US4742128A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for preparing a polymer alloy, molded product, and reaction injection molded products
Assignee: Stamicarbon BV
•
Filing: 1985-10-15
•
Granted: 1988-05-03
•
Expires: 2005-10-15
Abstract
Abstract The present invention provides a molded product composed of a polymer alloy of a polyamide polymer and at least one polyurethane polymer, polyurea polymer, and/or polyisocyanurate polymer. The polymer alloy is an interpenetrated network of different polymers, a semi-interpenetrating network of different polymers, or a polyblend of different polymers. Reactant streams containing the compounds for forming the polymers of the polymer alloy are admixed to form a reaction mixture. The liquid reaction mixture is preferably a substantially homogeneous mixture of the reactant compounds. Each reactant stream thus contains only a portion of the components required to obtain the polymer alloy product. The resulting mixture is then rapidly introduced into a mold wherein chemical reaction takes place and the polymer alloy forms. Preferably, the mold is heated. The solid polymer alloy product is then recovered from the mold.
Inventors
- 👤 Kurt C. Frisch
- 👤 Kaneyoshi Ashida
- 👤 Jozef L. M. van der Loos
- 👤 Albert A. Van Geenen
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 03:21
CPC Classifications
C; C08; C08L; C08L75/00; C08G; C08G18/00; C08G18/06; C08G18/08; C08G18/10; C08G18/28; C08G18/2805; C08G18/285; C08G18/2855; C08L77/00; C08L77/02; C08G2115/00; C08G2115/02; C08G2120/00; C08G2270/00; Y; Y10; Y10S; Y10S525/00; Y10S525/903
Claims Analysis
Total Claims: 53
Claim 1
Independent Claim
189 words
A process for preparing a polymer alloy comprising: (i) introducing into a mold a mixture comprising: (a) polyamide forming compounds wherein said polyamide forming compounds include at least one lactam, an anionic polymerization catalyst and a polymerization activator, and (b) polymer forming compounds for forming: (A) at least one polymer selected from the group consisting of polyurea and polyisocyanurate polymers, or (B) polyurethane polymers and at least one additional polymer selected from the group consisting of polyurea polymers, and polyisocyanurate polymers, wherein said polyurea polymer forming compounds include a polyamine or hydrazine containing compound and a polyisocyanate, said polyisocyanurate polymer forming compounds include a prepolymer containing isocyanate groups or a polyol and a polyisocyanate, and a trimerization catalyst, said polyurethane polymer forming compounds include a polyol, a polyisocyanate, and an urethane polymerization catalyst, said polymer forming compounds reacting to form a polymer alloy comprising: (A) polyamide polymers and polyurethane polymers, and at least one of the following polymers: polyurea polymers; and polyisocyanurate polymers; or (B) polyamide polymers and at least one of the following polymers: polyurea polymers and polyisocyanurate polymers; and (ii) recovering said polymer alloy from said mold.
Claim 2
Dependent Claim
189 words
A process for preparing a polymer alloy comprising: (i) introducing into a mold a mixture comprising: (a) polyamide forming compounds wherein said polyamide forming compounds include at least one lactam, an anionic polymerization catalyst and a polymerization activator, and (b) polymer forming compounds for forming: (A) at least one polymer selected from the group consisting of polyurea and polyisocyanurate polymers, or (B) polyurethane polymers and at least one additional polymer selected from the group consisting of polyurea polymers, and polyisocyanurate polymers, wherein said polyurea polymer forming compounds include a polyamine or hydrazine containing compound and a polyisocyanate, said polyisocyanurate polymer forming compounds include a prepolymer containing isocyanate groups or a polyol and a polyisocyanate, and a trimerization catalyst, said polyurethane polymer forming compounds include a polyol, a polyisocyanate, and an urethane polymerization catalyst, said polymer forming compounds reacting to form a polymer alloy comprising: (A) polyamide polymers and polyurethane polymers, and at least one of the following polymers: polyurea polymers; and polyisocyanurate polymers; or (B) polyamide polymers and at least one of the following polymers: polyurea polymers and polyisocyanurate polymers; and (ii) recovering said polymer alloy from said mold.
