COMPOSITE MATERIAL COMPOSED OF OUTER LAYER AND POLYURETHANE FOAM LAYER

• US 20170190080A1
• Filed: 05/29/2015
• Published: 07/06/2017
• Est. Priority Date: 06/02/2014
• Status: Abandoned Application

• Current Assignee: BASF SE
• Original Assignee: BASF SE
• Inventors: Rischko, Gerd, Pltl, Jrg, Albuerne, Julio
• Application Number:
  US15/314,854
• Publication Number:
  US 20170190080A1
• Time in Patent Office: Days
• CPC Class Codes: B29C 44/12 Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2627/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29L 2031/3008 Instrument panels
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: C08G 18/12 using two or more compounds having active hydrogen in the first polymerisation step
• CPC Class Codes: C08G 18/14 Manufacture of cellular products
• CPC Class Codes: C08G 18/1808 having alkylene polyamine groups
• CPC Class Codes: C08G 18/1825 having hydroxy or primary amino groups
• CPC Class Codes: C08G 18/1833 having ether, acetal, or orthoester groups
• CPC Class Codes: C08G 18/3206 aliphatic
• CPC Class Codes: C08G 18/324 : containing only one aromatic ring
• CPC Class Codes: C08G 18/3281 : containing three hydroxy groups
• CPC Class Codes: C08G 18/4018 : Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48
• CPC Class Codes: C08G 18/4216 : from mixtures or combinations of aromatic dicarboxylic acids and aliphatic dicarboxylic acids and dialcohols
• CPC Class Codes: C08G 18/4816 : mixtures of two or more polyetherpolyols having at least three hydroxy groups
• CPC Class Codes: C08G 18/482 : Mixtures of polyethers containing at least one polyether containing nitrogen
• CPC Class Codes: C08G 18/4837 : and other oxyalkylene units
• CPC Class Codes: C08G 18/5021 : having nitrogen
• CPC Class Codes: C08G 18/6622 : with compounds of group C08G18/3271
• CPC Class Codes: C08G 18/6674 : with compounds of group C08G18/3203
• CPC Class Codes: C08G 18/6681 : with compounds of group C08G18/32 or C08G18/3271 and/or polyamines of C08G18/38
• CPC Class Codes: C08G 18/6688 : with compounds of group C08G18/3271
• CPC Class Codes: C08G 18/721 : Two or more polyisocyanates not provided for in one single group C08G18/73 - C08G18/80
• CPC Class Codes: C08G 18/7657 : containing two or more aromatic rings
• CPC Class Codes: C08G 18/7664 : containing alkylene polyphenyl groups
• CPC Class Codes: C08G 18/7671 : containing only one alkylene bisphenyl group
• CPC Class Codes: C08G 18/797 : containing carbodiimide and/or uretone-imine groups
• CPC Class Codes: C08G 2110/0016 : semi-rigid
• CPC Class Codes: C08G 2110/0058 : ≥50 and <150kg/m3
• CPC Class Codes: C08G 2110/0066 : ≥ 150kg/m3
• CPC Class Codes: C08G 2110/0083 : prepared using water as the sole blowing agent

Abstract

In a process for producing a composite element having at least a covering layer and polyurethane foam, the covering layer is inserted into a mold and a polyurethane reaction mixture is introduced onto the covering layer. The polyurethane reaction mixture is reacted to form a polyurethane foam, wherein the polyurethane reaction mixture is obtained by mixing a) polyisocyanate with b) compounds having isocyanate-reactive OH groups, c) blowing agents including water, d) thickeners and e) catalysts. Bis(N,N-dimethylaminoethoxyethyl) carbamate, N,N,N-trimethyl-N-hydroxyethylbis(aminopropyl ether), N,N,N-trimethyl-N-hydroxyethyl(aminoethyl ether) or mixtures thereof and/or tetramethyldiaminoethyl ether are employed as catalysts and the polyurethane foam has a density of not more than 200 g/dm³.

Claims

1. A process for producing a composite element comprising at least a covering layer and polyurethane foam, the process comprising inserting the covering layer into a mold, introducing a polyurethane reaction mixture onto the covering layer and reacting the polyurethane reaction mixture to form a polyurethane foam, wherein the polyurethane reaction mixture is obtained by mixing

a) polyisocyanate with

b) compounds having isocyanate-reactive OH groups,

c) blowing agents comprising water,

d) thickeners and

e) catalysts

wherein bis(N,N-dimethylaminoethoxyethyl) carbamate, N,N,N-trimethyl-N-hydroxyethylbis(aminopropyl ether), N,N,N-trimethyl-N-hydroxyethyl(aminoethyl ether) or mixtures thereof and/or tetramethyldiaminoethyl ether are employed as catalysts and the polyurethane foam has a density of not more than 200 g/dm³.

2. The process according to claim 1, wherein the polyurethane foam has an average thickness averaged over the surface of the covering layer coated with polyurethane foam of not more than one cm.

3. The process according to claim 1, wherein the thickener (d) is a thickener having two primary or secondary amino groups and a molecular weight of less than 500 g/mol.

4. The process according to claim 3, wherein the amino groups are primary amino groups.

5. The process according to claim 3, wherein the amino groups are bonded to aromatic hydrocarbons.

6. The process according to claim 1, wherein the thickener (d) is diethyltoluenediamine.

7. The process according to claim 1, wherein the isocyanates comprise monomeric and polymeric diphenylmethane diisocyanate.

8. The process according to claim 1, wherein the catalysts (e) comprise incorporable polyurethane catalysts.

9. The process according to claim 8, wherein the incorporable catalysts employed are from the group consisting of:

bis(N,N-dimethylaminoethoxyethyl) carbamate, N,N,N-trimethyl-N-hydroxyethylbis(aminopropyl ether), N,N,N-trimethyl-N-hydroxyethyl(aminoethyl ether) and mixtures thereof.

10. The process according to claim 1, wherein the compounds having isocyanate-reactive OH groups (b) comprise polyether polyols.

11. The process according to claim 1, wherein the isocyanate index is 90 to 120.

12. A composite element obtainable by a process according to claim 1.

13. A transport means having an interior comprising a composite element according to claim 12.