Polyurethane-polyisocyanurate resins for fiber composite materials with a longer open time

• US 10,640,618 B2
• Filed: 05/20/2016
• Issued: 05/05/2020
• Est. Priority Date: 05/29/2015
• Status: Active Grant

• Current Assignee: BASF SE
• Original Assignee: BASF SE
• Inventors: Goeschel, Julia, Albuerne, Julio, Illguth, Rolf, Gehring, Margit
• Primary Examiner(s): Uselding, John E
• Application Number:
  US15/576,328
• Publication Number:
  US 20180148551A1
• Time in Patent Office: 1,446 Days
• CPC Class Codes: C08G 18/225 of alkali or alkaline earth metals
• CPC Class Codes: C08G 18/283 Compounds containing ether groups, e.g. oxyalkylated monohydroxy compounds
• CPC Class Codes: C08G 18/3206 aliphatic
• CPC Class Codes: C08G 18/4804 Two or more polyethers of different physical or chemical nature
• CPC Class Codes: C08G 18/4833 Polyethers containing oxyethylene units
• CPC Class Codes: C08G 18/4854 Polyethers containing oxyalkylene groups having four carbon atoms in the alkylene group
• CPC Class Codes: C08G 18/58 Epoxy resins C08G18/42, C08G18/48 take precedence; reaction products of epoxy resins with at least equivalent amounts of compounds containing active hydrogen C08G18/6407, with at least equivalent amounts of amines C08G18/6415; polymeric products of isocyanates or isothiocyanates with epoxy compounds having no active hydrogen C08G18/003
• CPC Class Codes: C08G 18/7671 containing only one alkylene bisphenyl group
• CPC Class Codes: C08J 5/043 with glass fibres

Abstract

A process is disclosed for producing polyurethane-polyisocyanurate-fiber composite parts, wherein a composition comprising polyisocyanate, a mixture obtainable by introducing an alkali metal salt or alkaline earth metal salt into a compound R—NH—CO—R′ containing urethane groups, with R′ being not hydrogen and/or not COR″, a compound containing one or more epoxide groups, polyetherol having an average functionality of 1.8 to 5.0 and a hydroxyl number of 200 to 500, a chain extender, fibrous reinforcing agents and optionally further additives form a reaction mixture. The reaction mixture is applied to the fibrous reinforcing agent and caused to react to form the polyurethane-polyisocyanurate-fiber composite part. Further disclosed is a polyurethane-polyisocyanurate-fiber composite part producible by such a process, and also the use of a polyurethane-polyisocyanurate-fiber composite part as a bodywork component of vehicles, such as bumpers, fenders or roof parts, or as structural or semistructural components for vehicles or wind turbines.

Claims

1. A process for producing polyurethane-polyisocyanurate-fiber composite parts, wherein

component (a) polyisocyanate,

component (b) a mixture comprising an alkali metal salt or alkaline earth metal salt and a compound comprising urethane groups obtained by reaction of:

(i) a polyisocyanate selected from the group consisting of 2,2′

-diphenylmethane diisocyanate;

2,4′

-diphenylmethane diisocyanate;

4,4′

-diphenylmethane diisocyanate;

mixtures of monomeric diphenylmethane diisocyanates and polymeric diphenylmethane diisocyanate;

isophorone diisocyanate or its oligomers;

2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, and mixtures thereof;

tetramethylene diisocyanate and its oligomers;

hexamethylene diisocyanate and its oligomers;

naphthylene diisocyanate; and

mixtures thereof, with

(ii) a monoalcohol, a dialcohol, or a polyol,

component (c) a compound containing one or more epoxide groups, and

component (d) a polyetherol having an average functionality of 1.8 to 5.0 and a hydroxyl number of 200 to 500,

component (e) a chain extender, and

component (f) at least one fibrous reinforcing agent

are mixed to form a reaction mixture, the reaction mixture is applied to the at least one fibrous reinforcing agent and caused to react to form the polyurethane-polyisocyanurate-fiber composite part, the amount of alkali metal ions or alkaline earth metal ions per urethane group in the component (b) being 0.0001 to 3.5, based on the number of alkali metal or alkaline earth metal ions and urethane groups, the fraction of the component (c) containing one or more epoxide groups being from 0.3 to 15 wt %, based on the total weight of components (c) and (d), and an isocyanate index being 200 to 850.

2. The process according to claim 1, wherein the isocyanate index is 200 to 450.

3. The process according to claim 1, wherein the component (a) is a polyisocyanate prepolymer having an NCO content of 5 to 33 wt %.

4. The process according to claim 1, wherein an amount of alkali metal ions or alkaline earth metal ions per isocyanate group in the component (a) and also in the component (b) is 0.0001 to 0.3, based on a number of alkali metal or alkaline earth metal ions and isocyanate groups.

5. The process according to claim 1, wherein the compound containing one or more epoxide groups in component (c) comprises two or more epoxide groups per molecule.

6. The process according to claim 1, wherein the alkali metal salt or alkaline earth metal salt in component (b) is lithium chloride.

7. The process according to claim 1, wherein the compounds containing one or more epoxide groups in component (c) are used in an amount such that an equivalents ratio of epoxide group to isocyanate group in the polyisocyanate in component (a) is 0.1 to 2.0.

8. The process according to claim 1, further comprising mixing components (a), (b), (c), (d), (e), and (f) with component (g) additives to form the reaction mixture.

9. The process according to claim 1, wherein the compounds containing one or more epoxide groups in component (c) are used in an amount such that an equivalents ratio of epoxide group to isocyanate group in the polyisocyanates in component (a) and isocyanate groups present in the component (b) is 0.1 to 2.0.

10. The process according to claim 1, wherein the polyisocyanate is selected from the group consisting of 2,2′

-diphenylmethane diisocyanate;

2,4′

-diphenylmethane diisocyanate;

4,4′

-diphenylmethane diisocyanate, and mixtures thereof.

11. The process according to claim 1, wherein the monoalcohol is selected from the group consisting of methanol, ethanol, propanol, butanol, pentanol, hexanol, poly(ethylene oxide) monomethyl ether, and mixtures thereof.

12. The process according to claim 1, wherein the dialcohol is selected from the group consisting of ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, butanediol, hexanediol, and mixtures thereof.

13. The process according to claim 1, wherein the polyol is selected from the group consisting of polyetherols, polyesterols, and mixtures thereof.

14. The process according to claim 13, wherein the polyol is polypropylene oxide.