Claim 3
Dependent Claim
18 words
Process according to claim 1, wherein said mixture comprises polyisocyanurate polymer forming compounds and polyamide polymer forming compounds.
Claim 4
Dependent Claim
18 words
Process according to claim 1, wherein said mixture comprises polyurea polymer forming compounds and polyamide polymer forming compounds.
Claim 5
Dependent Claim
20 words
Process according to claim 1, wherein said mixture comprises polyurethane polymer forming compounds, polyisocyanurate forming compounds and polyamide forming compounds.
Claim 6
Dependent Claim
22 words
Process according to claim 1, wherein said mixture comprises polyurethane polymer forming compounds, polyurea polymer forming compounds and polyamide polymer forming compounds.
Claim 7
Dependent Claim
22 words
Process according to claim 1, wherein said mixture comprises polyurea polymer forming compounds, polyisocyanurate polymer forming compounds and polyamide polymer forming compounds.
Claim 8
Dependent Claim
26 words
Process according to claim 1, wherein said mixture comprises polyurea polymer forming compounds, polyurethane polymer forming compounds, polyisocyanurate polymer forming compounds and polyamide polymer forming compounds.
Claim 9
Dependent Claim
23 words
Process according to claim 1, wherein said polyisocyanurate polymer forming compounds comprise at least one isocyanate-terminated prepolymer and at least one trimerization catalyst.
Claim 10
Dependent Claim
26 words
Process according to claim 1, wherein said polyisocyanurate polymer forming compounds comprise at least one polyisocyanate, at least one polyol, and at least one trimerization catalyst.
Claim 11
Dependent Claim
26 words
Process according to claim 9, wherein the equivalent ratio of the NCO-groups in the polyisocyanate and the OH-groups in the polyol is from 1.2 to 10.
Claim 12
Dependent Claim
13 words
Process according to claim 10, wherein said ratio is between 1.3 and 3.0.
Claim 13
Dependent Claim
29 words
Process according to claim 9, wherein the equivalent ratio of the NCO-groups in the polyisocyanate and the OH groups in the polyol ranges from about 1.3 to about 5.0.
Claim 14
Dependent Claim
48 words
Process according to claim 1, wherein said trimerization catalyst is selected from the group consisting of alkali metal lactamates, alkali metal carboxylates, hexahydrotriazine derivatives, Zwitter-ion compounds, tertiary alkanolamine compounds, tertiary amines in combination with epoxy compounds, tertiary amines in combination with alkali metal carboxylates and quaternary ammonium carboxylates.
Claim 15
Dependent Claim
13 words
Process according to claim 13, wherein said catalyst is an alkali metal lactamate.
Claim 16
Dependent Claim
28 words
Process according to claim 8, wherein said isocyanate-terminated prepolymer is the reaction product of a polymer containing active hydrogen groups reactive with an isocyanate group and a polyisocyanate.
Claim 17
Dependent Claim
23 words
Process according to claim 1, wherein said anionic lactam polymerization catalyst is an alkali metal compound, a Grignard compound, or a combination thereof.
Claim 18
Dependent Claim
20 words
Process according to claim 1, wherein said lactam polymerization activator comprises a lactam blocked isocyanate, or an acyl lactam compound.
Claim 19
Dependent Claim
12 words
Process according to claim 17, wherein said activator is a carbamoyl lactam.
Claim 20
Dependent Claim
21 words
Process according to claim 18 wherein said carbamoyl lactam is the reaction product of an isocyanate terminated compound with a lactam.
Claim 21
Dependent Claim
40 words
Process according to claim 1, wherein said polyurethane polymer forming compounds include at least one polyol selected from the group consisting of polyether polyols, polyester polyol, polybutadiene polyol, grafted polyether polyol, polyrea-dispersion in polyether polyol, polyester polyol, and mixtures thereof.
Claim 22
Dependent Claim
31 words
Process according to claim 1, wherein said polyurethane polymer forming compounds include at least one polyisocyanate selected from the group consisting of aromatic, aliphatic, araliphatic and/or cyloaliphatic polyisocyanates and mixtures thereof.
