Bead Foam Density Ratio for Resin Composite Strength
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Solution Overview
Problem
The challenge is to produce a resin composite with both high strength and lightness while maintaining a good appearance, as existing methods often result in surface voids and fiber exposure due to weak compression strength of bead expanded articles.
Innovation Solution
Increasing the density of bead expanded articles within a specific range of 10% compression stress to density ratio, combined with high air permeability resistance and thermal fusion rate, allows for the production of resin composites with improved strength, lightness, and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the density of bead expanded article is increased to improve compression strength, then compression strength is improved, but mass increases unnecessarily
Solution Approach 1:
The invention changes the physical and chemical parameters of the bead expanded article by controlling the polycarbonate resin composition, blowing agent content, and expansion conditions to achieve a specific density range (0.05-0.20 g/cm³) and compression strength range (10% compression stress/density ratio of 5-20 MPa·cm³/g), resolving the contradiction between compression strength and mass
Solution Approach 2:
The invention uses composite materials by combining polycarbonate-based resin with specific blowing agents and optional additives to create a bead expanded article that achieves both lightness and sufficient compression strength through material composition optimization rather than simple density increase
2Ease of manufacture
If pressure is applied during lamination of fiber-reinforced resin material, then lamination is achieved, but surface appearance deteriorates due to voids and fiber exposure
Solution Approach 1:
The invention applies beforehand cushioning by pre-expanding the beads to a controlled density and incorporating expansion control mechanisms that prevent excessive expansion during lamination, thereby cushioning against the harmful effect of surface voids and fiber exposure while still allowing proper lamination
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 approach results in resin composites that are excellent in strength, lightness, and appearance, with enhanced surface smoothness and desired thickness, avoiding surface imperfections and resin depletion.
Implementation Method 1
heating the expandable particles to prepare pre-expanded particles
Implementation Method 2
a plurality of expanded particles which are mutually thermally fused
Implementation Method 3
impregnating a thermoplastic resin composition containing a polycarbonate-based resin having an aromatic skeleton as a main component with a blowing agent to prepare expandable particles; preparing pre-expanded particles by heating the expandable particles
Implementation Method 4
filling a mold with the pre-expanded particles to which the internal pressure is applied and introducing steam to the mold to secondarily expand the pre-expanded particles
Data Source
Figure 1~2
Figure 3
AI summary
A bead expanded article containing a plurality of expanded particles, in which the bead expanded article has a property that a value obtained by dividing a 10% compression stress (MPa) of the bead expanded article by a density (g/cm3) is 9.0 (MPa·cm3/g) or more.