Polyurethane composite system having high compressive strength and rigidity

Patent metadata

Field	Value
Publication number	US-10125230-B2
Application number	US-201013516880-A
Country	US
Kind code	B2
Filing date	Dec 16, 2010
Priority date	Dec 18, 2009
Publication date	Nov 13, 2018
Grant date	Nov 13, 2018

Abstract

The present invention relates to a polyurethane composite system comprising a rigid polyurethane foam and a coating material composed of a compact polyurethane or a compact polyurea, wherein the rigid polyurethane foam comprises a porous three-dimensional reinforcing material which forms a network, where the network encloses at least 50% of the volume of the rigid polyurethane foam, or at least two layers of a porous, at least two-dimensional reinforcing material. The present invention further relates to a process for producing the polyurethane composite system and also a sports article, cladding part or furniture item comprising such a polyurethane composite system.

First claim

The invention claimed is:

1. A polyurethane composite system, comprising:
a rigid polyurethane foam; and
a coating material comprising a compact polyurethane or a compact polyurea,
wherein the rigid polyurethane foam comprises at least two layers of a porous, at least two-dimensional reinforcing material,
wherein a maximum distance between two adjacent layers among one another or between an upper layer and an upper side of the foam or between a lower layer and an underside of the foam differs from the minimum distance between two layers among one another or between the upper layer and the upper side of the foam or between the lower layer and the underside of the foam by a factor of not more than 2,
wherein the two-dimensional reinforcing material is homogenously distributed in the rigid polyurethane foam,
wherein the rigid polyurethane foam has a density of from 30 g/l to 100 g/l, and
wherein the rigid polyurethane foam has a density-independent compressive strength of at least 5*10 −4 MPa*(l/g) 1.6 .

2. The system of claim 1 , wherein the reinforcing material is a fiberglass mat.

3. The system of claim 1 , wherein the rigid polyurethane foam is obtained by a process comprising:
(I) mixing a) a polyisocyanate, b) a compound comprising a group which is reactive toward isocyanates, c) a blowing agent comprising water, d) a catalyst mixture comprising a tertiary amine, and optionally e) an further additive, to obtain a reaction mixture;
(II) applying the reaction mixture to a reinforcing material; and then
(III) curing the reaction mixture.

4. The system of claim 3 , wherein the compound (b) comprises a first polyetherol (b1) having a functionality of 4 or more and a viscosity at 25° C. of 10 000 mPas or less, and a second polyetherol (b2) having a functionality of 3.5 or less and a viscosity at 25° C. of 600 mPas or less.

5. The system of claim 4 , wherein the compound (b) further comprises a third polyesterol (b3) having a viscosity at 25° C. of 2000 mPas or less, a chain extender (b4), and optionally, a crosslinker (b5).

6. The system of claim 1 , wherein the rigid polyurethane foam comprises an isocyanate component comprising PMDI.

7. The system of claim 1 , wherein the rigid polyurethane foam has a density-independent compressive E modulus of at least 8*10 −3 MPa*(l/g) 1.7 .

8. The system of claim 1 , wherein the coating material is a compact polyurea obtained by mixing a first compound comprising at least two isocyanate groups with a second compound comprising at least two primary or secondary amino groups.

9. A sports article, a vehicle construction part, a cooling container, a wind turbine blade, an aircraft part, a furniture item, or a building industry component comprising:
the polyurethane composite system of claim 1 .

10. The system of claim 1 , wherein the rigid polyurethane foam has a density-independent compressive strength of at least 5.5*10 −4 MPa*(l/g) 1.6 .

11. The system of claim 1 , wherein the rigid polyurethane foam has a density-independent compressive E modulus of at least 9.5*10 −3 MPa*(l/g) 1.7 .

12. The system of claim 1 , wherein
a maximum distance between two adjacent layers among one another or between an upper layer and an upper side of the foam or between a lower layer and an underside of the foam differs from the minimum distance between two layers among one another or between the upper layer and the upper side of the foam or between the lower layer and the underside of the foam by a factor of not more than 1.5.

13. The system of claim 1 , wherein the rigid polyurethane foam has a density of from 40 g/l to 60 g/l.

14. The system of claim 1 , wherein the rigid polyurethane foam exhibits a combined compressive strength and compressive E-modulus value of from 9.17 to 9.42 MPa.

15. A process for producing the polyurethane composite system of claim 1 , the process comprising:
coating the rigid polyurethane foam with the compact polyurethane or the compact polyurea.

16. The process of claim 15 , wherein the coating comprises spraying a reaction mixture, which produces the compact polyurethane or the compact polyurea, onto the rigid polyurethane foam.

17. A process for producing the polyurethane composite system of claim 1 , the process comprising:
spraying a first reaction mixture, which produces the compact polyurethane or the compact polyurea onto a part of or an entire surface of a mold; and then
adding the reinforcing material and a second reaction mixture, which produces the rigid polyurethane foam, into the mold and reacting the first and second reaction to completion.

Assignees

• Prissok Frank
• Balbo Block Marco
• Felix Florian
• Basf Se

Inventors

• Prissok Frank
• Balbo Block Marco
• Felix Florian

Classifications

• C08L75/04

  Polyurethanes · CPC title

• C08G18/324

  containing only one aromatic ring · CPC title

• C08G18/4816

  mixtures of two or more polyetherpolyols having at least three hydroxy groups · CPC title

• Y10T428/249969

  Of silicon-containing material [e.g., glass, etc.] · CPC title

• C08J9/365

  Coating · CPC title