Non-blocked Urethane Prepolymer Adhesive for Coated Abrasives

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Solution Overview

Problem

The use of polyurethane adhesives in coated abrasive tools poses safety and environmental concerns due to hazardous blocking agents and curing agents, and non-blocked urethane prepolymers have a short pot life and rapid viscosity increase, making them unsuitable for stable coating processes.

Innovation Solution

A polyurethane adhesive composition combining a non-blocked urethane prepolymer with a polymeric polyol, such as a phenoxy resin, is used to create a stable viscosity and extended pot life, eliminating the need for hazardous blocking agents and special tooling, and allowing for improved bonding without additional hazardous curing agents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If blocked urethane prepolymers are used, then stable viscosity during coating process is achieved, but hazardous blocking agents and special tooling are required

Engineering Contradiction:

Improveviscosity stabilityVSAvoidhazardous blocking agents

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent removes the blocking group from the urethane prepolymer structure, extracting the hazardous component while maintaining the desired viscosity stability through alternative means (using non-blocked prepolymers with controlled molecular weight and structure).

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the potential harm of rapid reaction (which would be a problem with non-blocked prepolymers) into a benefit by using non-blocked prepolymers with optimized structure that provide sufficient reaction time while maintaining stability, eliminating the need for hazardous blocking agents entirely.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If non-blocked urethane prepolymers are used, then hazardous blocking agents are eliminated, but pot life is shortened and viscosity increases rapidly

Engineering Contradiction:

Improveelimination of hazardous blocking agentsVSAvoidpot life

Core Design Contradiction:

Object-affected harmful factorsVSDuration of action of moving object

Solution Approach 1:

The patent changes the molecular weight, structure, and composition parameters of the non-blocked urethane prepolymer to optimize its reaction characteristics, extending pot life while maintaining the benefits of eliminating blocking agents.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite adhesive system combining non-blocked urethane prepolymer with specific curing agents and additives that work together to extend pot life and maintain viscosity stability without requiring hazardous blocking groups.

Inventive Principle:

Principle #40Composite materials

3Strength

If conventional polyurethane adhesives are used, then bonding is achieved, but safety and environmental concerns arise from hazardous curing agents

Engineering Contradiction:

Improvebonding strengthVSAvoidhazardous curing agents

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces expensive and hazardous curing agents with safer, more environmentally friendly alternatives that achieve the same bonding function without the harmful side effects, making the process safer and more sustainable.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 approach results in coated abrasive tools with superior performance in cut rates and G-ratios, reducing safety and environmental concerns while simplifying manufacturing processes and improving product performance.

Implementation Method 1

a polyurethane adhesive composition that includes a non-blocked urethane prepolymer and a polymeric polyol, such as a phenoxy resin, as a curing agent

Methodology Applied

Scientific EffectPolymerization reaction: Photopolymerisation

Implementation Method 2

heating the polyurethane-adhesive-composition-coated substrate to thereby form a polyurethane-adhesive-coated substrate

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS7811342B1Coated abrasive tools from non-blocked urethane prepolymer

Publication Date: 2010.10.12 SAINT GOBAIN ABRASIFS SA

AI summary

A polyurethane adhesive composition, formed by combining a non-blocked urethane prepolymer and a polymeric polyol, is used for preparing a coated abrasive tool. The polyurethane adhesive composition is applied over a substrate to thereby form a polyurethane-adhesive-composition-coated substrate. Curing the polyurethane-adhesive-composition-coated substrate forms a polyurethane-adhesive-coated substrate. An abrasive material is applied over the substrate at a time selected from the group consisting of prior to, after, and simultaneously with, the application of the polyurethane adhesive composition to the substrate, to thereby form the coated abrasive tool. The coated abrasive tool preferably includes a polyurethane adhesive resin coating over the substrate, the resin coating being formed from a polymerization reaction of a non-blocked urethane prepolymer and a phenoxy resin.