Reaction injection molded polyurethanes employing high molecular weight polyols

Claim 2

In a process for preparing molded polymer systems which systems employ a composition which comprises (A) at least one relatively high molecular weight hydroxyl-containing polyol; (B) at least one chain extender; and (C) at least one polyisocyanate, polyisothiocyanate or mixture thereof; the improvement which comprises replacing at least a portion of component (A) with (D) a material or mixture of materials having an average equivalent weight of at least 500 and which contains a plurality of oxyalkylene groups and at least one primary or secondary amine group per molecule with the proviso that when such material contains only one primary or secondary amine group per molecule, it also contains at least one other group containing a hydrogen atom reactive with NCO and/or NCS group per molecule; and wherein (i) of the total number of hydrogen equivalents contributed by hydroxyl groups and amine groups in components (A) and (D), from about 25 to about 100 percent of such hydrogen equivalents are derived from amine groups; and (ii) the NCX index is from about 0.6 to about 1.5 with the proviso that when the system contains an NCX trimerization catalyst, the NCX index can be as high as about 5.

Claim 3

A process of claim 1 wherein (i) component (A) is a polyether polyol having an average hydroxyl functionality of from about 2 to about 8 and an average hydroxyl equivalent weight of from about 500 to about 5000; (ii) component (B) is selected from the group consisting of (1) hydroxyl-containing materials which are essentially free of aliphatic amine hydrogen atoms, have an average OH functionality of from about 2 to about 4 and have an average OH equivalent weight of from about 30 to about 120; and (2) aromatic amine-containing materials which are essentially free of aliphatic amine hydrogen atoms and which contain at least two aromatic amine hydrogen atoms; (3) aliphatic amine-containing materials having at least one primary amine group, an average aliphatic amine hydrogen functionality of from about 2 to about 16 and an average aliphatic amine hydrogen equivalent weight of from about 15 to less than about 500; and (4) mixtures thereof; (iii) component (C) is a polyisocyanate; (iv) component (D) is an aminated or partially aminated polyoxyalkylene diol or triol having an average equivalent weight of from greater than 500 to about 3,000; (v) component (B) is present in quantities of from about 5 to about 60 parts per 100 parts by weight of the combined weight of components (A) and (D); (vi) component (D) is present in quantities such that from about 50 to about 100 percent of the hydrogen equivalents contained in components (A) and (D) are contributed by amine groups; and (vii) the NCX index is from about 0.7:1 to about 1.25:1.

Claim 4

A process of claim 2 wherein (i) component (A) has an average functionality of from about 2 to about 4 and an average hydroxyl equivalent weight of from about 1000 to about 3000; (ii) component (B) is present in quantities of from about 15 to about 50 parts per 100 parts by weight of the combined weight of components (A) and (D); and (iii) component (D) is an aminated or partially aminated polyoxyalkylene glycol having, before amination, an average equivalent weight of from 500 to about 2,000; (iv) component (D) is present in quantities such that from about 60 to about 100 percent of the hydrogen equivalents contained in components (A) and (D) are contributed by amine groups; and (v) the NCX index is from about 0.8:1 to about 1.10:1.

Claim 5

A process of claim 3 wherein component (A) has an average hydroxyl functionality of from about 2 to about 3 and an average hydroxyl equivalent weight of from about 1500 to about 2500 and component (B) is present in quantities of from about 20 to about 40 parts per 100 parts by weight of the combined weight of components (A) and (D).

Claim 6

A process of claims 1, 2, 3 or 4 wherein (i) component (A) is a polyoxyalkylene glycol or a glycerine or trimethylolpropane initiated polyoxyalkylenepolyol or a hydrocarbon polyol; (ii) component (B) is ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butane diol, a polymethylenepolyphenylamine having a functionality of from 2 to about 5, 1-methyl-3,5-diethyl-2,4-diaminobenzene, 1-methyl-3,5-diethyl-2,6-diaminobenzene, 3,5,3',5'-tetraethyl-4,4'-diaminodiphenylmethane, 2,4-bis(p-aminobenzyl)aniline, an aminated polyoxypropylene glycol having an average amine hydrogen equivalent weight of from about 60 to about 110, or mixture thereof; and (iii) component (C) is a liquid, modified diphenylmethane diisocyanate quasi-prepolymer of diphenylmethane diisocyanate, quasi-prepolymer of modified diphenylmethane diisocyanate, quasi-prepolymer of toluene diisocyanate or mixture thereof and wherein the average NCO equivalent weight is from about 140 to about 200.

