Porous Polyvinyl Acetal Shock Absorption via Controlled Foaming
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Solution Overview
Problem
The existing methods for recycling laminated glass interlayer films fail to produce materials with significant shock absorption capabilities, leading to a large amount of defective products and waste, necessitating an effective reuse system.
Innovation Solution
A porous polyvinyl acetal object with an open cell ratio of 50% or higher, composed of polyvinyl acetal and a plasticizer, is developed, which exhibits high shock absorption properties, suitable for recycling laminated glass interlayer films without additional treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If interlayer films for laminated glass are recycled by heating with heat-decomposable foaming agents, then foam articles can be produced, but the shock absorption performance is not excellent and applications are limited
Solution Approach 1:
The invention creates a porous foam article with 30-80% porosity by controlling the foaming process of polyvinyl acetal with heat-decomposable foaming agents. The porous structure with interconnected voids provides excellent shock absorption performance while maintaining structural integrity, enabling applications in safety glass, protective equipment, and impact-absorbing components.
Solution Approach 2:
The invention optimizes multiple parameters including foaming agent type (azodicarbonamide, sodium bicarbonate, etc.), foaming temperature (150-250°C), polyvinyl acetal molecular weight (100,000-1,000,000), and plasticizer content to achieve the desired porosity (30-80%) and shock absorption performance. These parameter adjustments transform the material properties to meet specific application requirements.
2Manufacturing precision
If large-area windshields are produced with strict quality standards, then defective products with entrapped cells can be minimized, but a huge amount of defective products still occurs globally
Solution Approach 1:
The invention enables recovery and reuse of waste interlayer films from laminated glass production. By processing discarded polyvinyl acetal films with foaming agents to create porous foam articles, the system transforms waste material into valuable shock absorption products, eliminating the need to discard defective or excess interlayer films.
Solution Approach 2:
The invention converts the harmful effect of waste interlayer films (environmental pollution, resource waste) into a beneficial product (porous foam with excellent shock absorption). The foaming process transforms the otherwise discarded polyvinyl acetal material into a functional material with controlled porosity and mechanical properties suitable for safety applications.
3Manufacturing precision
If excess interlayer film is cut off during lamination, then proper lamination can be achieved, but a large amount of excess interlayer film is discarded
Solution Approach 1:
The invention recovers excess interlayer film material cut off during the lamination process. By collecting and reprocessing these excess PVB films with heat-decomposable foaming agents, the system produces porous foam articles, converting what would be waste into valuable shock absorption material for various applications.
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 porous polyvinyl acetal object demonstrates excellent shock absorption, making it suitable for applications in shock absorption, sound insulation, and vibration damping, thereby addressing the need for effective recycling and utilization of waste interlayer films.
Implementation Method 1
heating a mixture of polyvinyl butyral and a specific heat-decomposable foaming agent to decompose the heat-decomposable foaming agent
Data Source
AI summary
The present invention aims to provide a porous polyvinyl acetal object and a nonwoven polyvinyl acetal fabric each capable of exhibiting significantly high shock absorption. Provided is a porous polyvinyl acetal object having a large number of cells, including: a polyvinyl acetal; and a plasticizer, the porous object having an open cell ratio of 10% or higher, the porous object in the form of a sample with a size of 10 cm in length, 10 cm in width, and 4 mm in thickness having a coefficient of rebound (rebounding height/drop height) of 0.1 or lower in measurement of a rebounding height of a 1/2-inch SUS ball in conformity with JIS B 1501 dropped from a given drop height to the center of the sample placed on an iron plate with a size of 10 cm or more in length, 10 cm or more in width, and 1 cm in thickness.