Foaming Composition Viscosity Control for Hollow Member Filling
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Solution Overview
Problem
Conventional foaming compositions for filling hollow members, such as automotive pillars, often result in insufficient filling properties due to shape-dependent performance, leading to incomplete filling and potential noise and vibration transmission.
Innovation Solution
A foaming composition comprising a polymer, organic peroxide, azodicarbonamide, and a (meth)acryloyl-group-containing compound, with specific viscosity and melt flow rate ranges, ensures stable foaming and excellent filling properties by controlling cross-linking and expansion ratios, thereby effectively filling complex shapes with minimal voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional foaming composition is used, then the filling process is simple, but the filling property is insufficient in complex hollow shapes
Solution Approach 1:
The invention changes the viscosity parameter of the foaming composition to a specific range (1050 to 4950 Pa·s at 120°C and 500 MPa) to achieve optimal filling properties. This parameter optimization allows the composition to properly fill complex hollow shapes while maintaining composition simplicity.
Solution Approach 2:
The invention uses a composite foaming composition containing polymer, organic peroxide, and azodicarbonamide in specific combinations. This composite material approach improves filling property by combining multiple functional components while keeping the overall composition relatively simple.
2Manufacturing precision
If viscosity is increased to improve filling, then expansion ratio decreases, but if viscosity is decreased for better expansion, then filling stability worsens
Solution Approach 1:
The invention optimizes the viscosity parameter to a specific range (1050 to 4950 Pa·s) that balances filling stability and expansion ratio. This parameter change ensures the foam expands sufficiently while maintaining stable filling without excessive voids.
Solution Approach 2:
The invention achieves different local properties within the foam structure - high stability in regions requiring filling retention and adequate expansion in regions requiring volume increase. This is accomplished through the optimized viscosity range that allows differential behavior during the foaming process.
3Reliability
If foaming composition is heated for stable foaming, then cross-linking occurs, but excessive cross-linking reduces flexibility
Solution Approach 1:
The invention changes the heating parameters and composition formulation to achieve controlled cross-linking. The specific viscosity range and component ratios ensure that cross-linking occurs at an optimal level during heating, providing foaming stability while preventing excessive cross-linking that would reduce flexibility.
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 composition achieves reliable and satisfactory filling of hollow members with a foam that provides reinforcement, sound insulation, and vibration control, ensuring effective noise reduction and shape conformity.
Implementation Method 1
a foaming composition for filling containing ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, dicumyl peroxide, and azodicarbonamide is prepared, and heated to be foamed
Implementation Method 2
a foaming composition for filling containing ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, dicumyl peroxide, and azodicarbonamide is prepared, and heated to be foamed
Data Source
AI summary
A foaming composition for filling contains a polymer, an organic peroxide, and azodicarbonamide, and a viscosity thereof measured at a temperature of 120° C. and under a pressure of 500 MPa with a flow tester is in a range of 1050 to 4950 Pa·s.