Resin Composition Fiber Length Control via Side Feed Extrusion
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Solution Overview
Problem
Existing methods for manufacturing resin compositions with controlled weight average fiber length of fibrous fillers, such as those used in liquid crystalline polyesters, lack efficiency in adjusting fiber length within the desired range of not more than 400 μm without repeated melt-kneading processes.
Innovation Solution
A method involving an extruder with a cylinder and screw, where a resin and fibrous filler are supplied through main and optional side feed ports, allowing for melt-kneading and extrusion to control the weight average fiber length of the fibrous filler within the desired range in a single process, using a resin composition comprising liquid crystalline polyester with glass, basalt, or alumina fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fibers with long fiber length (1 mm or more) are used as fibrous filler, then the molded article strength and fluidity are improved, but the weight average fiber length exceeds the desired range of not more than 400 μm, causing increased dust generation
Solution Approach 1:
The patent applies dynamics by making the fiber length distribution adjustable and variable. Instead of using fixed-length fibers, the invention uses a mixture of fibers with different lengths (1 mm or more as starting material) and controls the melt-kneading process to achieve a dynamic fiber length distribution where the weight average fiber length is reduced to 400 μm or less while maintaining sufficient strength through optimized fiber orientation and distribution in the resin composition
Solution Approach 2:
The patent changes the parameter of fiber length through controlled mechanical degradation during melt-kneading. By adjusting kneading conditions (temperature, shear rate, kneading time) and using fibers with initial length of 1 mm or more, the process transforms the fiber length parameter to achieve weight average fiber length of 400 μm or less, reducing dust generation while maintaining molded article strength through optimized fiber-resin interface and distribution
2Length of moving object
If repeated melt-kneading processes are performed to control fiber length, then the weight average fiber length is reduced to within the desired range, but the manufacturing efficiency decreases and production time increases
Solution Approach 1:
The patent applies preliminary action by pre-selecting glass fibers with specific initial characteristics (fiber length of 1 mm or more, specific diameter range) before the melt-kneading process. This preliminary preparation of the fibrous filler allows the subsequent single-stage melt-kneading to efficiently achieve the target fiber length distribution, eliminating the need for repeated processing cycles and improving manufacturing efficiency
Solution Approach 2:
The patent skips the traditional multi-stage fiber length control process by implementing a single, optimized melt-kneading step. Through careful selection of initial fiber parameters and optimization of kneading conditions (temperature profile, shear rate, residence time), the process rapidly achieves the desired fiber length reduction in one pass, rushing through what would traditionally require multiple iterative steps
3Stability of the object's composition
If glass fibers are mixed with liquid crystalline polyester, then the anisotropy in molding shrinkage rate and mechanical properties is reduced, but the fiber length must be precisely controlled to prevent dust generation from dislodged fibers
Solution Approach 1:
The patent changes the fiber length parameter to 400 μm or less (weight average) through controlled melt-kneading of initial fibers with length of 1 mm or more. This parameter change reduces the tendency of fibers to dislodge and generate dust while maintaining the anisotropy-reducing effect of fibrous fillers in the liquid crystalline polyester composition
Solution Approach 2:
The patent creates an optimized composite material system combining liquid crystalline polyester with specifically processed glass fibers. The composite achieves both functions: reducing anisotropy through fiber reinforcement and minimizing dust generation through controlled fiber length (400 μm or less weight average), creating a synergistic material composition where the fiber-resin interface and fiber distribution are optimized
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
This method efficiently produces resin compositions with controlled fiber length, enhancing moldability and reducing dust generation, suitable for producing molded articles with improved anti-dust properties and mechanical strength.
Implementation Method 1
performing melt-kneading
Implementation Method 2
melt-kneading
Implementation Method 3
extruding the melt-kneaded material
Data Source
AI summary
A method for producing a resin composition using an extruder, the extruder having a cylinder and a screw disposed inside the cylinder, the cylinder being provided with a main feed port and further optionally provided with a side feed port disposed downstream in an extrusion direction from the main feed port, and the method comprising: supplying a resin (A) in the total amount to the extruder from the main feed port; supplying a fibrous filler (B), whose a weight average fiber length is 1 mm or more, in the total amount to the extruder from the main feed port, or, with the extruder being provided with the side feed port, supplying the fibrous filler (B) partly to the extruder from the main feed port and the remainder to the extruder from the side feed port; melt-kneading the supplied resin (A) and the fibrous filler (B); and extruding the melt-kneaded material.