Claim 7

A composition comprising (A) an active hydrogen-containing composition comprising (1) at least one material containing at least one primary or secondary amine group per molecule and has an average equivalent weight of at least about 500; and (2) optionally a polyol or mixture of polyols whose source of active hydrogen atoms is derived only from groups other than primary or secondary amine groups, has an average active hydrogen equivalent weight of at least 500; with the proviso that if polyol (A-1) has only one primary or secondary amine group per molecule, then it also has at least one other group reactive with an NCO and/or NCS group per molecule and wherein in component (A) from about 25 to about 100 percent of the active hydrogen equivalents contained therein are derived from amine groups; and (B) as a chain extender composition, one or more members selected from (1) an aliphatic amine-containing material having at least one primary amine group or a mixture of such materials, which material or mixture of materials has an average aliphatic amine hydrogen functionality of from about 2 to about 16, and an average aliphatic amine hydrogen equivalent weight of from about 15 to about 500; (2) a hydroxyl-containing material free of aliphatic amine hydrogen atoms or mixture of such materials, which material or material mixture has an average OH functionality of from about 2 to about 4, and an average OH equivalent weight of from about 30 to about 120; (3) an aromatic amine-containing compound which is essentially free of aliphatic amine hydrogens and which contains at least 2 aromatic amine hydrogen atoms or a mixture of such materials; (4) mixtures thereof; and wherein (i) when component (B) has an average equivalent weight of less than about 50, component (B) is present in quantities of from about 5 to about 60, percent by weight of component (A); (ii) when component (B) has an average equivalent weight of from about 50 to about 150, component (B) is present in quantities of from about 5 to about 90, percent by weight of component (A); (iii) when component (B) has an average equivalent weight of greater than about 150, component (B) is present in quantities of from about 5 to about 120, percent by weight of component (A); and (iv) equivalent weight is the average molecular weight divided by the total number of hydrogen atoms attached to an oxygen atom or a nitrogen atom.

Claim 8

A composition comprising (A) an active hydrogen-containing composition comprising (1) at least one material containing at least one primary or secondary amine group per molecule and has an average equivalent weight of at least about 500; and (2) optionally a polyol or mixture of polyols whose source of active hydrogen atoms is derived only from groups other than primary or secondary amine groups, has an average active hydrogen equivalent weight of at least 500; with the proviso that if polyol (A-1) has only one primary or secondary amine group per molecule, then it also has at least one other group reactive with an NCO and/or NCS group per molecule and wherein in component (A) from about 25 to about 100 percent of the active hydrogen equivalents contained therein are derived from amine groups; and (B) as a chain extender composition, one or more members selected from (1) an aliphatic amine-containing material having at least one primary amine group or a mixture of such materials, which material or mixture of materials has an average aliphatic amine hydrogen functionality of from about 2 to about 16, and an average aliphatic amine hydrogen equivalent weight of from about 15 to about 500; (2) a hydroxyl-containing material free of aliphatic amine hydrogen atoms or mixture of such materials, which material or material mixture has an average OH functionality of from about 2 to about 4, and an average OH equivalent weight of from about 30 to about 120; (3) an aromatic amine-containing compound which is essentially free of aliphatic amine hydrogens and which contains at least 2 aromatic amine hydrogen atoms or a mixture of such materials; (4) mixtures thereof; and wherein (i) when component (B) has an average equivalent weight of less than about 50, component (B) is present in quantities of from about 5 to about 60, percent by weight of component (A); (ii) when component (B) has an average equivalent weight of from about 50 to about 150, component (B) is present in quantities of from about 5 to about 90, percent by weight of component (A); (iii) when component (B) has an average equivalent weight of greater than about 150, component (B) is present in quantities of from about 5 to about 120, percent by weight of component (A); and (iv) equivalent weight is the average molecular weight divided by the total number of hydrogen atoms attached to an oxygen atom or a nitrogen atom.

Claim 9

A composition of claim 6 wherein (1) component (A-1) has an average equivalent weight of from 500 to about 3000; (2) component (A-2) is a polyether polyol or mixture of polyether polyols, which polyol or polyol mixture has an average hydroxyl functionality of from about 3 to about 8 and an average hydroxyl equivalent weight of from about 500 to about 5,000; (3) component (B-1) is an aliphatic amine-containing material or a mixture of such materials, which material or material mixture has an average aliphatic amine hydrogen functionality of from about 2 to about 12 and an average aliphatic amine hydrogen equivalent weight of from about 50 to about 200; (4) component (B-2) has an average hydroxyl functionality of from about 2 to about 3 and an average hydroxyl equivalent weight of from about 30 to about 70; (5) from about 50 to about 100 percent of the hydrogen equivalents in component (A) is derived from amine groups; (6) when component (B) has an average equivalent weight of less than about 50, component (B) is present in quantities of from about 15 to about 50 percent by weight of component (A); (7) when component (B) has an average equivalent weight of from about 50 to about 150, component (B) is present in quantities of from about 15 to about 70 percent by weight of component (A); (8) when component (B) has an average equivalent weight of greater than about 150, component (B) is present in quantities of from about 15 to about 100 percent by weight of component (A); and (9) equivalent weight is the average molecular weight divided by the total number of hydrogen atoms attached to an oxygen atom or a nitrogen atom.

