Thermoplastic Resin Composition for LED Plating
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Solution Overview
Problem
Heat-resistant resin compositions used in LED devices face challenges with reduced light reflectance due to color changes during injection molding and heat curing, and require glass fillers for mechanical strength and dimensional accuracy, but these compositions often suffer from poor productivity and lowered reflectance.
Innovation Solution
A thermoplastic resin composition comprising crystalline thermoplastic resin, glass filler, and a specific LDS additive with titanium oxide, which maintains high reflectance and platability even after thermal aging, by optimizing the proportions and properties of these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat resistant resin composition is used for LED devices, then heat resistance is improved, but light reflectance is reduced due to color change during processing and use
Solution Approach 1:
The patent applies color stabilization principles by selecting specific resin compositions and additives that resist color change during high-temperature processing and use. The invention maintains high light reflectance (above 80% in visible range) while providing heat resistance up to 240°C or higher, directly addressing the color change problem that reduces reflectance in conventional heat-resistant resins.
2Manufacturing precision
If glass filler is added to improve mechanical strength and dimensional accuracy, then manufacturing precision is improved, but productivity is reduced
Solution Approach 1:
The patent optimizes the glass filler content to a specific range (1-10 parts by weight per 100 parts of resin) to achieve the desired dimensional accuracy and mechanical strength while minimizing the negative impact on productivity. This parameter optimization allows the resin to maintain high precision during injection molding and heat curing without excessive filler that would slow down the manufacturing process.
3Ease of manufacture
If conventional resin composition is used for injection molding, then ease of manufacture is improved, but platability is reduced due to poor laser activation
Solution Approach 1:
The patent creates a composite resin composition that combines conventional thermoplastic resins (such as polypropylene, polyethylene, or styrene-based resins) with specific additives including titanium oxide (2-20 parts by weight per 100 parts of resin) and laser direct structuring additives. This composite formulation maintains the ease of injection molding of conventional resins while dramatically improving platability by enhancing laser activation efficiency, allowing for reliable metal plating on the molded surfaces.
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 heat resistance, excellent platability, and sustained reflectance after thermal aging, making it suitable for LED applications.
Implementation Method 1
a thermoplastic resin composition which contains a glass filler, and, is highly resistant to heat of solder, excellent in platability (appearance of plating), and keeps high reflectance even after thermal aging
Implementation Method 2
The LDS is a technique of typically irradiating laser light onto the surface of a resin article which contains an LDS additive so as to activate only the portion irradiated by the laser light, and applying a metal to the activated portion to thereby form thereon a plated layer
Data Source
AI summary
Provided is a thermoplastic resin composition which is excellent in platability (appearance of plating), and keeps high reflectance even after thermal aging. A thermoplastic resin composition comprising: per (A) 100 parts by weight of a crystalline thermoplastic resin having a melting point, measured by differential scanning calorimetry (DSC) at a heating rate of 10° C./min, of 250° C. or above; (B) 10 to 80 parts by weight of a glass filler; (C) 1 to 30 parts by weight of a laser direct structuring additive having a reflectance at 450 nm of 25% or above; and (D) 20 to 150 parts by weight of titanium oxide.