PEF Extruded Foam for Wind Turbine Strength
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Solution Overview
Problem
Existing thermoplastic foams, such as those based on polyethylene terephthalate (PET), face challenges in being both environmentally friendly and possessing excellent performance properties, particularly in applications requiring high mechanical integrity and strength, like wind turbine blades.
Innovation Solution
The development of foam articles comprising extruded thermoplastic, closed-cell foams made from polyethylene furanoate (PEF) combined with a blowing agent comprising hydrohaloolefins, which provides a balance of low density and high mechanical strength while being environmentally advantageous.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyester resins are used to create foam, then environmental friendliness and recyclability are improved, but mechanical strength and structural integrity deteriorate
Solution Approach 1:
The patent uses a composite material system combining polyethylene furanoate (PEF) thermoplastic with hydrohaloolefin blowing agents to create foam that achieves both environmental sustainability and high mechanical strength. The PEF provides the sustainable base while the foam structure delivers the required strength properties.
Solution Approach 2:
The patent changes the chemical composition parameters by using PEF instead of conventional PET and selecting specific hydrohaloolefin blowing agents, which alters the foam's physical and mechanical properties to achieve both environmental and performance goals simultaneously.
2Weight of moving object
If foam density is reduced to decrease weight, then weight is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent optimizes the foam density parameter by controlling the blowing agent-to-polymer ratio and selecting appropriate molecular weights for PEF, achieving a low density (reducing weight) while maintaining high mechanical strength through proper parameter selection.
Solution Approach 2:
The foam structure created by PEF and hydrohaloolefin combines to achieve a composite material with low density but high strength, where the cellular structure provides both weight reduction and structural integrity simultaneously.
3Ease of manufacture
If conventional PET foam is used, then manufacturing process is simple, but environmental sustainability deteriorates
Solution Approach 1:
The patent changes the polymer composition parameter from PET to PEF, which maintains compatibility with existing extrusion manufacturing processes while improving environmental sustainability. The process remains simple but the material becomes more sustainable.
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 use of PEF-based foams with hydrohaloolefin blowing agents results in foams with improved mechanical strength, reduced density, and enhanced environmental sustainability, making them suitable for demanding applications such as wind turbine blades.
Implementation Method 1
foamable thermoplastic compositions, thermoplastic foams, and systems and articles made from same
Data Source
AI summary
Disclosed are extruded foam comprising an extruded thermoplastic, closed-cell foam having at least a first surface and comprising: (i) thermoplastic polymer cell walls formed by an extrusion step, with the walls being comprised of at least about 0.5% by weight of ethylene furanoate moieties and optionally one or more co-monomer moieties; (ii) blowing agent contained in at least a portion of said closed cells; and a material different than said thermoplastic, closed-cell foam attached to and/or integral with at least a portion of said first foam surface.