Composite fibre components and the production thereof

Patent metadata

Field	Value
Publication number	US-9868831-B2
Application number	US-201515307649-A
Country	US
Kind code	B2
Filing date	Apr 24, 2015
Priority date	Apr 28, 2014
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

Abstract

The present invention fiber composite components obtainable, for example, by impregnating fibers with a reactive polyurethane resin mixture of polyisocyanates, polyols, thermo-latent catalysts and optionally additives, and to a method for the production thereof.

First claim

The invention claimed is:

1. A fiber composite component based on polyurethane, comprising one or more fiber layers each impregnated with polyurethane, wherein the polyurethane is obtained from a reaction mixture consisting of:
A) one or more organic NCO prepolymers having an NCO content of 27% to 31% by weight and a monomer content of 35% to 55% by weight, wherein the NCO prepolymers comprise a reaction product of:
aliphatic, cycloaliphatic, and/or aromatic di-isocyanates and/or polyisocyanates, and
5% to 7.5% by weight, based on component A), of condensation products which have ester groups, each condensation product having a number-average molecular weight of 650 to 3000 g/mol, an acid number of less than 5, a hydroxyl number of 28 to 112, and in each case a number-average functionality of 1.0 to 3.0, and wherein the condensation products are formed from:
one or more fatty acids having 10 to 30 carbon atoms, one or more low molecular weight aliphatic and/or aromatic di-carboxylic and/or tricarboxylic acids each having number-average molecular weights of 50 to 500 g/mol, and/or derivatives thereof, and
one or more mono-hydric or polyhydric alcohols each having a number-average molecular weight up to 500 g/mol and each having a number-average functionality of 1.5 to 6,

B) a component comprising one or more polyols each having a number-average molecular weight of 62 to 3000 g/mol and each having a number-average functionality of 1.8 to 6,
C) two or more thermolatent catalysts, and
D) optionally additives,
wherein component B) contains 2.5% to 3.5% by weight, based on component B), of an internal mold release agent, wherein the internal mold release agent comprises condensation products which have ester groups, each condensation product having a number-average molecular weight of 650 to 3000 g/mol, an acid number of less than 5, a hydroxyl number of 28 to 112, and a number-average functionality of 1.0 to 3.0, and wherein the condensation products are formed from:
one or more fatty acids having 10 to 30 carbon atoms, one or more low molecular weight aliphatic and/or aromatic di-carboxylic and/or tricarboxylic acids each having a number-average molecular weight of 50 to 500 g/mol, and/or derivatives thereof, and
one or more mono-hydric or polyhydric alcohols each having a number-average molecular weight up to 500 g/mol and each having a number-average functionality of 1.5 to 6,

wherein the total amount of the condensation products having ester groups used in the fiber composite component is 5% to 5.7% by weight, and wherein the reaction mixture at 25° C. has a viscosity directly after the mixing of 200 to 700 mPas (measured according to DIN EN ISO 1342) and the ratio of the number of NCO groups of component A) to the number of OH groups of component B) is 1:1 to 1.15:1.

2. A process for producing the fiber composite components as claimed in claim 1 , comprising:
i) charging one or more fiber layers in one or both halves of a mold,
ii) closing the mold, and
iii) introducing into the closed mold a reaction mixture consisting of:
A) one or more organic NCO prepolymers having an NCO content of 27% to 31% by weight and a monomer content of 35% to 55% by weight, wherein the NCO prepolymers comprise a reaction product of:
aliphatic, cycloaliphatic, and/or aromatic di-isocyanates and/or polyisocyanates, and
5% to 7.5% by weight, based on component A), of condensation products which have ester groups, each condensation product having a number-average molecular weight of 650 to 3000 g/mol, an acid number of less than 5, a hydroxyl number of 28 to 112, and in each case a number-average functionality of 1.0 to 3.0, and wherein the condensation products are formed from:
one or more fatty acids having 10 to 30 carbon atoms, one or more low molecular weight aliphatic and/or aromatic di-carboxylic and/or tricarboxylic acids each having number-average molecular weights of 50 to 500 g/mol, and/or derivatives thereof, and
one or more mono-hydric or polyhydric alcohols each having a number-average molecular weight up to 500 g/mol and each having a number-average functionality of 1.5 to 6,

B) a component comprising one or more polyols each having a number-average molecular weight of 62 to 3000 g/mol and each having a number-average functionality of 1.8 to 6,
C) two or more thermolatent catalysts,
D) optionally additives,
wherein component B) contains 2.5% to 3.5% by weight, based on component B), of an internal mold release agent, wherein the internal mold release agent comprises condensation products which have ester groups, each condensation product having a number-average molecular weight of 650 to 3000 g/mol, an acid number of less than 5, a hydroxyl number of 28 to 112, and a number-average functionality of 1.0 to 3.0, and wherein the condensation products are formed from:
one or more fatty acids having 10 to 30 carbon atoms, one or more low molecular weight aliphatic and/or aromatic di-carboxylic and/or tricarboxylic acids each having a number-average molecular weight of 50 to 500 g/mol, and/or derivatives thereof, and
one or more mono-hydric or polyhydric alcohols each having a number-average molecular weight up to 500 g/mol and each having a number-average functionality of 1.5 to 6, and

wherein the total amount of condensation products having ester groups used in the fiber composite component is 5% to 5.7% by weight, and wherein the reaction mixture at 25° C. has a viscosity directly after the mixing of 200 to 700 mPas (measured according to DIN EN ISO 1342) and the ratio of the number of NCO groups of component A) to the number of OH groups of component B) is 1:1 to 1.15:1, and
wherein introducing the reaction mixture results in impregnation of the one or more fiber layers, and

iv) curing the reaction mixture from iii) at a temperature of 50° C. to 120° C.

3. The process of claim 2 , wherein the reaction mixture is cured at a temperature of 70° C. to 100° C.

4. The process of claim 2 , wherein the reaction mixture is under pressure when the reaction mixture is introduced into the closed mold.

5. The process of claim 2 , wherein the closed mold is under reduced pressure when the reaction mixture is introduced into the closed mold.

6. The process of claim 2 , wherein the reaction mixture is cured at a temperature of 70° C. to 100° C., wherein the reaction mixture is under pressure when the reaction mixture is introduced into the closed mold, and wherein the closed mold is under reduced pressure when the reaction mixture is introduced into the closed mold.

Assignees

• Covestro Deutchland Ag
• Covestro Deutschland Ag

Inventors

• Schornstein Marcel
• Hupka Florian
• Wegener Dirk
• Rasselnberg Harald

Classifications

• C08J2375/06

  from polyesters · CPC title

• C08J2375/04

  Polyurethanes · CPC title

• C08J5/043 Primary

  with glass fibres · CPC title

• C08G18/3206

  aliphatic · CPC title

• C08J5/24

  Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs · CPC title