Polyurethane Composite Material with Extended Gel Time

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Solution Overview

Problem

Traditional polyurethane composite materials have a short gel time or pot life, making them demanding to process, and they often exhibit insufficient mechanical properties and strength, limiting their application in fiber-reinforced high molecular composite materials.

Innovation Solution

A polyurethane composite material is developed with a polyurethane resin matrix prepared through simultaneous addition polymerization of isocyanate groups and hydroxyl groups, and radical polymerization, using a composition comprising an isocyanate component, an isocyanate-reactive component with specific organic polyols, and a radical reaction initiator, processed via methods like compression molding or vacuum infusion to extend gel time and enhance mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional polyurethane system is used, then the material has good basic properties, but the gel time is short making it demanding on application process

Engineering Contradiction:

ImproveprocessabilityVSAvoidgel time

Core Design Contradiction:

Ease of operationVSDuration of action of moving object

Solution Approach 1:

The patent changes the chemical composition parameters by introducing a hybrid system combining polyisocyanate, polyol, and ethylenically unsaturated monomer. This compositional parameter change extends the gel time from traditional short durations to a more workable range, directly improving processability without sacrificing the reactive curing mechanism

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite chemical system integrating three distinct components: polyisocyanate (A), polyol (B), and ethylenically unsaturated monomer (C). This composite material approach allows the system to exhibit extended pot life and gel time while maintaining curing capability, resolving the contradiction between workability and reaction speed

Inventive Principle:

Principle #40Composite materials

2Strength

If traditional polyurethane system is used, then the material is easy to process, but the mechanical properties and strength are insufficient

Engineering Contradiction:

Improvemechanical propertiesVSAvoidprocessability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent merges two different polymerization mechanisms: polyurethane addition polymerization (between isocyanate and hydroxyl groups) and radical polymerization (of ethylenically unsaturated monomers). This merging of reaction pathways creates a dual-crosslinked network that simultaneously enhances mechanical strength and maintains extended gel time, resolving the contradiction between strength and processability

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If process conditions are optimized for mechanical properties, then strength improves, but gel time becomes too short for practical application

Engineering Contradiction:

Improvemechanical propertiesVSAvoidgel time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The hybrid system enables continuous useful action by maintaining an extended gel time window that allows sufficient time for fiber reinforcement incorporation and processing operations. The dual-polymerization mechanism ensures that both polymerization processes proceed concurrently, continuously building network structure and mechanical properties throughout the extended processing window

Inventive Principle:

Principle #20Continuity of useful action

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 process results in a polyurethane composite material with improved processability and mechanical properties, including extended gel time, increased tensile strength, and thermal deformation temperature, suitable for various applications such as wind generator blades and automobile parts.

Implementation Method 1

the polyurethane composition undergoes addition polymerization reaction of isocyanate groups and hydroxyl groups

Methodology Applied

Scientific EffectAddition polymerization: Chemical Bonding

Implementation Method 2

radical polymerization reaction

Methodology Applied

Scientific EffectRadical polymerization: Photopolymerisation

Data Source

PatentEP3129422B1Polyurethane composite material and process of preparing same

Publication Date: 2021.03.17 COVESTRO INTELLECTUAL PROPERTY GMBH & CO KG

AI summary

The present invention relates to a polyurethane composite material, comprising a polyurethane resin matrix prepared from a polyurethane composition, and a reinforcement material, wherein the polyurethane composition comprises: A) an isocyanate component comprising one or more organic polyisocyanates; B) an isocyanate-reactive component comprising: bl) one or more organic polyols having an amount of 21-60 wt.% based on 100 % by weight of the polyurethane composition; b2) one or more (meth)acrylates comprising hydroxyl groups; and C) a radical reaction initiator; wherein the polyurethane resin matrix is prepared under such reaction conditions that the polyurethane composition undergoes addition polymerization reaction of isocyanate groups and hydroxyl groups and radical polymerization reaction simultaneously. The present invention further relates to the preparation process of the polyurethane composite material.