Resin Sheet Silicone Coating for Carrier Tape Stability
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Solution Overview
Problem
Resin sheets with low adhesiveness face challenges in maintaining shape stability during winding and deep-drawing molding, leading to potential deviations and reduced strength in embossed carrier tapes and electronic component packaging.
Innovation Solution
A resin sheet with a base material composition of Styrene-conjugated diene block copolymer, polystyrene resin, and high-impact polystyrene resin, coated with a surface layer containing silicone, which provides enhanced adhesion and moldability, reducing winding deviations and ensuring sufficient strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adhesiveness of resin sheet is excessively low, then ease of operation is improved, but manufacturing precision deteriorates due to winding deviation and molding position deviation
Solution Approach 1:
The patent applies parameter changes by precisely controlling the silicone content in the surface layer within 0.3 to 4.0 g/m2. This quantitative parameter adjustment optimizes the balance between adhesiveness and shape stability, preventing both excessive adhesion that would cause winding deviation and insufficient adhesion that would lead to molding position deviation.
Solution Approach 2:
The patent uses composite materials by combining a base material sheet with a surface layer containing silicone. This layered composite structure allows the base material to provide structural integrity while the silicone-containing surface layer provides controlled adhesiveness, resolving the contradiction between ease of operation and manufacturing precision.
2Adaptability or versatility
If deep-drawing molding is performed to provide pockets, then adaptability is improved for component packaging, but manufacturing precision deteriorates due to hole generation and reduced strength
Solution Approach 1:
The patent applies parameter changes by optimizing the resin composition ratios (component A: 29-65 parts, component B: 25-60 parts, component C: 8-20 parts) and silicone content (0.3-4.0 g/m2). These parameter adjustments enable the material to withstand deep-drawing molding forces without generating holes while maintaining molding precision and pocket strength.
Solution Approach 2:
The composite structure of base material sheet plus silicone-containing surface layer provides the necessary combination of ductility for deep-drawing and strength for hole prevention. The surface layer modifies the surface properties to enable successful deep-drawing molding while maintaining overall structural integrity.
3Manufacturing precision
If resin sheet adhesiveness is increased to prevent deviation, then manufacturing precision is improved, but shape stability deteriorates during winding
Solution Approach 1:
The patent applies parameter changes by precisely controlling silicone content within 0.3 to 4.0 g/m2. This quantitative control ensures sufficient adhesiveness for molding precision while preventing excessive adhesion that would cause winding deviation and compromise shape stability during the winding process.
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 sheet exhibits improved shape stability and moldability, allowing for precise deep-drawing molding with reduced deviations and increased strength in the molded body, suitable for embossed carrier tapes and electronic component packaging.
Implementation Method 1
a surface layer provided on at least one surface of the base material sheet and including silicone, wherein the silicone content in the surface layer is 0.3 to 4.0 g/m2
Implementation Method 2
a required level of moldability is becoming higher with the increase in size of components for in-vehicle use and the like. Moreover, a provided pocket is required to have a sufficient strength so that it is unlikely to be crushed even in a state of being wound in a reel
Data Source
AI summary
A resin sheet for molding includes a base material sheet, and a surface layer provided on at least one surface of the base material sheet and including silicone, wherein the silicone content in the surface layer is 0.3 to 4.0 g/m2, and wherein the base material sheet is formed of a resin composition including 29 to 65 parts by mass of a Styrene-conjugated diene block copolymer (A), 25 to 60 parts by mass of a polystyrene resin (B), and 8 to 20 parts by mass of a high-impact polystyrene resin (C) (provided that a total amount of the component (A), the component (B), and the component (C) is 100 parts by mass). A carrier tape 100 is a molded body 16 of the resin sheet, wherein an accommodation portion 20 capable of accommodating an article is provided.