Crosslinked Polyolefin Foam Balancing Thickness, Strength, and Transparency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Polyolefin resin foams with a thickness more than 0.3 mm have low total light transmittance, and acrylic resin foams, while improving light transparency, lack mechanical properties and flexibility.
Innovation Solution
A cross-linked polyolefin resin foam is developed with controlled expansion ratio, resin components, and compounds to achieve total light transmittance of 45% or more at 0.3 mm to 1.0 mm and 30% or more at 1.0 mm to 5.0 mm, using polyolefin resins like polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, with additives like nucleating agents and elastomers to enhance transparency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyolefin resin foam thickness is increased to improve mechanical properties and impact absorption, then mechanical strength is improved, but total light transmittance decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the average cell size within 0.5-2.0 mm and expansion ratio within 1.05-1.30 times, along with controlling polyolefin resin composition (60-90 parts by mass) and additive content. These parameter optimizations enable the foam to achieve both adequate thickness for mechanical strength and sufficient light transmittance (20% or more) for display visibility.
Solution Approach 2:
The patent utilizes porous foam structure with controlled cell morphology to balance mechanical properties and light transmission. The specific pore size distribution and cellular architecture allow light to pass through while maintaining structural integrity and impact absorption capability.
2Illumination intensity
If acrylic resin foam is used to improve light transparency, then total light transmittance is improved, but mechanical properties and flexibility deteriorate
Solution Approach 1:
The patent employs composite material strategy by formulating a polyolefin resin composition containing 60-90 parts by mass of polyolefin resin and specific additives (0.1-10 parts by mass of crosslinking catalyst, 0.01-5 parts by mass of foaming agent). This composite formulation achieves both high light transmittance and excellent mechanical properties including flexibility and impact resistance that pure acrylic foam cannot provide.
Solution Approach 2:
The patent optimizes physical and chemical parameters including average cell size (0.5-2.0 mm), expansion ratio (1.05-1.30), and resin composition ratios to achieve the desired balance between transparency and mechanical performance.
3Illumination intensity
If average cell size is controlled to improve light transmittance, then total light transmittance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes specific parameter ranges for average cell size (0.5-2.0 mm) and expansion ratio (1.05-1.30) that optimize light transmittance while remaining achievable through conventional foam manufacturing processes. These parameter specifications balance optical performance with manufacturing feasibility.
Solution Approach 2:
The patent introduces specific additives (crosslinking catalysts and foaming agents) as intermediaries to control the foaming process and achieve uniform cell structure with the desired average size, making it easier to control manufacturing precision.
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 foam achieves high light transparency and flexible tactile feel, suitable for light display components, with improved mechanical properties and impact absorption.
Implementation Method 1
the cross-linked polyolefin resin foam having a total light transmittance of 45% or more when the thickness is 0.3 mm or more and less than 1.0 mm
Data Source
AI summary
The present invention relates to a cross-linked polyolefin resin foam obtained by cross-linking and foaming a polyolefin resin composition containing at least a polyolefin resin, wherein the cross-linked polyolefin resin foam has a total light transmittance of 45% or more at the thickness of 0.3 mm or more and less than 1.0 mm, and the cross-linked polyolefin resin foam has a total light transmittance of 30% or more at the thickness of 1.0 mm or more and 5.0 mm or less.The present invention provides a cross-linked polyolefin resin foam having excellent light transmittance.