivity, impact strength, and heat resistance due to limitations in chemical resistance and workability, particularly when using conductive additives like carbon black or carbon nanotubes, which can compromise mechanical properties.

Innovation Solution

A polyphenylene-ether-based resin composition combining 5-95 wt% polyphenylene ether resin with 5-95 wt% polyamide resin, 0.01-5 parts by weight carbon nanotubes, 1-20 parts by weight styrene-based copolymer, and 1-20 parts by weight olefin-based copolymer, along with a reactive monomer, to enhance electrical conductivity, impact strength, and heat resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If carbon black is added in significant amount to provide electrical conductivity, then electrical conductivity is improved, but mechanical properties such as impact resistance are significantly decreased

Engineering Contradiction:

Improveelectrical conductivityVSAvoidimpact resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the physical and chemical parameters of the conductive additive by using carbon nanotubes with specific diameter (0.5-100 nm) and length (0.01-100 μm) ratios, and specific aspect ratios, to achieve effective electrical conductivity at lower concentrations (0.01-5 parts by weight) while minimizing mechanical property deterioration

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining polyphenylene ether-based resin, polyamide resin, and carbon nanotubes, where the synergistic interaction between components achieves both electrical conductivity and mechanical strength that cannot be obtained by single additives alone

Inventive Principle:

Principle #40Composite materials

2Reliability

If carbon fiber is used to provide electrical conductivity and enhance strength, then electrical conductivity and strength are improved, but surface quality of composite deteriorates and impact strength and elongation are reduced

Engineering Contradiction:

Improveelectrical conductivityVSAvoidsurface quality

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent applies local quality by using carbon nanotubes with specific localized dimensions (diameter 0.5-100 nm, length 0.01-100 μm) that provide conductive pathways at the molecular level without creating visible surface defects, achieving conductivity through nanoscale rather than macroscale structures

Inventive Principle:

Principle #3Local quality

3Temperature

If polyphenylene ether resin is used to achieve excellent mechanical and electrical properties at high temperature, then heat resistance is improved, but chemical resistance and workability are poor

Engineering Contradiction:

Improveheat resistanceVSAvoidworkability

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent creates a composite material system combining polyphenylene ether-based resin with polyamide resin and carbon nanotubes, where the synergistic interaction between components achieves both electrical conductivity and mechanical strength that cannot be obtained by single additives alone

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters by incorporating polyamide resin and controlling the ratio of polyphenylene ether to polyamide (5-95 wt% each), improving chemical resistance and workability while maintaining heat resistance through compositional optimization

Inventive Principle:

Principle #35Parameter changes

4Reliability

If carbon nanotubes are used in small amount to provide electrical conductivity, then electrical conductivity is achieved, but impact strength deteriorates

Engineering Contradiction:

Improveelectrical conductivityVSAvoidimpact strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent optimizes the concentration parameter of carbon nanotubes to 0.01-5 parts by weight based on 100 parts by weight of base resin, and controls aspect ratio and diameter parameters, achieving effective conductivity percolation at low concentrations while minimizing disruption to the polymer matrix and preservation of impact strength

Inventive Principle:

Principle #35Parameter changes

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 an excellent balance of electrical conductivity, impact strength, and heat resistance, suitable for various applications such as automotive parts, while maintaining mechanical properties.

Implementation Method 1

Carbon nanotubes are conductive additives having excellent electrical conductivity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a styrene-based copolymer, and an olefin-based copolymer

Methodology Applied

Scientific EffectPolymer chain entanglement:

Implementation Method 3

about 1 to about 20 parts by weight of a styrene-based copolymer, based on about 100 parts by weight of the base resin; and (D) about 1 to about 20 parts by weight of an olefin-based copolymer

Methodology Applied

Scientific EffectCross-linking:

Data Source

PatentUS9062191B2Polyphenylene ether-based resin composition and molded product using the same

Publication Date: 2015.06.23 LOTTE ADVANCED MATERIALS CO LTD

AI summary

Disclosed is a polyphenylene ether-based resin composition that includes (A) a base resin including (A-1) polyphenylene ether-based resin and (A-2) polyamide resin, (B) carbon nanotubes, (C) a styrene-based copolymer, and (D) an olefin-based copolymer.