Composite component containing a polychloroprene and/or polyurethane binder
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Solution Overview
Problem
Existing lightweight composite components, particularly used in cushioning elements, lack point elasticity and have poor drapability, requiring additional comfort inserts and longer shaping times, while also emitting high levels of volatile organic compounds (VOCs).
Innovation Solution
A process for producing composite components involves applying an aqueous composition containing a polychloroprene dispersion and/or polyurethane dispersion to a nonwoven web, followed by coagulation and shaping, with the inclusion of a thickener in the aqueous composition to enhance bonding and vacuum compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset binder is used in composite components, then bonding strength is improved, but shaping time increases and drapability worsens
Solution Approach 1:
The patent changes the chemical composition parameters of the binder from thermoset to a specific thermoplastic polymer (polyester polyol with isocyanate groups) that exhibits both strong bonding capability and rapid shaping characteristics. This parameter change allows the binder to maintain high bonding strength while enabling short shaping times below 10 seconds.
Solution Approach 2:
The invention creates a composite binder system combining polyester polyol and isocyanate compounds that react to form a crosslinked network. This composite material approach provides both the bonding strength traditionally associated with thermosets and the rapid processing capabilities needed for short shaping cycles.
2Ease of operation
If additional comfort insert is added to improve comfort, then comfort is improved, but device complexity increases
Solution Approach 1:
The binder system is designed to perform multiple functions simultaneously: it provides structural bonding, creates point elasticity for comfort, and enables rapid shaping. This multi-functionality eliminates the need for separate comfort inserts, reducing structural complexity while maintaining comfort properties.
Solution Approach 2:
By adjusting the molecular weight and composition parameters of the polyester polyol and isocyanate ratio, the binder achieves optimal balance between bonding strength and point elasticity, providing comfort directly within the composite structure without additional layers.
3Ease of manufacture
If standard fiber material is used, then material availability is improved, but drapability worsens
Solution Approach 1:
The patent modifies the fiber material parameters by using specific polyester fibers with controlled orientation and surface properties that enhance drapability. The fiber arrangement parameters are optimized to work synergistically with the new binder system, improving flow and drape characteristics while maintaining material availability.
4Strength
If thermoset binder is used, then bonding strength is improved, but VOC emissions increase
Solution Approach 1:
The invention changes the chemical parameters of the binder system from conventional thermoset resins to a water-based or high-solids polyester polyol/isocyanate system. This parameter change significantly reduces VOC emissions while maintaining bonding strength through the crosslinked network structure formed by isocyanate reactions.
Solution Approach 2:
The patent incorporates catalysts and promotes oxidative curing mechanisms that enable rapid crosslinking at lower temperatures, reducing the need for high-VOC traditional thermoset systems while achieving equivalent or superior bonding strength with lower environmental impact.
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 composite components can be efficiently bonded, remain vacuum-compatible, and can be shaped quickly, eliminating the need for additional comfort inserts and reducing VOC emissions, while allowing for further lamination and welding operations.
Implementation Method 1
coagulating the aqueous composition on the nonwoven web by contacting with a coagulant and/or heating to 80 to 220° C. in order to form a semifinished product comprising a binder formed from the aqueous composition
Implementation Method 2
the aqueous composition comprises at least one thickener
Implementation Method 3
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
Data Source
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.