U.S. patent application number 12/410102 was filed with the patent office on 2009-11-12 for polyurethanes, articles and coatings prepared therefrom and methods of making the same.
This patent application is currently assigned to PPG INDUSTRIES OHIO, INC.. Invention is credited to Veronica L. Frain, Caroline S. Harris, Robert M. Hunia, Thomas G. Rukavina, Yan Wang.
Application Number | 20090280709 12/410102 |
Document ID | / |
Family ID | 41267234 |
Filed Date | 2009-11-12 |
United States Patent
Application |
20090280709 |
Kind Code |
A1 |
Rukavina; Thomas G. ; et
al. |
November 12, 2009 |
Polyurethanes, Articles and Coatings Prepared Therefrom and Methods
of Making the Same
Abstract
The present invention provides polyurethanes including a
reaction product of components including: (a) about 1 equivalent of
at least one polyisocyanate; (b) about 0.05 to about 1 equivalents
of at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups; (c) about 0.01 to about 0.3 equivalents of
at least one polycarbonate diol; and (d) about 0.1 to about 0.9
equivalents of at least one polyol different from the branched
polyol and having 2 to 18 carbon atoms, wherein the reaction
product components are essentially free of polyether polyol and the
reaction components are maintained at a temperature of at least
about 100.degree. C. for at least about 10 minutes; compositions,
coatings and articles made therefrom and methods of making the
same.
Inventors: |
Rukavina; Thomas G.; (New
Kensington, PA) ; Hunia; Robert M.; (Kittanning,
PA) ; Harris; Caroline S.; (Pittsburgh, PA) ;
Wang; Yan; (Seven Fields, PA) ; Frain; Veronica
L.; (Brackenridge, PA) |
Correspondence
Address: |
PPG INDUSTRIES INC;INTELLECTUAL PROPERTY DEPT
ONE PPG PLACE
PITTSBURGH
PA
15272
US
|
Assignee: |
PPG INDUSTRIES OHIO, INC.
Cleveland
OH
|
Family ID: |
41267234 |
Appl. No.: |
12/410102 |
Filed: |
March 24, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11639058 |
Dec 14, 2006 |
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12410102 |
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10932641 |
Sep 1, 2004 |
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11639058 |
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11303670 |
Dec 16, 2005 |
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10932641 |
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11303422 |
Dec 16, 2005 |
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11303670 |
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11303892 |
Dec 16, 2005 |
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11303422 |
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11303671 |
Dec 16, 2005 |
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11303892 |
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Current U.S.
Class: |
442/394 ;
428/412; 525/453; 525/454; 525/458; 528/60 |
Current CPC
Class: |
C08G 18/10 20130101;
C08G 18/305 20130101; C08G 18/10 20130101; C08G 18/381 20130101;
C08G 18/792 20130101; C09D 175/04 20130101; B32B 27/40 20130101;
C08G 18/671 20130101; C08G 18/758 20130101; Y10T 428/31591
20150401; C08G 18/12 20130101; C08G 18/44 20130101; C08G 18/10
20130101; C08G 18/6607 20130101; C08G 18/3868 20130101; C08G 64/42
20130101; C08G 18/3206 20130101; B32B 17/1077 20130101; Y10T
428/31551 20150401; Y10T 442/674 20150401; C08G 18/12 20130101;
C08G 18/3872 20130101; C08G 18/4018 20130101; C08G 18/6644
20130101; Y10T 428/31605 20150401; B32B 2605/18 20130101; C08G
18/7657 20130101; C08G 18/3212 20130101; C08G 18/3284 20130101;
C08G 18/12 20130101; C08G 18/12 20130101; C08G 18/10 20130101; C08G
18/765 20130101; Y10T 428/31507 20150401; Y10T 428/31554 20150401;
Y10T 428/31601 20150401; C08G 18/724 20130101; C08G 18/3215
20130101; C08G 18/3206 20130101; C08G 18/3212 20130101; C08G
18/3868 20130101; C08G 18/3212 20130101; C08G 18/305 20130101; C08G
18/3215 20130101 |
Class at
Publication: |
442/394 ; 528/60;
525/454; 525/458; 525/453; 428/412 |
International
Class: |
B32B 27/12 20060101
B32B027/12; C08G 18/32 20060101 C08G018/32; C08L 75/04 20060101
C08L075/04; B32B 27/08 20060101 B32B027/08 |
Claims
1. A polyurethane comprising a reaction product of components
comprising: (a) about 1 equivalent of at least one polyisocyanate;
(b) about 0.05 to about 1 equivalents of at least one branched
polyol having 4 to 18 carbon atoms and at least 3 hydroxyl groups;
(c) about 0.01 to about 0.3 equivalents of at least one
polycarbonate diol; and (d) about 0.1 to about 0.9 equivalents of
at least one polyol different from the branched polyol and having 2
to 18 carbon atoms, wherein the reaction product components are
essentially free of polyether polyol and the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes.
