Stretchable Epoxy Resin Composition for Tear-Resistant Flexible Circuits
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Solution Overview
Problem
Existing stretchable resin substrates face issues with low tear strength, high crosslinking density, and poor flexibility, making them unsuitable for applications in circuit boards, while other epoxy resins have low molecular weight, difficulty forming sheets, and poor productivity.
Innovation Solution
A stretchable resin composition with an epoxy resin having a weight average molecular weight of 50,000 to 3,000,000 and a polydispersity of 1.1≤Mw/Mn≤3, combined with a crystalline curing agent and a glass transition temperature of 60° C. or less, providing flexibility, heat resistance, and high tear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a polyrotaxane-based resin composition is used to achieve high flexibility, then flexibility is improved, but tear strength becomes low
Solution Approach 1:
The patent uses a composite resin composition containing polyrotaxane (A), epoxy resin (B), and curing agent (C) to combine the flexibility benefits of polyrotaxane with the strength and adhesion properties of epoxy resin, resolving the contradiction between flexibility and tear strength
Solution Approach 2:
The patent specifies precise parameter ranges: polyrotaxane (A) at 5-50 parts by mass, epoxy resin (B) at 45-95 parts by mass, and curing agent (C-1) acid anhydride at 0.1-10 parts by mass with respect to 100 parts by mass of the total composition, optimizing the balance between flexibility and tear strength
2Adaptability or versatility
If an epoxy resin with small molecular weight is used to achieve stretchability, then stretchability is improved, but tear strength becomes low and productivity decreases
Solution Approach 1:
The patent controls the molecular weight and crosslinking density parameters of the epoxy resin system to achieve optimal stretchability while maintaining high tear strength and acceptable cure time for productivity
3Temperature
If high crosslinking density is achieved to improve heat resistance, then heat resistance is improved, but tear strength becomes poor
Solution Approach 1:
The patent optimizes the crosslinking density by selecting specific curing agents (acid anhydrides) and controlling their content (0.1-10 parts by mass), achieving a balance where sufficient heat resistance is obtained without excessive crosslinking that would reduce tear strength
Solution Approach 2:
The combination of polyrotaxane and epoxy resin creates a composite network where the polyrotaxane provides flexibility and the epoxy provides structural integrity, allowing heat resistance without sacrificing tear strength
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 achieves high stretchability, flexibility, and tear strength, suitable for applications in IoT and flexible display devices, as well as fields like optics, electronics, and medical treatment.
Implementation Method 1
a stretchable resin composition containing at least an epoxy resin and a curing agent
Implementation Method 2
the curing agent is a crystalline compound
Data Source
AI summary
An aspect of the present invention relates to a stretchable resin composition containing an epoxy resin and a curing agent, in which the epoxy resin has a weight average molecular weight of 50,000 or more and 3,000,000 or less and a polydispersity of average molecular weights (Mw/Mn) that satisfies the following Formula (1): 1.1≤Mw/Mn≤3.0(1) (wherein, Mn represents a number average molecular weight and Mw represents a weight average molecular weight), the curing agent is a crystalline compound, and a glass transition temperature of a cured product of the stretchable resin composition is 60° C. or less.