Urethane Foam Composition for Heat-Resistant Thermal Insulation
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Solution Overview
Problem
Conventional urethane foam molded bodies exhibit low heat resistance, making them unsuitable for components that reach high temperatures, such as ECUs and junction boxes in vehicles, despite improvements in thermal conductivity and electrical insulation.
Innovation Solution
A urethane foam molded body composed of polyurethane foam with oriented composite particles and dispersed first insulating inorganic particles, where the composite particles include thermally conductive expanded graphite particles with controlled alkali metal ion content and magnetic particles, forming a heat transmission path and providing electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional polyurethane foam is used for soundproofing around heat-generating noise sources, then noise reduction is achieved, but heat accumulation occurs causing malfunction risk
Solution Approach 1:
The patent uses composite particles consisting of thermally conductive particles (expanded graphite) combined with magnetic particles and insulating inorganic particles. This composite structure enables simultaneous thermal conduction through the graphite particles and electrical insulation through the inorganic particles, resolving the contradiction between noise reduction and heat management.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the polyurethane foam by incorporating expanded graphite particles. The graphite particles form heat transmission paths that increase thermal conductivity from the typical 0.02-0.04 W/m·K to 0.1 W/m·K or higher, enabling heat dissipation while maintaining soundproofing functionality.
2Temperature
If thermally conductive particles are added to improve heat dissipation, then thermal conductivity increases, but electrical insulation deteriorates
Solution Approach 1:
The patent applies local quality by creating distinct functional zones within the composite particles. The thermally conductive expanded graphite particles provide heat transmission paths locally, while the insulating inorganic particles (alumina, silica, titania) provide electrical insulation locally. This spatial differentiation of functions resolves the contradiction between thermal conduction and electrical insulation.
Solution Approach 2:
The composite particle structure combines materials with complementary properties: expanded graphite for thermal conduction, magnetic particles for orientation control, and insulating inorganic particles for electrical insulation. This multi-material composite approach enables simultaneous achievement of thermal conductivity and electrical insulation.
3Temperature
If composite particles with thermally conductive particles are used to improve thermal conductivity, then heat dissipation improves, but heat resistance deteriorates at high temperatures around 150°C
Solution Approach 1:
The patent uses a composite particle system where expanded graphite particles (thermally conductive) are combined with heat-resistant inorganic particles (alumina, silica, titania). The inorganic particles maintain structural stability at high temperatures up to 150°C and above, preventing deterioration of physical properties while the graphite particles maintain thermal conductivity. This composite structure resolves the contradiction between thermal conductivity and heat resistance.
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 enhances thermal conductivity and heat resistance, suppressing polyurethane deterioration and maintaining physical properties under high temperatures, while ensuring electrical insulation and flame retardancy.
Implementation Method 1
the thermally conductive particles include expanded graphite particles... a heat transmission path is formed in the direction of the orientation, thereby improving heat dissipation properties
Implementation Method 2
composite particles, which are a composite of thermally conductive particles such as expanded graphite, magnetic particles, and insulating inorganic particles, are oriented and arranged in polyurethane foam
Implementation Method 3
electrical insulation may be imparted by dispersing insulating inorganic particles separately from the composite particles in the polyurethane foam
Data Source
AI summary
A urethane foam molded body includes a base material composed of polyurethane foam, a composite particle oriented and contained in the base material, and a first insulating inorganic particle dispersed in the base material. The composite particle includes a thermally conductive particle, and a magnetic particle adhered to a surface of the thermally conductive particle by a binder. The thermally conductive particle includes an expanded graphite particle, and an amount of an alkali metal ion contained in the expanded graphite particle is 500 ppm or higher and 2,000 ppm or lower.