2. The polyurethane according to claim 1, wherein an isocyanate
functional urethane prepolymer is prepared from the at least one
polyisocyanate and a portion of the polyol (d) prior to reaction
with the branched polyol and polycarbonate diol.
3. The polyurethane according to claim 1, wherein the
polyisocyanate is selected from the group consisting of
diisocyanates, triisocyanates, dimers, trimers and mixtures
thereof.
4. The polyurethane according to claim 2, wherein the
polyisocyanate is a diisocyanate selected from the group consisting
of ethylene diisocyanate, trimethylene diisocyanate,
1,6-hexamethylene diisocyanate, tetramethylene diisocyanate,
hexamethylene diisocyanate, octamethylene diisocyanate,
nonamethylene diisocyanate, decamethylene diisocyanate,
1,6,11-undecane-triisocyanate, 1,3,6-hexamethylene triisocyanate,
bis(isocyanatoethyl)-carbonate, bis(isocyanatoethyl)ether,
trimethylhexane diisocyanate, trimethylhexamethylene diisocyanate,
2,2'-dimethylpentane diisocyanate, 2,2,4-trimethylhexane
diisocyanate, 2,4,4,-trimethylhexamethylene diisocyanate,
1,8-diisocyanato-4-(isocyanatomethyl) octane,
2,5,7-trimethyl-1,8-diisocyanato-5-(isocyanatomethyl)octane,
2-isocyanatopropyl-2,6-diisocyanatohexanoate, lysinediisocyanate
methyl ester, 4,4'-methylene-bis-(cyclohexyl isocyanate),
4,4'-isopropylidene-bis-(cyclohexyl isocyanate), 1,4-cyclohexyl
diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 3-isocyanato
methyl-3,5,5-trimethylcyclohexyl isocyanate,
meta-tetramethylxylylene diisocyanate, diphenyl methane
diisocyanates, diphenyl isopropylidene diisocyanate, diphenylene
diisocyanate, butene diisocyanate, 1,3-butadiene-1,4-diisocyanate,
cyclohexane diisocyanate, methylcyclohexane diisocyanate,
bis(isocyanatomethyl)cyclohexane, bis(isocyanatocyclohexyl)methane,
bis(isocyanatocyclohexyl)-2,2-propane,
bis(isocyanatocyclohexyl)-1,2-ethane,
2-isocyanatomethyl-3-(3-isocyanatopropyl)-5-isocyanatomethyl-bicyclo[2.2.-
1]-heptane,
2-isocyanatomethyl-3-(3-isocyanatopropyl)-6-isocyanatomethyl-bicyclo[2.2.-
1]-heptane,
2-isocyanatomethyl-2-(3-isocyanatopropyl)-5-isocyanatomethyl-bicyclo[2.2.-
1]-heptane,
2-isocyanato-methyl-2-(3-isocyanatopropyl)-6-isocyanatomethyl-bicyclo[2.2-
.1]-heptane,
2-isocyanatomethyl-3-(3-isocyanatopropyl)-6-(2-isocyanatoethyl)-bicyclo[2-
.2.1]-heptane,
2-isocyanatomethyl-2-(3-isocyanatopropyl)-5-(2-isocyanatoethyl)-bicyclo-[-
2.2.1]-heptane,
2-isocyanatomethyl-2-(3-isocyanatopropyl)-6-(2-isocyanatoethyl)-bicyclo[2-
.2.1]-heptane, .alpha.,.alpha.'-xylene diisocyanate,
bis(isocyanatoethyl)benzene,
.alpha.,.alpha.,.alpha.',.alpha.'-tetramethylxylene diisocyanate,
1,3-bis(1-isocyanato-1-methylethyl)benzene,
bis(isocyanatobutyl)benzene, bis(isocyanatomethyl)naphthalene,
bis(isocyanatomethyl)diphenyl ether, bis(isocyanatoethyl)
phthalate, mesitylene triisocyanate, 2,5-di(isocyanatomethyl)furan,
.alpha.,.alpha.'-xylene diisocyanate, bis(isocyanatoethyl)benzene,
