Polyurea Composite Layering for Seamless Interlayer Bond Strength
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Solution Overview
Problem
Existing polyurea composite structures exhibit weak bonds between layers, prone to breaking under force impact, shear, and pull of adhesion.
Innovation Solution
A method involving the application of a polyurethane elastomer layer followed by an elastomer foam layer using high-pressure, high-temperature plural component spray systems, with specified temperature and pressure ranges, to form a seamless bond between the layers, enhanced by additional polyurethane elastomer layers if desired, utilizing reactions of polyisocyanates, amines, and polyols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional plural component spray systems are used to apply polyurea coatings on a mold, then the composite structure can be manufactured, but the bond between different coatings is weak and prone to breaking under force impact, shear, and pull of adhesion
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of components within 70-200°F and spray pressure within 1,000-3,000 psi ranges. These optimized parameters ensure proper material flow, mixing, and bonding characteristics that create strong interlayer bonds while preventing defects that would weaken the composite structure.
Solution Approach 2:
The patent creates a composite material system by sequentially applying different polyurea/polyurethane coatings with specific properties onto the mold. Each layer is formulated with particular rheological and adhesive characteristics that, when bonded under controlled conditions, create a multi-layer composite with superior overall strength and reliability compared to single-layer structures.
2Strength
If high-pressure, high-temperature spray systems are used to apply polyurethane elastomer and elastomer foam layers, then a seamless bond is achieved between layers, but the process complexity and equipment requirements increase
Solution Approach 1:
The patent merges the application of multiple components (polyurethane elastomer and elastomer foam) into a single integrated spray process. By combining the coating application steps and using a unified spray system with controlled temperature and pressure parameters, the method achieves seamless bonding while avoiding the need for separate, complex processing equipment for each layer.
Solution Approach 2:
The patent optimizes spray system parameters (temperature: 70-200°F, pressure: 1,000-3,000 psi) to achieve the desired bonding quality. By establishing specific parameter ranges, the complex spray process becomes controllable and repeatable, reducing the need for overly complex equipment while maintaining high bond strength.
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 resulting composite structure achieves a strong, inseparable bond resistant to various forces, suitable for diverse applications including sinks, bathtubs, boats, automobiles, and industrial structures.
Implementation Method 1
utilizing reactions of polyisocyanates, amines, and polyols
Implementation Method 2
spraying a first set of components with a first spray system... spraying a second set of components with a second spray system... temperature of the first set of components can each individually range from 70 degrees Fahrenheit to 200 degrees Fahrenheit... spray pressure ranging from 1,000 psi to 3,000 psi
Data Source
AI summary
Methods for producing molded composite products are disclosed whereby a polyurethane elastomer layer can be applied to a mold, followed by the application of a elastomer foam layer upon that polyurethane layer. If desired, a second polyurethane elastomer layer can be applied upon the exposed elastomer foam layer. After application and curing of all layers, the composite structure may be removed from the mold. The resulting structure may have a seamless bond between the elastomer foam layer and any polyurethane elastomer layers, which could be strong enough to remain inseparable by forces like impact, shear, and pull off adhesion.