Porous Laminate Structure With Controlled Voidage and Strength
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Solution Overview
Problem
Existing laminates produced by integral molding with thermoplastic resin beads having a high aspect ratio L/D suffer from insufficient mechanical strength and difficulty in controlling voidage differences between layers.
Innovation Solution
Integrally mold cylindrical expanded thermoplastic resin beads A and B with specific diameter and outer diameter differences, and aspect ratio L/D of less than 2, to create a laminate with interconnected voids and a voidage difference of 5% or more, satisfying certain diameter and outer diameter requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rod-shaped pre-expanded beads with large aspect ratio L/D are used, then voidage is increased, but mechanical strength becomes insufficient
Solution Approach 1:
The patent changes the aspect ratio parameter from large (rod-shaped) to less than 2 (cylindrical), and controls the relationship between outer diameter and hole diameter to achieve both high voidage and sufficient mechanical strength. This parameter optimization resolves the contradiction between voidage and mechanical strength.
2Adaptability or versatility
If a laminate with different voidages is produced by integral molding, then functional characteristics are improved, but control of voidage in each layer becomes difficult
Solution Approach 1:
The patent applies local quality by using different types of expanded beads (with different outer diameters and hole diameters) for different layers, allowing each layer to have optimized voidage characteristics. This enables precise control of voidage in each layer while maintaining the functional benefits of a laminate structure.
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 method enables the production of a laminate with excellent mechanical strength and controlled voidage differences, facilitating a wide range of molding conditions and improved properties such as sound absorption and permeability.
Implementation Method 1
integrally molding cylindrical expanded thermoplastic resin beads A having a through-hole and an aspect ratio L/D of less than 2 and cylindrical expanded thermoplastic resin beads B having a through-hole
Data Source
AI summary
The present invention relates to a method for producing a laminate, wherein the laminate is obtained by integrally laminating an expanded beads molded article (a) composed of expanded beads A and having interconnected voids and an expanded beads molded article (b) composed of expanded particles B and having interconnected voids, the difference [Pb−Pa] between the voidage (Pa) of the expanded beads molded article (a) and the voidage (Pb) of the expanded beads molded article (b) is 5% or more, and the expanded beads A and the expanded beads B satisfy the following (1) to (3): (1) a difference [dB−dA] between an average hole diameter (dA) of the through-holes of the expanded beads (A) and an average hole diameter (dB) of the through-holes of the expanded beads (B) is 0.3 mm or more and 2 mm or less; (2) the expanded beads (B) have an average outer diameter DB of 3.5 mm or more and 5 mm or less; (3) a difference [DB−DA] between an average outer diameter DA of the expanded beads (A) and an average outer diameter DB of the expanded beads (B) is −0.3 mm or more and 2 mm or less.