Silcone foam compositions

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Solution Overview

Problem

Existing silicone foams struggle to achieve a low density while maintaining excellent mechanical and fire-resistant properties, which are crucial for applications in harsh environments such as electronic devices and automotive parts.

Innovation Solution

A dual-blowing silicone foam composition is developed using a combination of a porogenic agent (water, hydrogel, or aqueous silicone emulsion) and a chemical blowing agent (hydrogencarbonate salt) to create a homogeneous and stable cellular structure, incorporating a crosslinkable organopolysiloxane with alkenyl groups and an organosilicon compound with hydrogen atoms, catalyzed by a hydrosilylation catalyst.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If silicone foam density is reduced to achieve weight savings, then mechanical properties and fire resistance deteriorate

Engineering Contradiction:

Improvesilicone foam densityVSAvoidmechanical properties

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies parameter changes by carefully controlling the viscosity of linear polydimethylsiloxane (specifically setting it between 50-100,000 mPa·s at 25°C) and adjusting the composition ratios of crosslinkable organopolysiloxane, organosilicon compound, and blowing agents. This optimization of physical and chemical parameters enables the foam to achieve low density (below 0.20 g/cm³) while maintaining adequate mechanical strength and fire resistance properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining multiple components: crosslinkable organopolysiloxane with alkenyl groups, organosilicon compound with hydrogen atoms bonded to silicon, linear polydimethylsiloxane as a viscosity modifier, and a combination of porogenic agents (water, hydrogel, or aqueous silicone emulsion) with chemical blowing agents. This composite approach allows the low-density foam to maintain mechanical integrity and fire-resistant properties through synergistic interactions among components.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If silicone foam density is reduced to achieve weight savings, then fire resistance properties deteriorate

Engineering Contradiction:

Improvesilicone foam densityVSAvoidfire resistance properties

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent optimizes chemical composition parameters, specifically the ratios of crosslinkable organopolysiloxane, organosilicon compound, and linear polydimethylsiloxane, to achieve a balanced structure that provides both low density and fire resistance. The controlled viscosity range of the linear polydimethylsiloxane (50-100,000 mPa·s) contributes to proper foam cell formation and structural integrity that maintains fire-resistant properties even at densities below 0.20 g/cm³.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If porosity is introduced in silicone cured materials to create foam structure, then mechanical properties deteriorate

Engineering Contradiction:

ImproveporosityVSAvoidmechanical properties

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent deliberately creates a porous foam structure using a dual-blowning system combining porogenic agents (water, hydrogel, or aqueous silicone emulsion) with chemical blowing agents. The porosity is controlled through the specific viscosity of linear polydimethylsiloxane (50-100,000 mPa·s) and composition ratios, achieving a cellular structure that provides weight savings while maintaining adequate mechanical properties through optimized pore size and distribution.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent controls the degree of porosity by adjusting the viscosity parameter of linear polydimethylsiloxane (50-100,000 mPa·s) and the composition ratios of all components. This parameter optimization ensures that the foam cellular structure forms uniformly with appropriate cell size and wall thickness, achieving porosity for weight reduction while maintaining mechanical integrity.

Inventive Principle:

Principle #35Parameter changes

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 resulting silicone foam exhibits low density, enhanced mechanical stability, and a soft shock-resistant feel, retaining excellent mechanical and fire-resistant properties.

Implementation Method 1

the porogenic agent D, which is water, a hydrogel, or an aqueous silicone emulsion, generates hydrogen bubbles while incorporated into the polyaddition-crosslinking silicone composition

Methodology Applied

Scientific EffectBubble formation: Bubble

Implementation Method 2

the chemical blowing agent E releases gas, typically carbon dioxide, by decomposition

Methodology Applied

Scientific EffectDecomposition: Decomposition (biological)

Implementation Method 3

at least one hydrosilylation catalyst C

Methodology Applied

Scientific EffectHydrosilylation: Chemical Bonding

Data Source

PatentUS20250346731A1Silcone foam compositions

Publication Date: 2025.11.13 ELKEM SILICONES USA CORP

AI summary

The present invention relates to a new silicone foam obtained from a blowable crosslinkable silicone composition comprising an organopolysiloxane having at least two alkenyl groups bonded to silicon per molecule, an organosilicon compound having at least two and preferably at least three hydrogen atoms bonded to silicon per molecule, a hydrosilylation catalyst, at least one porogenic agent which is water, a hydrogel, or an aqueous silicone emulsion, at least one chemical blowing agent, and a linear polydimethylsiloxane.