Extruded Propylene Foam with Segmented Cell Structure
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Solution Overview
Problem
Conventional extruded polypropylene-based resin foams often lack simultaneous high insulation efficiency, sound absorption performance, vibration suppressive performance, and energy-absorbing capability, making them inadequate for applications requiring multiple properties.
Innovation Solution
The development of an extruded polypropylene-based resin composite foam, comprising first and second extruded foams with specific closed cell content and expansion ratios, arranged in a laminate structure to enhance insulation, sound absorption, and vibration suppression, utilizing a propylene-based resin with a multistage polymer and olefin-based polymer for improved mechanical and viscoelastic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional extruded polypropylene-based resin foam is used, then it provides basic insulation and structural properties, but it cannot simultaneously achieve high insulation efficiency, sound absorption performance, vibration suppressive performance, and energy-absorbing capability
Solution Approach 1:
The foam is divided into two distinct types with different cell structures: closed-cell foam for insulation and vibration suppression, and open-cell foam for sound absorption and energy absorption. This segmentation allows each region to optimize its function independently while working together as a composite material system.
Solution Approach 2:
The invention creates a composite foam structure combining two different foam types (closed-cell and open-cell) within a single polypropylene-based resin system. This composite approach integrates multiple functional properties that cannot be achieved by a single homogeneous foam structure.
2Temperature
If closed-cell content is increased to improve insulation efficiency, then insulation performance improves, but sound absorption performance deteriorates
Solution Approach 1:
Different regions of the foam are assigned different cell structures optimized for their specific functions: closed-cell regions for insulation and open-cell regions for sound absorption. This local differentiation allows each region to excel at its designated function without compromising the other.
Solution Approach 2:
The composite foam structure combines closed-cell and open-cell foam types, where the closed-cell portion provides insulation efficiency while the open-cell portion provides sound absorption performance, achieving both functions simultaneously.
3Object-affected harmful factors
If open-cell content is increased to improve sound absorption performance, then sound absorption improves, but insulation efficiency deteriorates
Solution Approach 1:
The foam structure implements local quality differentiation where open-cell regions are specifically positioned to maximize sound absorption while closed-cell regions maintain insulation efficiency, allowing both functions to coexist optimally.
4Strength
If foam density is increased to improve mechanical strength, then strength improves, but weight increases
Solution Approach 1:
The composite foam structure achieves enhanced mechanical strength through the synergistic combination of closed-cell and open-cell foam types, obtaining superior strength-to-weight ratio compared to conventional single-structure foams of equivalent or higher density.
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 foam achieves excellent insulation efficiency, sound absorption performance, and vibration suppressive capabilities while maintaining a lightweight structure, with enhanced mechanical strength and recyclability, suitable for various structural applications.
Implementation Method 1
first extruded foam having a closed cell content of 40 percent or more and an expansion ratio of 10 or more
Implementation Method 2
second extruded foam having a closed cell content of less than 40 percent and an expansion ratio of 10 or more
Implementation Method 3
formed by extrusion-foaming a molding material including a propylene-based resin
Data Source
AI summary
The extruded propylene-based resin composite foam (1) according to the present invention is provided by extrusion-foaming a molding material containing a propylene-based resin. The propylene-based resin forming the extruded foam has an olefin-based polymer whose loss tangent (tan δ) is 0.04 to 100 at a temperature of 298 K and a frequency of 10 Hz. The molding material includes a fibrous filler in an amount of more than 0 mass % and 60 mass % or less of the entirety of the molding material. The extruded composite foam (1) includes: first extruded foam (2) whose closed cell content is 40 percent or more and whose expansion ratio is 10 or more; and second extruded foam (3) whose closed cell content is less than 40 percent and whose expansion ratio is 10 or more.