Multilayer Polyester Foam Composite with Resin Surface
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Solution Overview
Problem
Polyester foams face challenges in achieving optimal foaming ratios and physical properties due to high melt viscosity, leading to issues with bubble collection and appearance in foamed molded articles, and existing solutions with glass fibers generate dust and hinder recycling.
Innovation Solution
A multilayer composite structure comprising n-layered polyester foams stacked with a polyester resin layer on their surfaces, which improves durability, strength, and light weight, and can be reused, avoiding the use of glass fibers to prevent dust generation and facilitate recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a separate functional additive is mixed in an extrusion-foaming process of the polyester resin, then the foaming ratio may be lowered, but the appearance of the foamed molded article may become poor
Solution Approach 1:
The patent divides the additive system into two distinct components: a viscosity modifier added before extrusion to control melt viscosity, and a foaming agent added separately. This segmentation allows independent optimization of viscosity control and foaming performance, preventing the trade-off between foaming ratio and appearance quality that occurs when additives are mixed together.
Solution Approach 2:
The viscosity modifier is incorporated into the polyester resin before the extrusion-foaming process to pre-adjust the melt viscosity to an optimal range. This preliminary action ensures that when the foaming agent is subsequently introduced and activated, the bubbles are properly collected and stabilized, achieving both high foaming ratio and good appearance quality without the need to mix additives during extrusion.
2Reliability
If polyester resin with high melt viscosity is used, then bubble collection is improved, but foaming ratio is reduced
Solution Approach 1:
The patent modifies the melt viscosity parameter of the polyester resin by incorporating a viscosity modifier, adjusting it to an optimal range that balances bubble collection and foaming ratio. This parameter change allows the resin to maintain sufficient viscosity for effective bubble collection while remaining low enough to achieve high foaming ratios, resolving the contradiction between these two properties.
3Strength
If glass fibers are added to improve strength, then durability is improved, but dust generation occurs and recycling becomes difficult
Solution Approach 1:
The patent removes glass fibers from the composite material formulation while maintaining strength and durability through the optimized polyester resin matrix with controlled viscosity and proper foaming structure. This extraction eliminates the dust generation problem associated with glass fiber handling and processing, and also facilitates recycling since the resulting composite consists solely of polyester materials that can be reprocessed.
4Strength
If glass fibers are added to improve strength, then durability is improved, but recycling becomes hindered
Solution Approach 1:
The patent removes glass fibers from the composite material formulation while maintaining strength and durability through the optimized polyester resin matrix with controlled viscosity and proper foaming structure. This extraction eliminates the dust generation problem associated with glass fiber handling and processing, and also facilitates recycling since the resulting composite consists solely of polyester materials that can be reprocessed.
Solution Approach 2:
The patent creates a homogeneous polyester-based composite material without heterogeneous glass fiber inclusions. This homogeneity ensures that the entire material can be uniformly reprocessed and recycled through standard polyester recycling methods, eliminating the separation and processing difficulties that arise when recycling glass fiber-reinforced composites.
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 composite achieves enhanced flexural modulus, flexural strength, and insulation properties while maintaining light weight, with improved durability and resistance to deformation and UV damage, and can be effectively recycled.
Implementation Method 1
a polyester resin layer which is melted and bonded to a surface of the polyester foam
Implementation Method 2
WO 2013/085773 A1 discloses methods of bonding polyester substrates together, comprising externally delivering thermal energy onto the bonding surfaces of the substrates and bringing the bonding surfaces into proximity with each other and bonding the substrates to each other
Data Source
Figure 1~2
AI summary
The present invention relates to a composite of a multilayer structure comprising a polyester foam and a polyester resin layer, and a use thereof. A polyester composite according to the present invention provides a composite which is capable of improving a working environment, improves durability and strength and has light weight; is easy to reuse; and can be variously utilized for different uses such as a vehicle interior or exterior material or building insulation materials.