Polyurethane composite for electric automobile

Abstract

The present invention is a polyurethane composite for electric automobiles. The said composite comprises at least one polyether polyol in the range of 50% to 65% by weight, at least one blowing agent in the range of 4% to 20% by weight, at least one isocyanate in the range of 25% to 30% by weight, and a carbon source in the range of 1% to 15% by weight which is selected from the group consisting of carbon black, graphene, carbon nanotube, carbon fiber, MXene, and combinations thereof.

Description

[0001] POLYURETHANE COMPOSITE FOR ELECTRIC AUTOMOBILE

[0002] Field of the Invention

[0003] The present invention relates to polyurethane composites produced from recycled materials for electric automobiles. In particular, the said composites can be used as sound insulators and electromagnetic shields.

[0004] State of the Art

[0005] Electronic pulse wave in electric cars interact with other electronic devices used by users other than the automobile system. This interaction disrupts the functions of electronic devices and causes them to give functional errors before their service life expires.

[0006] On the other hand, with the removal of internal combustion engines from cars and the transition to electrical systems, the sounds from the environment reduce in-vehicle comfort and leads to a lower quality of driving pleasure. The main reason for this is that the internal combustion engine dampens external sounds as it emits low and medium frequency sounds during operation. Since there is no sound source to dampen the sound coming from outside in electric cars, the sounds in this frequency range (800-1600Hz) are easily heard.

[0007] Polyurethane is one of the most indispensable polymers in the automotive industry considering its moldability, low density, sound insulation properties and production costs. The use of low density materials in vehicles provides an increase in range and reduces the carbon footprint with energy savings in electric vehicles. Therefore, new polyurethane composites are needed to overcome the above problems.

[0008] Brief Description of the Invention

[0009] In electric cars, there is a need for low-cost high-performance products that will serve as sound isolators and electromagnetic shields.

[0010] In this context, the invention provides a polyurethane composite for the electric cars. The said composite comprises at least one polyether polyol in the range of 50% to 65% by weight, at least one blowing agent in the range of 4% to 20% by weight, at least one isocyanate in the range of 25% to 30% by weight, and a carbon source in the range of 1% to 15% by weight which is selected from the group consisting of carbon black, graphene, carbon nanotube, carbon fiber, MXene, and combinations thereof.

[0011] The product provided by the present invention has the advantages of being a low cost and sustainable product.

[0012] Brief Description of the Figures

[0013] Figure 1 shows in the range 0-6300 Hz, polyurethane containing 0.5% recycled carbon black has 2.3% better sound transmission coefficient than polyurethane without filler.

[0014] Figure 2 shows in the range 10-17 GHz, polyurethane containing recycled carbon black has 14.9% better electromagnetic shielding than polyurethane without filler.

[0015] Detailed Description of the Invention

[0016] The present invention increases electromagnetic shielding and acoustic performance in electric cars thanks to the recyclable additives contained in the polyurethane composite. Polyurethane composites of the invention are suitable for use as sound isolators and electromagnetic signal shields in electric car technologies.

[0017] In the polyurethane composite formulation provided with the present invention, especially the semi-integral polyurethane comprising composite was surprisingly determined to be a high performance electromagnetic signal shield and a sound isolator for electric cars.

[0018] The solution presented by the invention is provided in particular with carbon black added to said composite. Carbon black has been proven to increase the sound insulation property of polyurethane composite. The carbon black used is especially carbon black belonging to the company ICARBON. The feature of said carbon black that distinguishes the same from other counterparts in the market is that the semi integral polyurethane burrs of the production waste are obtained by the hydrothermal recycling method.

[0019] In order to provide the objects described in the above paragraphs, the invention provides a polyurethane composite for the electric cars. Said composite comprises at least one polyether polyol in the range of 50% to 65% by weight, at least one blowing agent in the range of 4% to 20% by weight, at least one isocyanate in the range of 25% to 30% by weight, and a carbon source in the range of 1 % to 15% by weight which is selected from the group consisting of carbon black, graphene, carbon nanotube, carbon fiber, MXene, and combinations thereof. Polyether polyol is mixed with a certain amount of carbon source. This mixture is mixed in a stirrer capable of reaching high speeds which has a rotor-stator set and a cooler unit. In order to prevent the carbon black in the polyether polyol from accumulating in the mixture and to ensure homogeneity, the rotor stator set should be at high speed and the set should be connected to a cooling unit in order to keep the heated mixture at more stable temperatures due to friction at high speeds.

