High flexual modulus polyurethane polymers and rim processes employing said polymers

Claim 2

In a polymer molding composition, which composition comprises a polyisocyanate and an aromatic diamine chain extender for reaction with the polyisocyanate and optionally a catalytic amount of a catalyst to effect a reaction between the polyisocyanate and the aromatic diamine to provide a thermoset polymeric reaction product having "cold break" properties on demolding, the improvement which comprises a "cold break"-reducing amount of an additive compound, the additive compound selected from the group consisting of triethanol amine and a triethanol amine-polyalkylene oxide reaction product to provide a thermoset polymer having a flexual modulus of over about 80,000 psi at 75° F. and the thermoset polymer substantially free of "cold break" properties after reaction.

Claim 3

The polymer composition of claim 1 wherein the polyisocyanate comprises an MDI polyol prepolymer with the excess isocyanate groups ranging from about 5% to 30% excess isocyanate.

Claim 4

The polymer composition of claim 2 wherein the MDI polyol prepolymer comprises an MDI-polypropylene glycol prepolymer having from about 15% to 30% excess isocyanate.

Claim 5

The polymer composition of claim 1 which includes a reactive amount of a polyol or amine polyol.

Claim 6

The polymer composition of claim 1 wherein the composition comprises a separate A side of an MDI polyisocyanate polyol prepolymer with excess isocyanate and a separate B side comprising the aromatic diamine, an organo-metallic catalyst and the "cold break"-reducing additive and the B side substantially free of a polyol.

Claim 7

The polymer composition of claim 1 which includes an organo-metallic catalyst which comprises a di-alkyl tin fatty acid catalyst.

Claim 8

The polymer composition of claim 1 which includes as the "cold break"-reducing additive a triethanol amine ethylene oxide end capped reaction product having a molecular weight of from about 600 to 1,200.

Claim 9

The polymer composition of claim 1 wherein the aromatic diamine comprises a di-ethyl toluene diamine.

Claim 10

The polymer composition of claim 1 wherein the aromatic diamine comprises a dimethyl thiotoluene diamine.

Claim 11

The polymer composition of claim 1 wherein the composition includes an impact-strength-increasing amount of a fatty acid saturated polyester.

Claim 12

The polymer composition of claim 10 wherein the saturated polyester comprises a polyethylene adipate diol.

Claim 13

The polymer composition of claim 11 wherein the thermoset polymer has an impact strength of greater than about 5 izod notched foot-pounds and a flexual modulus of greater than about 150,000 psi.

Claim 14

The polymer composition of claim 1 wherein the "cold break"-reducing additive compound is present in an amount ranging from about 5 to 40 parts per 100 parts of the composition.

Claim 15

In a hybrid polyurea-polyurethane composition suitable for use in a RIM molding process and which composition consists essentially of an MDI polyol prepolymer with excess isocyanate groups, a di-ethyl toluene diamine chain extender for reaction with the MDI isocyanate prepolymer, and a catalytic amount of a catalyst, the improvement which comprises a "cold break"-reducing amount of from about 5 to 40 parts of the composition of an additive compound selected from the group consisting of triethanol amine and a triethanol amine-ethylene oxide end capped reaction product to provide a thermoset polymer product and a flexual modulus over about 80,000 psi at 75° F. and substantially free of "cold break" properties after demolding of the thermoset polymer from the mold.

Claim 16

In a hybrid polyurea-polyurethane composition suitable for use in a RIM molding process and which composition consists essentially of an MDI polyol prepolymer with excess isocyanate groups, a di-ethyl toluene diamine chain extender for reaction with the MDI isocyanate prepolymer, and a catalytic amount of a catalyst, the improvement which comprises a "cold break"-reducing amount of from about 5 to 40 parts of the composition of an additive compound selected from the group consisting of triethanol amine and a triethanol amine-ethylene oxide end capped reaction product to provide a thermoset polymer product and a flexual modulus over about 80,000 psi at 75° F. and substantially free of "cold break" properties after demolding of the thermoset polymer from the mold.

Claim 17

The polymer composition of claim 14 which includes an impact-strength-enhancing amount of a saturated polyester fatty acid.

Claim 18

The polymer composition of claim 14 which includes a dimethyl thiotoluene diamine to increase the gel time of the composition.

Claim 19

In a hybrid polyurea-polyurethane polymer composition for use in a RIM cast molding process which composition consists essentially of an MDI polyol prepolymer with excess isocyanate groups and a chain extending amount of a dimethyl thiotoluene diamine for reaction with the MDI isocyanate prepolymer and a catalytic amount of a catalyst to effect the reaction, the improvement which comprises a "cold break"-reducing amount of from about 5 to 40 parts of the composition of an additive compound selected from the group consisting of triethanol amine and a triethanol amine-ethylene oxide end capped reaction product to provide a thermoset polymer having a flexual modulus over about 80,000 psi at 75° F., substantially free of "cold break" properties and substantially free of any thio odor.

Claim 20

In a hybrid polyurea-polyurethane polymer composition for use in a RIM cast molding process which composition consists essentially of an MDI polyol prepolymer with excess isocyanate groups and a chain extending amount of a dimethyl thiotoluene diamine for reaction with the MDI isocyanate prepolymer and a catalytic amount of a catalyst to effect the reaction, the improvement which comprises a "cold break"-reducing amount of from about 5 to 40 parts of the composition of an additive compound selected from the group consisting of triethanol amine and a triethanol amine-ethylene oxide end capped reaction product to provide a thermoset polymer having a flexual modulus over about 80,000 psi at 75° F., substantially free of "cold break" properties and substantially free of any thio odor.

Claim 21

The process of preparing a molded thermoset polymer which process comprises: a) injecting into a closed mold under high pressure the polymer composition as set forth in claim 1; b) reacting said polymer composition in the closed mold to form a molded thermoset polymeric reaction product; and c) removing the thermoset molded polymeric reaction product from the mold, the product characterized by a flexual modulus of greater than 80,000 psi at 75° F. and exhibiting substantially no "cold break" properties.

Claim 22

A thermoset molded polymeric reaction product produced by the process of claim 18.

Claim 23

A chain-extending composition suitable for use in polymer compositions employed in RIM cast molding processes and which composition comprises: a) a di-alkyl aromatic diamine as a chain extender for the polyurethane composition; and b) a "cold break"-reducing amount of an additive compound selected from the group consisting of triethanol amine and a triethanol amine-alkylene oxide reaction product.

Claim 24

A chain-extending composition suitable for use in polymer compositions employed in RIM cast molding processes and which composition comprises: a) a di-alkyl aromatic diamine as a chain extender for the polyurethane composition; and b) a "cold break"-reducing amount of an additive compound selected from the group consisting of triethanol amine and a triethanol amine-alkylene oxide reaction product.

Claim 25

The chain-extending composition of claim 20 wherein the aromatic diamine comprises a di-ethyl toluene diamine.

Claim 26

The chain-extending composition of claim 20 wherein the aromatic diamine comprises a dimethyl thiotoluene diamine.

Claim 27

The chain-extending composition of claim 20 wherein the additive compound comprises a triethanol amine-ethylene oxide end capped reaction product having a molecular weight of from about 600 to 1,200.

Claim 28

The polymer composition of claim 1 wherein the gel time of the reaction is over two seconds and the aromatic diamine comprises a diethyl toluene diamine.

Claim 29

The polymer composition of claim 1 wherein the gel time of the reaction is less than about twenty seconds and the aromatic diamine comprises dimethyl thiotoluene diamine.

Claim 30

The polymer composition of claim 14 which includes a polyol or an amine polyol and which composition has a gel time of from about two to twenty seconds.