PEF Thermoplastic Foam Closed-Cell Structure
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Solution Overview
Problem
Current thermoplastic foams, such as those based on polyethylene terephthalate (PET), face challenges in being environmentally friendly, recyclable, and produced from sustainable sources while maintaining good performance properties like low density and high mechanical integrity.
Innovation Solution
The development of foam articles using a thermoplastic foam composition comprising polyethylenefuranoate (PEF) with a surface covered by a sheet, mat, film, scrim, or similar surface covering, and utilizing a blowing agent such as hydrohaloolefins to achieve closed-cell foams with improved environmental and performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermoplastic resins like PET are used to produce foams, then good performance properties such as low density and high mechanical integrity can be achieved, but environmental friendliness and recyclability are compromised
Solution Approach 1:
The patent changes the chemical composition parameter of the thermoplastic resin from conventional PET to PEF (polyethylene furanoate), which is derived from renewable resources and has improved recyclability. This parameter change maintains the desired mechanical integrity while improving environmental compatibility, allowing the foam to achieve both strength requirements and environmental friendliness
Solution Approach 2:
The patent creates a composite foam structure combining PEF thermoplastic resin with specific blowing agents (hydrohaloolefins) to achieve a closed-cell foam configuration. This composite material system provides both the mechanical integrity needed for structural applications and the environmental benefits of using renewable-resource-based polymers with low-GWP blowing agents
2Weight of moving object
If the foam density is reduced to achieve lightweight properties, then weight benefits are gained, but mechanical strength may be compromised
Solution Approach 1:
The patent utilizes a controlled porous foam structure with closed cells formed by the reaction of PEF with hydrohaloolefin blowing agents. The foam density is reduced to achieve lightweight properties while the closed-cell configuration and PEF matrix maintain mechanical strength. The porosity is optimized to balance weight reduction with structural integrity for applications like wind turbine blades
Solution Approach 2:
The patent optimizes the molecular weight and composition parameters of the PEF polymer to ensure that even at reduced densities, the foam maintains sufficient mechanical strength. By controlling the PEF resin characteristics and blowing agent ratios, the foam achieves the desired weight-to-strength balance for structural applications
3Object-affected harmful factors
If environmentally friendly blowing agents are selected to reduce GWP and ODP, then environmental impact is reduced, but achieving good foam performance properties becomes more difficult
Solution Approach 1:
The patent uses PEF as an intermediary substance that is compatible with hydrohaloolefin blowing agents. The PEF polymer acts as a mediator that enables the formation of stable closed-cell foam structures using environmentally friendly blowing agents with low GWP and ODP, while still achieving the desired mechanical properties and foam quality for structural applications
Solution Approach 2:
The patent adjusts the chemical parameters of the blowing agent system by selecting specific hydrohaloolefins that are environmentally friendly yet effective. The PEF resin parameters are also optimized to work synergistically with these blowing agents, ensuring that low-GWP/ODP agents can produce foams with good performance properties including mechanical strength and dimensional stability
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
This approach results in foam articles that are lightweight, strong, and environmentally advantageous, offering a combination of low density and high compressive strength while being recyclable and produced from sustainable sources.
Implementation Method 1
utilizing a blowing agent such as hydrohaloolefins to achieve closed-cell foams
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.