Process for the production of polyurethane articles from uretonimine based compositions and ethylene oxide rich polyether polyols

Claim 2

A reaction injection molding process comprising reacting: A) an isocyanate quasi pre-polymer component comprising the reaction product of: i) a uretonimine modified MDI having a free isocyanate content of from 20-30% by weight NCO; and ii) a polyether triol component obtained from the reaction of a triol starter with a mixture of ethylene oxide and propylene oxide, containing 10-85% by weight of ethylene oxide and having a number average molecular weight of from 400-6,000; and wherein said isocyanate quasi pre-polymer has a free isocyanate content of from 10-27% by weight NCO; and B) a polyol component comprising: i) 25-250 pbw of a polyether polyol component of functionality of 2-3 having from 65-100% by weight ethylene oxide units and 0-50% by weight propylene oxide units and a number average molecular weight of 400-6,000; ii) 25 pbw of an aromatic diamine; and iii) 0-40 pbw of an aminic polyol; iv) 0.01-0.5 pbw of an organometallic urethane forming catalyst; and v) 0-5.0 pbw of an amine urethane forming catalyst, wherein pbw is based on 25 pbw of the aromatic diamine component.

Claim 3

The process of claim 1, wherein said polyether polyol (B(i)) component contains 65-85% EO and 15-35% PO.

Claim 4

The process of claim 1, wherein said polyether polyol (B(i)) contains 70% EO and 30% PO.

Claim 5

The process of claim 1, wherein said polyether polyol (B(i)) component has a number average molecular weight of from 4,000-5,000.

Claim 6

The process of claim 1, wherein said polyether triol (A(ii)) has a number average molecular weight of from 4,000-5,000.

Claim 7

The process of claim 1, wherein said process is reinforced reaction injection molding.

Claim 8

The process of claim 1, wherein said process is structural reaction injection molding.

Claim 9

The process of claim 1, wherein said process is spray molding.

Claim 10

A composition for a RIM process comprising: A) an isocyanate quasi pre-polymer component comprising the reaction product of: i) a uretonimine modified MDI having a free isocyanate content of from 20-30% by weight NCO; and ii) a polyether triol component obtained from the reaction of a triol starter with a mixture of ethylene oxide and propylene oxide, containing 10-85% by weight of ethylene oxide and having a number average molecular weight of from 400-6,000; wherein said isocyanate quasi pre-polymer has a free isocyanate content of from 10-27% by weight NCO; and B) a polyol component comprising: i) 25-250 pbw of a polyether polyol component of functionality of 2-3 having from 50-100% by weight ethylene oxide units and 0-50% by weight propylene oxide units and a number average molecular weight of 400-6,000; ii) 25 pbw of an aromatic diamine; and iii) 0-40 pbw of an aminic polyol; iv) 0.01-0.5 pbw of an organometallic urethane forming catalyst; and v) 0-5.0 pbw of an amine urethane forming catalyst, wherein pbw is based on 25 pbw of the aromatic diamine component.

Claim 11

A composition for a RIM process comprising: A) an isocyanate quasi pre-polymer component comprising the reaction product of: i) a uretonimine modified MDI having a free isocyanate content of from 20-30% by weight NCO; and ii) a polyether triol component obtained from the reaction of a triol starter with a mixture of ethylene oxide and propylene oxide, containing 10-85% by weight of ethylene oxide and having a number average molecular weight of from 400-6,000; wherein said isocyanate quasi pre-polymer has a free isocyanate content of from 10-27% by weight NCO; and B) a polyol component comprising: i) 25-250 pbw of a polyether polyol component of functionality of 2-3 having from 50-100% by weight ethylene oxide units and 0-50% by weight propylene oxide units and a number average molecular weight of 400-6,000; ii) 25 pbw of an aromatic diamine; and iii) 0-40 pbw of an aminic polyol; iv) 0.01-0.5 pbw of an organometallic urethane forming catalyst; and v) 0-5.0 pbw of an amine urethane forming catalyst, wherein pbw is based on 25 pbw of the aromatic diamine component.

Claim 12

A method of forming a polyurethane molded article comprising reaction injection molding the composition of claim 9.

Claim 13

A method of forming a reinforced polyurethane molded article with an A class surface comprising; i) forming a first layer of the composition of claim 9; ii) forming a second layer of the composition of claim 9 by structural reaction injection molding.

