Polyurethane Composite Panel Using Natural Oil Polyols
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing sandwich structural parts using polyurethane (PU) materials are not environmentally friendly, as they rely on petroleum-based components and lack significant incorporation of renewable materials, which limits their sustainability and environmental impact.
Innovation Solution
A method involving the application of natural oil-based polyols and isocyanate components to form a polyurethane-coated sandwich structure, using a core material with fiber layers, where the polyurethane-forming mixture is cured at controlled temperatures to create a lightweight, load-bearing molded article with a high percentage of renewable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If petroleum-based polyurethane components are used for production, then structural strength and load-bearing performance are achieved, but environmental friendliness and renewable material content deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the polyol component by incorporating natural oil-based polyols (soybean oil, castor oil, sunflower oil) alongside conventional polyols. This parameter change allows the formulation to maintain adequate load-bearing performance while improving environmental compatibility and renewable material content to 20-80% of the total polyol component.
Solution Approach 2:
The patent creates a composite polyurethane system combining conventional polyols with natural oil-based polyols in specific ratios. This composite approach allows the material to exhibit both the structural performance characteristics of conventional polyurethanes and the environmental benefits of renewable resources, resolving the contradiction between strength and environmental friendliness.
2Object-affected harmful factors
If high content of natural oil based polyols is used, then environmental friendliness and renewable material content are improved, but structural strength and load-bearing capacity may deteriorate
Solution Approach 1:
The patent optimizes the concentration parameter of natural oil-based polyols within the range of 20-80% of the total polyol component. This parameter optimization ensures that environmental friendliness is improved while structural strength requirements are maintained through careful formulation balancing.
Solution Approach 2:
The patent applies different polyol compositions to different functional requirements within the polyurethane system. The natural oil-based polyols provide environmental benefits and specific mechanical properties, while conventional polyols contribute to structural strength, creating a functionally differentiated composite material that resolves the strength-environmental contradiction.
3Manufacturing precision
If controlled temperature curing is applied, then curing quality and material properties are improved, but energy consumption and production cost increase
Solution Approach 1:
The patent specifies a controlled temperature range of 100-160°C for the curing process. This parameter control ensures optimal curing quality and material properties while managing energy consumption within acceptable limits for industrial production.
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 method results in environmentally friendly polyurethane molded articles with enhanced load-bearing performance and high renewable content, suitable for applications such as automobile load floors, while minimizing environmental impact through the use of natural oil-based polyols and renewable materials.
Implementation Method 1
applying a polyurethane-forming mixture comprising an isocyanate component and a polyol component comprising one or more natural oil based polyol
Implementation Method 2
shaping the polyurethane-forming mixture coated sandwich structure in a mold at a temperature between 100° C. and 160° C. while curing the polyurethane-forming mixture
Data Source
AI summary
The present invention is a method to make an environmentally friendly polyurethane molded article (100) comprising at least 20 percent renewable materials and molded articles made therefrom. Specifically, the method provides for molding a polyurethane coated sandwich structure (40) comprising a honey comb core (30) having fiber reinforcing layers (10, 20) to provide an environmentally friendly polyurethane molded article with a desired shape such as an automobile load floor. The polyurethane coating is derived from a polyurethane—forming mixture comprising an isocyanate component and a polyol component. Specifically, the polyol component comprises one or more natural oil based polyol, preferably comprising at least one of a hydroxymethylated fatty acid or a hydroxymethylated fatty acid (methyl) ester.