Resin Blend Layer Separation for Weather Resistance
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Solution Overview
Problem
Plastic resins used in applications like home appliances and automobiles face issues with weather resistance and strength due to degradation from oxygen, ozone, and light, requiring additional coatings or plating processes that can be inefficient and generate toxic materials.
Innovation Solution
A resin blend with a first resin and a second resin having a difference in melt viscosity is used to create a layer-separated structure during the melting process, eliminating the need for additional coatings or plating and enhancing mechanical and surface characteristics of the resin article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional coating or plating process is applied to plastic resins to improve weather resistance and strength, then the resistance to degradation is improved, but manufacturing efficiency decreases and toxic materials are generated
Solution Approach 1:
The patent combines the base resin and functional resin into a single melt processing step, merging the base material production and surface layer formation into one operation. This eliminates the need for separate coating or plating processes, thereby improving manufacturing efficiency while maintaining enhanced weather resistance and strength properties.
Solution Approach 2:
The patent uses a composite material system consisting of a base resin and a functional resin with specific melt viscosity characteristics. The functional resin forms a surface layer on the base resin through layer separation during melt processing, creating a composite structure that provides both the base resin's properties and enhanced surface resistance without requiring additional coating steps.
2Reliability
If additional coating or plating process is applied to plastic resins to improve weather resistance and strength, then the resistance to degradation is improved, but toxic materials are generated during the process or disposal
Solution Approach 1:
The functional resin automatically forms the protective surface layer on the base resin through layer separation during the melt processing step. This self-organizing behavior eliminates the need for external coating applications that would generate toxic materials, as the functional resin itself provides the protective function through its inherent properties and phase separation during processing.
3Strength
If inorganic particles are added to high molecule resins to improve abrasion resistance and stiffness, then the physical properties are improved, but processability and impact strength deteriorate
Solution Approach 1:
The patent changes the approach from adding inorganic particles to using organic functional resins with specific melt viscosity parameters. By controlling the melt viscosity ratio between the functional and base resins (0.1 to 3000 Pa·s at 100 to 1000 s−1), the system achieves improved surface properties and abrasion resistance while maintaining good processability and impact strength, avoiding the drawbacks of inorganic particle addition.
4Strength
If inorganic particles are added to high molecule resins to improve physical properties, then the stiffness and abrasion resistance are improved, but gloss and impact strength are deteriorated
Solution Approach 1:
The patent employs a composite resin system where the functional resin forms a continuous surface layer on the base resin through layer separation. This organic composite structure provides uniform surface properties and gloss while maintaining impact strength, avoiding the surface defects and gloss deterioration associated with inorganic particle additions.
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 layer-separated structure improves the mechanical and surface properties of the resin article without additional processing steps, reducing manufacturing time and cost while maintaining productivity.
Implementation Method 1
enabling formation of a surface layer on the resin article through a layer separation
Implementation Method 2
a first resin and a second resin having a difference in melt viscosity from the first resin of 0.1 to 3000 pa*s at a shear rate of 100 to 1000 s−1 and at a processing temperature of the resin blend
Data Source
AI summary
Provided are a resin blend for melt processing, a pellet and a method of preparing a resin article using the same. The resin blend may include a first resin, and a second resin having a difference in melt viscosity from the first resin of 0.1 to 3000 pa*s at a shear rate of 100 to 1000 s−1 and a processing temperature of the resin blend. The resin blend can improve mechanical and surface characteristics of a resin article. Further, since coating or plating is not required for manufacturing a resin article, a manufacturing time and/or cost can be reduced, and productivity can be increased.