.alpha.,.alpha.,.alpha.',.alpha.'-tetramethylxylene diisocyanate,
1,3-bis(1-isocyanato-1-methylethyl)benzene,
bis(isocyanatobutyl)benzene, bis(isocyanatomethyl)naphthalene,
bis(isocyanatomethyl)diphenyl ether, bis(isocyanatoethyl)
phthalate, 2,5-di(isocyanatomethyl)furan, diphenylether
diisocyanate, bis(isocyanatophenylether)ethyleneglycol,
bis(isocyanatophenylether)-1,3-propyleneglycol, benzophenone
diisocyanate, carbazole diisocyanate, ethylcarbazole diisocyanate,
dichlorocarbazole diisocyanate, and dimers, trimers and mixtures
thereof.
5. The polyurethane according to claim 4, wherein the diisocyanate
is dicyclohexylmethane diisocyanate.
6. The polyurethane according to claim 1, wherein the branched
polyol is selected from the group consisting of glycerol, glycerin,
tetramethylolmethane, trimethylolethane, trimethylolpropane,
erythritol, pentaerythritol, dipentaerythritol, tripentaerythritol,
sorbitan, alkoxylated derivatives thereof and mixtures thereof.
7. The polyurethane according to claim 6, wherein the branched
polyol is trimethylolpropane.
8. The polyurethane according to claim 1, wherein the polycarbonate
diol is polyhexylene carbonate diol.
9. The polyurethane according to claim 1, wherein the polyol (d) is
a diol.
10. The polyurethane according to claim 9, wherein the diol (d) is
an aliphatic diol selected from the group consisting of ethylene
glycol, diethylene glycol, triethylene glycol, tetraethylene
glycol, 1,2-ethanediol, propanediol, butanediol, pentanediol,
hexanediol, heptanediol, octanediol, nonanediol, decanediol,
dodecane diol, sorbitol, mannitol, cyclopentanediol,
1,4-cyclohexanediol, cyclohexanedimethanol, 1,4-benzenedimethanol,
xylene glycol, hydroxybenzyl alcohol, dihydroxytoluene
bis(2-hydroxyethyl) terephthalate, 1,4-bis(hydroxyethyl)piperazine,
N,N',bis(2-hydroxyethyl)oxamide and mixtures thereof.
11. The polyurethane according to claim 10, wherein the diol is
pentanediol or butanediol.
12. The polyurethane according to claim 1, wherein the reaction
product components comprise less than about 0.1 equivalents of
polyether polyol.
13. The polyurethane according to claim 1, wherein the reaction
product components are essentially free of amine curing agent.
14. The polyurethane according to claim 1, wherein the reaction
product components further comprise one or more polyurethane
polyols, acrylamides, polyvinyl alcohols, hydroxy functional
acrylates, hydroxy functional methacrylates, allyl alcohols,
dihydroxy oxamides, dihydroxyamides, dihydroxy piperidines,
dihydroxy phthalates, dihydroxyethyl hydroquinones and mixtures
thereof.
15. The polyurethane according to claim 1, wherein the reaction
components are maintained at a temperature of at least about
110.degree. C. for at least about 10 minutes.
16. The polyurethane according to claim 1, wherein reaction
components are maintained at a temperature of at least about
100.degree. C. for at least about 20 minutes.
