Single-Tg Thermoplastic Resin Foam for Heated Shape Stability
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Solution Overview
Problem
Existing thermoplastic resin foams and fiber-reinforced composites suffer from low heat resistance, leading to softening and reduced rigidity when heated, which is a limitation in applications requiring heat-dimensional stability.
Innovation Solution
A combination of crystalline and amorphous polyester resins, along with a polyimide resin, is used to create a thermoplastic resin foam and fiber-reinforced composite, achieving a single glass transition temperature and enhanced heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a thermoplastic resin foam is used for food containers requiring microwave heating, then light weight and high heat insulation are achieved, but heat resistance deteriorates causing softening and deformation
Solution Approach 1:
The patent uses a composite thermoplastic resin composition comprising multiple polyester resins (including crystalline and amorphous types) and polyimide resin. This composite material approach allows the foam to achieve both light weight and improved heat resistance by combining the advantages of different polymer materials, resolving the contradiction between weight and heat resistance.
Solution Approach 2:
The patent modifies the glass transition temperature parameter by selecting specific polyester resins with appropriate Tg values and combining them with polyimide resin. This parameter change enables the foam to maintain rigidity at microwave heating temperatures while preserving the lightweight characteristic, thus resolving the heat resistance issue without sacrificing weight advantage.
2Reliability
If a heat set step is added to promote crystallization and improve heat-dimensional stability, then heat resistance is improved, but molding time increases
Solution Approach 1:
The patent incorporates crystalline polyester resin and amorphous polyester resin with specific Tg values into the foam formulation in advance. This preliminary action of selecting appropriate resin combinations eliminates the need for subsequent heat set steps, achieving heat-dimensional stability directly during the molding process and reducing molding time.
Solution Approach 2:
The patent changes the resin composition parameters by using specific polyester resins with controlled crystallinity and Tg values. This parameter modification allows the foam to achieve heat-dimensional stability without requiring additional heat set processing, thus reducing molding time while maintaining reliability.
3Reliability
If a heat set step at high temperature is implemented to improve heat resistance, then heat-dimensional stability is improved, but equipment investment increases
Solution Approach 1:
The patent employs a composite resin system comprising crystalline polyester, amorphous polyester with specific Tg, and polyimide. This composite material approach achieves high heat resistance through material composition rather than high-temperature processing equipment, eliminating the need for expensive heat set equipment while maintaining reliability.
Solution Approach 2:
The patent modifies the material parameters by selecting polyester resins with appropriate Tg values and combining them with polyimide. This parameter change enables the foam to achieve heat resistance at lower processing temperatures, avoiding the need for high-temperature equipment investment while maintaining heat-dimensional stability.
4Reliability
If the glass transition temperature is increased to improve heat resistance, then heat-dimensional stability is improved, but ease of processing deteriorates
Solution Approach 1:
The patent uses a composite system with crystalline polyester, amorphous polyester having specific Tg, and polyimide resin. This composite approach balances heat resistance and processability by combining materials with different thermal properties, allowing the foam to maintain both high heat resistance and ease of processing during molding operations.
Solution Approach 2:
The patent optimizes the Tg parameter by selecting specific polyester resins with appropriate glass transition temperatures and combining them with polyimide. This parameter optimization ensures the foam has sufficient heat resistance while maintaining good processability during molding, resolving the contradiction between heat resistance and ease of operation.
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 materials exhibit improved heat resistance and heat-dimensional stability, maintaining rigidity and handling properties even when heated.
Implementation Method 1
the thermoplastic resin includes a polyester resin and a polyimide resin, and the thermoplastic resin foam shows a single glass transition temperature Tg
Data Source
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AI summary
A thermoplastic resin foam including a thermoplastic resin, wherein: the thermoplastic resin includes a polyester resin and a polyimide resin, and the thermoplastic resin foam shows a single glass transition temperature Tg. The glass transition temperature of the thermoplastic resin is preferably 80 to 130 °C. An absolute value of difference between heat absorption and heat generation, each determined by heat flux differential scanning calorimetry at a heating rate of 10 °C/min, is preferably 3 to 35 J/g.