Foamed PVC Sheet Structure With Microspheres for Bio-Based Lightweighting
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Solution Overview
Problem
The automotive industry seeks multi-layered materials with higher bio-based components and lower density, while avoiding hazardous blowing agents and maintaining lightweight properties.
Innovation Solution
A sheet structure comprising a carrier layer and a foamed cover layer with polyvinyl chloride, lignocellulosic components, and hollow microspheres, where the microspheres serve as the primary foaming agent, eliminating the need for chemical blowing agents and achieving a low density of less than 1500 kg/m3, with the lignocellulosic components and microspheres making up a significant volume of the foamed cover layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If chemical blowing agents are used to create foamed structures, then the material achieves desired foam morphology and volume, but hazardous substances are introduced and environmental safety deteriorates
Solution Approach 1:
The invention extracts and eliminates chemical blowing agents from the formulation by using physically expanding microspheres instead. The microspheres expand through physical mechanisms (thermal or mechanical) rather than chemical reactions, removing the harmful chemical substances while maintaining the foaming function.
Solution Approach 2:
The microspheres serve as an intermediary foaming mechanism. Instead of using chemical agents that react with the polymer matrix, the microspheres physically expand to create and maintain the foam structure, acting as a mediator between the desired foam morphology and the elimination of harmful chemicals.
2Quantity of substance
If high percentages of bio-based components are incorporated, then ecological sustainability is improved, but material performance and processing stability may deteriorate
Solution Approach 1:
The invention creates a composite material system combining PVC matrix with lignocellulosic fibers and expanding microspheres. This composite approach allows the bio-based components to contribute to ecological sustainability while the PVC matrix and microsphere expansion mechanism ensure maintained structural integrity and performance.
Solution Approach 2:
The invention changes the physical parameters of the bio-based components by using chemically modified lignocellulosic fibers with reduced hydrophilicity. This parameter modification improves compatibility with the hydrophobic PVC matrix, ensuring stable processing and reliable material performance while maintaining high bio-based content.
3Weight of moving object
If density is reduced to achieve lightweight properties, then weight is improved, but mechanical strength and structural integrity may deteriorate
Solution Approach 1:
The invention uses a porous foam structure created by expanding microspheres to reduce density and weight. The porous architecture provides insulation and lightweight properties while the PVC matrix and fiber reinforcement maintain structural integrity and mechanical strength within the pores and walls.
Solution Approach 2:
The composite structure of PVC, lignocellulosic fibers, and expanded microspheres creates a lightweight material system. The fibers provide structural reinforcement within the low-density foam matrix, maintaining mechanical strength despite the reduced overall density.
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 results in a material with a higher percentage of biological content, reduced stiffness, lower weight, and the elimination of hazardous blowing agents, offering a more ecological and aesthetically pleasing alternative for automotive interiors, suitable for flexible applications such as upholstery.
Implementation Method 1
the hollow microspheres have been thermally expanded
Data Source
AI summary
The present invention provides a sheet structure comprising a carrier layer and a foamed cover layer which contains polyvinyl chloride, lignocellulosic based components and hollow microspheres, and a method for producing the sheet structure. The sheet structure can be used as an artificial leather, e.g. for flexible automotive interiors.