17. A polyurethane comprising a reaction product of components
comprising: (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: (i) about 1
equivalent of at least one polyisocyanate; and (ii) about 0.3 to
about 0.4 equivalents of butanediol or cyclohexane dimethanol; and
(b) about 0.1 to about 0.3 equivalents of trimethylolpropane; (c)
about 0.4 to about 0.5 equivalents of butanediol or cyclohexane
dimethanol, and (d) about 0.01 to about 0.3 equivalents of at least
one polycarbonate diol, wherein the reaction product components are
essentially free of polyether polyol.
18. An article comprising the polyurethane of claim 1.
19. The article according to claim 18, wherein the article is a
molded article.
20. The article according to claim 15, wherein the article is
selected from the group consisting of transparencies, optical
articles, photochromic articles, ballistic resistant articles, and
glazings.
21. An article comprising the polyurethane of claim 17, wherein the
article is an airplane transparency.
22. The article according to claim 21, wherein the article
comprises at least one layer of the polyurethane of claim 17 and at
least one layer of polycarbonate.
23. A laminate comprising: (a) at least one layer of the
polyurethane of claim 1; and (b) at least one layer of a substrate
selected from the group consisting of paper, glass, ceramic, wood,
masonry, textile, metal or organic polymeric material and
combinations thereof.
24. A coating composition comprising the polyurethane of claim 1.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of
U.S. patent application Ser. No. 11/639,059, filed on Dec. 14,
2006, which is a continuation-in-part application of U.S. patent
application Ser. No. 10/932,641, filed on Sep. 1, 2004, and
application Ser. Nos. 11/303,670, 11/303,422, 11/303,892, and
11/303,671, each of which was filed on Dec. 16, 2005. Each of the
above applications is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] I. Field of the Invention
[0003] The present invention relates to polyurethanes and
poly(ureaurethanes) prepared from branched polyols, branched
polyisocyanates and/or polyisocyanate trimers, articles and
coatings prepared therefrom, and methods of making the same.
[0004] II. Technical Considerations
[0005] A number of organic polymeric materials, for example
plastics such as polycarbonates and acrylics, have been developed
as alternatives and replacements for glass in applications such as
optical lenses, fiber optics, windows and automotive, nautical and
aviation transparencies. For example, in aircraft glazings both
polycarbonates, such as LEXAN.RTM., and acrylics have enjoyed
widespread acceptance. These polymeric materials can provide
advantages relative to glass, including shatter or penetration
resistance, lighter weight for a given application, flexibility,
ease of molding and dyeability. Unfortunately, there are some
serious disadvantages associated with both polycarbonates and
acrylics. Polycarbonates scratch easily, and, if directly exposed
to sunlight and harsh environments, soon become difficult to view
through. Acrylics, although not as scratchable as polycarbonates,
do not have the physical properties of the polycarbonates such as
heat distortion temperature and impact resistance. Some "high
impact" strength polycarbonates, can have inconsistent impact
strength that can degrade over time, poor crack propagation
resistance (K-factor), poor optical quality, poor solvent
resistance and poor weatherability. Even though polycarbonates can
exhibit good impact strength when impacted at low speeds, at high
impact speeds of greater than about 1100 ft/sec (335.3 m/sec), such
as those exhibited in ballistics applications, a 9 mm bullet (125
grain) fired from about 20 feet (6.1 m) at a speed of about 1350
ft/sec (411 m/sec) can pass easily through a 1 inch (2.5 cm) thick
polycarbonate plastic.
[0006] Also, polycarbonates are typically extruded, which can
produce optical distortions in the extrudate in the direction of
extrusion. For optical applications such as fighter plane canopies,
polycarbonates typically must undergo an additional processing step
to remove the distortions, which can increase cost. Also, some
polycarbonates are birefringent which can also cause optical
distortions. For example, the Abbe number of LEXAN is 34. Higher
Abbe values indicate better visual acuity and less chromatic
aberrations.
[0007] Thus, there is a need in the art to develop polymers useful
for producing articles having good optical quality, high impact
resistance, high impact strength, high K factor, good ballistics
resistance, good solvent resistance and good weatherability. The
ability to fabricate articles by casting or reaction injection
molding rather than extrusion also is desirable.
