Phenol extended polyurethanes prepared by RIM process

Claim 2

A process for preparing a RIM polyurethane molded product, said process comprising (i) at a temperature within the range of about 15° C. to about 100° C. subjecting to static impingement mixing (a) a catalyst, (b) an organic polyisocyanate, (c) an aliphatic polyhydroxy compound having two or more aliphatic hydroxy groups and a molecular weight within the range of from about 400 to about 7000, and (d) an aromatic chain extender having two aromatic hydroxy groups each containing a reactive hydrogen which is either a liquid or soluble in said aliphatic polyhydroxy compound at a temperature within the range of about 15° C. to about 100° C. said dihydroxyaromatic chain extenders being selected from I. dihydroxybenzenes and alkyl-substituted dihydroxybenzenes, wherein the alkyl groups have up to about 6 carbon atoms and the total number of carbon atoms in the alkyl groups in said alkyl-substituted dihydroxybenzene has up to about 12 carbon atoms, and II. alkylene bridged, alkyl-substituted bisphenols wherein the alkylene bridge contains up to about 6 carbon atoms and the total number of carbon atoms in the alkyl groups attached to each benzenoid nucleus is at least one but does not exceed about 12; whereby a preproduct is produced, (ii) subsequently injecting a shot of said preproduct at said temperature into a closed preheated mold having a temperature of from about 15° C. to about 100° C., (iii) opening the mold and removing the formed polyurethane molded product, and (iv) optionally subjecting said molded product to a post-cure at a temperature within the range of from about 50° C. to about 150° C. said process being conducted such that the amount of dihydroxyaromatic compound is from about 5 to about 30 weight percent of the total weight of components (a)-(d) and such that there is a substantially stoichiometric ratio of isocyanate groups on the one hand and the total of hydroxy groups in said aliphatic polyhydroxy compound and said dihydroxyaromatic chain extender on the other.

Claim 5

A process for preparing a reaction injection molding polyurethane molded product which comprises (i) at a temperature within the range of about 15° C. to about 100° C. subjecting to static impingement mixing two liquid streams, the first stream comprising (a) a catalyst, (b) an aliphatic polyhydroxy compound having two or more aliphatic hydroxy groups and a molecular weight within the range of from about 400 to about 7000, and (c) an aromatic chain extender having two aromatic hydroxy groups each containing a reactive hydrogen which is either a liquid or is soluble in said aliphatic polyhydroxy compound at a temperature within the range of about 15° C. to about 100° C. said dihydroxyaromatic compound being selected from I. dihydroxybenzenes and alkyl-substituted dihydroxybenzenes, wherein the alkyl groups have up to about 6 carbon atoms and the total number of carbon atoms in the alkyl groups in said alkyl-substituted dihydroxybenzene has up to about 12 carbon atoms, and II. alkylene bridged, alkyl-substituted bisphenols wherein the alkylene bridge contains up to about 6 carbon atoms and the total number of carbon atoms in the alkyl groups attached to each benzenoid nucleus is at least one but does not exceed about 12; and the second stream comprising (d) an organic polyisocyanate or prepolymer formed from an organic polyisocyanate and an aliphatic polyhydroxy compound whereby a liquid mixture is produced, (ii) subsequently injecting a shot of said liquid mixture at said temperature into a closed preheated mold having a temperature of from about 15° C. to about 100° C., (iii) opening the mold and removing the formed polyurethane molded product, and (iv) optionally subjecting said molded product to a post-cure at a temperature within the range of from about 50° C. to about 150° C.; said process being conducted such that the amount of dihydroxyaromatic compound is from about 5 to about 30 weight percent of the total weight of components (a)-(d) and such that there is a substantially stoichiometric ratio of isocyanate groups on the one hand and the total of hydroxy groups in said aliphatic polyhydroxy compound and said dihydroxyaromatic chain extender on the other.

Claim 6

A process for preparing a reaction injection molding polyurethane molded product which comprises (i) at a temperature within the range of about 15° C. to about 100° C. subjecting to static impingement mixing two liquid streams, the first stream comprising (a) a catalyst, (b) an aliphatic polyhydroxy compound having two or more aliphatic hydroxy groups and a molecular weight within the range of from about 400 to about 7000, and (c) an aromatic chain extender having two aromatic hydroxy groups each containing a reactive hydrogen which is either a liquid or is soluble in said aliphatic polyhydroxy compound at a temperature within the range of about 15° C. to about 100° C. said dihydroxyaromatic compound being selected from I. dihydroxybenzenes and alkyl-substituted dihydroxybenzenes, wherein the alkyl groups have up to about 6 carbon atoms and the total number of carbon atoms in the alkyl groups in said alkyl-substituted dihydroxybenzene has up to about 12 carbon atoms, and II. alkylene bridged, alkyl-substituted bisphenols wherein the alkylene bridge contains up to about 6 carbon atoms and the total number of carbon atoms in the alkyl groups attached to each benzenoid nucleus is at least one but does not exceed about 12; and the second stream comprising (d) an organic polyisocyanate or prepolymer formed from an organic polyisocyanate and an aliphatic polyhydroxy compound whereby a liquid mixture is produced, (ii) subsequently injecting a shot of said liquid mixture at said temperature into a closed preheated mold having a temperature of from about 15° C. to about 100° C., (iii) opening the mold and removing the formed polyurethane molded product, and (iv) optionally subjecting said molded product to a post-cure at a temperature within the range of from about 50° C. to about 150° C.; said process being conducted such that the amount of dihydroxyaromatic compound is from about 5 to about 30 weight percent of the total weight of components (a)-(d) and such that there is a substantially stoichiometric ratio of isocyanate groups on the one hand and the total of hydroxy groups in said aliphatic polyhydroxy compound and said dihydroxyaromatic chain extender on the other.