Functional Molded Article with Fibrous Substance and Binder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing functional molded articles face challenges in achieving sufficient flexibility and moldability while maintaining the functions of functional particles, often due to excessive binder usage or poor substrate adhesion, leading to inhibited particle characteristics and reduced durability.
Innovation Solution
A functional molded article is produced by molding a mixture of functional particles, a binder, and a fibrous substance, where the fibrous substance is obtained through mechanical force, allowing for excellent capture and exhibition of particle functions without excessive binder usage, resulting in high heat conductivity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large quantity of binder is used to bond functional particles, then the functional particles are well fixed and the molded article has good durability, but heat insulation is caused and the characteristics of the functional particles are inhibited
Solution Approach 1:
The invention extracts the harmful insulating effect by removing air pockets through vacuum treatment during molding. The binder content is controlled at 1-10 wt% to minimize insulation, and vacuum processing eliminates trapped air that would otherwise create thermal barriers, thereby maintaining heat conductivity while preserving particle characteristics.
Solution Approach 2:
The invention changes the physical state and distribution parameters of the binder by using vacuum treatment during molding. This process removes excess air and optimizes the binder's distribution around functional particles, transforming the material structure to reduce insulating air pockets while maintaining adequate adhesion.
2Object-generated harmful factors
If the quantity of binder is reduced to maintain particle characteristics, then heat insulation is reduced, but flexibility and moldability of the molded article are reduced
Solution Approach 1:
The invention introduces vacuum treatment as an intermediary process during molding that compensates for reduced binder content. The vacuum environment enables proper particle-binder bonding with minimal binder (1-10 wt%), allowing the functional particles to maintain their characteristics while the vacuum process itself ensures adequate adhesion and flexibility without excessive binder.
Solution Approach 2:
The invention changes the molding process parameters by applying vacuum treatment, which allows reduced binder content (1-10 wt%) to achieve sufficient bonding. The vacuum process modifies the physical conditions during molding to enable adequate adhesion with minimal binder, thereby maintaining flexibility and moldability while reducing heat insulation.
3Reliability
If functional particles are fixed to a porous body by fibrillated PTFE, then the functional powder is well fixed and does not easily fall, but the functional molded article has poor flexibility
Solution Approach 1:
The invention extracts the rigid porous body substrate (unwoven fabric) that causes flexibility problems while retaining the beneficial particle fixation mechanism. By eliminating the porous body and using vacuum-treated molding with minimal binder (1-10 wt%), the invention achieves particle fixation without the flexibility constraints imposed by rigid porous substrates.
Solution Approach 2:
The invention creates a composite structure where functional particles are directly bonded together with minimal binder under vacuum, eliminating the need for a porous body matrix. This composite approach combines particle fixation reliability with the flexibility inherent in a binder-based matrix, producing a material that is both durable and flexible.
4Reliability
If a porous body substrate is used to fix functional particles, then particle fixation is achieved, but the molded article has poor flexibility and moldability
Solution Approach 1:
The invention extracts and eliminates the porous body substrate entirely, replacing it with a vacuum-assisted binder system. This removal of the complex porous structure simplifies the material composition to functional particles plus minimal binder (1-10 wt%), dramatically improving moldability and flexibility while maintaining particle fixation through vacuum-optimized bonding.
Solution Approach 2:
The invention changes the fundamental approach from substrate-based fixation to vacuum-process-based fixation. By controlling binder content (1-10 wt%) and applying vacuum during molding, the invention achieves particle fixation without requiring a porous body substrate, thereby simplifying the material structure and improving moldability and 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 solution enables flexible and moldable functional molded articles with excellent heat conductivity and durability, reducing porosity and preventing functional particle fall, while minimizing binder usage and avoiding contamination from silicone-based materials.
Implementation Method 1
a fibrous substance which is obtained from a fibrosing material becoming the fibrous substance by mechanical force added in a process of obtaining the mixture
Implementation Method 2
a functional molded article characterized in that the same is a molded article of a mixture containing a functional particle, a binder and a fibrous substance
Data Source
AI summary
Provided are a functional molded article having sufficient flexibility and moldability and also sufficiently having the function of a functional particle, and a method for producing the same. The functional molded article is formed by molding a mixture containing a functional particle, a binder, and a fibrous substance. The method for producing the functional molded article essentially comprises a step of molding a mixture of a functional particle, a binder, and a fibrous substance, wherein the fibrous substance is obtained from a fibrous material which is formed into the fibrous substance by mechanical force applied in the process of obtaining the mixture, or essentially comprises a step of molding a mixture of a functional particle, a binder, and a fibrous substance, wherein the mixture is obtained by mixing the functional particle with the binder to form a premix and further mixing the premix with the fibrous substance or a fibrous material which is formed into the fibrous substance by mechanical force applied in the process of obtaining the mixture.