Polyurethane-Polyacrylate Resin Matrix for Large Composite Parts
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Solution Overview
Problem
Traditional polyurethane resins used in composite materials have short pot-life and high initial viscosities, limiting their application in large composite parts, and existing one-pot processes for polyurethane-polyacrylate resin matrices do not achieve satisfactory conversion ratios, affecting mechanical properties and processing ease.
Innovation Solution
Incorporating specific adjuvants, such as aryl-substituted olefins, into the isocyanate-reactive composition to adjust the polycondensation reaction conversion ratio, reducing residual isocyanate groups and extending material life, while allowing for higher NCO-conversion ratios in a one-pot process with polyisocyanates and radical reaction initiators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If standard polyurethane resins are used for large composite parts, then the resin provides basic structural properties, but the pot-life is rather short and initial viscosity is high
Solution Approach 1:
The patent modifies the polyol formulation by incorporating glycerol-based polypropylene oxide polyethers and dianhydrohexitol, which changes the chemical parameters of the resin system. This results in extended pot-life and reduced initial viscosity while maintaining curing performance, directly resolving the contradiction between duration of action and ease of manufacture
Solution Approach 2:
The invention creates a hybrid resin system combining polyurethane with epoxy and polyether modifications. This composite material approach integrates multiple polymer chemistries to achieve synergistic effects: the polyurethane provides structural properties while the modified polyol components extend pot-life and reduce viscosity, simultaneously addressing both contradictory requirements
2Duration of action of moving object
If simultaneous polyaddition and radical polymerization are performed in one-pot process, then the reactive composition achieves sufficient long pot-life, but the conversion ratios are not yet satisfying
Solution Approach 1:
The patent introduces specific catalyst systems that act as intermediaries to control the simultaneous polyaddition and radical polymerization reactions. By using carefully selected catalysts and inhibitors, the reaction pathways are regulated to achieve both long pot-life and high conversion ratios, resolving the contradiction between duration of action and manufacturing precision
Solution Approach 2:
The invention optimizes reaction parameters including catalyst selection, inhibitor concentration, and temperature control to balance the competing reactions. These parameter changes enable the one-pot process to achieve both extended pot-life and satisfactory conversion ratios by fine-tuning the reaction kinetics
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 approach results in a polyurethane-polyacrylate resin matrix with improved mechanical properties, extended pot-life, and enhanced processing flexibility, enabling the production of large composite parts with consistent mechanical properties and reduced material aging.
Implementation Method 1
the addition polymerization reaction of isocyanate groups and hydroxyl groups and the radical polymerization of olefinic groups take place simultaneously
Implementation Method 2
the addition polymerization reaction of isocyanate groups and hydroxyl groups and the radical polymerization of olefinic groups take place simultaneously
Implementation Method 3
the addition polymerization reaction of isocyanate groups and hydroxyl groups and the radical polymerization of olefinic groups take place simultaneously
Data Source
AI summary
The present invention relates to an isocyanate-reactive component B) comprising: B1) one or more organic polyols selected from the group consisting of polyether polyols, polyester polyols, polyetherester polyols, polymer polyols, polycarbonate polyols and polyethercarbonate polyols; B2) one or more compounds having the structure of Formula (I) wherein R1 is selected from the group consisting of hydrogen, methyl or ethyl; R2 is selected from the group consisting of alkylene having 2 to 6 carbon atoms, 2,2-bis(4-phenylene)propane, 1,4-bis(methylene)benzene, 1,3-bis(methylene)benzene, 1,2-bis(methylene)benzene; n is an integer selected from 1 to 6; and B3) at least one radical reaction adjuvant selected from the group consisting of aryl-substituted olefins, a composite material comprising a thermosetting polyurethane-polyacrylate resin matrix made with such isocyanate-reactive component B) and a reinforcement material and a process of preparing the same.