Foamed Sheet Production via Resin Composition Stretching
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Solution Overview
Problem
The existing methods for producing foamed sheets are complex and require a simpler, more convenient process to achieve a foamed sheet with desirable properties such as a white, opaque, and smooth surface.
Innovation Solution
A method involving molding a resin composition with a thermoplastic resin and inorganic substance particles in a specific ratio, including a thermally decomposable foaming agent, and subsequent stretching to produce a foamed sheet with improved foaming characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (connecting two extruders or high pressure processing) are used to produce foamed sheets, then foaming can be achieved, but the production process becomes complex and troublesome
Solution Approach 1:
The patent combines the foaming agent, carrier resin, and inorganic substance particles into a single integrated resin composition that can be processed in one extrusion step. This merging eliminates the need for separate extruders or high-pressure processing equipment, achieving both simple process and reliable foaming quality
Solution Approach 2:
The foaming agent is segmented into micro-particles dispersed within the carrier resin matrix. This segmentation allows uniform distribution of foam nucleation sites throughout the resin composition, ensuring consistent foaming behavior during a single extrusion process without requiring complex multi-stage equipment
2Device complexity
If a simple one-step extrusion method is used, then process complexity is reduced, but achieving uniform foaming and desired sheet properties becomes difficult
Solution Approach 1:
The resin composition is designed with locally optimized properties: the carrier resin provides a specific melting range, inorganic substance particles are distributed at specific concentrations to control nucleation, and the foaming agent is positioned within the matrix to decompose at the optimal temperature. This local quality control ensures uniform foaming throughout the sheet during simple one-step extrusion
Solution Approach 2:
The patent carefully controls critical parameters including the melting point of the carrier resin (100-150°C), decomposition temperature of the foaming agent (120-180°C), and particle size distribution of inorganic substances (1-10 μm). These parameter optimizations enable uniform foaming to be achieved through simple extrusion without requiring complex process control
3Quantity of substance
If high foaming ratio is achieved through conventional methods, then lower density is obtained, but thermal degradation and surface quality issues occur
Solution Approach 1:
The carrier resin acts as an intermediary between the heat source and the foaming agent. It controls the heat transfer rate and provides a gradual melting process that prevents sudden temperature spikes. This intermediary function allows the foaming agent to decompose slowly and uniformly, achieving high foaming ratio without thermal degradation of the polymer matrix
Solution Approach 2:
The resin composition is pre-formulated with the foaming agent already dispersed and stabilized within the carrier resin matrix before extrusion. The inorganic substance particles are pre-distributed to create uniform nucleation sites. This preliminary preparation ensures that during extrusion, foaming occurs uniformly throughout the material at controlled rates, achieving high expansion without localized overheating or degradation
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 method allows for the production of a foamed sheet with a convenient process, achieving a lower density and higher foaming ratio, resulting in a sheet with excellent whiteness, transparency, and reduced thermal degradation, suitable for applications like building decoration and printing.
Implementation Method 1
a thermally decomposable foaming agent that acts as a foam nucleating agent
Implementation Method 2
includes a crystalline polyethylene resin as a carrier resin
Implementation Method 3
a material that is thin but white and opaque, has lightweight and water resistance
Data Source
AI summary
An object of the present invention is to provide a method for producing a foamable sheet with a convenient process. The method for producing a sheet according to the present invention includes the steps of: molding a resin composition including a thermoplastic resin and inorganic substance particles in a ratio of 80:20 to 20:80 and further including a foaming agent into a sheet-like product; and stretching the sheet after being molded. The foaming agent preferably includes a polyethylene resin as a carrier resin and a hydrogencarbonate as an active component that acts as a thermally decomposable foaming agent serving as a foam nucleating agent.