Isosorbide Polycarbonate Copolymer Foaming
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Solution Overview
Problem
The foaming performance of polycarbonate resin containing isosorbide as a raw material has been poorly studied and developed, with conventional methods not consistently achieving good results, limiting the expansion of its applications due to inadequate mechanical properties and production challenges.
Innovation Solution
A polycarbonate copolymer with structural units derived from isosorbide and other dihydroxy compounds, such as cyclohexanedimethanols and hexanediols, is developed, which has a specific glass transition temperature range, enhancing foaming performance and resulting in a lightweight, high-strength molded body with improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polycarbonate resin containing isosorbide as a raw material is used for foaming, then the mechanical properties and heat resistance are improved, but the foaming performance is insufficient
Solution Approach 1:
The patent changes the glass transition temperature parameter of the polycarbonate resin to a specific range (50-150°C) through copolymerization with other dihydroxy compounds. This parameter optimization enables the resin to achieve both good mechanical properties and excellent foaming performance by controlling the molecular structure and chain mobility of the polymer.
Solution Approach 2:
The patent creates a composite polycarbonate resin system by combining isosorbide-derived structural units with other dihydroxy compound units (such as cyclohexanedimethanol, tricyclodecanedimethanol, or hexanediol). This composite structure integrates the strength and heat resistance of isosorbide polycarbonate with the foaming capability provided by the copolymer components.
2Strength
If a polycarbonate resin with high strength is produced, then the mechanical properties are improved, but the foaming expansion ratio is reduced
Solution Approach 1:
The patent optimizes the glass transition temperature to a balanced range (50-150°C) that allows the material to maintain high strength while achieving sufficient expansion during foaming. This parameter control enables the resin to exhibit appropriate viscosity and cell growth characteristics during the foaming process.
Solution Approach 2:
The patent introduces different dihydroxy compound units at specific ratios (1-50 mol% of other dihydroxy compounds) to create local structural variations in the polymer chain. These local modifications affect specific properties such as chain flexibility and gas solubility, enabling simultaneous achievement of high strength and good expansion ratio.
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 method produces a foam-molded body with high expansion ratio and excellent impact resistance, being particularly lightweight and strong, suitable for various industrial applications.
Implementation Method 1
a molded body obtained by foaming a polymer (foam-molded body) is a lightweight structure... Patent Document 4 discloses Comparative Example using a polycarbonate resin having dissolved therein carbon dioxide
Implementation Method 2
a polycarbonate copolymer having a structural unit derived from isosorbide and a structural unit derived from other dihydroxy compounds and having a glass transition temperature in a specific range
Data Source
AI summary
An object of the present invention is to provide a molded body that is easy to produce and obtained by foaming a polycarbonate copolymer containing, as a raw material, isosorbide that is lightweight and excellent in mechanical properties and like. The present invention relates to a foam-molded body containing a polycarbonate copolymer having a structural unit derived from a dihydroxy compound represented by the following formula (1): and a structural unit derived from other dihydroxy compounds, and having a glass transition temperature (Tg) of less than 145°C.