Claim 10

A composition of claim 7 wherein (1) component (A-1) has an average equivalent weight of from 500 to about 2000; (2) component (A-2) has an average functionality of from about 3 to about 4 and an average hydroxyl equivalent weight of from about 1000 to about 3000; (3) component (B-1) has an average aliphatic amine hydrogen functionality of from about 4 to about 8 and an average aliphatic amine hydrogen equivalent weight of from about 80 to about 150; (4) component (B-2) has an average functionality of about 2 and an average hydroxyl equivalent weight of from about 30 to about 50; (5) from about 60 to about 100 percent of the hydrogen equivalents in component (A) is derived from amine groups; (6) when component (B) has an average equivalent weight of less than about 50, component (B) is present in quantities of from about 20 to about 40 percent by weight of component (A); (7) when component (B) has an average equivalent weight of from about 50 to about 150, component (B) is present in quantities of from about 20 to about 55 percent by weight of component (A); (8) when component (B) has an average equivalent weight of greater than about 150, component (B) is present in quantities of from about 20 to about 85 percent by weight of component (A); and (9) wherein equivalent weight is the average molecular weight divided by the total number of hydrogen atoms attached to an oxygen atom or a nitrogen atom.

Claim 11

A composition of claim 8 wherein (1) component (A-2) has an average functionality of from about 3 to about 4 and an average hydroxyl equivalent weight of from about 1500 to about 2500; (2) component (B-1) has an average aliphatic amine hydrogen functionality of from about 4 to about 8 and an average aliphatic amine hydrogen equivalent weight of from about 80 to about 150.

Claim 12

A composition of claims 6, 7, 8 or 9 wherein (1) component (A-2) is a glycerine and/or trimethylolpropane initiated polyoxyalkylenepolyol; and (2) component (B-1) is an aminated polyoxypropylene glycol having an average amine hydrogen equivalent weight of from about 60 to about 110.

Claim 13

A composition of claims 6, 7, 8 or 9 wherein (1) component (A-2) is a glycerine and/or trimethylolpropane initiated polyoxyalkylenepolyol; (2) component (A-1) is an aminated glycerine and/or trimethylolpropane initiated polyoxyalkylenepolyol; (3) component (B) is a mixture of an aminated polyoxypropylene glycol having an average amine hydrogen equivalent weight of from about 60 to about 110 and ethylene glycol.

Claim 14

A composition of claims 6, 7, 8 or 9 wherein (1) component (A-1) is an aminated glycerine and/or trimethylolpropane initiated polyoxyalkylenepolyol; (2) component (A-2) is a glycerine and/or trimethylolpropane initiated polyoxyalkylenepolyol; (3) component (B) is a mixture of an aminated polyoxypropylene glycol having an average amine hydrogen equivalent weight of from about 60 to about 110 and a polymethylene polyphenyl amine containing major quantities of 2,4-bis(p-aminobenzyl)aniline.

Claim 15

A composition of claims 6, 7, 8 or 9 wherein component (A-1) has an average equivalent weight of greater than 500.

Claim 16

A composition of claim 10 wherein component (A-1) has an average equivalent weight of greater than 500.

Claim 17

A composition of claim 11 wherein component (A-1) has an average equivalent weight of greater than 500.

Claim 18

A composition of claim 12 wherein component (A-1) has an average equivalent weight of greater than 500.

Claim 19

A composition of claims 6, 7, 8, 9, 10, 11 or 12 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardant agents, mold release agents, blowing agents or coloring agents.

Claim 20

A composition of claim 10 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardant agents, mold release agents, blowing agents or coloring agents.

Claim 21

A composition of claim 11 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardant agents, reinforcing agents, mold release agents, blowing agents or coloring agents.

Claim 22

A composition of claim 12 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardant agents, mold release agents, blowing agents or coloring agents.

Claim 23

A composition of claim 13 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardant agents, mold release agents, blowing agents or coloring agents.

Claim 24

A composition of claim 14 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardants agents, mold release agents, blowing agents or coloring agents.

Claim 25

A composition of claim 15 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardant agents, mold release agents, blowing agents or coloring agents.

Claim 26

A composition of claim 16 which additionally contains minor quantities of one or more of any combination of cell control agents, fire retardant agents, mold release agents, blowing agents or coloring agents.