Elastomer-Polyurethane Layered Component Impact Resistance
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Solution Overview
Problem
Existing components with layer structures, such as those used in the coal and steel industry, suffer from limited resistance to impact and abrasion, often resulting in shattering or permanent deformation due to their brittle nature.
Innovation Solution
A component composed of a layer structure featuring an elastomer layer with a density greater than 800 g/L and a thermoset layer comprising at least 50% by weight of polyurethane, which provides enhanced impact resistance, elastic deformability, and heat resistance, along with a foamed or compact thermoset layer to manage weight and dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a glassfiber-reinforced polymer layer and polyurethane layer are used, then the component provides structural support and wear resistance, but the layers are brittle and can fracture on exposure to impact
Solution Approach 1:
The patent applies composite materials by combining an elastomer layer with a thermoset layer comprising polyurethane. This composite structure resolves the contradiction by integrating materials with complementary properties: the elastomer provides impact resistance and flexibility, while the thermoset layer provides structural support and wear resistance. The combination creates a component that simultaneously achieves both wear resistance and impact resistance without the brittleness problems of conventional glassfiber-reinforced polymers.
Solution Approach 2:
The patent changes the material parameters by specifying that the elastomer layer has a density greater than 800 g/L, which is higher than conventional elastomers. This parameter change enhances the elastomer's ability to provide impact resistance while maintaining structural integrity. Additionally, the thermoset layer is specified to comprise at least 50% by weight of polyurethane, optimizing the balance between flexibility and rigidity to prevent fracture under impact while maintaining wear resistance.
2Stability of the object's composition
If a thermoplastic sheet and polyurethane reinforcing layers are used, then the component provides structural integrity, but it has limited resistance to stress due to impact and abrasion and tends to shatter
Solution Approach 1:
The patent replaces the thermoplastic sheet with a composite structure consisting of an elastomer layer and a thermoset layer. The elastomer layer specifically addresses the abrasion resistance problem while the thermoset layer maintains structural integrity. This composite approach eliminates the shattering tendency of thermoplastics under impact stress while preserving the necessary structural stability through the thermoset component.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different layers: the elastomer layer is optimized for impact absorption and abrasion resistance, while the thermoset layer is optimized for structural integrity and dimensional stability. This division of functions allows each layer to excel at its specific task, resolving the contradiction between structural integrity and resistance to impact/abrasion.
3Weight of moving object
If a foamed thermoset layer is used, then the component achieves weight reduction, but the density and dimensional stability may be compromised
Solution Approach 1:
The patent uses a composite structure where the foamed thermoset layer is combined with an elastomer layer. The foamed thermoset provides weight reduction through its cellular structure, while the elastomer layer compensates for any potential compromises in dimensional stability. The high-density elastomer (density > 800 g/L) provides a stable outer layer that maintains the component's dimensional integrity while allowing the inner thermoset layer to be lightweight and foamed.
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 layer structure achieves high impact resistance, puncture resistance, and resistance to shattering over a wide temperature range, while maintaining dimensional stability at high temperatures, and allows for weight reduction and precise replication of geometries.
Implementation Method 1
Another advantage of the elastomer layer is elastic deformability thereof over a wide temperature range, specifically at low temperatures
Implementation Method 2
Because of the thermoset used, the structure remains dimensionally stable even at high temperatures of up to 150° C
Data Source
AI summary
The invention relates to a component having at least to some extent a layer structure, wherein the layer structure includes an elastomer layer with a density greater than 800 g/L, and a thermoset layer including at least 50% by weight of a first polyurethane. The invention further relates to a process for the production of a component of this type, the process including (i) provision of a female mold into which the individual layers of the layer structure are introduced, or of a male mold to which the individual layers of the layer structure are applied; (ii) production of the elastomer layer via spraying; (iii) production of the thermoset layer via spraying; and (iv) demolding of the resultant component. Step (ii) can be carried out before step (iii) or step (iii) can be carried out before step (ii).