Core-Shell Foaming Agent for Uniform Pore Distribution
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Solution Overview
Problem
The production of foamed plastic products through extrusion blow molding often results in uneven pore distribution and mechanical defects due to differences in particle sizes between polymer resin and foaming agents, leading to lower mechanical strength and visual flaws.
Innovation Solution
A master batch composition comprising a bi-component carrier resin, core-shell foaming agents, and lubricants is developed, where the core-shell foaming agents have an outer polymeric shell encapsulating an alkane core, and the composition is integrated into the plastic product through extrusion blow molding to achieve uniform pore sizes and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder foaming agents are added to the polymer resin feeding mixture, then foaming function is achieved, but particle size uniformity deteriorates leading to defects
Solution Approach 1:
The foaming agent is nested inside a carrier resin particle to form a core-shell structure. The core contains the foaming agent particles while the shell is made of carrier resin. This nesting approach allows the foaming agent to be incorporated into the feeding mixture without creating broad particle size distribution, as the entire core-shell particle has a uniform size determined by the carrier resin particle size.
Solution Approach 2:
The invention creates a composite particle structure where the foaming agent (core) is combined with carrier resin (shell) to form a core-shell composite. This composite structure integrates two different materials with different functions while maintaining uniform particle size, resolving the contradiction between achieving foaming function and maintaining particle size uniformity.
2Weight of moving object
If foaming agents are incorporated into the feeding mixture, then weight reduction is achieved through foaming, but uneven pore distribution occurs leading to mechanical defects
Solution Approach 1:
The foaming agent is localized within specific carrier resin particles rather than being uniformly distributed as separate powder throughout the mixture. Each carrier resin particle acts as a localized container for foaming agents, ensuring controlled and uniform foam generation throughout the final product, which prevents uneven pore distribution while achieving weight reduction.
3Ease of manufacture
If broad particle size distribution exists in feeding mixture, then processing is simplified, but defect formation increases reducing product quality
Solution Approach 1:
The invention merges the foaming agent particles with carrier resin particles to create integrated core-shell structures. This combining approach allows the feeding mixture to maintain uniform particle size (improving manufacturing precision) while still incorporating all necessary components (maintaining ease of manufacture), as the core-shell particles can be easily mixed with the polymer resin without complex processing steps.
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 solution achieves a weight reduction of up to 20% in foamed plastic products with maintained mechanical strength and uniform pore sizes, preventing defects and ensuring product quality.
Implementation Method 1
The inner foaming agent core includes alkane... create a foamed plastic having a foaming pore size from 10 to 80 μm
Implementation Method 2
The master batch composition includes... at least one lubricant
Data Source
AI summary
A master batch composition for a weight-reduced plastic product includes a bi-component carrier resin, a core-shell foaming agent, and at least one lubricant. The core-shell foaming agent includes at least one outer polymeric shell and at least one inner foaming agent core. The outer polymeric shell encapsulates the inner foaming agent core. The inner foaming agent core includes alkane. The master batch composition is configured to be integrated into the weight-reduced plastic product by extrusion blow molding with a base plastic resin to create a foamed plastic having a foaming pore size from 10 to 80 μm.