Method for Making Skinned Polyurethane Composites

Patent metadata

Field	Value
Publication number	US-2016016387-A1
Application number	US-201314410091-A
Country	US
Kind code	A1
Filing date	Jun 20, 2013
Priority date	Jun 27, 2012
Publication date	Jan 21, 2016
Grant date	—

Abstract

Skinned composites contain a plasticized polymer skin layer adhered to a layer of a polyurethane. The polyurethane is made from a reaction mixture that contains specified amounts of a polyester polyol and an acidic material. The presence of both the polyester polyol and acid leads to significantly improved adhesion between the polyurethane and skin layer. The invention is particularly useful when the skin is highly plasticized.

First claim

1 . A method for forming a skinned composite comprising forming a layer of a polyurethane-forming reaction mixture against a skin layer, and then curing the reaction mixture to form a polyurethane layer adhering to the skin, wherein the polyurethane-forming reaction mixture comprises
a) one or more polyols; b) one or more organic polyisocyanates; c) at least one blowing agent; d) at least one catalyst for the reaction of isocyanate groups towards hydroxyl groups; wherein component a) includes at least one polyester polyol, and/or component b) includes at least one isocyanate-terminated prepolymer which is a reaction product of a polyester polyol with an excess of one or more polyisocyanates, and further wherein the polyester polyol in component a) and/or present in an isocyanate-terminated prepolymer included within component b) constitutes from 0.5 to 7% of the combined weight of components a) and b); and further wherein component a) contains from 0.01 to 1% by weight of a Bronsted acid having a molecular weight of up to about 400 selected from one or more of formic acid, acetic acid, an alkanoic acid having three to 3 eight carbon atoms, sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, benzene sulfonic acid and an alkyl benzene sulfonic acid in which the alkyl group contains 1 to 20 carbon atoms, based on the combined weight of the polyols and the Bronsted acid.

2 . (canceled)

3 . The method of claim 1 , wherein the Bronsted acid is formic acid or acetic acid.

4 . The method of claim 3 wherein the polyester polyol has a hydroxyl functionality of at least 2.0 and an equivalent weight of 350 to 1500.

5 . The method of claim 4 wherein the polyester polyol is an aliphatic polyester which is a reaction product of an aliphatic dicarboxylic acid or corresponding acid chloride or diester with at least one polyol having at least 2 hydroxyl groups and a hydroxyl equivalent weight of 150 or less.

6 . The method of claim 5 , wherein the polyol includes at least one tri- or higher functionality polyol and/or a diol having alkyl side groups.

7 . The method of claim 1 wherein the skin is a plasticized thermoplastic.

8 . The method of claim 7 wherein the skin contains 25 to 45% by weight of plasticizer, based on the combined weight of plasticizer and thermoplastic.

9 . The method of claim 8 wherein the skin is a plasticized polymer of vinyl chloride.

10 . The method of claim 9 wherein the skin contains 25 to 40% by weight of a plasticizer.

11 . The method of claim 1 , wherein the density of the polyurethane layer is from 48 to 480 kg/m 3 .

12 . The method of claim 1 wherein the polyisocyanate(s) have an average functionality of at least 2.0 and an isocyanate equivalent weight of 85-200.

13 . The method of claim 1 , wherein the polyurethane-forming reaction mixture is formed into a layer between the skin and a substrate, and cured to form a polyurethane layer intermediate to the skin and the substrate and adhering to both.

14 . A skinned composite made in accordance with the method of claim 1 .

Assignees

• Dow Global Technologies Llc

Inventors

• Cavalca Sara
• Fregni Sabrina

Classifications

• C08J9/04

  using blowing gases generated by a previously added blowing agent · CPC title

• C08G18/4816

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

• B32B2266/0278

  Polyurethane · CPC title

• B32B5/20

  foamed in situ · CPC title

• C08J2375/04

  Polyurethanes · CPC title