Claim 23
Dependent Claim
20 words
Process according to claim 1, wherein said polyurethane catalyst is a tertiary amine, tin carboxylate salt, or a combination thereof.
Claim 24
Dependent Claim
39 words
Process according to claim 1, wherein the polyurethane polymer forming compounds include a chain extender selected from the group consisting of aliphatic unbranched or branched diols and triols, low molecular weight polyethylene glycols and cycloaliphatic diols and mixtures thereof.
Claim 25
Dependent Claim
23 words
Process according to claim 1, wherein said polyurea forming compounds include at least one polyamine having an equivalent weight of 100 to 3000.
Claim 26
Dependent Claim
18 words
Process according to claim 24 wherein said polyamine has an equivalent weight from about 1,000 to about 25,00.
Claim 27
Dependent Claim
82 words
Process according to claim 1, wherein said polyisocyanate is selected from the group consisting of 2,4- or 2,6-toluene diisocyanate, 4,4' diphenylmethane diisocyanate, polymethylene polyphenylpolyisocyanates, isophorone diisocyanate, 1,6- and 1,5-hexane diisocyanate, xylylene diisocyanate, carbodiimide modified 4,4' diphenylmethane diisocyanate, hydrogenated 2,4-, 2,6'- toluene diisocyanate, hydrogenated xylylene diisocyanate, hydrogenated 4,4' diphenylmethane diisocyanate, trimers of isophorone diisocyanate, isocyanate-terminated polyether triols, adducts of 2,4- and 2,6-toluene diisocyanate and trimethylolpropane, adducts of 4,4' diphenylmethane diisocyanate and trimethylolpropane, adducts of 1,6- and 1,5-hexane diisocyanate and trimethylolpropane, and combinations thereof.
Claim 28
Dependent Claim
22 words
Process according to claim 1, wherein the residence time of said mixture in said mold is between 10 seconds and 60 minutes.
Claim 29
Dependent Claim
16 words
Process according to claim 27, wherein said residence time is between 10 seconds and 10 minutes.
Claim 30
Dependent Claim
29 words
A reaction injection molded product comprising a polyamide polymer and a polyurethane polymer and at least one of the following polymers: a polyisocyanurate polymer and a cross-linked polyurea polymer.
Claim 31
Dependent Claim
29 words
A reaction injection molded product comprising a polyamide polymer and a polyurethane polymer and at least one of the following polymers: a polyisocyanurate polymer and a cross-linked polyurea polymer.
Claim 32
Dependent Claim
22 words
A product according to claim 29, wherein only one of said polyamide polymer or said polyurethane polymer is cross-linked, linear or branched.
Claim 33
Dependent Claim
19 words
A product according to claim 29, wherein both said polyamide and said polyurethane polymer are substantially linear or branched.
Claim 34
Dependent Claim
24 words
A reaction injection molded product comprising at least one polyamide polymer and at least one of the following: polyisocyanurate polymers, and cross-linked polyurea polymers.
Claim 35
Dependent Claim
24 words
A reaction injection molded product comprising at least one polyamide polymer and at least one of the following: polyisocyanurate polymers, and cross-linked polyurea polymers.
Claim 36
Dependent Claim
36 words
A product according to claim 32, wherein said product is an interpenetrating polymer network of said polyamide polymer and: (A) said polyisocyanurate polymer; (B) said polyurea polymer, or (C) said polyisocyanurate polymer and said polyurea polymer.
Claim 37
Dependent Claim
158 words
A molded polymer alloy product obtained by admixing substantially stable reactant streams to obtain an admixture, (i) introducing said admixture into a mold, said admixture comprising: (a) polymer forming compounds for forming polyurethane polymer(s) and at least one polymer selected from the group consisting of polyurea polymers and polyisocyanurate polymers, said polyurethane polymer forming compounds including a polyisocyanate, and a polyurethane polymerization catalyst, said polyurea polymer forming compounds including a polyamine or hydrazine containing compound and a polyisocyanate, said polyisocyanurate polymer forming compounds including at least one prepolymer containing reactive isocyanate groups or a polyol and a polyisocyanate, and a trimerization catalyst; and (b) polyamide polymer forming compounds, said polyamide polymer forming compounds including at least one lactam, an anionic polymerization catalyst and a polymerization activator, said polymer forming compounds reacting in said mold wherein a molded product composed of the polymers is obtained from the respective polymer forming compounds; and (ii) recovering said product from said mold.
