Perforated Double-Conveyor Forming of Thermosetting Resin Foam Plate
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Solution Overview
Problem
Conventional methods for manufacturing thermosetting resin foam plates face challenges such as increased facility costs, inefficient drying, and reduced compression strength due to long exposure times in heating ovens, and the use of unnecessary surface materials and non-moisture-permeable conveyors that hinder effective moisture and gas dissipation.
Innovation Solution
A double conveyor-type forming device with apertures on the conveyor surfaces, having an aperture area ratio of 15% to 80%, allows for efficient drying and curing of thermosetting resin foam plates by enabling the release of water vapor and foaming gas, eliminating the need for additional surface materials and optimizing the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional double conveyor with solid surface is used, then the structure is simple and easy to manufacture, but moisture and foaming gas cannot dissipate efficiently leading to long drying times and reduced production rate
Solution Approach 1:
The conveyor surface is designed with apertures (perforations) to create a porous structure that enables moisture and foaming gas to pass through during the drying process. This porous design allows efficient dissipation of volatiles from both top and bottom surfaces of the foam plate simultaneously, dramatically increasing drying speed without requiring additional surface materials or complex multilayer structures
2Productivity
If additional surface materials are added for moisture permeation, then drying efficiency improves, but the process becomes more complex and costly
Solution Approach 1:
The conveyor itself is designed to provide the moisture permeation function through its perforated surface, eliminating the need for separate surface materials. The conveyor structure performs the dual function of transporting the foam plate and enabling efficient moisture dissipation, simplifying the overall process and reducing costs
3Productivity
If exposure time in heating oven is reduced for high production rate, then productivity increases, but curing becomes insufficient and compression strength decreases
Solution Approach 1:
The perforated conveyor enables continuous and simultaneous drying from both surfaces of the foam plate throughout the heating process. This continuous efficient moisture removal allows the curing reaction to proceed effectively even at reduced exposure times, maintaining compression strength while increasing production rate
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 enables high-speed, stable, and efficient production of thermosetting resin foam plates with improved compression strength and reduced production costs by facilitating effective moisture and gas dissipation during the curing process.
Implementation Method 1
water vapor, a foaming gas and the like in a thermosetting resin composition dissipate only from edges of a thermosetting foam plate
Implementation Method 2
apertures are formed on the surface of conveyors in a specific proportion
Data Source
AI summary
There are provided a forming device capable of drying at a high speed and of manufacturing a thermosetting resin foam plate more efficiently and stably without multilayering any unnecessary surface material, and a method of efficiently manufacturing a thermosetting resin foam plate therefor. A thermosetting resin foam plate is manufactured by: mixing a resin composition containing at least a thermosetting resin, a foaming agent and a curing agent in a mixer; continuously discharging the resin composition on a traveling air-permeable and flexible surface material, and at the same time covering the upper surface of the resin composition with an air-permeable and flexible surface material; and passing the covered resin composition through a forming device equipped with conveyors having apertures having an aperture area ratio of 15% or more and 80% or less to form and cure the resin composition.