PS/PPO Closed Cell Foam for Composite Laminates
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Solution Overview
Problem
Current composite laminated articles face challenges in minimizing resin absorption and material waste, while achieving high mechanical and thermal properties, particularly in the use of foam cores for structural applications like wind turbine blades and boat hulls, where existing foams are costly, difficult to recycle, and have limited heat resistance and mechanical performance.
Innovation Solution
A composite laminated article featuring a closed cell foam with a homogeneous cell size of less than 100 microns, composed of a blend of polystyrene and polyphenylene oxide (PS/PPO), which minimizes resin absorption and enhances bonding with fibre-reinforced layers, reducing material waste and weight, and is compatible with conventional manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional foams (PVC, SAN, PMI) are used for high mechanical and thermal performance, then heat resistance and mechanical properties are improved, but manufacturing cost increases and recyclability deteriorates
Solution Approach 1:
The patent changes the material composition parameters by using PS/PPO blend foam with controlled density (50-600g/L) and cell structure, achieving both heat resistance (up to 75°C) and cost-effectiveness through optimized formulation rather than relying on expensive crosslinked foams
Solution Approach 2:
The patent creates a composite foam material by blending polystyrene with polyphenylene oxide (PPO) in specific ratios, combining the low cost of PS with the heat resistance of PPO to achieve a balanced performance-cost ratio that outperforms conventional single-material foams
2Productivity
If foam pieces are pre-machined to speed up assembly, then assembly time is reduced, but foam material waste increases
Solution Approach 1:
The patent segments the foam core into modular pieces with standardized interfaces that can be quickly assembled, allowing pre-machining of only the necessary features while maintaining material efficiency through precise fit-and-fasten design rather than excessive pre-machining
3Reliability
If resin is added to ensure complete bonding between fibre reinforced layer and core layer, then bonding reliability is improved, but component weight and material cost increase
Solution Approach 1:
The patent creates a homogeneous bonding interface by matching the surface properties of the foam core with the resin characteristics, ensuring uniform adhesion across the interface without requiring excessive resin thickness or amount, thus achieving reliable bonding with minimal material usage
Solution Approach 2:
The patent uses a bonding agent composition that replicates the chemical and physical properties needed for effective adhesion, creating a thin but sufficient bonding layer that provides reliable connection without the need for thick resin layers that would increase weight
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 achieves reduced resin absorption, improved mechanical properties, and cost-effectiveness by using a closed cell foam structure that is recyclable and suitable for high-temperature applications, while minimizing material waste and component weight, thus addressing the limitations of existing foams in the composite industry.
Implementation Method 1
the closed cell foam has an average cell size, the cell size being substantially homogeneous in the closed cell foam, of less than 100 microns... achieves reduced resin absorption
Data Source
AI summary
A composite laminated article comprising: a first layer of a closed cell foam of a thermoplastic material, a second layer of a fibre-reinforced resin, the resin adhering a surface of the second layer to a surface of the first layer, wherein the closed cell foam has an average cell size of from 15 to 75 microns.