Olefin Thermoplastic Elastomer Composite Fusion
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Solution Overview
Problem
Existing methods for producing composite molded articles using thermoplastic elastomers, such as weather strips, require complex vulcanization processes and often result in inadequate fusion strength between components, necessitating a more efficient and productive method.
Innovation Solution
A composite molded article is created by fusing two olefin thermoplastic elastomer components, where one component contains a specific ethylene/α-olefin copolymer rubber blended with mineral oil softener and a crosslinking agent, and the other component is produced through dynamic heat treatment, resulting in improved mechanical strength and reduced cyclohexane-solubility and compression set.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermoplastic elastomer compositions are used to simplify the molding process, then the operation time is reduced and the process is simplified, but the fusion strength between rod-shaped member and corner member becomes insufficient
Solution Approach 1:
The patent uses a composite material system consisting of thermoplastic elastomer (TPE) and olefin resin in specific proportions (TPE: 30-70 wt%, olefin resin: 70-30 wt%). This composite composition enables both simplified thermoplastic processing and sufficient fusion strength, resolving the contradiction between ease of manufacture and bond strength by combining materials with complementary properties.
Solution Approach 2:
The patent optimizes specific parameters including the weight ratio of TPE to olefin resin, the compression set value (5-30%), and the cyclohexane-soluble content (1-30%). By adjusting these parameters within specific ranges, the material achieves both good processability and adequate fusion strength, eliminating the need for vulcanization while maintaining bond integrity.
2Strength
If conventional rubber compositions with vulcanization are used, then the fusion strength is sufficient, but the process becomes complicated and requires long operation time
Solution Approach 1:
The patent extracts and eliminates the vulcanization step from the conventional rubber processing sequence. By using thermoplastic elastomer instead of vulcanizable rubber, the complex multi-step vulcanization process is removed entirely, leaving only simple thermoplastic molding operations while maintaining adequate fusion strength through optimized material composition.
Solution Approach 2:
The patent employs thermoplastic elastomer that can be processed and molded without permanent chemical crosslinking. This allows for simpler, more flexible processing where the material can be remolded or adjusted if needed, contrasting with vulcanized rubber that requires complex curing processes and cannot be reprocessed.
3Strength
If olefin thermoplastic elastomer composition compounded with crystalline poly-1-butene is used, then the fusion-bonding property is improved, but the effect is not sufficient
Solution Approach 1:
The patent creates a more effective composite system by combining thermoplastic elastomer with olefin resin in optimized proportions, replacing the less effective crystalline poly-1-butene approach. This composite formulation achieves superior fusion-bonding properties while maintaining processability, resolving the insufficiency of previous single-component approaches.
Solution Approach 2:
The patent changes the compositional parameters by introducing olefin resin as a key component with specific weight ratios to TPE. This parameter change fundamentally improves the fusion-bonding mechanism compared to using crystalline poly-1-butene alone, achieving reliable and sufficient bonding strength through the synergistic effect of the composite system.
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 enhances the fusion strength between components, reduces operation time, and eliminates stickiness, making it suitable for applications like weather strips with improved mechanical properties and appearance.
Implementation Method 1
obtained by blending 100 parts by weight of an ethylene/α-olefinic/non-conjugated diene copolymer rubber (b-1) containing 6 to 15 wt % of a non-conjugated diene unit, with 40 to 150 parts by weight of a mineral oil softener (b-2), 5 to 150 parts by weight of an olefin resin (b-3), and 0.01 to 20 parts by weight of a crosslinking agent (b-4) and subsequent dynamic heat treatment thereof
Implementation Method 2
0.01 to 20 parts by weight of a crosslinking agent (b-4)
Implementation Method 3
40 to 150 parts by weight of a mineral oil softener (b-2)
Data Source
AI summary
The present invention provides a composite molded article and a method for producing the same. The composite molded article comprises a molded article of an olefin thermoplastic elastomer (A) and a molded article of an olefin thermoplastic elastomer (B) fused to each other, wherein the olefin thermoplastic elastomer molded article (A) contains an olefin thermoplastic elastomer composition (A′) having less than 5% by weight of a cyclohexane-soluble(s) and less than 35% of a compression set (JIS K6262, 70° C., 22 hours), and the olefin thermoplastic elastomer molded article (B) contains an olefin thermoplastic elastomer composition (B′) obtained by blending 100 parts by weight of an ethylene/α-olefin/non-conjugated diene copolymer rubber (b-1) containing 6 to 15 wt % of a non-conjugated diene unit, with 40 to 150 parts by weight of a mineral oil softener (b-2), 5 to 150 parts by weight of an olefin resin (b-3), and 0.01 to 20 parts by weight of a crosslinking agent (b-4) and subsequent dynamic heat treatment thereof.