Polyurethane Hybrid Material Adhesion and Recyclability

Solution Overview

Problem

Existing hybrid materials comprising polyurethane and foamed particles suffer from poor adhesion between the matrix and foamed particles, limited mechanical properties, and restricted recycling capabilities, particularly when using high glass transition temperature materials like polystyrene, which affects their elasticity and utility in applications requiring elastic responses.

Innovation Solution

A hybrid material is developed comprising a polyurethane matrix with foamed thermoplastic polyurethane particles, where the matrix can fully or partially surround the foamed particles, using a specific formulation of polyisocyanates, polyols, and blowing agents to enhance adhesion and mechanical properties, and incorporating chain extenders and catalysts to optimize the reaction conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If foamed particles are introduced into polyurethane matrix to reduce density and cost, then material density and cost are improved, but adhesion between matrix and foamed particles deteriorates

Engineering Contradiction:
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent changes the chemical composition parameters of both the matrix and foamed particles by using polyurethane for both components, allowing control of molecular weight, functionality, and crosslinking density to optimize adhesion while maintaining low density

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses the same base material (polyurethane) for both the matrix and foamed particles, creating a homogeneous material system that ensures compatible chemical properties and strong interfacial adhesion between different phases

Inventive Principle:
Principle #33Homogeneity

2Strength

If high glass transition temperature materials like polystyrene are used as foamed particles, then material strength is improved, but elasticity below glass transition temperature deteriorates

Engineering Contradiction:
Core Design Contradiction:
StrengthVSAdaptability or versatility

Solution Approach 1:

The patent changes the glass transition temperature parameter by selecting polyurethane with appropriate soft segment composition and molecular weight, achieving a balance between strength and elasticity that suits the application requirements

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure where polyurethane foamed particles are embedded in a polyurethane matrix, combining the cellular structure for strength with the elastomeric properties of polyurethane for elasticity

Inventive Principle:
Principle #40Composite materials

3Adaptability or versatility

If different types of materials are combined in hybrid materials, then property profile is improved, but recyclability deteriorates

Engineering Contradiction:
Core Design Contradiction:
Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent uses polyurethane as the common base material for both matrix and foamed particles, creating a homogeneous material system that can be easily separated and recycled as a single material type while still providing enhanced properties through the hybrid structure

Inventive Principle:
Principle #33Homogeneity

4Quantity of substance

If conventional hybrid materials are used, then cost is reduced, but mechanical properties deteriorate

Engineering Contradiction:
Core Design Contradiction:
Quantity of substanceVSStrength

Solution Approach 1:

The patent creates a composite material system where polyurethane foamed particles provide structural support and the polyurethane matrix provides continuity and load transfer, achieving superior mechanical properties compared to conventional hybrids while maintaining cost effectiveness through material optimization

Inventive Principle:
Principle #40Composite materials

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 hybrid material exhibits improved adhesion and mechanical properties, such as increased elasticity and ultimate tensile strength, and allows for better recycling, making it suitable for applications like shoe soles, upholstery, and floor coverings without the drawbacks of conventional materials.

Implementation Method 1

polyisocyanate polyaddition products

Methodology Applied
Scientific EffectPolyaddition: Chemical Bonding

Implementation Method 2

foamed particles of thermoplastic polyurethane

Methodology Applied
Scientific EffectFoaming: Foam

Data Source

PatentUS10501596B2Hybrid systems consisting of foamed thermoplastic elastomers and polyurethanes
Publication Date: 2019.12.10

AI summary

The present invention relates to a hybrid material comprising a matrix of polyurethane and foamed particles of thermoplastic polyurethane comprised therein and also a process for producing such hybrid materials and the use of these hybrid materials as bicycle saddles, upholstery and shoe soles.