SUMMARY OF THE INVENTION
[0008] Discussion of the various aspects and embodiments of
polyurethanes and poly(ureaurethanes) of the present invention have
been grouped below. While the various aspects of the invention have
been grouped for discussion purposes, the groupings are not
intended to limit the scope of the invention and aspects of one
grouping may be relevant to the subject matter of other
groupings.
Group A
[0009] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0010] (a) about 1 equivalent of at least one
polyisocyanate; [0011] (b) about 0.05 to about 0.9 equivalents of
at least one branched polyol having 4 to 12 carbon atoms and at
least 3 hydroxyl groups; and [0012] (c) about 0.1 to about 0.95
equivalents of at least one diol having 2 to 18 carbon atoms,
wherein the reaction product components are essentially free of
polyester polyol and polyether polyol and the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes.
[0013] In other non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
consisting of: [0014] (a) about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); [0015] (b) about 0.3 to
about 0.5 equivalents of trimethylolpropane; and [0016] (c) about
0.3 to about 0.7 equivalents of 1,10-dodecanediol, butanediol or
pentanediol, wherein the reaction components are maintained at a
temperature of at least about 100.degree. C. for at least about 10
minutes.
[0017] In some non-limiting embodiments, the present invention
provides an article comprising a polyurethane comprising a reaction
product of components comprising: [0018] (a) about 1 equivalent of
at least one polyisocyanate; [0019] (b) about 0.1 to about 0.9
equivalents of at least one branched polyol having 4 to 18 carbon
atoms and at least 3 hydroxyl groups; and [0020] (c) about 0.1 to
about 0.9 equivalents of at least one diol having 2 to 12 carbon
atoms, wherein the reaction product components are essentially free
of polyester polyol and polyether polyol, and the article has a
Gardner Impact strength of at least about 200 in-lb (23 Joules)
according to ASTM-D 5420-04.
[0021] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the step of
reacting in a one-potprocess components comprising: [0022] (a)
about 1 equivalent of at least one polyisocyanate; [0023] (b) about
0.1 to about 0.9 equivalents of at least one branched polyol having
4 to 18 carbon atoms and at least 3 hydroxyl groups; and [0024] (c)
about 0.1 to about 0.9 equivalents of at least one diol having 2 to
12 carbon atoms, wherein the components are essentially free of
polyester polyol and polyether polyol and the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes.
[0025] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the steps of:
[0026] (a) reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and [0027] (b) reacting
the polyurethane prepolymer with at least one diol having 2 to 12
carbon atoms to form the polyurethane wherein the reaction
components are maintained at a temperature of at least about
100.degree. C. for at least about 10 minutes.
Group B
[0028] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0029] (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: [0030] (i)
about 1 equivalent of at least one polyisocyanate; and [0031] (ii)
about 0.1 to about 0.5 equivalents of at least one polyol having 2
to 18 carbon atoms; and [0032] (b) about 0.05 to about 1.0
equivalents of at least one branched polyol having 4 to 18 carbon
atoms and at least 3 hydroxyl groups; and [0033] (c) up to about
0.9 equivalents of at least one polyol different from branched
polyol (b) and having 2 to 18 carbon atoms, wherein the reaction
product components are essentially free of polyester polyol and
polyether polyol.
[0034] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes from reaction
components comprising: [0035] (a) reacting about 1 equivalent of at
least one polyisocyanate; and about 0.1 to about 0.5 equivalents of
at least one polyol having 2 to 18 carbon atoms to form an
isocyanate functional urethane prepolymer; and [0036] (b) reacting
the isocyanate functional urethane prepolymer, about 0.05 to about
1.0 equivalents of at least one branched polyol having 4 to 18
carbon atoms and at least 3 hydroxyl groups; and up to about 0.9
equivalents of at least one polyol different from branched polyol
(b) and having 2 to 18 carbon atoms, wherein the reaction product
components are essentially free of polyester polyol and polyether
polyol.
