Amorphous Thermoplastic Resin Foam with Fine Bubbles

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Solution Overview

Problem

Conventional light reflecting materials face challenges in achieving fine and uniform bubble diameters, which affect moldability and light reflectivity, while also being cost-effective and efficient in applications like lighting and liquid crystal displays.

Innovation Solution

Incorporating a specific amount of a melt-type crystallization nucleating agent into an amorphous thermoplastic resin to produce a foam with uniform bubble diameters of 10 µm or less, using compounds like trimesic acid tris(t-butylamide, and foaming above the glass transition temperature to enhance moldability and reflectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If an amorphous thermoplastic resin is foamed without a crystallization nucleating agent, then the moldability is excellent, but coarse bubbles with a size of 1 mm or more are easily generated

Engineering Contradiction:

ImprovemoldabilityVSAvoidbubble uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention changes the chemical composition parameter by adding a specific amount (0.01-5 parts by mass per 100 parts of resin) of crystallization nucleating agent to the amorphous thermoplastic resin. This parameter change enables the resin to form fine and uniform bubbles (average diameter 10 µm or less) while maintaining good moldability, resolving the contradiction between ease of manufacture and manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If an amorphous thermoplastic resin is foamed at a temperature lower than glass transition temperature (Tg), then fine bubbles are formed, but the expansion ratio is not improved

Engineering Contradiction:

Improvebubble finenessVSAvoidexpansion ratio

Core Design Contradiction:

Manufacturing precisionVSVolume of stationary object

Solution Approach 1:

The invention changes the temperature parameter by setting the foaming temperature to Tg or higher (specifically 100-200°C above Tg). Combined with adding crystallization nucleating agent, this temperature parameter change enables both fine bubble formation (average diameter 10 µm or less) and improved expansion ratio (1.05-5 times), resolving the contradiction between bubble fineness and expansion ratio.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If a crystalline resin like polyethylene terephthalate is used to create fine bubbles, then fine and uniform bubbles are achieved, but problems in moldability occur

Engineering Contradiction:

Improvebubble uniformityVSAvoidmoldability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention creates a composite system by combining amorphous thermoplastic resin with crystallization nucleating agent. This composite approach allows the amorphous resin to maintain its inherent moldability while the nucleating agent provides the bubble uniformity typically associated with crystalline resins, achieving both fine bubbles (average diameter 10 µm or less) and good moldability simultaneously.

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 method results in a thermoplastic resin foam with high light reflectivity and improved moldability, reducing coarse bubble generation and achieving desired performance while maintaining cost-effectiveness.

Implementation Method 1

a nucleating agent which is characterized by melting and dispersing in a resin in melt-kneading when added to a thermoplastic resin and being coagulated and solidified (crystallized) to deposit in a temperature-dropping coagulation step

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

being coagulated and solidified (crystallized) to deposit in a temperature-dropping coagulation step

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Implementation Method 3

foaming at a temperature of a glass transition temperature of the amorphous thermoplastic resin or more

Methodology Applied

Scientific EffectGlass transition:

Implementation Method 4

foaming the composition impregnated with the inert gas by heating at a temperature of a glass transition temperature of the amorphous thermoplastic resin or more under a released pressure

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 5

depositing the melt-type crystallization nucleating agent by solidifying the composition followed by impregnating an inert gas to the composition under pressure

Methodology Applied

Scientific EffectGas impregnation under pressure: Pressurisation

Data Source

PatentEP2607416B1Thermoplastic resin foam, method of producing the same, and light reflecting material using the same

Publication Date: 2019.10.02 FURUKAWA ELECTRIC CO LTD

AI summary

A thermoplastic resin foam, having a bubble with an average bubble diameter of 10 µm or less in the inside thereof, in which wherein the thermoplastic resin foam is prepared by using and foaming a thermoplastic resin composition containing 0.25 to 2.5 part(s) by mass of a melt-type crystallization nucleating agent (B), with respect to 100 parts by mass of an amorphous thermoplastic resin (A).