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1. (WO2019067856) POLYURETHANE FOAMS CONTAINING ADDITIVE MANUFACTURING WASTE AS FILLER FOR AUTOMOTIVE APPLICATIONS AND PROCESSES FOR MANUFACTURING THE SAME
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Pub. No.: WO/2019/067856 International Application No.: PCT/US2018/053344
Publication Date: 04.04.2019 International Filing Date: 28.09.2018
IPC:
C08G 18/48 (2006.01) ,C08G 18/66 (2006.01) ,C08G 18/76 (2006.01) ,C08J 9/00 (2006.01) ,C08G 18/32 (2006.01) ,C08G 18/40 (2006.01) ,C08G 18/42 (2006.01) ,C08G 18/44 (2006.01) ,C08L 75/04 (2006.01) ,C08L 75/08 (2006.01)
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
G
MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
18
Polymeric products of isocyanates or isothiocyanates
06
with compounds having active hydrogen
28
characterised by the compounds used containing active hydrogen
40
High-molecular-weight compounds
48
Polyethers
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
G
MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
18
Polymeric products of isocyanates or isothiocyanates
06
with compounds having active hydrogen
28
characterised by the compounds used containing active hydrogen
65
Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
66
Compounds of groups C08G18/42, C08G18/48, or C08G18/52111
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
G
MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
18
Polymeric products of isocyanates or isothiocyanates
06
with compounds having active hydrogen
70
characterised by the isocyanates or isothiocyanates used
72
Polyisocyanates or polyisothiocyanates
74
cyclic
76
aromatic
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
J
WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H142
9
Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
G
MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
18
Polymeric products of isocyanates or isothiocyanates
06
with compounds having active hydrogen
28
characterised by the compounds used containing active hydrogen
30
Low-molecular-weight compounds
32
Polyhydroxy compounds; Polyamines; Hydroxy amines
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
G
MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
18
Polymeric products of isocyanates or isothiocyanates
06
with compounds having active hydrogen
28
characterised by the compounds used containing active hydrogen
40
High-molecular-weight compounds
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
G
MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
18
Polymeric products of isocyanates or isothiocyanates
06
with compounds having active hydrogen
28
characterised by the compounds used containing active hydrogen
40
High-molecular-weight compounds
42
Polycondensates having carboxylic or carbonic ester groups in the main chain
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
G
MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
18
Polymeric products of isocyanates or isothiocyanates
06
with compounds having active hydrogen
28
characterised by the compounds used containing active hydrogen
40
High-molecular-weight compounds
42
Polycondensates having carboxylic or carbonic ester groups in the main chain
44
Polycarbonates
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
L
COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
75
Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
04
Polyurethanes
C CHEMISTRY; METALLURGY
08
ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
L
COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
75
Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
04
Polyurethanes
08
from polyethers
Applicants:
FORD GLOBAL TECHNOLOGIES, LLC [US/US]; 330 Town Center Drive Suite 800 Dearborn, MI 48126, US
Inventors:
KIZILTAS, Alper; TR
DOWLING, Zachary; US
BEDELL, Mathew, Linden; US
MIELEWSKI, Deborah; US
Agent:
HARPER, Mark, A.; US
Priority Data:
62/564,98728.09.2017US
Title (EN) POLYURETHANE FOAMS CONTAINING ADDITIVE MANUFACTURING WASTE AS FILLER FOR AUTOMOTIVE APPLICATIONS AND PROCESSES FOR MANUFACTURING THE SAME
(FR) MOUSSES DE POLYURÉTHANE CONTENANT DES DÉCHETS DE FABRICATION ADDITIVE COMME CHARGE POUR APPLICATIONS AUTOMOBILES, ET PROCÉDÉS DE FABRICATION DESDITES MOUSSES
Abstract:
(EN) A closed loop recycling process of manufacturing a foam part includes dispersing a filler material recycled from an additive manufacturing (AM) process in at least one foam reactant and pouring or injecting the at least one foam reactant with the filler material into a mold and forming the foam part. The foam part has a foam matrix with between 2.5 wt.% and 30 wt.% of the filler material. The filler material can be a recycled powder from a selective laser sintering process that is not graded (i.e., sized) before being dispersed in the at least one foam reactant. For example, the recycled powder can be a recycled polyamide 12 (rPA12) powder with an average particle diameter of less than 100 micrometers. Also, the least one foam reactant can be a polyol reactant and an isocyanate reactant such that a polyurethane foam matrix with recycled rPA12 filler material is formed.
(FR) L'invention concerne un procédé de recyclage en boucle fermée pour la fabrication d'un module en mousse, qui consiste à disperser un matériau de charge recyclé issu d'un processus de fabrication additive (AM) dans au moins un réactif pour mousse, et à verser ou injecter le(s) réactif(s) pour mousse comportant le matériau de charge dans un moule pour former le module en mousse. Le module en mousse présente une matrice de mousse comportant entre 2,5% en poids et 30% en poids du matériau de charge. Le matériau de charge peut être une poudre recyclée non calibrée (c'est-à-dire, non criblée) issue d'un processus sélectif de frittage laser, qui est ensuite dispersée dans le(s) réactif(s) de mousse. Par exemple, la poudre recyclée peut être une poudre de polyamide 12 recyclé (rPA12) présentant un diamètre des particules moyen inférieur à 100 micromètres. En outre, au moins un réactif de mousse peut être un réactif polyol et un réactif isocyanate permettant de former une matrice de mousse de polyuréthane avec un matériau de charge rPA12 recyclé.
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Designated States: AE, AG, AL, AM, AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DJ, DK, DM, DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, HN, HR, HU, ID, IL, IN, IR, IS, JO, JP, KE, KG, KH, KN, KP, KR, KW, KZ, LA, LC, LK, LR, LS, LU, LY, MA, MD, ME, MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ, OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SA, SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW
African Regional Intellectual Property Organization (ARIPO) (BW, GH, GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, ST, SZ, TZ, UG, ZM, ZW)
Eurasian Patent Office (AM, AZ, BY, KG, KZ, RU, TJ, TM)
European Patent Office (EPO) (AL, AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, LV, MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM, TR)
African Intellectual Property Organization (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW, KM, ML, MR, NE, SN, TD, TG)
Publication Language: English (EN)
Filing Language: English (EN)