TPU Flooring Panel Composition for Thermal-Stable High Hardness
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Solution Overview
Problem
Conventional thermoplastic polyurethane (TPU) materials with high hardness and high flexural modulus face challenges such as a narrow processing window, thermal instability, and susceptibility to degradation during processing, making large-scale manufacturing difficult, and they often require solvent casting with environmental and health risks.
Innovation Solution
Development of TPU materials with a high hardblock content (>70 wt %) and a glass transition temperature above room temperature, processed at temperatures below 250°C, using a reactive formulation with aromatic dicarboxylic acid based diol chain extenders and a balanced isocyanate index, enabling thermal recyclability and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If TPU materials with high hardness and high flexural modulus are used, then mechanical strength is improved, but processing window becomes narrow and thermal stability deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of TPU by incorporating specific ratios of polyols (polyester polyol 30-70 wt%, polyether polyol 20-50 wt%) and chain extenders (aromatic dicarboxylic acid based diol 10-30 wt%) to achieve optimal balance between mechanical strength and thermal stability. This parameter optimization allows processing at temperatures below 250°C while maintaining high hardness (>50 Shore D) and flexural modulus (>300 MPa).
Solution Approach 2:
The patent creates a composite TPU system combining multiple polyol components with specific chain extenders to achieve synergistic effects. The composite formulation integrates the advantages of different polyols while using aromatic dicarboxylic acid based diol chain extenders to enhance thermal stability, resolving the contradiction between mechanical properties and processing window.
2Strength
If TPU materials with high hardblock content are used, then mechanical properties are improved, but processing temperature approaches degradation temperature
Solution Approach 1:
The patent introduces aromatic dicarboxylic acid based diol chain extenders as intermediaries that facilitate controlled polymerization at lower temperatures. These chain extenders act as mediators between the high hardblock content requirement and the need for manageable processing temperatures, enabling production at temperatures below 250°C while maintaining high mechanical properties.
Solution Approach 2:
The patent optimizes the hardblock content parameter to 70-90 wt% while compensating with specific polyol selections and chain extender additives. This parameter adjustment allows maintaining high mechanical properties through controlled polymerization at lower temperatures, preventing the processing temperature from approaching degradation temperature.
3Ease of manufacture
If conventional TPU materials are processed, then manufacturing is possible, but environmental and health risks increase due to solvent casting requirements
Solution Approach 1:
The patent replaces the traditional solvent casting process with a water-based or solvent-free processing method. The modified TPU formulation enables processing at temperatures below 250°C without requiring harmful solvents, substituting the chemical solvent-based system with a thermal processing approach that eliminates environmental and health risks while maintaining ease of manufacture.
Solution Approach 2:
The patent converts the potential harm of high processing temperatures into a benefit by using aromatic dicarboxylic acid based diol chain extenders that enable controlled polymerization at lower temperatures. This transformation eliminates the need for solvent casting and harmful processing conditions while maintaining manufacturability, turning a potential hazard into an environmental advantage.
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 TPU materials exhibit high hardness (>50 Shore D), flexural modulus (>300 MPa), and thermal stability with a degradation temperature above 250°C, allowing for large-scale manufacturing and recyclability without significant property loss.
Implementation Method 1
a glass transition temperature (Tg, measured according to ISO 11357-2:2020) above room temperature
Implementation Method 2
thermal stability and have high degradation temperatures (temperature of 5 wt % loss measured according to ISO 11358-1 under Air condition) which is >250° C.
Data Source
AI summary
An exemplary embodiment provides a flooring panel, comprising a core layer comprising a thermoplastic polyurethane (TPU) having a shore D hardness in the range 50-100 and a glass transition temperature above room temperature. The TPU can be formed from a reactive formulation, comprising an isocyanate composition, an isocyanate-reactive composition, optionally a catalyst compound, and optionally additives and/or fillers. The isocyanate composition can comprise at least one difunctional isocyanate compound. The isocyanate-reactive composition can comprise at least one aromatic dicarboxylic acid based diol chain extender having a molecular weight <500 g/mol. The hardblock content of the reactive formulation can be >70 wt % based on the total weight of the isocyanate and isocyanate-reactive composition, the isocyanate index can be in the range 75 up to 125, and the number average isocyanate functionality and/or the number average hydroxy functionality can be in the range of 1.8 up to 2.5.