Claim 38
Dependent Claim
158 words
A molded polymer alloy product obtained by admixing substantially stable reactant streams to obtain an admixture, (i) introducing said admixture into a mold, said admixture comprising: (a) polymer forming compounds for forming polyurethane polymer(s) and at least one polymer selected from the group consisting of polyurea polymers and polyisocyanurate polymers, said polyurethane polymer forming compounds including a polyisocyanate, and a polyurethane polymerization catalyst, said polyurea polymer forming compounds including a polyamine or hydrazine containing compound and a polyisocyanate, said polyisocyanurate polymer forming compounds including at least one prepolymer containing reactive isocyanate groups or a polyol and a polyisocyanate, and a trimerization catalyst; and (b) polyamide polymer forming compounds, said polyamide polymer forming compounds including at least one lactam, an anionic polymerization catalyst and a polymerization activator, said polymer forming compounds reacting in said mold wherein a molded product composed of the polymers is obtained from the respective polymer forming compounds; and (ii) recovering said product from said mold.
Claim 39
Dependent Claim
136 words
A polymer alloy comprising at least one polyamide polymer and at least one polyurethane polymer and at least one polymer selected from the group consisting of polyisocyanurate polymers and polyurea polymers, wherein said polyamide is a polymerization product of 4 to 15 carbon ring lactams, said polyurethane polymer is the reaction product of a polyhydroxy compound having an equivalent weight of 100 to 3000 with an organic polyisocyanate, said polyisocyanurate polymer is the trimerization reaction product of an isocyanate-terminated urethane prepolymer or the reaction product of the trimerization of a polyol with an excess amount of an organic polyisocyanate in the presence of a urethane catalyst, and a trimerization catalyst, said polyurea polymer is the in-mold reaction product of an organic polyisocyanate and an amine-terminated poly(oxyalkylene) compound having an equivalent weight of about 1000 to 2000.
Claim 40
Dependent Claim
136 words
A polymer alloy comprising at least one polyamide polymer and at least one polyurethane polymer and at least one polymer selected from the group consisting of polyisocyanurate polymers and polyurea polymers, wherein said polyamide is a polymerization product of 4 to 15 carbon ring lactams, said polyurethane polymer is the reaction product of a polyhydroxy compound having an equivalent weight of 100 to 3000 with an organic polyisocyanate, said polyisocyanurate polymer is the trimerization reaction product of an isocyanate-terminated urethane prepolymer or the reaction product of the trimerization of a polyol with an excess amount of an organic polyisocyanate in the presence of a urethane catalyst, and a trimerization catalyst, said polyurea polymer is the in-mold reaction product of an organic polyisocyanate and an amine-terminated poly(oxyalkylene) compound having an equivalent weight of about 1000 to 2000.
Claim 41
Dependent Claim
58 words
The process according to claim 1, wherein in said process at least two reactions streams are prepared, said first reactant stream comprising caprolactam and an alkali lactamate; said second reactant stream comprising an isocyanate-terminated prepolymer and lactam adduct; said first and said second streams are mixed to obtain said mixture; and said mixture is introduced into the mold.
Claim 42
Dependent Claim
56 words
The process according to claim 1, wherein in said process at least two reaction streams are prepared, admixed, and then introduced into the mold, said first stream comprising at least one lactam, alkali metal lactamate catalyst, at least one polyol and a tin catalyst, and said second stream comprising a lactam blocked adduct and a polyisocyanate.
