Method for producing a polyurethane layer
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Solution Overview
Problem
The use of PVC in entrance mats is hindered by environmental concerns due to chlorinated compounds and plasticizers, which are harmful and can migrate, reducing mechanical properties and causing staining, while alternatives face cost and performance issues.
Innovation Solution
A method for producing polyurethane-based entrance mats using a mixture of a filler, polyisocyanate, polyol, and catalyst, with a crosslinker, to create a reactive polyurethane gel that is then cured into a film, allowing for high production rates and mechanical stability without premature curing, using existing infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If PVC is used in entrance mats, then cost efficiency and ease of manufacture are improved, but environmental harm and mechanical property degradation occur due to plasticizer migration
Solution Approach 1:
The patent changes the chemical composition parameters by replacing PVC with polyurethane-based reactive gels that cure to form crosslinked networks, eliminating plasticizers and their associated environmental harm while maintaining manufacturability through adapted dosing and mixing techniques
Solution Approach 2:
The patent uses composite materials by combining polyisocyanate, polyol, filler, and catalyst to create a reactive polyurethane gel system that provides both structural integrity and environmental safety, replacing the homogeneous PVC-plasticizer mixture
2Object-affected harmful factors
If polyurethane is used as alternative to PVC, then environmental harm is reduced, but production cost and process complexity increase
Solution Approach 1:
The patent applies universality by adapting the existing plastisol production infrastructure to process polyurethane reactive gels, allowing the same equipment to serve multiple material systems and reducing the need for entirely new production lines
Solution Approach 2:
The patent uses an intermediary approach by introducing a catalyst system that mediates the curing reaction of polyurethane gels, enabling controlled crosslinking that simplifies process management and maintains compatibility with existing production workflows
3Productivity
If curing reaction is accelerated to match PVC production rates, then productivity is improved, but premature curing occurs during mixing and processing
Solution Approach 1:
The patent applies preliminary action by pre-mixing the polyisocyanate, polyol, and filler to form a homogeneous reactive gel before adding the catalyst, ensuring that the curing reaction is initiated at the optimal moment and proceeds uniformly without premature crosslinking
Solution Approach 2:
The patent uses periodic action by controlling the catalyst addition and curing process in stages, allowing the reaction to progress through controlled phases that match the production rate requirements while preventing premature curing
4Strength
If high filler content is used to achieve firmness, then mechanical stability is improved, but processing difficulty and viscosity increase
Solution Approach 1:
The patent changes the rheological parameters by selecting specific polyol viscosities and molecular weights that remain fluid despite high filler content, allowing easy processing while achieving the desired firmness through the crosslinked network structure after curing
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
This process enables the production of polyurethane mats with high firmness, dimensional stability, cost efficiency, and good washability, matching production rates of traditional PVC-based mats while avoiding environmental hazards.
Implementation Method 1
mixing at least a filler, at least a polyisocyanate, at least a polyol and at least a catalyst, thereby obtaining a reactive polyurethane gel; curing said reactive polyurethane film, thereby obtaining a polyurethane layer
Data Source
AI summary
The present invention relates to a method for producing a polyurethane layer, comprising the steps: (i) mixing at least a filler, at least a polyisocyanate, at least a polyol and at least a catalyst, thereby obtaining a reactive polyurethane gel; (ii) dimensioning said reactive polyurethane gel into a reactive polyurethane film; (iii) optionally, applying a textile layer on a first side of said reactive polyurethane film; (iv) curing said reactive polyurethane film, thereby obtaining a polyurethane mat.