Oriented Microporous Foam via Supercritical Foaming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional polymer microporous foam materials exhibit uneven cell distribution, disordered cell structures, and non-adjustable cell sizes, which compromise their mechanical properties, heat insulation, and sound absorption, limiting their applications.
Innovation Solution
A method involving the preparation of polymer composite fibers through melting, mixing, thermal stretching, and hot-pressing to create a polymer composite board with oriented fibers, followed by a supercritical fluid foaming process to produce microporous foam materials with consistently oriented cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional polymer foaming methods are used, then the preparation process is simple, but the cell distribution is uneven and disordered
Solution Approach 1:
The patent applies preliminary action by pre-forming polymer composite fibers with oriented structure before foaming. The fibers are prepared in advance through melting, mixing, and thermal stretching processes, creating a predetermined structure that guides subsequent cell formation. This preliminary structuring ensures uniform and oriented cell distribution in the final foam material.
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature, pressure, and time parameters during the foaming process. Specifically, the supercritical fluid foaming is conducted at controlled temperatures (160-255°C for melting, 255-230°C for stretching) and pressures, which enables precise control over cell size, distribution, and orientation while maintaining process simplicity.
2Ease of manufacture
If conventional polymer foaming methods are used, then the process is straightforward, but the cell structure cannot be adjusted
Solution Approach 1:
The patent applies dynamics by making the foaming process adjustable through variable parameters. The supercritical fluid foaming conditions (temperature, pressure, time) can be dynamically adjusted to achieve different cell structures, sizes, and orientations according to specific application requirements, while maintaining a straightforward overall process flow.
Solution Approach 2:
The patent enables cell structure adjustability through parameter changes in the supercritical fluid foaming process. By varying temperature (160-255°C), pressure (17.90-21.69 Mpa), and holding time (0.5-5 hours), the cell structure can be precisely controlled and adjusted for different applications while keeping the process straightforward.
3Ease of manufacture
If conventional polymer foaming methods are used, then the preparation is easy, but mechanical properties are reduced
Solution Approach 1:
The patent applies preliminary action by pre-preparing polymer composite fibers with oriented structure before foaming. This preliminary fiber formation creates a strong骨架 (skeleton) that maintains structural integrity during foaming, resulting in foam materials with improved mechanical properties while keeping the overall preparation process easy.
Solution Approach 2:
The patent uses composite materials by combining polymer matrix with fiber-forming phase substances (such as polyethylene terephthalate or polyamide) and processing aids. This composite approach creates a multi-phase material structure that enhances mechanical properties while maintaining ease of manufacture through the developed process.
4Ease of manufacture
If conventional polymer foaming methods are used, then the process is simple, but heat insulation and sound absorption are compromised
Solution Approach 1:
The patent applies preliminary action by pre-forming oriented fiber structures that create uniform cell distribution before foaming. This preliminary structuring ensures that the final foam material has consistent cell morphology throughout, which is crucial for achieving reliable heat insulation and sound absorption properties while maintaining process simplicity.
Solution Approach 2:
The patent improves heat insulation and sound absorption by controlling foaming parameters (temperature 160-255°C, pressure 17.90-21.69 Mpa, time 0.5-5 hours) to achieve uniform cell size and distribution. These controlled parameters create optimal foam structure for thermal and acoustic performance while keeping the process simple.
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 results in microporous foam materials with uniform cell sizes and orientations, enhancing mechanical properties and application prospects, such as in oil-absorbing foams, while being simple, cost-effective, and repeatable.
Implementation Method 1
The polymer composite board prepared in step (2) is subjected to a supercritical fluid foaming process to obtain a microporous foam material with oriented cells
Implementation Method 2
a temperature of the supercritical fluid foaming process is 130° C. to 165° C., the pressure of the supercritical fluid is 17.90 Mpa to 21.69 Mpa
Implementation Method 3
The polymer composite fibers prepared in step (1) are arranged in the same direction and then hot-pressed to obtain a polymer composite board with oriented fibers
Implementation Method 4
the pressure of the vacuum laminator is 3000 kg to 5000 kg
Implementation Method 5
The raw materials for preparing a polymer composite material are melted and mixed and then thermally stretched to obtain polymer composite fibers
Implementation Method 6
the temperature for thermal stretching treatment is 255° C. to 230° C.
Data Source
AI summary
The disclosure relates to the technical field of new foaming materials, in particular to a preparation method of a microporous foam material with oriented cells, which comprises the following steps: (1) melting and mixing raw materials for preparing a polymer composite material, and then carrying out hot stretching to obtain polymer composite fibers; the raw materials comprise a polymer matrix, a fiber-forming phase substance and a processing aid; (2) arranging the polymer composite fibers prepared in the step (1) in the same direction, and performing hot pressing to obtain a polymer composite board with oriented fibers; and (3) carrying out supercritical fluid foaming on the polymer composite board prepared in the step (2) to obtain the microporous foam material with oriented cells.