Thermoplastic Resin Binding Material With High-Melting Fluorescent Whitener
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Solution Overview
Problem
The dry method for manufacturing sheet-shaped molded bodies using a composite with a colorant and resin often requires high-temperature heating, which can result in undesirable color and reduced whiteness, making it difficult to achieve the desired properties.
Innovation Solution
A binding material comprising a thermoplastic resin and a fluorescent whitener with a melting point higher than the resin's fusing point, mixed with fibers in a vapor phase and molded under controlled temperature and pressure, to produce a molded body with high whiteness and strength without degrading at high heating temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature heating is applied to melt the resin in dry method sheet manufacturing, then the resin binding function is improved, but the whiteness and color quality of the sheet deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the binding system by introducing a fluorescent whitener compound with specific molecular structure and photoluminescent properties. This compound has a melting point higher than the resin's fusing point, allowing it to remain stable during the heating process while providing whiteness enhancement and UV absorption capabilities that prevent yellowing.
Solution Approach 2:
The patent creates a composite binding material system combining the thermoplastic resin with the fluorescent whitener compound. This composite approach allows the resin to provide binding function while the fluorescent whitener provides whiteness enhancement and thermal stability, with the two components working synergistically to resolve the contradiction between binding strength and color quality.
2Strength
If heating temperature is increased to ensure resin melting and binding, then the molded body strength is improved, but the fluorescent whitener may melt and cause non-uniform dispersion
Solution Approach 1:
The patent carefully controls the heating temperature parameter to remain below the melting point of the fluorescent whitener compound while being sufficient to melt the resin. This parameter optimization ensures the fluorescent whitener remains in solid dispersed state maintaining uniform distribution, while the resin melts to provide binding function.
Solution Approach 2:
The fluorescent whitener is pre-dispersed uniformly in the resin matrix before the molding process. This preliminary dispersion action ensures that when heating occurs, the fluorescent whitener particles are already evenly distributed and will not aggregate or melt, maintaining composition stability throughout the process.
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 effectively maintains high whiteness and enhances the strength and moldability of the molded body, while preventing the fluorescent whitener from melting and ensuring uniform dispersion, thus achieving excellent whiteness and structural integrity.
Implementation Method 1
a thermoplastic resin and a fluorescent whitener, and the fluorescent whitener has a melting point higher than a fusing point of the thermoplastic resin
Implementation Method 2
a thermoplastic resin and a fluorescent whitener
Implementation Method 3
a mixing step of mixing the binding material according to the above application example of the present disclosure and fibers in a vapor phase to obtain a mixture
Implementation Method 4
a molding step of pressurizing and heating the mixture to obtain the molded body
Data Source
AI summary
A binding material to obtain a molded body by binding fibers to each other, includes a thermoplastic resin and a fluorescent whitener, and the fluorescent whitener has a melting point higher than a fusing point of the thermoplastic resin. The melting point of the fluorescent whitener is preferably 200°C or more. A content of the fluorescent whitener in the binding material is preferably 1.0 percent by mass or less. The binding material preferably further includes a white pigment.