Foamed Thermoplastic Polyurethane Elastomer Binder Coating Process
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Solution Overview
Problem
Existing methods for processing foamed thermoplastic polyurethane elastomers are costly, complex, and inefficient, particularly due to the need for high-cost steam-molding equipment and molds, which results in unstable bonding and limited yield.
Innovation Solution
A method involving coating expanded thermoplastic polyurethane elastomer particles with a binder, followed by curing and molding in a vulcanizing machine, using a universal mould foaming process that adjusts the mixing ratio and curing temperature to bond the particles effectively, eliminating the need for high-pressure steam processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam-molding equipment and molds are used to process foamed thermoplastic polyurethane elastomers, then the particles can be sintered and molded, but the equipment cost becomes high and the process becomes complicated
Solution Approach 1:
The patent replaces the complex steam-molding mechanical system with a simpler vulcanizing machine system. Instead of using steam injection and high-pressure molding equipment, the invention uses a vulcanizing machine to heat-cure binder-coated expanded TPU particles, achieving bonding through thermal curing of the binder rather than mechanical steam molding. This substitution dramatically simplifies the equipment while maintaining bonding reliability.
2Reliability
If steam-molding equipment and molds are used to process foamed thermoplastic polyurethane elastomers, then the particles can be sintered and molded, but the production cost becomes high
Solution Approach 1:
The patent replaces expensive steam-molding equipment with a more economical vulcanizing machine. The vulcanizing machine is a common, cost-effective device that can provide the necessary heating for binder curing without requiring the complex high-pressure steam generation and control systems of steam-molding equipment. This substitution significantly reduces production costs while achieving reliable bonding through the binder curing process.
3Reliability
If steam-molding equipment and molds are used to process foamed thermoplastic polyurethane elastomers, then the particles can be sintered and molded, but the yield becomes low
Solution Approach 1:
The patent replaces the steam-molding process with a vulcanizing machine-based binder curing process that eliminates the need for complex mold designs and high-pressure steam control. This simpler system allows for better process control, more uniform heating, and reduced defects, leading to higher production yields. The binder-coated particle approach also facilitates more consistent bonding across all particles in the molded product.
4Strength
If conventional foaming materials like polyurethane-based foamed plastics are used, then cellular structures provide excellent properties, but isocyanate remains in the material which is harmful to the human body
Solution Approach 1:
The patent uses expanded thermoplastic polyurethane elastomer particles as the base material and coats them with a binder that cures to form strong bonds. This composite structure maintains the excellent cellular properties of the expanded TPU particles while the binder system avoids the use of harmful isocyanates. The binder-cured bonding mechanism provides an alternative to traditional isocyanate-based crosslinking, eliminating the harmful substance while preserving the mechanical strength and cellular structure benefits.
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
This method reduces production costs, simplifies the process, and results in products with superior elasticity, tensile strength, and flex resistance, while avoiding the investment in high-cost steam-molding equipment and molds.
Implementation Method 1
coating a binder: coating the binder on the surfaces of expanded thermoplastic polyurethane elastomer particles
Implementation Method 2
curing and molding: adding the product obtained from step 1) to a mold and then placing it in a vulcanizing machine for curing and molding
Data Source
AI summary
The present invention relates to a method for preparing a foamed thermoplastic polyurethane elastomer product, comprising the steps of: 1) coating a binder: coating the binder on the surfaces of expandable thermoplastic polyurethane elastomer particles; 2) curing and molding: adding the product obtained from step 1) to a mold and then placing it in a vulcanizing machine for curing and molding; and 3) cooling and setting: cooling the mold after the molding in step 2) to obtain the product of the present invention. By means of pre-coating the binder on the surfaces of expanded thermoplastic polyurethane elastomer particles according to the present invention, the weight of the binder can be reduced, and the properties of the expanded thermoplastic polyurethane elastomer particles can be utilized to the maximum extent.