Fine Basic Magnesium in Polyolefin Foam for Fogging and Cell Control
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Solution Overview
Problem
The production of polyolefin resin foam using an extruder often results in stagnated materials accumulating, leading to foam rupture and the generation of huge cells, which complicates its use in vehicle interior members due to poor appearance, and existing solutions like basic magnesium compounds can exacerbate this issue.
Innovation Solution
Incorporating a specified amount (0.05 to 0.5 parts by mass) of basic magnesium with a small particle diameter (0.1 to 15 µm) into the polyolefin resin composition, along with azodicarbonamide, to prevent fogging and suppress the formation of huge cells during the cross-linking and foaming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If basic magnesium compound is blended in resin to prevent fogging, then fogging is prevented, but huge cells are generated due to foam rupture
Solution Approach 1:
The invention changes the particle size parameter of basic magnesium from conventional large particles to fine particles with specific surface area of 0.5 m²/g or more. This parameter change allows the basic magnesium to effectively prevent fogging while avoiding foam rupture and huge cell formation, as the fine particles are more uniformly distributed and do not create stress concentration points that lead to rupture.
Solution Approach 2:
The invention uses fine basic magnesium particles that replicate the fog-preventing function of conventional basic magnesium while eliminating its harmful effects on foam structure. The fine particles copy the chemical function of fog prevention without the mechanical drawback of causing foam rupture.
2Productivity
If stagnated materials are accumulated in extruder, then production continues, but foam rupture occurs causing huge cells
Solution Approach 1:
The invention changes the particle size parameter of basic magnesium to fine particles that do not act as nucleation sites for foam rupture even when stagnated materials are present in the extruder. The fine particles maintain uniform foam structure despite production continuity and material stagnation.
3Object-affected harmful factors
If basic magnesium with large particle size is used, then fogging is prevented, but foam rupture is promoted
Solution Approach 1:
The invention fundamentally changes the particle size parameter of basic magnesium from large particles to fine particles with specific surface area of 0.5 m²/g or more. This parameter change transforms basic magnesium from a substance that promotes foam rupture to one that maintains foam structure integrity while still preventing fogging.
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 effectively prevents fogging and suppresses the generation of huge cells, resulting in a polyolefin resin foam suitable for vehicle interior members with improved appearance and functionality.
Implementation Method 1
a basic magnesium compound and/or a basic calcium compound is blended in a resin together with azodicarbonamide
Implementation Method 2
azodicarbonamide allows a minute amount of decomposition residue to remain in the resin
Implementation Method 3
cross-linking and foaming a polyolefin resin composition
Data Source
AI summary
The cross-linked polyolefin resin foam of the present invention is obtained by cross-linking and foaming a polyolefin resin composition, the composition including a polyolefin resin-containing resin (A), azodicarbonamide (B), and at least one basic magnesium (C) selected from the group consisting of magnesium oxide and magnesium hydroxide, wherein the amount of basic magnesium (C) included in the polyolefin resin composition is 0.05 to 0.5 parts by mass relative to 100 parts by mass of the resin (A), and the basic magnesium (C) has an average particle diameter of 0.1 to 15 µm.