Two-Component Polyurethane Adhesive for Bonding Dissimilar Materials

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Solution Overview

Problem

There is a need for a structural adhesive with improved adhesion and functionality in the 2K polyurethane and thermoset polyurethane industry, as existing adhesives do not adequately meet the requirements for bonding diverse materials with varying thermal expansion coefficients and providing enhanced mechanical resistance, stiffness, and surface finish.

Innovation Solution

A two-component polyurethane composition comprising a prepolymer component with isocyanate-terminated intermediate compounds and a curative component with polyol-terminated intermediate compounds, optionally including liquid rubber, catalysts, polyols, amine compounds, and chain extenders, which react to form a strong adhesive bond.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional structural adhesives are used for bonding diverse materials, then bonding capability is achieved, but adhesion strength and mechanical resistance are insufficient

Engineering Contradiction:

Improveadhesion strengthVSAvoidbonding performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs a two-component polyurethane adhesive system combining isocyanate-terminated prepolymer and polyol-terminated intermediate compounds, creating a composite chemical structure that achieves superior adhesion strength and mechanical resistance through synergistic interaction between components

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters by incorporating specific ratios of isocyanate compounds, polyol compounds, and active hydrogen containing compounds, along with controlling molecular weight and functional group concentrations to optimize adhesion strength and bonding reliability

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If structural adhesives are used to bond materials with different thermal expansion coefficients, then joining capability is achieved, but stress concentrations occur

Engineering Contradiction:

Improvebonding capabilityVSAvoidstress concentrations

Core Design Contradiction:

Adaptability or versatilityVSStress or pressure

Solution Approach 1:

The patent adjusts the polyurethane adhesive's molecular structure parameters and composition to achieve optimal flexibility and elasticity, enabling the bond to accommodate thermal expansion differences between materials while distributing stresses uniformly across the bond area

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The polyurethane adhesive acts as an intermediary material between dissimilar substrates, providing a compliant bonding layer that absorbs thermal stress through its viscoelastic properties and prevents stress concentration at the interface

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If mechanical fastening techniques are used for joining, then structural connection is achieved, but weight increases and design flexibility decreases

Engineering Contradiction:

Improvestructural connectionVSAvoidoverall weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces mechanical fastening systems (screws, rivets, welds) with a chemical bonding system using two-component polyurethane adhesive, eliminating the need for physical connectors and thereby reducing overall weight while maintaining or improving structural strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The polyurethane adhesive provides multiple functions simultaneously: structural bonding, stress distribution, flexibility accommodation, and design freedom, replacing multiple separate mechanical components with a single multifunctional bonding material

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 two-component polyurethane composition exhibits improved adhesion and functionality, enabling the bonding of diverse materials with enhanced mechanical resistance, stiffness, and surface finish, while distributing loads uniformly and reducing stress concentrations.

Implementation Method 1

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Implementation Method 2

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Data Source

PatentUS20240052090A1A two-component polyurethane composition, process for preparing the same and a method of use thereof

Publication Date: 2024.02.15 ARKEMA FRANCE SA

AI summary

This present disclosure relates to a two-component polyurethane composition comprising: (A) a prepolymer component comprising: (i) at least one isocyanate terminated intermediate compound prepared from a reaction mixture comprising at least one isocyanate compound and at least one active hydrogen containing compound selected from the group consisting of a polyol compound, a polyamine compound and a combination thereof, (ii) at least one isocyanate compound, and (iii) optionally at least one liquid rubber; and (B) a curative component comprising: (i) at least one polyol terminated intermediate compound prepared from a reaction mixture comprising at least one isocyanate compound and at least one active hydrogen containing compound selected from the group consisting of a polyol compound, a polyamine compound and a combination thereof, (ii) at least one liquid rubber, (iii) at least one catalyst, (iv) at least one polyol, (v) optionally at least one amine compound, and (vi) optionally a chain extender.