Claim 14

A molded article obtained by reaction injection molding of A) an isocyanate quasi pre-polymer component comprising the reaction product of: i) a uretonimine modified MDI having a free isocyanate content of from 20-30% by weight NCO; and ii) a polyether triol component obtained from the reaction of a triol starter with a mixture of ethylene oxide and propylene oxide, containing 10-85% by weight of ethylene oxide and having a number average molecular weight of from 400-6,000; and wherein said isocyanate quasi pre-polymer has a free isocyanate content of from 10-27% by weight NCO; and B) a polyol component comprising: i) 25-250 pbw of a polyether polyol component of functionality of 2-3 having from 65-100% by weight ethylene oxide units and 0-50% by weight propylene oxide units and a number average molecular weight of 400-6,000; ii) 25 pbw of an aromatic diamine; and iii) 0-40 pbw of an aminic polyol; iv) 0.01-0.5 pbw of an organometallic urethane forming catalyst; and v) 0-5.0 pbw of an amine urethane forming catalyst, wherein pbw is based on 25 pbw of the aromatic diamine component.

Claim 15

A molded article obtained by reaction injection molding of A) an isocyanate quasi pre-polymer component comprising the reaction product of: i) a uretonimine modified MDI having a free isocyanate content of from 20-30% by weight NCO; and ii) a polyether triol component obtained from the reaction of a triol starter with a mixture of ethylene oxide and propylene oxide, containing 10-85% by weight of ethylene oxide and having a number average molecular weight of from 400-6,000; and wherein said isocyanate quasi pre-polymer has a free isocyanate content of from 10-27% by weight NCO; and B) a polyol component comprising: i) 25-250 pbw of a polyether polyol component of functionality of 2-3 having from 65-100% by weight ethylene oxide units and 0-50% by weight propylene oxide units and a number average molecular weight of 400-6,000; ii) 25 pbw of an aromatic diamine; and iii) 0-40 pbw of an aminic polyol; iv) 0.01-0.5 pbw of an organometallic urethane forming catalyst; and v) 0-5.0 pbw of an amine urethane forming catalyst, wherein pbw is based on 25 pbw of the aromatic diamine component.

Claim 16

A molded article obtained by reaction injection molding of A) an isocyanate quasi pre-polymer component comprising the reaction product of: i) a uretonimine modified MDI having a free isocyanate content of from 20-30% by weight NCO; and ii) a polyether triol component obtained from the reaction of a triol starter with a mixture of ethylene oxide and propylene oxide, containing 10-85% by weight of ethylene oxide and having a number average molecular weight of from 400-6,000; and wherein said isocyanate quasi pre-polymer has a free isocyanate content of from 10-27% by weight NCO; and B) a polyol component comprising: i) 25-250 pbw of a polyether polyol component of functionality of 2-3 having from 65-100% by weight ethylene oxide units and 0-50% by weight propylene oxide units and a number average molecular weight of 400-6,000; ii) 25 pbw of an aromatic diamine; and iii) 0-40 pbw of an aminic polyol; iv) 0.01-0.5 pbw of an organometallic urethane forming catalyst; v) 0-5.0 pbw of an amine urethane forming catalyst; vi) 0.05-1.0 pbw of water; vii) 0.01-0.1 pbw of a chemical blowing catalyst; and viii) 0.5-1.0 pbw of a foam stabilizer, wherein pbw is based on 25 pbw of the aromatic diamine component.

Claim 17

A molded article obtained by reaction injection molding of A) an isocyanate quasi pre-polymer component comprising the reaction product of: i) a uretonimine modified MDI having a free isocyanate content of from 20-30% by weight NCO; and ii) a polyether triol component obtained from the reaction of a triol starter with a mixture of ethylene oxide and propylene oxide, containing 10-85% by weight of ethylene oxide and having a number average molecular weight of from 400-6,000; and wherein said isocyanate quasi pre-polymer has a free isocyanate content of from 10-27% by weight NCO; and B) a polyol component comprising: i) 25-250 pbw of a polyether polyol component of functionality of 2-3 having from 65-100% by weight ethylene oxide units and 0-50% by weight propylene oxide units and a number average molecular weight of 400-6,000; ii) 25 pbw of an aromatic diamine; and iii) 0-40 pbw of an aminic polyol; iv) 0.01-0.5 pbw of an organometallic urethane forming catalyst; v) 0-5.0 pbw of an amine urethane forming catalyst; vi) 0.05-1.0 pbw of water; vii) 0.01-0.1 pbw of a chemical blowing catalyst; and viii) 0.5-1.0 pbw of a foam stabilizer, wherein pbw is based on 25 pbw of the aromatic diamine component.

Claim 18

The molded article according to claim 12, wherein said molded article has a flexural modulus of ≧80,000 psi at 75° F. and being substantially free of "cold break properties".

Claim 19

The reaction injection molding process of claim 1, wherein said polyether polyol component is a random heteropolymer of polyethylene oxide and polypropylene oxide units.

Claim 20

The composition of claim 9, wherein said polyether polyol component is a random heteropolymer of polyethylene oxide and polypropylene oxide units.

Claim 21

The molded article of claim 12, wherein said polyether polyol component is a random heteropolymer of polyethylene oxide and polypropylene oxide units.

Claim 22

The molded article of claim 13, wherein said polyether polyol component is a random heteropolymer of polyethylene oxide and polypropylene oxide units.