Article and method of producing same

• US 8,168,298 B2
• Filed: 11/09/2007
• Issued: 05/01/2012
• Est. Priority Date: 12/01/2006
• Status: Active Grant

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: BASF Corporation (BASF SE)
• Inventors: Stearns, Robert B.
• Primary Examiner(s): Tran, Thao T.
• Application Number:
  US11/937,521
• Publication Number:
  US 20080143083A1
• Time in Patent Office: 1,635 Days
• Field of Search: 428/423.3, 428/423.1, 280/728.1, 280/729, 264/45.1
• US Class Current: 428/423.1
• CPC Class Codes: B60R 21/2165 characterised by a tear line for defining a deployment opening
• CPC Class Codes: C08G 18/3206 aliphatic
• CPC Class Codes: C08G 18/4812 Mixtures of polyetherdiols with polyetherpolyols having at least three hydroxy groups
• CPC Class Codes: C08G 18/4829 Polyethers containing at least three hydroxy groups C08G18/4833 - C08G18/5096 take precedence
• CPC Class Codes: C08G 18/6674 with compounds of group C08G18/3203
• CPC Class Codes: C08G 18/725 Combination of polyisocyanates of C08G18/78 with other polyisocyanates
• 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 18/797 containing carbodiimide and/or uretone-imine groups
• CPC Class Codes: C08K 3/36 Silica
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31554 Next to second layer of polyamidoester

Abstract

An article is formed in a mold having a mold cavity, has a periphery, and defines a score line having a tensile heal strength of less than 200 ppi along the score line. The article includes a cured urethane composition including the reaction product of an isocyanate component and a resin composition. The cured urethane composition is used in a method of forming the article. The method includes the steps of determining a theoretical tensile heal strength along the score line and applying the isocyanate component into the mold cavity in response to the determining of the theoretical tensile heal strength. The method also includes the steps of applying the resin composition into the mold cavity, reacting the isocyanate component and the resin composition to form a urethane composition, curing the urethane composition, and de-molding the article from the mold cavity.

Claims

1. A method of forming an article having a periphery and defining a score line within the periphery dividing the article into at least a first portion and a second portion separable from the first portion under application of pressure, said method comprising the steps of:

a) applying an isocyanate component and a resin composition into a mold cavity, wherein the resin composition comprises a polyol, wherein the polyol comprises an ethylene oxide cap of from 10 to 20 percent by weight based on the total weight of the polyol;

b) reacting the isocyanate component and the resin composition to form a urethane composition;

c) curing the urethane composition to form a cured urethane composition, wherein the cured urethane composition is elastomeric;

d) de-molding the article from the mold cavity; and

e) scoring the article within the periphery to form the score line having a tensile heal strength of less than 200 pounds per inch along the score line.

2. A method as set forth in claim 1 wherein the tensile heal strength is less than 150 pounds per inch.

3. A method as set forth in claim 1 wherein the isocyanate component is selected from the group of polymeric methylene diphenyl diisocyanate, 4,4′

-methylene diphenyl diisocyanate, 2,4′

-methylene diphenyl diisocyanate and combinations thereof.

4. A method as set forth in claim 1 wherein the resin composition further comprises an additive that is structurally symmetric.

5. A method as set forth in claim 4 wherein the additive that is structurally symmetric comprises a diol having less than 6 carbon atoms.

6. A method as set forth in claim 1 wherein the step of scoring the article within the periphery is completed prior to de-molding the article.

7. A molded article having a periphery, defining a score line within said periphery dividing said article into at least a first portion and a second portion separable from said first portion under application of pressure, having a tensile heal strength of less than 200 pounds per inch along said score line, and comprising a cured urethane composition which is elastomeric and includes the reaction product of an isocyanate component and a resin composition comprising a polyol, wherein said polyol comprises an ethylene oxide cap of from 10 to 20 percent by weight based on the total weight of said polyol.

8. An article as set forth in claim 7 wherein said tensile heal strength is less than 150 pounds per inch along said score line.

9. An article as set forth in claim 7 wherein said isocyanate component is selected from the group of polymeric methylene diphenyl diisocyanate, 4,4′

-methylene diphenyl diisocyanate, 2,4′

-methylene diphenyl diisocyanate and combinations thereof.

10. An article as set forth in claim 7 wherein said resin composition further comprises an additive that is structurally symmetric and comprises a diol having less than 6 carbon atoms.

11. An article as set forth in claim 7 having a graves tear strength of greater than 100 pounds per inch as determined by ASTM D624 Die C, a tensile strength of greater than 900 pounds per linear inch as determined by ASTM D412 Die A, and an elongation of greater than 150% as determined by ASTM D412 Die A.

12. An article as set forth in claim 7 including a first layer comprising said cured urethane composition and a second layer disposed on said first layer and comprising a second cured urethane composition different from said cured urethane composition.

13. An article as set forth in claim 12 wherein said second cured urethane composition is foamed.

14. A method of forming an article having a periphery and defining a score line within the periphery dividing the article into at least a first portion and a second portion separable from the first portion under application of pressure, said method comprising the steps of:

a) determining a theoretical tensile heal strength along the score line;

b) applying an isocyanate component into a mold cavity in response to the determining of the theoretical tensile heal strength;

c) applying a resin composition comprising a polyol into the mold cavity, wherein the polyol comprises an ethylene oxide cap of from 10 to 20 percent by weight based on the total weight of the polyol;

d) reacting the isocyanate component and the resin composition to form a urethane composition;

e) curing the urethane composition to form a cured urethane composition, wherein the cured urethane composition is elastomeric;

f) de-molding the article from the mold cavity; and

g) scoring the article within the periphery to form the score line wherein the article has a tensile heal strength of less than 200 pounds per inch along the score line.

15. A method as set forth in claim 14 wherein the step of determining a theoretical tensile heal strength along the score line comprises the step of determining a suitable isocyanate component for use in effecting the theoretical tensile heal strength along the score line.

16. A method as set forth in claim 15 wherein the step of applying an isocyanate component into the mold cavity in response to the determining of the theoretical tensile heal strength comprises the step of applying the suitable isocyanate component into the mold cavity.

17. A method as set forth in claim 14 wherein the isocyanate component is selected from the group of polymeric methylene diphenyl diisocyanate, 4,4′

-methylene diphenyl diisocyanate, 2,4′

-methylene diphenyl diisocyanate and combinations thereof.

18. A method as set forth in claim 14 wherein the resin composition further comprises an additive that is structurally symmetric and has less than 6 carbon atoms.

19. A molded article having a periphery, defining a score line within said periphery dividing said article into at least a first portion and a second portion separable from said first portion under application of pressure, having a tensile heal strength of less than 200 pounds per inch along said score line, and comprising a cured urethane composition which is elastomeric and includes the reaction product of an isocyanate component and a resin composition comprising a polyol, wherein said molded article includes a first layer comprising said cured urethane composition and a second layer disposed on said first layer and comprising a second cured urethane composition different from said cured urethane composition.

20. An article as set forth in claim 19 wherein said second cured urethane composition is foamed.