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Method and compositions for spray molding polyurethane three dimensional objects

  • US 6,362,302 B1
  • Filed: 11/29/1999
  • Issued: 03/26/2002
  • Est. Priority Date: 11/29/1999
  • Status: Active Grant
First Claim
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1. A method of making a molded polyurethane three dimensional shape, the method comprisingcreating a mold and supporting cradle having a mold cavity conforming to the exterior of shape desired, said mold having a substantial degree of flexibility;

  • spraying a quasi-gel polymer precursor composition into the mold cavity, said quasi-gel polymer precursor composition comprising a mixture of an isocyanate portion and a curative portion and being mixed prior to introduction into a spray gun, carrying out said spraying to build up the molded three dimensional shape to a desired thickness and stippling said cradle and mold from the molded polyurethane three dimensional shape after the curing of said quasi-gel polymer precursor, wherein the curative portions of the quasi-gel polymer precursor includes a rigid polymer resin, a gelling agent, a flexible polymer resin, a molecular sieve drying agent, a crosslinking agent, a suspension agent and a polymerization co-catalyst, and wherein the rigid polymer resin is a combination of penta erythritol base quadra functional polyol and a polyether base triol, the gelling agent is a aromatic diamine the flexible polymer resin is a polyether base triol, the molecular sieve drying agent is an aluminosilicate, the crosslinking agent is selected from aldimines, ketimines and oxazolidines, the suspension agent is a mixture of salts from alkylamides and esters, and the polymerization co-catalyst is phenyl mercuric neodecanoate.

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