Polyester Elastomer Foam Micro Cell Structure
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Solution Overview
Problem
Polyester foam used in electronic appliances faces challenges with permanent set characteristics and cell structure when blackened, leading to reduced dustproofness, water resistance, soundproofing, and processability.
Innovation Solution
A polyester elastomer foam is developed using a composition with a polyester elastomer having a melting point of 180-240°C and an epoxy-modified polymer, which is expanded using a high-pressure inert gas, resulting in a micro cell structure and improved compression set characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyolefin elastomer foam is used for sealing materials, then cushioning properties are improved, but permanent set increases leading to poor processability and shape maintenance
Solution Approach 1:
The patent changes the material composition parameters by using polyester elastomer with specific melting point (180-240°C) and incorporating epoxy-modified polymer (5-50 parts by weight per 100 parts polyester elastomer). This parameter change resolves the contradiction by achieving both good cushioning properties and reduced permanent set, enabling better processability and shape maintenance during punching operations.
2Manufacturing precision
If thermoplastic polyester resin foam is used for reduction in size and weight, then compression residual strain is reduced, but compression set characteristics deteriorate at high temperatures
Solution Approach 1:
The patent creates a composite material system by combining polyester elastomer with epoxy-modified polymer. The epoxy-modified polymer acts as a crosslinking agent that forms a three-dimensional network structure, providing high-temperature resistance. This composite approach maintains low compression residual strain while significantly improving compression set characteristics at elevated temperatures (tested at 70°C and 100°C).
Solution Approach 2:
The patent applies local quality by introducing epoxy-modified polymer specifically to address high-temperature performance in critical regions. The epoxy content (5-50 parts by weight) can be adjusted locally to optimize the balance between low-temperature flexibility and high-temperature stability, allowing different areas of the foam to have tailored properties for specific application requirements.
3Ease of manufacture
If polyester foam is blackened by adding colorant, then appearance is improved, but permanent set characteristics deteriorate and cell structure becomes coarse
Solution Approach 1:
The patent converts the harmful effect of colorants on foam structure into a benefit by optimizing the base composition. The epoxy-modified polymer (10-50 parts by weight per 100 parts polyester elastomer) creates a robust three-dimensional network that compensates for the disruptive effect of colorants. This allows the foam to be blackened while maintaining fine cell structure (average cell diameter 50-200 μm) and good permanent set characteristics (compression set at 70°C: 30-70%).
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 solution provides a polyester elastomer foam with excellent compression set characteristics and micro cell structure, maintaining product quality and processability even when blackened, and is suitable for use in electronic appliances.
Implementation Method 1
a polyester elastomer foam which is formed by allowing a polyester elastomer composition containing a polyester elastomer having a melting point of 180 to 240° C. and an epoxy-modified polymer to expand
Data Source
AI summary
There is provided a polyester elastomer which is excellent in compression set characteristics and has a micro cell structure.The polyester elastomer foam is formed by allowing a polyester elastomer composition containing a polyester elastomer having a melting point of 180 to 240° C. and an epoxy-modified polymer to expand. The epoxy-modified polymer is an epoxy-modified polymer having a weight average molecular weight of 5,000 to 100,000 and an epoxy equivalent of 100 to 3000 g/eq.