Resin Composition Phase Structure for Impact Strength
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Solution Overview
Problem
Existing resin compositions face challenges in producing molded articles with excellent impact strength due to the aggregation of dispersed particles when combining amorphous resins and fluorine-containing copolymers, leading to a decrease in mechanical and electrical properties.
Innovation Solution
A resin composition is formulated with specific ratios of amorphous resin and fluorine-containing copolymer, controlled through shear rate during kneading to prevent particle aggregation, resulting in a phase structure with a continuous and dispersed phase, enhancing impact strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If amorphous resin and fluorine-containing copolymer are combined to improve mechanical and electrical properties, then sliding properties, heat resistance, and chemical resistance are enhanced, but dispersed particles aggregate leading to decreased mechanical and electrical properties
Solution Approach 1:
The patent applies parameter changes by controlling the melt flow rate ratio (r2/r1) between the fluorine-containing copolymer and amorphous resin to be within a specific range (0.05-5.0). This parameter control prevents particle aggregation during processing while maintaining the enhanced mechanical and electrical properties derived from the resin combination.
Solution Approach 2:
The patent uses composite materials by combining amorphous resin with fluorine-containing copolymer in specific proportions (by mass). This composite approach leverages the complementary properties of both materials - the amorphous resin provides structural integrity while the fluorine-containing copolymer enhances sliding, heat, and chemical resistance - without allowing harmful aggregation to occur.
2Ease of operation
If fluorine-containing copolymer is added to amorphous resin to enhance flexibility and electrical properties, then sliding properties and heat resistance improve, but particle aggregation occurs reducing overall performance
Solution Approach 1:
The patent controls the melt flow rate ratio parameter (r2/r1) within the range of 0.05-5.0 to prevent particle aggregation. This parameter adjustment allows the fluorine-containing copolymer to enhance flexibility and sliding properties while maintaining mechanical and electrical reliability by preventing harmful aggregation.
Solution Approach 2:
The patent applies local quality by ensuring uniform distribution of the fluorine-containing copolymer within the amorphous resin matrix. The controlled melt flow rate ratio ensures that the copolymer is dispersed homogeneously at the local level, allowing enhanced flexibility and sliding properties without creating aggregation zones that would reduce overall mechanical and electrical performance.
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 produces molded articles with improved impact strength, mechanical properties, and dielectric performance, suitable for high-frequency circuit boards and laminates.
Implementation Method 1
the resin composition has a phase structure including a continuous phase and a dispersed phase that contains a component constituting the continuous phase
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.