Thermoplastic Polyester Foam Sheet Crystallization Accelerator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for molding thermoplastic polyester resin foam sheets into containers face challenges with heat resistance and productivity, as preheating at temperatures below the crystallization temperature can result in insufficient crystallinity and prolonged molding processes.
Innovation Solution
A thermoplastic polyester resin foam sheet incorporating a crystallization accelerator, such as talc, carbon black, or zinc oxide, is used to enhance crystallinity and heat resistance, while maintaining a balanced thickness and expansion ratio for improved heat insulation and ease of molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preheating temperature is higher than the crystallization temperature of the thermoplastic polyester resin, then crystallization of the resin on the surface proceeds, but the extension of the foam sheet becomes poor and molding defects occur
Solution Approach 1:
The patent applies parameter changes by modifying the preheating temperature range (100-150°C below crystallization temperature) and controlling the molding temperature (above crystallization temperature) to achieve optimal crystallization during molding while preventing surface crystallization defects during preheating
2Manufacturing precision
If preheating temperature is lower than the crystallization temperature of the thermoplastic polyester resin, then molding can proceed without surface crystallization, but crystallization becomes insufficient and heat resistance becomes insufficient
Solution Approach 1:
The patent applies preliminary action by performing preheating at a controlled temperature below the crystallization point to prepare the foam sheet for molding, then using the molding process itself to achieve the necessary crystallization and heat resistance properties
Solution Approach 2:
The patent changes the temperature parameters dynamically: preheating at 100-150°C below crystallization temperature, then molding at temperatures above the crystallization temperature to ensure sufficient crystallization for heat resistance
3Reliability
If the foam sheet remains interposed between the mold halves for a long time to increase crystallinity, then heat resistance is improved, but the molding process takes a long time and productivity cannot be improved
Solution Approach 1:
The patent optimizes the time-temperature parameters by using a preheating time of 5-30 minutes at controlled temperature, followed by molding at higher temperature to achieve sufficient crystallinity in a total process time of under 60 seconds, balancing heat resistance with productivity
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 enables the production of containers with high heat resistance and increased productivity by accelerating crystallization, reducing molding time, and enhancing the heat insulation and strength of the foam containers.
Implementation Method 1
crystallization of the thermoplastic polyester resin becomes insufficient
Data Source
Figure 1
AI summary
A thermoplastic polyester resin foam sheet including: a thermoplastic polyester resin; and at least one crystallization accelerator selected from an inorganic crystallization accelerator and an organic crystallization accelerator, wherein the thermoplastic polyester resin foam sheet has a crystallization time of 14 minutes or less, determined from a DSC curve obtained using a heat flux differential scanning calorimetry (DSC) apparatus by performing a second heating from 30 °C to 110 °C at a heating rate of 100 °C/min, and holding the temperature at 110 °C for 30 minutes, wherein the crystallization time is determined in terms of a time between initiation of the second heating and a time of emergence of a peak top of a last appearing exothermic peak in the DSC curve.