Resin Composition Orientation Tracer for Injection Molding
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Solution Overview
Problem
Existing resin compositions for injection molding exhibit anisotropy due to the use of fibrous inorganic particles, which restrict resin deformation and enhance anisotropy, making it difficult to estimate resin orientation while maintaining dimensional accuracy and isotropy.
Innovation Solution
A resin composition incorporating a first thermoplastic resin, non-fibrous inorganic particles, and a tracer composed of an aggregate or resin composition with specific aspect ratios and sizes, allowing for the estimation of resin orientation without increasing anisotropy, using aggregates of inorganic particles with high aggregation properties and a second thermoplastic resin that maintains shape under thermal changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fibrous inorganic particles are used as fillers in injection molded articles, then the resin orientation can be estimated through fiber direction analysis, but the resin deformation is restricted and anisotropy is enhanced
Solution Approach 1:
The patent extracts the orientation estimation function from fibrous inorganic particles and transfers it to non-fibrous inorganic particles with specific aspect ratios. By removing the fibrous component and replacing it with particles having controlled geometry (aspect ratio between 1.5-5.0), the patent eliminates the harmful restriction on resin deformation while preserving the ability to estimate resin orientation through particle alignment analysis.
Solution Approach 2:
The patent changes the geometric parameters of the inorganic particles from fibrous morphology to non-fibrous morphology with specific aspect ratios. By controlling the particle shape parameters (transitioning from high aspect ratio fibrous structures to controlled non-fibrous geometries with aspect ratios between 1.5-5.0), the patent achieves both orientation estimation capability and reduced anisotropy.
2Loss of information
If fibrous inorganic particles are used to estimate resin orientation, then orientation information can be obtained, but anisotropy is enhanced and dimensional accuracy is reduced
Solution Approach 1:
The patent extracts the orientation tracking function from fibrous particles and implements it through non-fibrous particles with controlled aspect ratios. This extraction eliminates the harmful anisotropy enhancement while maintaining the ability to obtain orientation information through the alignment of non-fibrous particles with the resin flow.
Solution Approach 2:
The patent uses a composite approach by combining non-fibrous inorganic particles with specific aspect ratios into the resin composition. This composite material design allows the particles to serve as orientation tracers while their non-fibrous nature prevents excessive anisotropy, thereby maintaining dimensional accuracy.
3Measurement precision
If inorganic particles with large particle diameter are used, then the particles provide good orientation indication, but they restrict resin flow and increase anisotropy
Solution Approach 1:
The patent optimizes the particle size parameters by limiting the particle diameter to 0.1-10 μm and controlling the aspect ratio between 1.5-5.0. These parameter changes ensure that the inorganic particles are small enough to not restrict resin flow significantly, while their controlled aspect ratios maintain their effectiveness as orientation indicators.
Data Source
AI summary
The present invention intends to estimate the orientation of a resin while suppressing anisotropy. The resin composition for injection molding according to the present invention including a first thermoplastic resin and a filler including a non-fibrous first inorganic particle, further including at least one of an aggregate of second inorganic particles and a resin composition of a second thermoplastic resin. A ratio of a longest first length to a shortest second length among lengths of the aggregate and the resin composition in three directions orthogonal to each other is larger than or equal to 2 and smaller than or equal to 20, and the first length is larger than or equal to 25 μm and smaller than or equal to 100 μm. The aggregate or the resin composition does not include the first inorganic particles having a particle diameter of larger than or equal to 25 μm.