Foaming Curable Composition for Complete Void Filling
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Solution Overview
Problem
Conventional application-type foamable fillers lack sufficient properties after being left uncured, leading to deteriorated workability and inadequate sound insulation due to restricted foaming direction and incomplete filling.
Innovation Solution
A foamable and curable composition comprising a thermally curable elastomer, a chemical foaming agent, and expandable particles with a shell and enclosed component, where the foaming peak temperature difference is controlled within a specific range, and azodicarbonamide is minimized or excluded, enhancing foaming and adhesive properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional application-type foamable fillers are used, then foaming properties are achieved, but properties after being left uncured are insufficient leading to deteriorated workability
Solution Approach 1:
The invention uses a composite system combining thermally curable elastomer (A) with chemical foaming agent (B) and expandable particles (C). This composite approach creates a material that maintains stable uncured properties while achieving reliable foaming, resolving the contradiction between reliability and workability.
Solution Approach 2:
The invention controls the peak temperature difference between foaming agent decomposition and expandable particle expansion within -10°C to 40°C. This parameter control ensures proper foaming sequence while maintaining good uncured properties and workability, eliminating the trade-off between reliability and ease of operation.
2Object-affected harmful factors
If foamable molded article is used to fill voids, then sound insulation is improved, but foaming direction is restricted and filling is insufficient
Solution Approach 1:
The invention segments the foaming function into two components: chemical foaming agent (B) for gas generation and expandable particles (C) for volume expansion. This segmentation allows the composition to flow and fill voids completely before expanding, achieving both complete filling and effective sound insulation.
Solution Approach 2:
The invention adds the dimension of compositional flexibility by using an application-type composition rather than pre-formed molded articles. This allows the material to adapt to any void geometry, ensuring complete filling while maintaining sound insulation performance.
3Object-affected harmful factors
If foamable molded article is bonded in voids, then noise blocking is achieved, but manufacturing cost increases and automation is difficult
Solution Approach 1:
The invention uses an application-type foamable composition that self-adheres and self-foams in place, eliminating the need for separate bonding and foaming operations. This self-service approach reduces manufacturing complexity and enables automation while maintaining noise blocking effectiveness.
Solution Approach 2:
The invention merges the bonding function (thermally curable elastomer) and foaming function (chemical foaming agent + expandable particles) into a single composition. This consolidation eliminates the need for separate bonding operations, reducing cost and enabling automated application while achieving complete void filling for noise blocking.
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 exhibits superior uncured properties, improved foaming performance, and enhanced sound insulation by controlling viscosity and expansion ratio, facilitating automated application and ensuring complete filling without gas leakage.
Implementation Method 1
a chemical foaming agent (B); wherein the chemical foaming agent (B) includes a hydrazine-based foaming agent (B1)
Implementation Method 2
expandable particles (C) having a shell and an enclosed component, wherein a peak temperature difference defined by [a foaming peak temperature of the chemical foaming agent (B)]−[an expansion peak temperature of the expandable particles (C)] is −10° C. or more and 40° C. or less
Implementation Method 3
a thermally curable elastomer (A)
Data Source
AI summary
Provided is a foaming curable composition containing a heat-curable elastomer (A), a chemical foaming agent (B), and expandable particles (C) having a shell and an encapsulated component, wherein the chemical foaming agent (B) contains a hydrazine-based foaming agent (B1), and the peak foaming temperature of the chemical foaming agent (B) is 5° C. to 50° C. higher than the peak expansion temperature of the expandable particles (C). This novel foaming curable composition has good foaming and adhesive properties, as well as good properties after standing uncured.