Composite Resin Odor Reduction via Fluidized Gas Treatment
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Solution Overview
Problem
Composite resin particles containing polyolefin-based and polystyrene-based resins face challenges in reducing odor levels, which is essential for automotive interior applications, as high temperatures for odor reduction can cause resin particles to bond prematurely, and existing methods do not effectively address odor generation from raw materials and production methods.
Innovation Solution
Fluidizing composite resin particles with a gas at a temperature range of (T-40) °C to (T-10) °C, where T is the softening temperature, to efficiently reduce odor, achieving an average odor strength of 3 or less in expanded molded articles, and incorporating a blowing agent for pre-expansion and in-mold forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If high temperature treatment is applied to reduce odor, then odor content is reduced, but resin particles bond prematurely
Solution Approach 1:
The patent applies parameter changes by precisely controlling the treatment temperature within the range of (T-40)°C to (T-10)°C, where T is the softening temperature of the composite resin particles. This temperature parameter optimization allows sufficient odor reduction while preventing premature resin bonding that would occur at higher temperatures. The method also controls treatment time and uses fluidization to enhance mass transfer without requiring excessive temperature
Solution Approach 2:
The patent employs fluidization technology using gas flow to suspend and uniformly distribute composite resin particles during odor reduction treatment. This pneumatic approach enhances heat and mass transfer efficiency, allowing odor removal at lower temperatures compared to conventional static heating methods, thereby preventing resin particle bonding while achieving effective odor reduction
2Strength
If polystyrene-based resin is used for rigidity, then rigidity is improved, but chemical resistance and impact resistance deteriorate
Solution Approach 1:
The patent creates a composite resin system combining polystyrene-based resin (providing rigidity) with polyolefin-based resin (providing chemical and impact resistance). The composite achieves synergistic properties where the polystyrene component contributes to rigidity while the polyolefin component compensates for poor chemical and impact resistance, producing a material that meets all three performance requirements simultaneously
3Reliability
If polyolefin-based resin is used for chemical resistance and impact resistance, then chemical resistance and impact resistance are improved, but rigidity deteriorates
Solution Approach 1:
The patent creates a composite resin system combining polystyrene-based resin (providing rigidity) with polyolefin-based resin (providing chemical and impact resistance). The composite achieves synergistic properties where the polystyrene component contributes to rigidity while the polyolefin component compensates for poor chemical and impact resistance, producing a material that meets all three performance requirements simultaneously
4Object-generated harmful factors
If polyolefin-based resin is used for reduced odor, then odor is reduced, but expansion molding control difficulty increases
Solution Approach 1:
The patent optimizes expansion molding parameters including temperature, pressure, and time to compensate for the poor blowing gas retention of polyolefin-based resin. By precisely controlling these parameters, the method achieves successful expansion molding despite the material's inherent difficulties, balancing odor reduction benefits with manufacturing feasibility
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 significantly reduces odor in composite resin particles, enabling their use in automotive interiors by maintaining impact resistance and chemical resistance while minimizing odor content, resulting in expanded molded articles with odor strength of 3 or less.
Implementation Method 1
fluidizing the composite resin particles in a container with a gas that is blown thereinto from its bottom
Data Source
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AI summary
A method of reducing an odor of composite resin particles comprising the step of: fluidizing the composite resin particles, which contain a polyolefin-based resin and a polystyrene-based resin and which are used for producing an expanded molded article, in a container with a gas that is blown thereinto from its bottom and that has a temperature of (T-40) °C to (T-10) °C (T is a softening temperature of the composite resin particles), to reduce the odor generated from a raw material of the composite resin particles and generated according to a method of the composite resin particles, wherein the composite resin particles whose odor is reduced are impregnated with a blowing agent; and the resultant is pre-expanded and then subject to an in-mold forming to make the expanded molded article have an odor strength of 3 or less in average value in odor test in which odor of an isovaleric acid diluted 100000 times is defined as 3, which means a reference odor, within 0 to 5 levels of the odor strength.