Laminated Foam Sheet with Controlled Surface Roughness
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Solution Overview
Problem
Laminated expanded sheets require both high strength and excellent thermoformability, but existing solutions do not adequately satisfy these demands.
Innovation Solution
A laminated expanded sheet with a resin expanded layer as the outermost layer and a resin non-expanded layer, featuring a surface roughness of 3 μm to 10 μm and a bending strength of 5 MPa or more, achieved through a coextrusion method using biodegradable resins and controlled blowing agents to enhance formability and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laminated expanded sheet uses a resin expanded layer as the outermost layer to improve strength, then the bending strength increases, but the surface roughness becomes too high causing excessive adherence during thermoforming
Solution Approach 1:
The patent applies local quality by creating a multi-layer structure where the outermost layer has controlled surface roughness (3-10 μm) to prevent excessive adherence during thermoforming, while inner layers provide structural strength. This localized differentiation of surface properties resolves the contradiction between strength and thermoformability.
Solution Approach 2:
The patent uses composite materials by combining resin expanded layers with controlled surface roughness with resin non-expanded layers. This composite structure achieves both high bending strength (5 MPa or more) and excellent thermoformability by preventing excessive adherence to molds during forming.
2Strength
If a laminated expanded sheet uses a resin non-expanded layer to improve strength, then the bending strength increases, but the surface roughness becomes too low reducing formability
Solution Approach 1:
The patent applies local quality by positioning the resin non-expanded layer with controlled surface roughness (3-10 μm) at the outermost surface to ensure good formability, while inner resin expanded layers provide structural strength support. This localized functional differentiation resolves the contradiction between strength and formability.
Solution Approach 2:
The patent uses composite materials by strategically combining resin non-expanded layers with controlled surface roughness and resin expanded layers. This composite configuration achieves both high bending strength (5 MPa or more) and excellent formability by optimizing the surface properties of the outermost layer.
3Ease of manufacture
If the surface roughness is increased to prevent excessive adherence during thermoforming, then the formability improves, but the bending strength decreases
Solution Approach 1:
The patent applies local quality by creating a multi-layer structure where only the outermost layer has controlled surface roughness (3-10 μm) to prevent excessive adherence and improve formability, while inner layers maintain high bending strength (5 MPa or more). This localized surface treatment resolves the contradiction between formability and strength.
Solution Approach 2:
The patent uses composite materials by combining at least one resin expanded layer with controlled surface roughness with resin non-expanded layers. This composite structure achieves the dual benefit of improved formability through controlled surface roughness (preventing excessive adherence) and maintained high bending strength through the layered configuration.
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 laminated expanded sheet exhibits improved strength and formability, preventing excessive adherence during thermoforming and maintaining suitable sliding properties for accurate shape reflection in molded articles.
Implementation Method 1
achieved through a coextrusion method using biodegradable resins and controlled blowing agents
Implementation Method 2
controlled blowing agents to enhance formability and strength
Data Source
AI summary
The present invention provides a laminated expanded sheet excellent in strength and formability. More specifically, the present invention relates to a laminated expanded sheet comprising a laminate of a resin expanded layer and a resin non-expanded layer, wherein the resin expanded layer is provided as an outermost layer, the laminated expanded sheet has a bending strength of 5 MPa or more, and an arithmetic average roughness of a surface formed of the resin expanded layer is 3 μm or more and 10 μm or less.