Multilayer Polyurethane Adhesion via Segmented Bonding
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Solution Overview
Problem
Existing processes for adhering polyurethane layers to supports of different chemical natures are complex, inflexible, and costly, limiting their application to articles of specific dimensions and shapes.
Innovation Solution
A multilayer material comprising a first compact polyurethane layer and a second adhesive layer, which can be easily and economically produced without a vulcanization step, allowing polyurethane to adhere to supports of varying chemical nature and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct vulcanisation of polyurethane on the support is used, then adhesion to supports of various chemical nature is achieved, but the process becomes complex, inflexible and costly
Solution Approach 1:
The invention divides the single-step vulcanisation process into two separate steps: (1) bonding the polyurethane layer to the support using a bonding agent at lower temperatures, and (2) subsequently vulcanising the polyurethane. This segmentation allows each step to be optimized independently, reducing overall process complexity while maintaining adhesion reliability.
Solution Approach 2:
The invention introduces a bonding agent as an intermediary substance between the polyurethane layer and the support. This bonding agent facilitates adhesion at lower temperatures without requiring direct high-temperature vulcanisation of the polyurethane on the support, thereby simplifying the process and expanding compatibility with different support materials.
2Reliability
If direct vulcanisation of polyurethane on the support is used, then adhesion is achieved, but the process is inflexible for articles of different dimensions and shapes
Solution Approach 1:
By separating the bonding and vulcanisation steps, the invention enables flexible processing of articles with varying dimensions and shapes. The bonding step can be performed on articles of any size or configuration, and the subsequent vulcanisation can be adjusted according to specific article requirements, greatly enhancing adaptability.
Solution Approach 2:
The invention changes the processing parameters by using lower bonding temperatures followed by controlled vulcanisation. This parameter change allows the process to accommodate articles of different dimensions and shapes that would be unsuitable for direct high-temperature vulcanisation, improving versatility.
3Reliability
If direct vulcanisation of polyurethane on the support is used, then adhesion is achieved, but the process is costly
Solution Approach 1:
The segmented process allows bonding to be performed at lower temperatures using cost-effective bonding agents, avoiding the high energy costs and specialized equipment requirements of direct vulcanisation. This reduces manufacturing costs while maintaining adhesion strength.
Solution Approach 2:
The bonding agent acts as an intermediary that enables adhesion at lower temperatures, reducing energy consumption and eliminating the need for expensive high-temperature vulcanisation equipment. This intermediary approach significantly reduces manufacturing costs while achieving reliable adhesion.
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 multilayer material effectively adheres to diverse supports, enabling the creation of durable articles that resist detachment, and can be applied to various shapes and forms without the limitations of traditional vulcanization processes.
Implementation Method 1
a second adhesive layer different from the first polyurethane layer and arranged adjacent to the first polyurethane layer with the adhesive layer in contact with the support so as to adhere the polyurethane layer to the support
Data Source
AI summary
A multilayer material is described comprising: a first layer of compact thermosetting polyurethane, having a continuous network and having a density between 0.90 and 1.5 and hardnesses between 40 shore A and 75 shore D, a second layer made of an adhesive material on both faces, a primer interposed between said first layer and said second layer, said primer comprising at least one substance selected from the group consisting of acrylates, isocyanates, silanates, epoxides or polyurethanes.