Coextruded Polyolefin Foam with Virgin Surface Layer
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Solution Overview
Problem
Recycled metallized polyolefin materials in foam structures often result in unwanted surface variations, such as roughness, softness, firmness, and adhesive compatibility issues, which can negatively affect lamination strength and quality, particularly in automotive interior trim applications.
Innovation Solution
The development of coextruded multilayer foam structures with a surface foam layer made from virgin polyolefin material and an interior foam layer from recycled polyolefin material, sandwiched between non-recycled foam layers, utilizing chemical foaming agents like azodicarbonamide and ionizing radiation for crosslinking, to achieve consistent surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If recycled metallized polyolefin material is used in foam structures, then cost and environmental friendliness are improved, but surface properties deteriorate causing roughness, softness, firmness variations, and adhesive compatibility issues
Solution Approach 1:
The foam structure is divided into multiple layers with different material compositions. The surface layer uses virgin polyolefin material to ensure consistent surface properties, while the core layer incorporates recycled metallized polyolefin material to achieve cost-effectiveness and environmental benefits. This segmentation allows each layer to fulfill its specific function independently.
Solution Approach 2:
Different regions of the foam structure have different material qualities tailored to their specific requirements. The surface layer is made from virgin material with controlled surface properties for lamination and adhesive compatibility, while the interior layer uses recycled material for cost and environmental performance. Each region's material properties are optimized for its local function.
2Adaptability or versatility
If recycled material is used to create foam structures, then environmental friendliness is improved, but surface properties deteriorate affecting lamination strength and quality
Solution Approach 1:
The foam structure is divided into multiple layers with different material compositions. The surface layer uses virgin polyolefin material to ensure consistent surface properties, while the core layer incorporates recycled metallized polyolefin material to achieve cost-effectiveness and environmental benefits. This segmentation allows each layer to fulfill its specific function independently.
Solution Approach 2:
The surface layer acts as an intermediary between the recycled interior layer and the lamination process. This intermediate layer provides the necessary surface properties for successful lamination while allowing the recycled material to be utilized in the core structure, thus mediating between environmental goals and lamination reliability.
3Ease of manufacture
If recycled foam material is incorporated into foam structures, then cost is reduced, but surface variations occur including dark spots and gels that cause adhesion problems
Solution Approach 1:
The foam structure is divided into multiple layers with different material compositions. The surface layer uses virgin polyolefin material to ensure consistent surface properties, while the core layer incorporates recycled metallized polyolefin material to achieve cost-effectiveness and environmental benefits. This segmentation allows each layer to fulfill its specific function independently.
Solution Approach 2:
The problematic recycled material is extracted from the surface layer and placed in the interior core layer. By removing the recycled material from the surface region, the surface uniformity issue is eliminated while still allowing cost reduction through recycled material usage in the core. The harmful elements are taken out from the critical surface zone.
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
This approach allows for the creation of cost-effective, environmentally friendly foam products with consistent surface properties, improving lamination strength and quality while maintaining performance standards comparable to those made from non-recycled materials.
Implementation Method 1
The foam layer can include polypropylene and/or polyethylene and a chemical foaming agent
Implementation Method 2
The coextruded, crosslinked multilayer foam structures
Data Source
AI summary
A physically crosslinked, closed cell continuous multilayer foam structure comprising at least one polypropylene/polyethylene coextruded foam layer is obtained. The multilayer foam structure is obtained by coextruding a multilayer structure comprising at least one foam composition layer, irradiating the coextruded structure with ionizing radiation, and continuously foaming the irradiated structure.