Room Temperature Foamed Structural Carrier
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Solution Overview
Problem
Epoxy-based adhesives and foams in the transportation and construction industries require separate curing and blowing agents, additional strengthening features, and higher temperatures for curing, leading to increased costs and complexity in manufacturing structural carriers.
Innovation Solution
A structural carrier comprising a foam core and an outer layer, monolithically formed without reinforcing ribs or pockets, curable at room temperature, made from phosphate esters and epoxy resins, and free of secondary agents, with an adhesive that cures above 50°C, providing structural integrity and flame retardance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy-based adhesives and foams use separate curing agents and blowing agents, then the structural carrier achieves proper curing and expansion, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent combines the curing agent and blowing agent functions into a single integrated foam material system. The foam material contains both curing agents (such as polyamines or polyols) and blowing agents (such as water or carbon dioxide) built-in, eliminating the need for separate addition of these agents during manufacturing. This integration simplifies the manufacturing process while maintaining proper curing and expansion performance.
Solution Approach 2:
The foam material is designed to perform multiple functions simultaneously: it provides structural support, sealing, sound attenuation, and fire retardance all in one material system. The universal foam material replaces multiple separate components (adhesive, foam, curing agent, blowing agent, fire retardant) with a single multi-functional material that achieves all required performance characteristics.
2Strength
If epoxy-based adhesives and foams require additional strengthening features like ribs and pockets, then the structural integrity is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent changes the material parameters by using a foam material with optimized cell structure, density, and composition to achieve high structural integrity without requiring additional strengthening features. By adjusting foam parameters such as cell size, wall thickness, and material composition, the base foam structure itself provides the necessary strength, eliminating the need for time-consuming additions of ribs, pockets, or other reinforcement elements.
3Productivity
If epoxy-based adhesives and foams are cured at elevated temperatures, then the curing reaction is accelerated, but the energy consumption and manufacturing cost increase
Solution Approach 1:
The patent changes the curing temperature parameter from elevated temperatures to ambient or room temperature curing. The foam material is formulated with curing agents that remain active at lower temperatures, and the curing reaction is designed to proceed at acceptable speeds without requiring thermal energy input. This parameter change significantly reduces energy consumption while maintaining productive curing rates suitable for manufacturing environments.
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 simplifies the manufacturing process, eliminates the need for additional agents, and achieves structural integrity and flame retardance while being cost-effective and time-efficient, with improved energy absorption and flexibility.
Implementation Method 1
the structural carrier is curable at a temperature of about 0° C. to about 50° C.
Implementation Method 2
the structural carrier foams at room temperature
Implementation Method 3
an adhesive is disposed on at least a portion of the outer layer
Implementation Method 4
improved energy absorption and flexibility
Data Source
AI summary
A structural carrier comprising: a foam core and an outer layer, the foam core and the outer layer being free of structurally reinforcing ribs and open pockets, wherein the structural carrier is curable at a temperature of about 0° C. to about 50° C. The structural carrier may also foam at room temperature. The structural carrier may have an adhesive material disposed on at least a portion of the outer layer.