Thermoplastic Resin Composition with Polyfunctional Compound
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Solution Overview
Problem
Thermoplastic resin compositions, particularly polybutylene terephthalate-based resins, face challenges in achieving high flowability without compromising mechanical properties, low warping, laser transmittance, and laser weldability, which are essential for modern industrial applications such as electric and electronic components and automotive parts.
Innovation Solution
A thermoplastic resin composition is developed by mixing 0.1 to 4 parts by weight of a polyfunctional compound with three or more functional groups, specifically a compound with terminal structures represented by a certain formula, with 100 parts by weight of a thermoplastic resin, such as polyester or polycarbonate, along with optional additives like terminal blocking agents, ester interchange catalysts, inorganic fillers, and impact strength modifiers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polyester resin with trivalent or higher polyvalent carboxylic acid or polyhydric alcohol is used to enhance mechanical properties, then the viscosity increases and flowability decreases
Solution Approach 1:
The patent changes the chemical structure parameters of the polyester resin by incorporating specific cyclic carbonate units (1,3-propanesultone units) into the polymer chain. This structural modification allows the resin to maintain both high mechanical strength and improved flowability, resolving the contradiction between these two properties.
Solution Approach 2:
The patent creates a composite polyester resin system by combining polybutylene terephthalate with specific cyclic carbonate units (1,3-propanesultone) in controlled amounts (0.1-10 mol%). This composite structure integrates the strength benefits of the base resin with the flowability enhancements provided by the cyclic carbonate units.
2Strength
If polybutylene terephthalate is used for industrial moldings, then mechanical properties and chemical resistance are excellent, but flowability during melting is insufficient for smaller and lighter-weight articles
Solution Approach 1:
The patent modifies the polybutylene terephthalate by incorporating 1,3-propanesultone units at controlled concentrations (0.1-10 mol%). This parameter change in the polymer structure reduces viscosity while preserving the mechanical properties, enabling production of smaller and lighter-weight industrial articles.
3Manufacturing precision
If polyester resin composition with styrene-based resin and inorganic filler is used to achieve low warping and mechanical properties, then flowability is low and cannot respond to demands for smaller and lighter-weight moldings
Solution Approach 1:
The patent introduces 1,3-propanesultone units into the polyester resin structure to fundamentally change the viscosity parameters. This allows the resin composition to maintain low warping properties from the inorganic filler while achieving sufficient flowability for manufacturing smaller and lighter-weight moldings.
4Reliability
If polybutylene terephthalate-based resin is used for laser welding, then laser beam transmittance is very low and thickness control is severe
Solution Approach 1:
The patent modifies the optical parameters of polybutylene terephthalate by incorporating 1,3-propanesultone units, which change the laser beam transmittance characteristics. This allows for improved laser weldability with more flexible thickness control, reducing the severity of thickness constraints in laser welding applications.
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 exhibits enhanced flowability, mechanical properties, low warping, laser transmittance, and laser weldability, making it suitable for complex and lightweight industrial moldings with improved design flexibility and processing efficiency.
Implementation Method 1
a polyfunctional compound having three or more functional groups, in which at least one of the terminal structures having the functional groups is a structure represented by the following formula (1)
Implementation Method 2
in the laser welding of molded resin parts, the overlapped resin parts are irradiated with a laser beam in such a manner that the laser beam is transmitted through one resin part
Implementation Method 3
the other resin part absorbs the laser beam
Data Source
Figure 1~3(b)
Figure 4(a)~5
Figure 6(a)~6(b)
AI summary
This invention relates to a thermoplastic resin composition and a molded article thereof, respectively excellent in flowability and mechanical properties, and, in a preferred mode, also excellent in low warping property, laser transmittance and laser weldability, and provides a thermoplastic resin composition obtained by mixing (B) 0.1 to 4 parts by weight of a polyfunctional compound having three or more functional groups, in which at least one of the terminal structures having the functional groups is a structure containing alkylene oxide units, with (A) 100 parts by weight of a thermoplastic resin, and further provides a molded particle thereof. It is preferred that the (A) thermoplastic resin is one or more selected from a polyester resin and polycarbonate resin.