Continuous Polyurethane Composite Production Using Matrix Heat Control
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Solution Overview
Problem
Current methods for producing multilayer composite bodies, such as coated leather or textiles, are discontinuous and labor-intensive, making them expensive to produce.
Innovation Solution
A continuous process involving a polyurethane layer produced with a matrix at 80-170°C, fixed onto a carrier material using a transforming connecting layer, utilizing a heat carrier with a heat capacity of 100-20,000 J/K·m², and an endless belt design for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If discontinuous production methods are used to produce multilayer composite bodies, then manufacturing precision and quality can be maintained, but productivity is low and production cost is high
Solution Approach 1:
The patent implements a continuous production process where the endless belt continuously transports the carrier material through all processing stages (coating, drying, curing) without interruption. This eliminates the discontinuous batch processing of conventional methods, enabling continuous production of multilayer composite bodies with improved productivity and reduced manual intervention.
Solution Approach 2:
The patent replaces manual operations with automated mechanical systems. The endless belt automatically transports the carrier material, applies the polyurethane composition, and controls the drying and curing processes. This substitution of manual labor with automated mechanical systems resolves the contradiction between productivity and ease of manufacture.
2Ease of manufacture
If conventional production methods are used, then process simplicity can be maintained, but production cost increases due to labor intensity
Solution Approach 1:
The patent combines multiple discrete production steps into a single integrated continuous process. The application of polyurethane composition, drying, and curing are merged into one continuous operation on the endless belt, maintaining process simplicity while dramatically increasing production volume compared to separate batch operations.
3Manufacturing precision
If a matrix with sufficient heat capacity is used to produce polyurethane layer, then manufacturing precision of the layer can be improved, but use of energy increases
Solution Approach 1:
The patent optimizes the heat capacity parameter of the matrix to achieve the minimum necessary value for producing high-quality polyurethane layers. By carefully selecting and adjusting the heat capacity parameter, the process achieves manufacturing precision while minimizing energy consumption, resolving the contradiction between quality and energy use.
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
Enables the cost-effective production of breathable or non-breathable multilayer composite bodies with improved mechanical properties, breathability, and a pleasant feel, suitable for various applications.
Implementation Method 1
a heat carrier with a heat capacity in the range of 100 to 20,000 J/K·m² has and wherein the matrix is designed as an endless belt
Data Source
AI summary
Method for continuously producing multi-layered composite bodies, comprising (A) at least one support material, (B) at least one connection layer and (C) at least one polyurethane layer comprising capillaries passing through the entire thickness of the polyurethane layer, characterized in that the polyurethane layer (C) is produced using a matrix and that the polyurethane layer (C) is fixed to the support material (A) using a material that converts to a connection layer (B), wherein the matrix has a temperature in the range of 80 to 170°C and a heat capacity in the range of 100 to 20,000 J/K·m2.