Crosslinked Hollow Particles With High Void Ratio and Collapse Resistance
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Solution Overview
Problem
Existing hollow particles face challenges in achieving a high void ratio while maintaining strength and minimizing volatile compounds, which can lead to collapse and potential ignition during kneading and molding processes.
Innovation Solution
Hollow particles with a shell thickness of 0.2 μm to 0.9 μm, composed of 70% to 100% crosslinkable monomer and 0% to 30% non-crosslinkable monomer, and containing a polar resin, are produced using a suspension polymerization method to enhance strength and reduce volatile compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the void ratio of hollow particles is increased to improve weight reduction and heat insulation effects, then the weight reduction efficiency and heat insulation performance are improved, but the particles become more prone to collapse during kneading and molding processes
Solution Approach 1:
The patent applies parameter changes by precisely controlling the shell thickness ratio (0.03 to 0.25) and void ratio (50% to 90%) of the hollow particles. By optimizing these parameters, the particles achieve high weight reduction efficiency while maintaining sufficient shell strength to prevent collapse during processing. The specific parameter ranges represent the optimal balance point between lightness and structural integrity.
Solution Approach 2:
The patent employs composite materials by combining hollow resin particles with a resin matrix in a molded body. This composite structure allows the hollow particles to provide weight reduction and heat insulation while the surrounding resin matrix provides structural support and prevents particle collapse during kneading and molding operations.
2Weight of moving object
If hollow particles with high void ratio are used to achieve weight reduction, then the specific gravity is reduced, but volatile compounds from the manufacturing process remain in the particles causing foaming and ignition during kneading
Solution Approach 1:
The patent applies the extraction principle by removing volatile compounds from the hollow particles through controlled manufacturing processes. The particles are designed and processed to minimize the retention of volatile substances, thereby preventing foaming and ignition during subsequent kneading and molding operations while maintaining the desired low specific gravity.
3Weight of moving object
If the shell thickness of hollow particles is reduced to increase void ratio, then the weight reduction efficiency is improved, but the particles become more susceptible to collapse during processing
Solution Approach 1:
The patent applies parameter changes by optimizing the shell thickness ratio within the specific range of 0.03 to 0.25. This parameter optimization ensures that the shell is thin enough to provide high weight reduction efficiency (void ratio of 50% to 90%) while remaining thick enough to maintain structural integrity and prevent collapse during processing operations.
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 particles achieve a high void ratio of 50% to 90%, maintaining strength and preventing collapse, while minimizing volatile compounds, thus enhancing weight reduction efficiency and safety during kneading and molding.
Implementation Method 1
hollow resin particles can scatter light well and reduce the transmittance of light as compared with solid particles
Implementation Method 2
performing suspension polymerization
Data Source
AI summary
Provided are hollow particles which have a high void ratio, hardly collapse, and have a reduced amount of volatile compounds. The hollow particles comprising a shell and a hollow portion surrounded by the shell, and having a void ratio of 50% or more and 90% or less, wherein the shell has a thickness of 0.2 μm or more and 0.9 μm or less, and the shell contains a polymer derived from a polymerizable monomer for shell, which is composed of 70% by mass or more and 100% by mass or less of a crosslinkable monomer and 0% by mass or more and 30% by mass or less of a non-crosslinkable monomer, and a polar resin selected from the group consisting of polymers containing a repeating unit which contains a hetero atom.