Rapid setting polyurethane elastomers and process of preparation

Claim 2

Non-cellular, non-elastomeric polyurethanes having a density of at least about 1 g/cc, a percent elongation of less than about 100, a heat distortion temperature of at least about 180° F (82° C) and which can be demolded within a period of about 5 minutes without the addition of an external source of heat which polyurethane results from the admixture and reaction of a composition which comprises: (A) a polyhydroxyl-containing material having from about 2 to about 8 hydroxyl groups and an average OH equivalent weight of not greater than about 250; (B) an organic polyisocyanate; (C) as a modifier, from about 1% to about 20% weight based upon the combined weight of Components (A), (B) and (C) of a polymer of one or more ethylenically unsaturated monomers said polymer having the following characteristics: (1) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02 inch orifice employing a total weight of 2160 grams at 80° C of from about 1 to about 250 decigrams/minute; (2) a solubility parameter at 25° C of at least about 8; (3) and a specific heat of at least about 0.35 cal/g/° C and (D) a non-amine containing catalyst for urethane formation; wherein Components (A) and (B) are present in quantities so as to provide an NCO:OH ratio of from about 0.8:1 to about 1.5:1 and with the proviso that when Component (A) has an average functionality of substantially less than about 3, then the average functionality of Component (B) is at least about 2.5.

Claim 3

A polyurethane of claim 1 where Component (C) has a grease melt flow index of from about 75 to about 200 and is present in quantities of from about 5% to about 18% by weight and wherein the NCO:OH ratio is from about 0.9:1 to about 1.2:1.

Claim 4

A polyurethane of claim 2 wherein Component (C) is present in quantities of from about 9% to about 15% by weight.

Claim 5

A polyurethane of claim 3 wherein Component (C) is a copolymer of ethylene and an ester of a carboxylic acid and has a solubility parameter at 25° C of from about 8 to about 12.5.

Claim 6

A polyurethane of claim 4 wherein said ester of a carboxylic acid is vinyl acetate or isobutyl acrylate.

Claim 7

A polyurethane of claim 3 wherein Component (C) is a polymer of alpha-methylstyrene.

Claim 8

A polyurethane of claim 4 wherein Component (A) is an adduct of glycerine and propylene oxide.

Claim 9

The composition of claim 1 cast as a furniture component.

Claim 10

The composition of claim 1 cast as a decorative object.

Claim 11

The composition of claim 1 cast as a machine component.

Claim 12

A process for preparing polyurethanes having a density of at least about 1 g/cc, a percent elongation of less than about 100, a heat distortion temperature of at least about 180° F (82° C) and which can be demolded within a period of about 5 minutes without the application of an external source of heat which process comprises: (1) admixing the components of a composition comprising: (A) a polyhydroxyl-containing material having from about 2 to about 8 hydroxyl groups and an average OH equivalent weight of not greater than about 250; (B) an organic polyisocyanate; (C) as a modifier, from about 1% to about 20%, by weight based upon the combined weight of Components (A), (B) and (C) of a polymer of one or more ethylenically unsaturated monomers having the following characteristics: (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02 inch orifice employing a total weight of 2160 grams at 80° C of from about 1 to about 250 decigrams/minute; (b) a solubility parameter at 25° C of at least about 8; (c) and a specific heat of at least about 0.35 cal/g/° C; and (D) a non-amine containing catalyst for urethane formation; wherein Components (A) and (B) are present in quantities so as to provide an NCO:OH ratio of from about 0.8:1 to about 1.5:1 and with the proviso that when Component (A) has an average functionality of substantially less than about 3, then the average functionality of Component (B) is at least about 2.5; (2) placing the admixed composition into a suitable mold wherein said composition solidifies within less than about 5 minutes to a solid having the aforesaid density, percent elongation and heat distortion temperature; and (3) subsequently demolding the resultant article from the mold.

Claim 13

A process for preparing polyurethanes having a density of at least about 1 g/cc, a percent elongation of less than about 100, a heat distortion temperature of at least about 180° F (82° C) and which can be demolded within a period of about 5 minutes without the application of an external source of heat which process comprises: (1) admixing the components of a composition comprising: (A) a polyhydroxyl-containing material having from about 2 to about 8 hydroxyl groups and an average OH equivalent weight of not greater than about 250; (B) an organic polyisocyanate; (C) as a modifier, from about 1% to about 20%, by weight based upon the combined weight of Components (A), (B) and (C) of a polymer of one or more ethylenically unsaturated monomers having the following characteristics: (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02 inch orifice employing a total weight of 2160 grams at 80° C of from about 1 to about 250 decigrams/minute; (b) a solubility parameter at 25° C of at least about 8; (c) and a specific heat of at least about 0.35 cal/g/° C; and (D) a non-amine containing catalyst for urethane formation; wherein Components (A) and (B) are present in quantities so as to provide an NCO:OH ratio of from about 0.8:1 to about 1.5:1 and with the proviso that when Component (A) has an average functionality of substantially less than about 3, then the average functionality of Component (B) is at least about 2.5; (2) placing the admixed composition into a suitable mold wherein said composition solidifies within less than about 5 minutes to a solid having the aforesaid density, percent elongation and heat distortion temperature; and (3) subsequently demolding the resultant article from the mold.

Claim 14

The process of claim 11 wherein Component (C) has a grease melt flow index of from about 75 to about 200 and is present in quantities of from about 5% to about 18% by weight and wherein the NCO:OH ratio is from about 0.9:1 to about 1.2:1.

Claim 15

The process of claim 12 wherein Component (C) is present in quantities of from about 9% to about 15% by weight.

Claim 16

Th process of claim 13 wherein Component (C) is a copolymer of ethylene and an ester of a carboxylic acid and has a solubility parameter of from about 8 to about 12.5.

Claim 17

The process of claim 14 wherein said ester is vinyl acetate or isobutyl acrylate.

Claim 18

The process of claim 13 wherein Component (C) is a polymer of alpha-methylstyrene.

Claim 19

The process of claim 14 wherein Component (A) is an adduct of glycerine and propylene oxide.

Claim 20

The process of claim 11 wherein said mold is in the form of a furniture component.

Claim 21

The process of claim 11 wherein said mold is in the form of a decorative object.

Claim 22

The process of claim 11 wherein said mold is in the form of a machine component.