[0020] A certain amount of blowing agent and surface modifier are added to the homogeneous mixture. No cooling unit is used. If blowing agents are not added to the mixture under room conditions, these components will move away from the mixture due to low evaporation temperatures. Following this process, isocyanate is added to the homogeneous mixture, the mixture is molded to obtain the polyurethane composite presented by the invention.

[0021] In an embodiment of the present invention, a mixture of polyether polyol and carbon source is added to the paste paint diluted 1 :1 with acetone as an alternative to the step of mixing the mixture in a stirrer that can reach high speeds with a rotor-stator set and a cooler unit. The mixture is preferably stirred at 2000rpm for 5 minutes and sprayed into the mold to be injected at a rate of 2-3 bar.

[0022] The carbon source preferably comprises carbon and metal content in its structure. In this way, the conductivity of the polyurethane composite increases and dampens the signal wave on the surface when the material interacts with the electromagnetic wave. As a result, the polyurethane composite gains electromagnetic shielding property. Since the carbon source reduces the diameter sizes of the cells in the polyurethane composite, it provides an improvement in the sound transmission loss coefficient.

[0023] In a preferred embodiment of the present invention, the polyurethane composite comprises at least one polyether polyol 62.5% by weight, at least one blowing agent in the range of 6.2% by weight, at least one isocyanate 28.2% by weight, and a carbon source selected from the group comprising carbon black, graphene, carbon nanotube, carbon fiber, MXene, and combinations thereof 3.1% by weight.

[0024] The carbon source in question is preferably derived from the semi-integral polyurethane waste. The carbon source in question is obtained from the waste semi-integral polyurethane, preferably by the hydrothermal method. The carbon source in question is preferably carbon black. In a preferred embodiment of the present invention, the blowing agents in a polyurethane composite are 3.1% dimethoxymethane by weight and 3.1% pentafluorobutaneheptafluoropropane.

[0025] In another preferred embodiment of the present invention, the polyether polyol is preferably PEG 6000.

[0026] In another embodiment, the isocyanate is preferably 4,4'-diphenylmethane diisocyanate.

[0027] In a preferred embodiment of the invention, 62% polyether polyol is combined with 3.1% recovered carbon black at room conditions. It is mixed with the stirrer with the cap design used for solid-liquid dispersion at 6000 rpm. Since the mixture is exposed to high speed rotation speed for 10 minutes, it tends to heat up and the system must be connected to the cooler unit to lower the sample to room conditions, otherwise when blowing agents and surface modifier added to the mixture, they are likely to evaporate from the mixture as they have low evaporation temperatures. Chemicals (blowing agent and surface modifier) should be mixed at 600rpm for 1 minute such that the structure temperature does not change. After the isocyanate is mixed with the mixture at 1600 rpm for 20 seconds at room temperatures, polyurethane is obtained by casting into the preheated mold.

[0028] As an alternative to stirring for 10 minutes at 6000 rpm, 4% recycled carbon black to be added to the paint paste diluted 1 :1 with acetone is stirred at 2000rpm for 5 minutes and the injection mould can be sprayed at 2-3 bars.

Claims

CLAIMS1. A polyurethane composite for the electric cars, characterized by comprising; at least one polyether polyol in the range of 50% to 65% by weight, at least one blowing agent in the range of 4% to 20% by weight, at least one isocyanate in the range of 25% to 30% by weight, and a carbon source in the range of 1% to 15% by weight which is selected from the group comprising carbon black, graphene, carbon nanotube, carbon fiber, MXene, and combinations thereof.

2. The polyurethane composite according to claim 1, characterized by comprising; at least one polyether polyol 62.5% by weight, at least one blowing agent 6.2% by weight, at least one isocyanate 28.2% by weight and a carbon source of 3.1% by weight which is selected from a group comprising carbon black, graphene, carbon nanotube, carbon fiber, MXene, and combinations thereof.

3. The polyurethane composite according to claim 1 or claim 2, characterized in that; the said carbon source is obtained from semi-integral polyurethane waste.

4. The polyurethane composite according to claim 3, characterized in that; the carbon source is obtained by the hydrothermal method.

5. The polyurethane composite according to any one of the preceding claims, characterized in that; the carbon source is carbon black.

6. The polyurethane composite according to any one of the preceding claims, characterized by comprising; 3.1% dimethoxymethane by weight and 3.1% pentafluorobutane-heptafluoropropane by weight as blowing agents.

7. The polyurethane composite according to any one of the preceding claims, characterized in that; the polyether polyol is PEG 6000.

8. The polyurethane composite according to any one of the preceding claims, characterized in that; the isocyanate is 4,4'-diphenylmethane diisocyanate.

Images