POLYURETHANE-POLYISOCYANURATE RESINS FOR FIBER COMPOSITE MATERIALS WITH A LONGER OPEN TIME

• US 20180148551A1
• Filed: 05/20/2016
• Published: 05/31/2018
• 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
• Granted Patent: US 10,640,618 B2
• Time in Patent Office: 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 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″

,

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 a first polyisocyanate is used as component (a), and the compound containing urethane groups in component (b) is a reaction product of a second polyisocyanate and a compound having an OH group.

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

5. The process according to claim 1, wherein said compound containing urethane groups used in component (b) is a reaction product of a second polyisocyanate and a compound having at least two OH groups, the second isocyanate being used in a stoichiometric excess.

6. The process according to claim 5, wherein the second isocyanate comprises one or more isomers or homologs of diphenylmethane.

7. 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.

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

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

10. The process according to claim 1, wherein the component (b) is obtained by mixing polyisocyanate, a compound having a compound that is reactive toward isocyanate, and the alkali metal salt or alkaline earth metal salt.

11. 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) is 0.1 to 2.0.

12. A polyurethane-polyisocyanurate-fiber composite part obtainable by a process according to claim 1.

13. Structural or semistructural materials for wind turbines, vehicles, and marine components comprising a polyurethane-polyisocyanurate-fiber composite part produced according to the process of claim 1.

14. 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.

15. 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.