Cross-linkable thermoplastic polyurethanes
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Solution Overview
Problem
Thermoplastic polyurethanes face challenges in high temperature stability, durability, creep resistance, and solvent compatibility, particularly in coating applications, which often require solvent-based processes that are environmentally and operationally hazardous.
Innovation Solution
A cross-linkable mixture of thermoplastic polyurethane with radically polymerizable unsaturated groups and ethylenically unsaturated compounds, processed without solvents, which can be cross-linked to form a thermoset material with controlled molecular weight and viscosity, suitable for solvent-free coating applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based processes are used for TPU coating applications, then processability and flexibility are improved, but environmental pollution, operator exposure, fire hazards, and solvent recycling costs increase
Solution Approach 1:
The patent changes the fundamental parameter of the coating system from solvent-based to solvent-free by incorporating radically polymerizable unsaturated groups into the TPU molecular structure. This allows the material to be processed in a melt state without requiring volatile organic solvents, thereby eliminating environmental pollution and safety hazards while maintaining processability through controlled polymerization reactions
Solution Approach 2:
The patent creates a composite material system combining thermoplastic polyurethane with radically polymerizable unsaturated groups and crosslinking agents. This composite approach enables the material to exhibit both the processability of thermoplastics and the durability of thermosets, while the solvent-free formulation eliminates harmful environmental factors
2Ease of manufacture
If thermoplastic polyurethanes are used, then ease of processing is improved, but high temperature stability, durability, and creep resistance deteriorate
Solution Approach 1:
The patent introduces dynamic characteristics to the TPU material by incorporating radically polymerizable unsaturated groups that allow the material to transition from a thermoplastic state during processing to a thermoset state during application. This dynamic transformation enables the material to be easily processed initially and then locked into a stable, durable final state with improved high temperature resistance and creep resistance
Solution Approach 2:
The patent changes the crosslinking state parameter of the polyurethane from uncrosslinked (thermoplastic) to crosslinked (thermoset) through the incorporation of radically polymerizable groups and crosslinking agents. This parameter change fundamentally improves high temperature stability, durability, and creep resistance while maintaining ease of processing through controlled polymerization
3Reliability
If cross-linking is implemented to improve durability, then high temperature stability and creep resistance are improved, but processability and flexibility may deteriorate
Solution Approach 1:
The patent applies preliminary action by incorporating radically polymerizable unsaturated groups into the TPU molecular structure during synthesis, but delaying the actual crosslinking reaction until the coating is applied. This allows the material to be processed in its uncrosslinked, flexible state and then crosslinked in situ to achieve the desired durability without compromising processability
Solution Approach 2:
The patent creates a dynamic system where the TPU can exist in two states: uncrosslinked for easy processing and crosslinked for improved durability. The radically polymerizable groups remain dormant during processing and are activated only when needed, allowing the material to transition dynamically between processable and durable states
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 provides a solvent-free coating process with improved mechanical properties and processing advantages, enabling the production of materials like synthetic leather, adhesives, and coatings with enhanced viscoelastic performance and reduced environmental impact.
Implementation Method 1
a cross-linkable mixture of thermoplastic polyurethanes and radically polymerizable compounds and the conversion thereof into a thermoset material
Data Source
AI summary
The invention provides a cross-linkable mixture of thermoplastic polyurethanes and ethylenic unsaturated compounds and thermoset materials that can obtained therefrom. The invention also provides application of the cross-linkable mixtures and processes in a solvent-less coating process.