Composite component comprising a polychloroprene and/or polyurethane binder

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Solution Overview

Problem

Existing lightweight composite components, particularly those used in cushioning elements, are not point elastic and have poor draping properties, requiring additional comfort inserts and long pressing times, and they emit volatile organic compounds (VOCs).

Innovation Solution

A method involving the application of an aqueous composition containing a polychloroprene or polyurethane dispersion to a nonwoven, followed by coagulation with a coagulant and/or heating to form a semifinished product, which is then deformed using pressing and/or heating, with the inclusion of a thickener in the composition to enhance properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If natural rubber is used as binder, then processing safety and adhesion are improved, but service temperature range is limited to below 80°C

Engineering Contradiction:

Improveprocessing safety and adhesionVSAvoidservice temperature range

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent employs composite binder systems combining synthetic rubber (e.g., polychloroprene, polyurethane) with natural rubber or uses synthetic rubber alone to achieve both high-temperature resistance and adequate adhesion. This composite approach allows the binder to maintain processing safety and bonding performance while extending service temperature capability above 80°C.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention modifies binder chemical composition by selecting synthetic rubber types (polychloroprene, polyurethane, styrene-butadiene) with specific molecular structures and crosslinking characteristics. These parameter changes in material composition enable the binder to withstand temperatures exceeding 80°C while maintaining adequate adhesion and processing safety.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If synthetic rubber is used as binder, then service temperature range above 80°C is achieved, but adhesion and processing safety deteriorate

Engineering Contradiction:

Improveservice temperature rangeVSAvoidadhesion and processing safety

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent combines synthetic rubber with natural rubber or uses optimized synthetic rubber formulations to achieve both high-temperature resistance and adequate adhesion. This composite approach allows the binder to maintain processing safety and bonding performance while extending service temperature capability above 80°C.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If polysulfide rubber cement is used, then bonding of dissimilar substrates is improved, but toxic fumes are generated during curing

Engineering Contradiction:

Improvebonding of dissimilar substratesVSAvoidtoxic fumes during curing

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces polysulfide rubber cement with synthetic rubber alternatives (polychloroprene, polyurethane, styrene-butadiene) that eliminate toxic fume generation during curing. These alternative materials achieve comparable or superior bonding performance on dissimilar substrates without the harmful byproducts, converting a harmful curing process into a safe one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention adopts synthetic rubber binders that provide adequate bonding performance for dissimilar substrates without the toxic curing issues of polysulfide. These materials offer a practical, safe alternative that eliminates the need for special ventilation or safety precautions during application and curing.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Quantity of substance

If bitumen is used as binder, then cost is reduced, but service temperature is limited to below 60°C

Engineering Contradiction:

ImprovecostVSAvoidservice temperature

Core Design Contradiction:

Quantity of substanceVSTemperature

Solution Approach 1:

The patent changes the material composition from bitumen to synthetic rubber (polychloroprene, polyurethane, styrene-butadiene) or rubber blends. This parameter change in chemical composition fundamentally raises the service temperature capability from below 60°C to above 80°C while maintaining cost-effectiveness through efficient material usage and processing.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention may use composite binder systems combining synthetic rubber with other materials to achieve both cost-effectiveness and high-temperature resistance. This composite approach allows optimization of performance-to-cost ratio while extending service temperature capability well above 60°C.

Inventive Principle:

Principle #40Composite materials

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 method allows for the production of composite components that can be shaped quickly, without additional comfort inserts, are vacuum-capable, and have reduced VOC emissions, enabling further lamination, welding, and other processing methods.

Implementation Method 1

coagulating the aqueous composition on the web by contacting it with a coagulant and/or heating to 80 to 220°C to form a semifinished product comprising a binder formed from the aqueous composition

Methodology Applied

Scientific EffectCoagulation: Coagulation

Implementation Method 2

deforming the semi-finished product from step ii) or iii) by pressing and/or heating to 30 to 220 C° in order to obtain the composite component

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentEP3874081B1Composite component comprising a polychloroprene and/or polyurethane binder

Publication Date: 2023.02.08 COVESTRO INTELLECTUAL PROPERTY GMBH & CO KG

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AI summary

The invention relates to a method for producing a composite component, comprising the steps: i) applying an aqueous composition, which contains a polychloroprene dispersion and/or a polyurethane dispersion, to at least one nonwoven; ii) coagulating the aqueous composition on the nonwoven by bringing the aqueous composition into contact with a coagulant and/or heating to 80 to 220 °C, in order to form a semifinished product; and iii) optionally attaching a decoration, which comprises an adhesive film; and iv) thereafter, shaping the semifinished product from step ii) or iii) by pressing and/or heating to 30 to 220 °C, in order to obtain the composite component, characterized in that the aqueous composition contains at least one thickener. The invention further relates to the use of the composite component of the invention as part of an interior trim, of a sun visor, of a support part, of a 2- or 3-dimensional sound-proofing panel, of a 3D-printed component, of a padding material, of a collision protection means, of a seat shell and of an impact isolation means.