Resin Composition With Stable Fluoropolymer Dispersion for Impact Strength
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Solution Overview
Problem
Fluorine-containing copolymers have low compatibility with other resins, leading to aggregation of dispersed particles during molding, which decreases physical properties of resin compositions.
Innovation Solution
A resin composition is formulated with an amorphous resin and a fluorine-containing copolymer, where the average dispersed particle sizes satisfy a specific ratio (r2/r1 < 1.70), achieved through effective shear during kneading to suppress particle aggregation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fluorine-containing copolymer is mixed with other resins, then sliding properties and heat resistance are improved, but dispersed particles aggregate during molding causing decrease in physical properties
Solution Approach 1:
The patent applies parameter changes by controlling the average dispersed particle size ratio (r2/r1) to be 1.70 or less. This specific parameter control prevents particle aggregation during molding while maintaining the physical properties of the resin composition. The particle size parameter is measured after melt flow rate measurement under specific conditions (5000 g load at 380°C or melting temperature), ensuring consistent dispersion quality.
Solution Approach 2:
The patent creates a composite material system combining amorphous resin (A) and fluorine-containing copolymer (B). This composite approach allows the fluorine-containing copolymer to provide sliding properties and heat resistance while the controlled particle size ratio ensures good dispersion and compatibility, preventing aggregation and maintaining impact strength and other physical properties.
2Reliability
If fluorine-containing copolymer is used to improve sliding properties and heat resistance, then these properties are enhanced, but compatibility with other resins decreases leading to particle aggregation
Solution Approach 1:
The patent resolves the compatibility issue by changing the particle size parameter - specifically controlling the ratio of average dispersed particle sizes (r2/r1) to be 1.70 or less. This parameter control ensures that the fluorine-containing copolymer particles remain well-dispersed in the amorphous resin matrix, improving compatibility while maintaining the reliable sliding properties and heat resistance of the fluorine-containing copolymer.
Solution Approach 2:
The patent develops a composite material formulation where amorphous resin (A) and fluorine-containing copolymer (B) are combined in specific proportions. This composite structure allows the fluorine-containing copolymer to contribute its excellent sliding properties and heat resistance while the controlled particle size ratio ensures good interfacial compatibility and prevents aggregation, achieving both reliability and adaptability.
3Adaptability or versatility
If dispersed particle size is reduced to prevent aggregation, then compatibility improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a specific parameter threshold (r2/r1 ≤ 1.70) that balances dispersion uniformity with manufacturing feasibility. This parameter provides a clear target for production while allowing reasonable manufacturing tolerance. The particle sizes are measured under standardized conditions (after melt flow rate measurement with 5000 g load at 380°C or melting temperature), ensuring consistent and reproducible results without requiring excessive manufacturing precision.
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 maintains good mechanical properties and enhances impact strength, flexibility, and electrical properties of the molded articles.
Implementation Method 1
effective shear during kneading to suppress particle aggregation
Data Source
AI summary
Provided is a resin composition capable of producing a molded article with excellent impact strength. The resin composition contains an amorphous resin (A) belonging to super engineering plastics and a fluorine-containing copolymer (B), the amorphous resin (A) or the fluorine-containing copolymer (B) having an average dispersed particle size r1 and an average dispersed particle size r2 that is determined after measuring a melt flow rate in conformity with ASTM D1238 after preheating for five minutes and under a load of 5000 g at 380° C. or at a temperature at which the resin composition melts or higher, the r1 and the r2 satisfying a ratio r2/r1 of lower than 1.70, where the r1 and the r2 are obtained by measuring the same resin or the same copolymer.