Heat-expandable Microspheres with Organic Silicon Shell for Deformation Resistance

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Solution Overview

Problem

Hollow particles manufactured by expanding ordinary heat-expandable microspheres fail to impart the requisite properties to base materials due to deformation under high pressure loads, such as rupture or denting.

Innovation Solution

The development of heat-expandable microspheres with a shell containing a thermoplastic resin, a thermally gasifiable blowing agent, and an organic silicon compound, where the organic silicon compound exists below or on the surface of the shell, providing enhanced strength and resistance to deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If heat-expandable microspheres are expanded to manufacture hollow particles, then the base material can be lightened and design potential can be imparted, but the hollow particles deform (rupture or dent) under high pressure load during processing

Engineering Contradiction:
Improveweight of base materialVSAvoidstructural integrity of hollow particles
Core Design Contradiction:
Weight of moving objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining thermoplastic resin with cross-linking agents (silane-modified polyethylene, polyisocyanate, or carboxyl group-containing compound) to create a shell with enhanced mechanical properties. This composite structure provides both the lightweight特性 from the hollow structure and the structural integrity needed to resist deformation under high pressure during processing and application.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical and physical parameters of the shell material by introducing cross-linking reactions. The cross-linking degree is controlled to achieve optimal balance between shell strength and flexibility. This parameter change transforms the shell from a simple thermoplastic structure to a cross-linked network structure that resists deformation while maintaining expandability.

Inventive Principle:
Principle #35Parameter changes

2Weight of moving object

If the shell of heat-expandable microspheres is made thinner to reduce weight, then the lightweight effect is improved, but the mechanical strength decreases making particles susceptible to deformation

Engineering Contradiction:
Improveweight of hollow particlesVSAvoidmechanical strength of shell
Core Design Contradiction:
Weight of moving objectVSStrength

Solution Approach 1:

By using composite materials with cross-linked structures, the patent achieves high strength-to-weight ratio. The cross-linking provides structural reinforcement that compensates for the reduced shell thickness, allowing the hollow particles to maintain both lightweight characteristics and sufficient mechanical strength to withstand processing pressures.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by concentrating the cross-linked structure at the shell region where mechanical strength is needed, while maintaining the hollow interior for weight reduction. The cross-linking is specifically targeted in the shell material to provide localized reinforcement without adding overall weight.

Inventive Principle:
Principle #3Local quality

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 resulting hollow particles exhibit a shell that can resist deformation against high pressure loads, maintaining their structural integrity and lightweight properties.

Implementation Method 1

heat-expandable microspheres composed of a shell of thermoplastic resin and a blowing agent encapsulated therein can be expanded by heating

Methodology Applied
Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 2

the organic silicon compound contains at least one unit selected from T unit represented by R1SiO3/2 and D unit represented by R22SiO2/2

Methodology Applied
Scientific EffectCondensation reaction: Condensation

Data Source

PatentUS20250109280A1Heat-expandable microspheres, hollow particles and application thereof
Publication Date: 2025.04.03 MATSUMOTO YUSHI SEIYAKU CO LTD
  • US20250109280A1 patent drawing
  • US20250109280A1 patent drawing

AI summary

Heat-expandable microspheres comprise a shell containing a thermoplastic resin, a thermally gasifiable blowing agent and an organic silicon compound. The blowing agent is encapsulated in the shell, and the organic silicon compound exists below the outside surface of the shell and/or on the outside surface of the shell, the organic silicon compound contains at least one unit selected from T unit represented by R1SiO3/2 and D unit represented by R22SiO2/2, and each of R1 and R2 is a monovalent organic group having 1 to 15 carbon atoms.