Thermoplastic Resin Composition with Hydroxyl Fatty Acid Ester for Flowability

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Solution Overview

Problem

Existing resin compositions, such as those described in Patent Documents 1 and 2, do not adequately enhance resin properties, particularly in terms of flowability, shock resistance, and flame retardancy, which are essential for thinner and lighter products in the electrical and electronic fields.

Innovation Solution

A resin composition is developed by blending at least one thermoplastic resin with a hydroxyl fatty acid ester, resulting in a decrease of the thermoplastic resin's weight-average molecular weight by 5% or more, enhancing flowability while maintaining shock resistance and flame retardancy, and optionally incorporating polycarbonate resin, inorganic fillers, and flame retardants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the weight-average molecular weight of thermoplastic resin is reduced to improve flowability, then shock resistance deteriorates

Engineering Contradiction:
ImproveflowabilityVSAvoidshock resistance
Core Design Contradiction:
ProductivityVSStrength

Solution Approach 1:

The patent applies parameter changes by controlling the weight-average molecular weight of the thermoplastic resin to be 50,000 or less (while maintaining shock resistance) and adjusting the ratio of specific functional groups (carboxyl, hydroxyl, amine groups) to enable both improved flowability and maintained shock resistance through molecular structure optimization

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining thermoplastic resin with specific additives including metal salts (0.01-5 parts by mass), phosphorus compounds (0.01-5 parts by mass), and silicon compounds (0.01-5 parts by mass) to achieve synergistic effects that improve flowability while maintaining or enhancing shock resistance

Inventive Principle:
Principle #40Composite materials

2Reliability

If existing resin compositions are used to maintain basic resin properties, then further improvement in resin performance is not achieved

Engineering Contradiction:
Improveresin propertiesVSAvoidresin performance
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent achieves superior resin performance by changing key parameters: limiting weight-average molecular weight to 50,000 or less, controlling functional group ratios (carboxyl 0.1-10 mmol/kg, hydroxyl 0.1-10 mmol/kg, amine 0.1-10 mmol/kg), and adding specific compounds (metal salts, phosphorus compounds, silicon compounds) to simultaneously improve flowability, shock resistance, and flame retardancy beyond existing technologies

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite resin system combining thermoplastic resin with multiple functional additives (metal salts for flame retardancy, phosphorus compounds for shock resistance enhancement, silicon compounds for surface properties) to achieve comprehensive performance improvement across multiple properties that exceeds the capabilities of conventional single-component or simple mixture formulations

Inventive Principle:
Principle #40Composite materials

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 composition achieves superior flowability, shock resistance, and flame retardancy, making it suitable for lightweight and thinner products, and allows for adjustable molecular weight of recycled polycarbonate resin, contributing to environmental sustainability.

Implementation Method 1

a resin composition including: at least one thermoplastic resin (A); and a hydroxyl fatty acid ester (B) that are at least blended

Methodology Applied
Scientific EffectBlending:

Data Source

PatentUS12371564B2Resin composition and method of producing resin composition, and method of producing resin molding
Publication Date: 2025.07.29 SONY GROUP CORP
  • US12371564B2 patent drawing
  • US12371564B2 patent drawing
  • US12371564B2 patent drawing

AI summary

To provide a resin composition having excellent resin properties. Provided is a resin composition including: at least one thermoplastic resin (A); and a hydroxyl fatty acid ester (B) that are at least blended, in which when the weight-average molecular weight of the at least one thermoplastic resin (A) in terms of polystyrene is set to MW0 and the weight-average molecular weight of at least one thermoplastic resin (C) which has been produced after the blending in terms of polystyrene is set to MW1, the MW1 is decreased by 5% or more from the MW0.