Polyurethane Physical Properties via 100% Solids Acrylics
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Solution Overview
Problem
Polyurethanes formed with low molecular weight hydroxyl-functional polyethers have limited physical properties such as Shore hardness, tear strength, and tensile strength, and those formed with hydroxyl-functional acrylics often retain residual solvent smell due to batch solvent processes, posing environmental and safety concerns.
Innovation Solution
Incorporating 100% solids hydroxyl-functional acrylics with hydroxyl-functional polyethers and a 100% solids isocyanate component to form polyurethanes, eliminating solvents and improving physical properties like Shore hardness, tear strength, and tensile strength, while ensuring the absence of residual solvent smell through a solid grade oligomer process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hydroxyl-functional acrylics are used to improve physical properties of polyurethanes, then Shore hardness, tear strength and tensile strength are improved, but residual solvent smell remains due to batch solvent process
Solution Approach 1:
The patent changes the physical state parameter of the hydroxyl-functional acrylic from solution form to solid oligomer form (100% solids). This parameter change eliminates the solvent component entirely, removing the source of residual solvent smell while preserving the acrylic's ability to improve physical properties when incorporated into the polyurethane system.
Solution Approach 2:
The patent extracts and removes the solvent component from the hydroxyl-functional acrylic system, using only the solid oligomer portion. This extraction eliminates the harmful residual solvent smell while retaining the beneficial physical property enhancements that the acrylic oligomer provides to the polyurethane.
2Force
If hydroxyl-functional polyethers with low molecular weight are used, then solution viscosity is reduced, but Shore hardness and tensile strength are limited
Solution Approach 1:
The patent creates a composite isocyanate-reactive component by combining hydroxyl-functional polyether oligomers with hydroxyl-functional acrylic oligomers. This composite material synergistically combines the low viscosity advantage of the polyether with the physical property enhancement (Shore hardness, tensile strength) provided by the acrylic, overcoming the limitations of using either component alone.
Solution Approach 2:
The patent merges two different oligomer types (polyether and acrylic) into a single isocyanate-reactive component mixture. This combination allows the components to work together, where the acrylic oligomer compensates for the limited Shore hardness and tensile strength of the low molecular weight polyether, while the polyether maintains the low viscosity necessary for application.
3Object-affected harmful factors
If 100% solids formulation is used, then environmental safety is improved by eliminating solvents, but manufacturing complexity increases
Solution Approach 1:
The patent employs commercially available solid oligomer building blocks (polyether diols and acrylic oligomers) that are designed for direct use in 100% solids formulations. These pre-formed oligomers eliminate the need for complex in-process polymerization and solvent removal steps, making the 100% solids approach manufacturable without excessive complexity while maintaining environmental safety.
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 combination of 100% solids hydroxyl-functional acrylics and polyethers enhances the physical properties of polyurethanes, eliminating solvent-related issues and environmental concerns, resulting in improved Shore hardness, tear strength, and tensile strength without residual solvent smell.
Implementation Method 1
the reaction of the isocyanate-functional groups with the hydroxyl-functional groups thereafter forms the polyurethane composition
Data Source
AI summary
100% solids polyurethanes having improved physical properties in terms of Shore hardness, tear strength, elongation at break and/or tensile strength are realized through the introduction of 100% solids hydroxyl-functional acrylics in combination with the hydroxyl-functional polyether and 100% solids isocyanate-functional compounds. When an aromatic isocyanate is used, the isocyanate-reactive component includes from 5 to 70% by weight of a hydroxyl-functional polyether having a weight average molecular weight ranging from 180 to 6,500 g/mol, and 30 to 95% by weight of a hydroxyl-functional acrylic. When an aliphatic isocyanate is used, the isocyanate-reactive component includes from 40 to 70% by weight of a hydroxyl-functional polyether having a weight average molecular weight ranging from 180 to 6,500 g/mol, and 30 to 60% by weight of a hydroxyl-functional acrylic.