Resin Composition for Camera Module Laser Transmittance
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Solution Overview
Problem
Conventional resin compositions for camera modules face challenges in achieving excellent laser transmittance, dimensional stability, and bonding strength, especially when using semi-crystalline resins, which often result in decreased laser transmittance and increased molding shrinkage, making them unsuitable for precision parts requiring high chemical resistance and heat resistance.
Innovation Solution
A resin composition comprising 25 to 50 wt% polycarbonate resin, 5 to 30 wt% polycyclohexylenedimethylene terephthalate (PCT) resin, 30 to 50 wt% fibrous filler, and 0.001 to 5 wt% dye, optimized with specific molecular weights and intrinsic viscosities, along with additives like antioxidants and nucleating agents, to enhance laser transmittance, mechanical strength, and dimensional stability, while maintaining chemical resistance and water tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If semi-crystalline resins are used to improve chemical resistance and heat resistance, then material durability is improved, but laser transmittance decreases and molding shrinkage increases
Solution Approach 1:
The patent uses a composite resin composition consisting of amorphous resin (polycarbonate or polysulfone) as the base material with crystalline resin (polybutylene terephthalate, polyethylene terephthalate, or polyoxymethylene) dispersed therein. This composite structure allows the amorphous resin to provide laser transmittance while the crystalline resin particles provide chemical and heat resistance, resolving the contradiction between material durability and manufacturing precision
Solution Approach 2:
The patent creates local quality differentiation by dispersing crystalline resin particles throughout the amorphous resin matrix. The amorphous resin regions maintain high laser transmittance, while the crystalline resin particles provide localized chemical and heat resistance. This local quality approach allows different regions of the material to fulfill different functional requirements simultaneously
2Manufacturing precision
If amorphous resin is used to improve laser transmittance, then laser welding capability is improved, but chemical resistance and heat resistance decrease
Solution Approach 1:
The patent creates a composite material where amorphous resin provides the continuous matrix for laser transmittance, while dispersed crystalline resin particles provide enhanced chemical and heat resistance. This composite approach allows the material to exceed the properties of individual components, achieving both high laser transmittance and superior chemical/heat resistance
Solution Approach 2:
The amorphous resin acts as an intermediary matrix that allows laser energy to pass through while containing and distributing crystalline resin particles that provide chemical and heat resistance. The amorphous resin mediates between the laser transmission function and the durability function provided by crystalline particles
3Ease of manufacture
If conventional bonding methods are used, then ease of manufacture is maintained, but water tightness and bonding strength are insufficient
Solution Approach 1:
The patent replaces mechanical bonding methods (screws, clips, adhesives) with laser welding technology. The resin composition is specifically designed to transmit laser energy effectively, enabling direct laser welding between camera module members. This substitution provides superior water tightness and bonding strength while maintaining ease of manufacture through automated laser welding processes
Solution Approach 2:
The patent optimizes the resin composition parameters (amorphous to crystalline resin ratio, particle size distribution, molecular weight) to achieve optimal laser transmittance for laser welding. By controlling these parameters, the material enables effective laser welding with standard laser equipment, improving both bonding quality and manufacturing efficiency
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 laser transmittance of 80% or more, bonding strength of 2,500 N or more, and a molding shrinkage rate of 0.5% or less, ensuring excellent dimensional stability and water tightness, making it suitable for high-precision camera modules, particularly for vehicle applications.
Implementation Method 1
The laser-transmitting material is required to have a suitable laser transmittance depending on the required thickness of the product so that it transmits the laser in the above-described wavelength range
Implementation Method 2
The transmitted laser passes through the laser-transmitting material and meets a non-laser-transmitting material, thus causing bonding
Implementation Method 3
bonding by laser welding has been used to ensure excellent water tightness and ease of assembly
Data Source
AI summary
The present disclosure is directed to a resin composition for a camera module having excellent laser transmittance and a camera module member produced using the same. In one embodiment, the resin composition for a camera module includes: 25 to 50 wt % of a polycarbonate resin; 5 to 30 wt % of a polycyclohexylenedimethylene terephthalate (PCT) resin; 30 to 50 wt % of a fibrous filler; and 0.001 to 5 wt % of a dye.