Polyamide Resin Expanded Sheet Moisture Control
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Solution Overview
Problem
Resin expanded molded articles produced from polyamide-based resin sheets face challenges in maintaining shape stability due to high water absorption rates, leading to dimensional changes after outer shape processing.
Innovation Solution
The method involves pre-heating and thermally molding a polyamide-based resin expanded sheet with a moisture content of 30% or more at 23°C and 60% relative humidity to form a three-dimensional shape, which suppresses water absorption and subsequent shape changes during the production of resin expanded molded articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polyamide-based resin expanded sheet is used as a raw material, then the resin expanded molded article has high strength and heat resistance, but the water absorption rate increases causing dimensional changes after outer shape processing
Solution Approach 1:
The patent applies preliminary action by pre-heating the polyamide-based resin expanded sheet before outer shape processing. This pre-heating step prepares the material in advance to resist water absorption during subsequent processing, thereby preventing dimensional changes while maintaining the high strength characteristics of polyamide resin.
Solution Approach 2:
The patent changes the temperature parameter by pre-heating the resin expanded sheet to a specific temperature range before processing. This parameter change modifies the material's physical properties to reduce its tendency to absorb water and undergo dimensional changes during outer shape processing, while preserving the mechanical strength benefits of polyamide.
2Productivity
If the resin expanded sheet is subjected to outer shape processing in a dried state, then the processing efficiency is improved, but the water absorption rate increases after processing causing shape changes
Solution Approach 1:
The patent performs pre-heating as a preliminary action before outer shape processing. This step prepares the resin expanded sheet in advance to maintain shape stability during processing, allowing efficient processing while preventing subsequent dimensional changes due to water absorption.
Solution Approach 2:
The pre-heating step serves as a preliminary anti-action against water absorption. By heating the sheet before processing, the patent creates a state that resists water uptake during and after processing, thereby preventing shape changes while maintaining processing efficiency.
3Ease of manufacture
If thermal molding is performed on polyamide-based resin expanded sheet, then the three-dimensional shape can be formed, but the high water absorption rate causes dimensional changes in the final product
Solution Approach 1:
The patent applies pre-heating as a preliminary action before thermal molding. This prepares the polyamide-based resin expanded sheet to maintain dimensional stability during the molding process and after cooling, allowing successful formation of three-dimensional shapes while preventing water-induced dimensional changes.
Solution Approach 2:
The patent modifies the temperature parameter by pre-heating the sheet to a specific range before thermal molding. This parameter change enables the material to resist water absorption during molding and cooling, ensuring dimensional stability of the final three-dimensional product while maintaining ease of manufacture.
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 resin expanded molded articles with minimal dimensional changes, enhancing stability and mechanical strength, suitable for applications requiring dimensional stability and resistance to heat and chemicals.
Implementation Method 1
a water absorption rate is easily increased after outer shape processing, to generate change in an outer shape in the resin expanded molded article
Implementation Method 2
a pre-heating step of heating to soften a resin expanded sheet with a radiation heater or the like
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
In outer shape processing of a resin expanded sheet having a resin expanded layer including a polyamide-based resin composition, the outer shape processing is carried out while allowing a specified amount or more of moisture to be contained in the resin expanded layer.