Resin Blend Surface Hardening via Phase Separation
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Solution Overview
Problem
Plastic resins used in various applications face issues with low weather resistance, impact strength, and surface hardness, leading to the need for additional coating processes that are inefficient and environmentally harmful.
Innovation Solution
A resin blend for a melting process is developed, comprising a first resin and a second resin with specific organic functional groups, which allows for layer separation during processing, creating a surface layer with improved mechanical properties and surface hardness without the need for additional coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If painting or plating process is applied to improve surface characteristics, then surface hardness and weather resistance are improved, but process efficiency decreases and production cost increases
Solution Approach 1:
The patent combines the base resin and surface resin into a single blend composition that is processed in one injection molding operation. The surface resin containing aromatic rings migrates to the surface during processing, providing the desired surface hardness and weather resistance without requiring separate painting or plating steps, thus eliminating additional processing time and cost.
Solution Approach 2:
The surface resin with aromatic rings is pre-incorporated into the resin blend before molding. During the injection process, the aromatic ring-containing resin automatically migrates to the surface through diffusion and phase separation, pre-establishing the hard surface layer before the product leaves the mold, eliminating the need for post-processing coating steps.
2Strength
If inorganic particles are added to improve wear resistance and hardness, then physical properties are improved, but processability degrades and impact strength decreases
Solution Approach 1:
The patent changes the approach from adding inorganic particles to using organic resins with aromatic rings. This parameter change maintains improveability of wear resistance and hardness while preserving processability, as the organic resin blend flows and processes like conventional thermoplastics without the negative effects of particle addition.
Solution Approach 2:
The patent creates a composite resin system combining a base resin with a surface resin containing aromatic rings. This composite material approach achieves the desired surface properties through molecular-level composition rather than particulate addition, maintaining continuity of the polymer matrix and thus preserving impact strength and processability.
3Strength
If additional resin with high hardness is added to improve surface characteristics, then surface hardness is improved, but additional curing process is required and surface hardness is not improved to desired level
Solution Approach 1:
The patent utilizes phase separation and migration during the injection molding process. The surface resin containing aromatic rings undergoes phase separation from the base resin and migrates to the surface during cooling and solidification, automatically forming a hard surface layer without requiring additional curing processes or post-treatment steps.
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 blend enhances mechanical properties and surface hardness of molded articles, reduces processing time, and lowers production costs by eliminating the need for additional surface coating, while maintaining environmental sustainability.
Implementation Method 1
a resin blend for a melting process including a first resin and a second resin... has a melt viscosity difference of 0.1 to 3,000 Pa*s at a shear rate of 100 to 1,000 s−1 and a processing temperature of the resin blend and a glass transition temperature (Tg) difference of 10° C. to 150° C. with respect to the first resin
Data Source
AI summary
The present invention relates to a resin blend for a melting process, to a method for manufacturing a resin molding using same, and to a resin molding obtained thereby, the resin blend comprising a first resin and a second resin, wherein the second resin includes a polymer resin having at least one organic functional group selected from the group consisting of an alkyl group having 2 to 20 carbon atoms, an alicyclic ring having 5 to 40 carbon atoms and an aromatic ring having 6 to 40 carbon atoms, and has, with the first resin, a melt viscosity difference of 0.1 to 3,000 Pa*s at a shear rate of 100 to 1,000 s−1 and a processing temperature of the resin mixture, and a glass transition temperature (Tg) difference of 10° C. to 150° C.