Foaming Curable Composition for Uncured Workability
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Solution Overview
Problem
Conventional application-type foamable fillers suffer from insufficient foamability after being left uncured, leading to deteriorated workability and inadequate sound insulation due to restricted foaming direction and insufficient 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 hydrocarbon component, optimized for improved foamability and adhesive properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional application-type foamable filler is used, then foaming performance is improved, but foamability after being left uncured is insufficient leading to deteriorated workability
Solution Approach 1:
The patent changes the chemical composition parameters of the foamable filler by incorporating specific compounds (silane-modified polyepoxide, polyhydric alcohol, silane crosslinking agent) in defined proportions to achieve both good foaming performance and maintained workability after being left uncured. The composition controls the balance between reactivity and stability through parameter optimization.
Solution Approach 2:
The patent creates a composite foamable filler system combining multiple components: silane-modified polyepoxide as base resin, polyhydric alcohol as extender, silane crosslinking agent for network formation, and foaming agent. This composite approach allows the material to exhibit both immediate foaming capability and sustained workability by leveraging the synergistic effects of different materials.
2Reliability
If foamable molded article is used, then sound insulation effect is improved, but manufacturing cost increases and automation of bonding becomes difficult
Solution Approach 1:
The patent replaces expensive foamable molded articles with a more economical application-type foamable filler that can be directly applied and cured in situ. This disposable-like approach eliminates the need for expensive molded components while achieving the same sound insulation function through direct application and foaming expansion.
Solution Approach 2:
The patent substitutes the mechanical bonding process required for foamable molded articles with a chemical curing process. The silane crosslinking agent enables chemical bonding directly to the substrate, eliminating the need for mechanical bonding operations and associated automation equipment, thereby reducing manufacturing complexity and cost.
3Ease of operation
If foamable filler is used, then ease of application is improved, but foaming direction is restricted and filling efficiency is insufficient
Solution Approach 1:
The patent adjusts the viscosity and rheological parameters of the foamable filler through careful selection of polyepoxide molecular weight and polyhydric alcohol content. This optimization allows the material to flow freely for easy application while maintaining sufficient filling efficiency and the ability to expand in multiple directions to completely fill voids.
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 encapsulated component contains a hydrocarbon (C1) having 7 to 9 carbon atoms. This novel foaming curable composition had good foaming and adhesive properties, as well as good properties after standing uncured.