Aliphatic polyurethane sprayable coating compositions and method of preparation

Claim 2

A process for preparing a fast-curing urethane polymer, which process consists essentially of reacting about 100 parts by weight of an aliphatic polyisocyanate with from about 5 to 50 parts by weight of a caprolactone polyol in the presence of a catalytic amount of a metallo catalyst and in the presence of a curing amount of a polyalkanol amine sufficient to provide a reaction time of about 30 seconds or less and to provide a fast-reacting, color stable aliphatic urethane polymer.

Claim 3

The process of claim 1 wherein the aliphatic isocyanate comprises an aliphatic monomeric diisocyanate.

Claim 4

The process of claim 2 wherein the aliphatic isocyanate comprises a tetramethylene xylene diisocyanate.

Claim 5

The process of claim 1 wherein the alphatic isocyanate comprises a trimerized or biuret form of hexamethylene diisocyanate.

Claim 6

The process of claim 1 wherein the caprolactone polyol has a hydroxyl number ranging from about 200 to 600.

Claim 7

The process of claim 1 wherein the caprolactone polyol is a trifunctional or difunctional liquid polyol.

Claim 8

The process of claim 1 wherein the metallic catalyst comprises an organo metallic salt selected from the group consisting of lead, tin and zinc and combinations thereof.

Claim 9

The process of claim 1 wherein the catalyst comprises a combination of an organo metallic salt of lead and tin.

Claim 10

The process of claim 1 wherein the polyalkanol amine comprises a triethanol amine, a diethanol amine or a mixture thereof.

Claim 11

The process of claim 1 wherein the triethanol amine is present in a curing amount, to provide for a reaction time of less than about 15 seconds.

Claim 12

The process of claim 1 which includes carrying out the reaction in the presence of a color-producing amount of a pigment.

Claim 13

The process of claim 11 wherein the pigment comprises from about 1 to 30 parts by weight of titanium dioxide per 100 parts of the reaction mixture.

Claim 14

The process of claim 1 which includes carrying out the reaction in the presence of a blowing amount of a blowing agent, to provide a foam aliphatic urethane polymer.

Claim 15

The process of claim 1 which includes carrying out the reaction in the presence of a flame-retardant amount of a flame-retardant agent.

Claim 16

The process of claim 14 which includes carrrying out the reaction in the presence of a hologenated phosphate or a halogenated phosphate flame-retardant agent.

Claim 17

The process of claim 1 which includes carrying out the reaction in the presence of a small curing amount of diethy toluene diamine, and wherein the polyalkanol amine comprises a polyethanol amine.

Claim 18

The process of claim 1 wherein the polyalkanol amine comprises a polyethanol amine in an amount of from about 0.5% to 10% by weight of the composition.

Claim 19

The process of claim 1 wherein the caprolactone polyol is employed in an amount of about 5 to 50 parts per 100 parts of the aliphatic isocyanate, wherein the aliphatic isocyanate comprises a diisocyanate.

Claim 20

The process of claim 1 which includes preparing an A-side composition containing the aliphatic isocyanate and a B-side composition containing the caprolactone polyol, the catalyst and the curing agent, and spraying the A- and B-side compositions into a mold or onto a substrate in an open mold.

Claim 21

The process of claim 19 which includes spraying the A- and B-side compositions as a layer onto a substrate, wherein the substrate comprises a polyester resin gel coat layer in an open mold.

Claim 22

The aliphatic urethane polymer prepared by the process of claim 1.

Claim 23

The sprayed urethane coated substrate prepared by the process of claim 19.

Claim 24

The sprayed aliphatic urethane coated polymer substrate prepared by the process of claim 20.

Claim 25

A process for preparing a fast-reacting aliphatic urethane polymer suitable for use in a molding operation, and which process consists essentially of preparing A- and B-side compositions and spraying together the A- and B-side compositions onto a substrate, wherein the A-side composition comprises 100 parts by weight of an aliphatic trimerized or biuret diisocyanate or a monomeric aliphatic diisocyanate, and the B-side composition comprises from about 5 to 50 parts by weight of a liquid trifunctional or difunctional caprolactone polyol having a hydroxyl number ranging from about 200 to 600, and a catalytic amount of a tin and organo metallic catalyst and a curing amount of a polyethanol amine, the A- and B-side components reacting in about 15 seconds or less.

Claim 26

A process for preparing a fast-reacting aliphatic urethane polymer suitable for use in a molding operation, and which process consists essentially of preparing A- and B-side compositions and spraying together the A- and B-side compositions onto a substrate, wherein the A-side composition comprises 100 parts by weight of an aliphatic trimerized or biuret diisocyanate or a monomeric aliphatic diisocyanate, and the B-side composition comprises from about 5 to 50 parts by weight of a liquid trifunctional or difunctional caprolactone polyol having a hydroxyl number ranging from about 200 to 600, and a catalytic amount of a tin and organo metallic catalyst and a curing amount of a polyethanol amine, the A- and B-side components reacting in about 15 seconds or less.

Claim 27

The process of claim 24 which includes, in the B-side component, a color-producing amount of a metallic pigment, to provide a pigmented polymer of the desired color.

Claim 28

The aliphatic urethane polymer produced by the process of claim 24.

Claim 29

The process of claim 24 which includes spraying the reactive mixture onto an open mold or a resin gel coat substrate in an open mold.

Claim 30

The sprayed aliphatic urethane coated polymer substrate prepared by the process of claim 24.

Claim 31

The process of claim 1 wherein the polyalkanol amine comprises a substantially pure 99% triethanol amine.

Claim 32

The process of claim 1 which includes introducing the reactants into a mold and removing a molded part from said mold.

Claim 33

The molded part produced by the process of claim 30.