Claim 43
Dependent Claim
137 words
A molded polymer alloy product obtained by: (i) mixing substantially stable reactant streams to obtain a mixture, (ii) introducing said mixture into a mold, said mixture comprising: (a) polymer forming compounds for forming at least one polymer selected from the group consisting of polyurea polymers and polyisocyanurate polymers, said polyurea polymer forming compounds including a polyamine or hydrazine containing compound and a polyisocyanate, said polyisocyanurate polymer forming compounds including a prepolymer containing reactive isocyanate groups or a polyol and a polyisocyanate, and a trimerization catalyst; and (b) polyamide polymer forming compounds, said polyamide polymer forming compounds including at least one lactam, an anionic polymerization catalyst and a polymerization activator, said polymer forming compounds reacting in said mold wherein a molded product is formed from the respective polymer forming compounds; and (iii) recovering said product from said mold.
Claim 44
Dependent Claim
137 words
A molded polymer alloy product obtained by: (i) mixing substantially stable reactant streams to obtain a mixture, (ii) introducing said mixture into a mold, said mixture comprising: (a) polymer forming compounds for forming at least one polymer selected from the group consisting of polyurea polymers and polyisocyanurate polymers, said polyurea polymer forming compounds including a polyamine or hydrazine containing compound and a polyisocyanate, said polyisocyanurate polymer forming compounds including a prepolymer containing reactive isocyanate groups or a polyol and a polyisocyanate, and a trimerization catalyst; and (b) polyamide polymer forming compounds, said polyamide polymer forming compounds including at least one lactam, an anionic polymerization catalyst and a polymerization activator, said polymer forming compounds reacting in said mold wherein a molded product is formed from the respective polymer forming compounds; and (iii) recovering said product from said mold.
Claim 45
Dependent Claim
17 words
The molded polymer alloy according to claim 38, wherein said mixture is substantially free of entrapped gases.
Claim 46
Dependent Claim
104 words
A polymer alloy comprising a polyamide polymer and at least one polymer selected from the group consisting of polyisocyanurates and polyureas, wherein said polyamide polymer is polymerization product of 3 to 15 carbon ring lactams, said polyisocyanurate polymer is the trimerization reaction product of an isocyanate-terminated urethane prepolymer of the reaction product of the trimerization of a polyol with an excess amount of an organic polyisocyanate in the presence of a urethane catalyst, and a trimerization catalyst, and said polyurea polymer is the in-mold reaction product of an organic polyisocyanate and an amine-terminated poly(oxyalkylene) compound having an equivalent weight of about 1000 to 2000.
Claim 47
Dependent Claim
104 words
A polymer alloy comprising a polyamide polymer and at least one polymer selected from the group consisting of polyisocyanurates and polyureas, wherein said polyamide polymer is polymerization product of 3 to 15 carbon ring lactams, said polyisocyanurate polymer is the trimerization reaction product of an isocyanate-terminated urethane prepolymer of the reaction product of the trimerization of a polyol with an excess amount of an organic polyisocyanate in the presence of a urethane catalyst, and a trimerization catalyst, and said polyurea polymer is the in-mold reaction product of an organic polyisocyanate and an amine-terminated poly(oxyalkylene) compound having an equivalent weight of about 1000 to 2000.
Claim 48
Dependent Claim
16 words
The polymer alloy according to claim 40 wherein said alloy is substantially free of entrapped gases.
Claim 49
Dependent Claim
23 words
The polymer alloy according to claim 40, wherein said polyamide polymer is the block copolymerization product of 3 to 11 carbon ring lactams.
Claim 50
Dependent Claim
11 words
A body part for a vehicle obtained according to claim 1.
Claim 51
Dependent Claim
11 words
A body part for a vehicle obtained according to claim 39.
Claim 52
Dependent Claim
23 words
The process according to claim 1 wherein in the process the temperature of the mold is between about 100° C. and 160° C.
Claim 53
Dependent Claim
25 words
The product according to claim 32, wherein said product is a reaction injection molded product consisting essentially of a polyamide polymer and a polyurea polymer.
References Cited (Backward Citations)
GB1099265A
Cited
US4302553A
Cited
US4396729A
Cited
US4613440A
Cited
US4695483A
Cited
US4695509A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-05-03 | 1991-11-02 | 1992-05-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-05-03 | 1995-11-02 | 1996-05-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-05-03 | 1999-11-02 | 2000-05-03 | $7700.00 | Window Closed / Lapsed |