Coating composition and skinned polyurethane foam articles coated therewith

Claim 2

A coating composition, which comprises a combination of: [I] a two component type non-yellowing polyurethane solution, for top coat, comprising (a) at least one OH-terminated urethane prepolymer having a hydroxyl-equivalent of at least 1,400 derived from at least one non-aromatic polyisocyanate and excess of at least one polyol, and (b) at least one non-aromatic polyisocyanate; and [II] a two component type polyurethane, for under coat, comprising (c) at least one NCO-terminated urethane prepolymer derived from at least one polyol and at least one aromatic polyisocyanate, and (d) at least one polyol.

Claim 3

The composition of claim 1, wherein the prepolymer (a) is derived from at least one polyol selected from the group consisting of high molecular weight polyols having a hydroxyl equivalent of 200-2500 and low molecular weight polyols, and at least one organic polyisocyanate having all its isocyanate groups attached to non-benzenoid carbon atoms, which polyisocyanate is selected from the group consisting of aliphatic polyisocyanates having 2-12 carbon atoms, cycloaliphatic polyisocyanates having 4-15 carbon atoms, araliphatic polyisocyanates having 8-15 carbon atoms and modified polyisocyanates of the above polyisocyanates.

Claim 4

The composition of claim 2, wherein said high molecular weight polyol is at least one selected from the group consisting of polyether polyols, polyester polyols, polybutadiene polyols, acrylic polyols and polymer polyols, wherein said polymer polyols are derived from vinyl monomers and polyols.

Claim 5

The composition of claim 1, wherein the prepolymer (a) is obtained by reacting said polyisocyanate with at least one high molecular weight polyol having a hydroxyl equivalent of 200-2500 and at least one low molecular weight polyol.

Claim 6

The composition of claim 1, wherein the prepolymer (a) is obtained by reacting said polyisocyanate and said polyol in such an amount providing an equivalent ratio of NCO groups to active hydrogen atom-containing groups of 1:1.01-1:1.3.

Claim 7

The composition of claim 1, wherein the prepolymer (a) has a hydroxyl equivalent of 1,800-15,000.

Claim 8

The composition of claim 1, wherein the polyisocyanate (b) is at least one organic polyisocyanate having all its isocyanate groups attached to non-benzenoid carbon atoms, which polyisocyanate is selected from the group consisting of aliphatic polyisocyanates having 2-12 carbon atoms, cycloaliphatic polyisocyanates having 4-15 carbon atoms, araliphatic polyisocyanates having 8-15 carbon atoms, modified polyisocyanates of the above polyisocyanates and NCO-terminated prepolymer derived from these polyisocyanates.

Claim 9

The composition of claim 1, wherein at least a part of the polyisocyanate (b) is a polyisocyanate having three or more isocyanate groups.

Claim 10

The composition of claim 1, wherein the equivalent ratio of the polyisocyanate (b) to the prepolymer (a) is 1:1-5:1.

Claim 11

The composition of claim 1, wherein the prepolymer (c) is obtained by reacting said polyisocyanate with at least one high molecular weight polyol having a hydroxyl equivalent of 200-2,500, selected from the group of polyether polyols, polyester polyols, polybutadiene polyols, acrylic polyols and polymer polyols, wherein said polymer polyols are derived from vinyl monomers and polyols, in such an amount providing an NCO/OH ratio of at least 2.

Claim 12

The composition of claim 1, wherein the polyol (d) is a mixture of at least one high molecular weight polyol having a hydroxyl equivalent of 200-3,000 and at least one low molecular weight polyol.

Claim 13

The composition of claim 1, wherein the two component type polyurethane [II] contains at least one catalyst for urethane reaction, selected from the group consisting of amine catalysts and organometalic catalysts.

Claim 14

The composition of claim 12, wherein said catalyst is at least one organo tin compound or a combination thereof with triethylenediamine.

Claim 15

The composition of claim 1, wherein [I] is used in such amount providing a top coat layer having an average thickness of 0.01-0.1 mm, and [II] is used in such amount providing an under coat layer having an average thickness of 0.05-3 mm.

Claim 16

A self-skinned polyurethane foam article having thereon a cured coating formed from the composition of claim 1.

Claim 17

The article of claim 15, wherein the cured coating comprises: (1) a top coat having an average thickness of 0.01-0.1 mm, formed from said two-component type non-yellowing polyurethane [I]; and (2), an under coat having an average thickness of 0.05-3 mm, formed from said two-component type polyurethane [II].

Claim 18

A skin urethane foam, which comprises: (1) a cover layer of substantially solvent-insoluble non-yellowing polyurethane, having an average thickness of 0.01-0.1 mm, formed by applying to the mold cavity a two component type non-yellowing polyurethane solution comprising (a) at least one OH-terminated urethane prepolymer having a hydroxyl-equivalent of at least 1,400 derived from at least one non-aromatic polyisocyanate and excess of at least one polyol and (b) at least one non-aromatic polyisocyanate, and curing the non-yellowing polyurethane; (2) an intermediate layer applied onto the cover layer and formed from a two component type polyurethane comprising (c) at least one NCO-terminated urethane prepolymer derived from at least one polyol and at least one aromatic polyisocyanate and (d) at least one polyol; and (3) a polyurethane foam layer formed by introducing a urethane foam-forming mixture into the mold cavity onto the intermediate layer before the intermediate layer cures completely, and allowing the urethane foam-forming mixture to foam, whereby the resulting foam is integrally bound to the cover layer through the intermediate layer.

Claim 19

A skin urethane foam, which comprises: (1) a cover layer of substantially solvent-insoluble non-yellowing polyurethane, having an average thickness of 0.01-0.1 mm, formed by applying to the mold cavity a two component type non-yellowing polyurethane solution comprising (a) at least one OH-terminated urethane prepolymer having a hydroxyl-equivalent of at least 1,400 derived from at least one non-aromatic polyisocyanate and excess of at least one polyol and (b) at least one non-aromatic polyisocyanate, and curing the non-yellowing polyurethane; (2) an intermediate layer applied onto the cover layer and formed from a two component type polyurethane comprising (c) at least one NCO-terminated urethane prepolymer derived from at least one polyol and at least one aromatic polyisocyanate and (d) at least one polyol; and (3) a polyurethane foam layer formed by introducing a urethane foam-forming mixture into the mold cavity onto the intermediate layer before the intermediate layer cures completely, and allowing the urethane foam-forming mixture to foam, whereby the resulting foam is integrally bound to the cover layer through the intermediate layer.

Claim 20

The foam of claim 17, wherein said intermediate layer has an average thickness of 0.05-3 mm.

Claim 21

The foam of claim 17, wherein said polyurethane foam is a flexible foam or semi-rigid foam.

Claim 22

The foam of claim 17, wherein said polyurethane foam layer is formed from urethane foam-forming mixtures having a free rise density of 0.01-0.4 g/cm 3 .

Claim 23

The foam of claim 17, which has an over-all density of 0.05-0.8 g/cm 3 .

Claim 24

The composition of claim 1, wherein the prepolymer (a) is derived from at least one polyol, the average functionality of which is 2-3.

Claim 25

The composition of claim 1, wherein the average functionality of the total of the OH groups of (a) and the NCO groups of (b) is 2.05-3.5.