WPC Extrusion Profile Foam-Filled Hollow Chamber Design
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Solution Overview
Problem
WPC extrusion profiles face high material costs and susceptibility to microbacterial decomposition due to high density and water penetration into hollow chambers, which are exacerbated by limited foaming effectiveness that reduces reinforcing effects and increases surface area for decomposition.
Innovation Solution
A WPC extrusion profile with foam-filled hollow chambers using a physically acting blowing agent like CO2 to create a closed-pore foam with a density less than 0.4 g/cm3 and cell size less than 0.4 mm, matching the plastic matrix, which prevents water penetration and maintains structural integrity while reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hollow chambers are designed in WPC extrusion profiles to reduce material costs, then profile costs are reduced, but water penetration into cavities increases leading to microbacterial decomposition
Solution Approach 1:
The patent applies porous foam material to fill the hollow chambers of WPC extrusion profiles. The foam has a controlled pore structure that prevents water penetration while maintaining cost reduction benefits. The foam material absorbs and locks out water, preventing microbacterial decomposition while keeping the profile hollow for cost savings.
2Quantity of substance
If foaming is applied to WPC formulation to reduce density, then material costs are reduced, but the modulus of elasticity decreases disproportionately
Solution Approach 1:
The patent applies local quality by using foamed material only in the hollow chambers rather than throughout the entire WPC profile. The load-bearing WPC structure maintains its full density and reinforcing fiber content for high modulus of elasticity, while the non-structural hollow chambers are filled with cost-reducing foam material.
3Quantity of substance
If hollow chambers are created in WPC profiles, then profile costs are reduced, but the surface area approximately doubles creating more attack surface for microbacterial decomposition
Solution Approach 1:
The patent converts the harmful effect of increased surface area into a benefit by filling the hollow chambers with foam material. The foam's pore structure is designed to trap and lock out water, transforming the previously harmful increased surface area into a protective barrier that prevents water penetration and microbacterial attack.
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 effectively reduces material costs and prevents microbacterial decomposition by minimizing water ingress and maintaining the modulus of elasticity, providing a durable and cost-effective profile with improved slip resistance and visual cohesion.
Implementation Method 1
A WPC extrusion profile with foam-filled hollow chambers using a physically acting blowing agent like CO2 to create a closed-pore foam
Implementation Method 2
using a physically acting blowing agent like CO2 to create a closed-pore foam with a density less than 0.4 g/cm3
Implementation Method 3
create a closed-pore foam... which prevents water penetration
Data Source
AI summary
It is provided a WPC extrusion profile comprising a WPC material, in which plant fibers are embedded in a plastic matrix, wherein the WPC material has a content of naturally growing plant fibers of between 30 and 75 wt-%, and the WPC extrusion profile includes at least one foam-filled hollow chamber. The at least one hollow chamber of the WPC extrusion profile is completely filled up with a foam, in particular a closed-pore foam. The foam includes or consists of a plastic material of the same type of plastic as the matrix of the WPC material. The foaming is effected by using a physically acting blowing agent, in particular CO2, wherein the density of the foam is less than 0.4 g/cm3 and the average cell size of the foam has a mean diameter of less than 0.4 mm.