Single-Layer Shape Retaining Material for Balanced Strength
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Solution Overview
Problem
Conventional shape retaining materials made from polyolefin-type resins exhibit poor mechanical strength and directional shape retention properties, being prone to tearing and snapping when bent in directions orthogonal to the stretching direction, and require complex and costly multi-layer lamination for uniform strength.
Innovation Solution
A single-layer shape retaining material composed of high-density polyethylene resin and ethylene-α-olefin copolymer, with specific molecular weight and density ranges, and a method involving rolling and uniaxial stretching to achieve balanced mechanical strength and shape retention in all directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a polyolefin-type resin sheet is stretched to create shape retaining properties, then shape retention in the transverse direction is improved, but mechanical strength in the stretching direction decreases and the material snaps when bent parallel to stretching
Solution Approach 1:
The patent uses a composite material system consisting of polyolefin-type resin (50-90 wt%) combined with polyamide resin (10-50 wt%). This composite structure allows the material to achieve both shape retaining properties and high mechanical strength in the stretching direction, resolving the contradiction between shape retention and strength.
2Ease of manufacture
If conventional polyethylene resin is used for shape retaining material, then production cost is reduced, but tensile elastic modulus and tensile strength are insufficient
Solution Approach 1:
The patent combines cost-effective polyolefin-type resin with polyamide resin to create a composite material that achieves both economic viability and superior mechanical properties. The polyamide component significantly enhances tensile elastic modulus and tensile strength while maintaining reasonable production costs.
Solution Approach 2:
The patent optimizes the weight ratio of polyolefin to polyamide (50-90/10-50) to achieve the desired balance between cost and mechanical performance. This parameter optimization allows manufacturers to adjust the formulation based on specific application requirements.
3Shape
If multiple shape retaining sheets are laminated and adhered to achieve uniform mechanical strength in all directions, then non-directional shape retaining properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent achieves uniform mechanical strength and non-directional shape retaining properties in a single-layer structure through the composite action of polyolefin and polyamide resins. This eliminates the need for complex multi-layer lamination processes, significantly reducing manufacturing steps and costs.
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 material exhibits excellent anti-longitudinal tearing properties, tensile elastic modulus, and tensile strength, retaining shape with minimal return angles in both stretching and orthogonal directions, while being cost-effectively produced in a single layer.
Implementation Method 1
a fibrous, band-like, or sheet-like stretched formed material comprising 100 parts by weight of a high-density polyethylene resin... The shape retaining material is a single-layer shape retaining material having excellent shape retaining properties
Data Source
Figure 1(A)~1(C)
AI summary
The present invention provides a single-layer shape retaining material excellent in mechanical strengths, such as tensile elastic modulus and tensile strength, as well as in non-directional shape retaining properties; and a method for producing the same. The shape retaining material is a fibrous, band-like, or sheet-like stretched formed material comprising 100 parts by weight of a high-density polyethylene resin having a weight-average molecular weight of 100,000 to 500,000 and a density of 0.945 to 0.960 g/cm3 and 3 to 50 parts by weight of an ethylene-α-olefin copolymer obtained by copolymerizing ethylene with an α-olefin having 4 to 10 carbon atoms, the copolymer having a density of 0.935 to 0.960 g/cm3, the difference in density between the copolymer and the high-density polyethylene resin being ± 0.020 g/cm3 or less, wherein the material shows, after being bent at an angle of 180 degrees in a direction orthogonal to the stretching direction, held in the bent state for 1 minute, released, and left for 5 minutes after the release, a return angle of 15 degrees or less; and shows, after being bent in a direction parallel to the stretching direction, a return angle of 25 degrees or less.