Resin Composition with Bimodal Inorganic Particles for Optical Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resin compositions with inorganic particles suffer from high melt viscosity, poor formability, and surface roughness issues, which affect the coefficient of linear expansion and optical system alignment in precision optical systems.
Innovation Solution
A resin composition with a thermoplastic resin and inorganic particles of specific diameter ranges (10 nm to 100 nm and 120 nm to 10000 nm) is used, balancing coefficient of linear expansion and melt viscosity for improved formability and surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If inorganic particles with small mean diameter are added to organic resin to reduce coefficient of linear expansion, then temperature-dependent size changes are reduced, but melt viscosity increases causing poor formability
Solution Approach 1:
The patent divides the inorganic particles into two distinct size categories: first inorganic particles (10-100 nm) and second inorganic particles (120-10000 nm). This segmentation allows each particle size to serve different functions - the smaller particles reduce coefficient of linear expansion while the larger particles maintain acceptable melt viscosity and formability, resolving the contradiction between thermal stability and manufacturability.
2Stability of the object's composition
If high inorganic particle content is used to reduce coefficient of linear expansion, then temperature stability improves, but melt viscosity increases causing poor formability and surface roughness
Solution Approach 1:
The patent applies local quality by using different inorganic particle sizes in specific roles within the resin composition. The first inorganic particles (10-100 nm) are optimized for reducing coefficient of linear expansion, while the second inorganic particles (120-10000 nm) are optimized for maintaining surface smoothness and acceptable viscosity. This localized optimization of particle properties resolves the contradiction between thermal stability and surface quality.
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 resin composition achieves a low coefficient of linear expansion, suitable for optical applications, and a smooth surface, preventing optical system misalignment due to temperature changes, while maintaining practical thermoformability.
Implementation Method 1
Some devices used in a precision optical system have organic resin components as the optical elements or surrounding components thereof. These resin-made components can cause the optical system to be misaligned when the size thereof is greatly influenced by the temperature. A known way to reduce such temperature-dependent changes in the size of a resin component is to use an organic resin material with a smaller coefficient of linear expansion.
Implementation Method 2
Adding particles with a small diameter to a thermoplastic resin as a matrix, however, increases the melt viscosity of the resulting material. An increased melt viscosity causes some problems such as poor formability of the material in injection molding and other molding processes.
Data Source
AI summary
A formed article is made from a resin composition containing a thermoplastic resin, first inorganic particles having a mean volume diameter of primary-particle of 10 nm to 100 nm, both inclusive, and second inorganic particles having a mean volume diameter of primary-particle of 120 nm to 10000 nm, both inclusive. One hundred (100) parts by mass of the resin composition contains 9.0 to 40.5 parts by mass of the first inorganic particles and 4.5 to 36.0 parts by mass of the second inorganic particles.