[0037] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0038] (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: [0039] (i)
about 1 equivalent of at least one polyisocyanate; and [0040] (ii)
about 0.3 to about 0.4 equivalents of butanediol or pentanediol;
and [0041] (b) about 0.3 to about 0.7 equivalents of
trimethylolpropane; and [0042] (c) up to about 0.4 equivalents of
butanediol or pentanediol, wherein the reaction product components
are essentially free of polyester polyol and polyether polyol.
[0043] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0044] (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: [0045] (i)
about 1 equivalent of at least one polyisocyanate; and [0046] (ii)
about 0.1 to about 0.5 equivalents of at least one diol having 2 to
18 carbon atoms; and [0047] (b) about 0.05 to about 0.9 equivalents
of at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups; and [0048] (c) up to about 0.45
equivalents of at least one diol having 2 to 18 carbon atoms,
wherein the reaction product components are essentially free of
polyester polyol and polyether polyol.
[0049] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
consisting of: [0050] (a) an isocyanate functional urethane
prepolymer comprising a reaction product of components comprising:
[0051] (i) about 1 equivalent of at least one polyisocyanate; and
[0052] (ii) about 0.3 to about 0.4 equivalents of butanediol or
pentanediol; and [0053] (b) about 0.3 to about 0.6 equivalents of
trimethylolpropane; and [0054] (c) about 0.1 to about 0.4
equivalents of butanediol or pentanediol.
Group C
[0055] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0056] (a) at least one polyisocyanate selected from
the group consisting of polyisocyanate trimers and branched
polyisocyanates, the polyisocyanate having at least three
isocyanate functional groups; and [0057] (b) at least one aliphatic
polyol having 4 to 18 carbon atoms and at least two hydroxyl
groups, wherein the reaction product components are essentially
free of polyester polyol and polyether polyol.
[0058] In other non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
consisting of: [0059] (a) about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); [0060] (b) about 1.1
equivalents of butanediol; and [0061] (c) about 0.1 equivalents of
isophorone diisocyanate trimer.
[0062] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the step of
reacting in a one-potprocess components comprising: [0063] (a) at
least one polyisocyanate trimer or branched polyisocyanate, the
polyisocyanate having at least three isocyanate functional groups;
and [0064] (b) at least one aliphatic polyol having 4 to 18 carbon
atoms and at least two hydroxyl groups, wherein the reaction
product components are essentially free of polyester polyol and
polyether polyol.
Group D
[0065] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0066] (a) at least one polyisocyanate; [0067] (b) at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; and [0068] (c) at least one polyol having one or
more bromine atoms, one or more phosphorus atoms or combinations
thereof.
[0069] In other non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
consisting of: [0070] (a) about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); [0071] (b) about 0.3 to
about 0.5 equivalents of trimethylolpropane; [0072] (c) about 0.2
to about 0.5 equivalents of
bis(4-(2-hydroxyethoxy)-3,5-dibromophenyl) sulfone; [0073] (d)
about 0.2 to about 0.5 equivalents of 1,4-cyclohexane dimethanol;
and [0074] (e) about 0.2 to about 0.5 equivalents of
3,6-dithia-1,2-octanediol.
[0075] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0076] (a) at least one polyisocyanate selected from
the group consisting of polyisocyanate trimers and branched
polyisocyanates, the polyisocyanate having at least three
isocyanate functional groups; [0077] (b) at least one aliphatic
polyol having 4 to 18 carbon atoms and at least 2 hydroxyl groups;
and [0078] (c) at least one polyol having one or more bromine
atoms, one or more phosphorus atoms or combinations thereof.
[0079] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the step of
reacting in a one-potprocess components comprising: [0080] (a) at
least one polyisocyanate; [0081] (b) at least one branched polyol
having 4 to 18 carbon atoms and at least 3 hydroxyl groups; and
[0082] (c) at least one polyol having one or more bromine atoms,
one or more phosphorus atoms or combinations thereof.
[0083] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the steps of:
[0084] (a) reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and [0085] (b) reacting
the polyurethane prepolymer with at least one polyol having one or
more bromine atoms, one or more phosphorus atoms or combinations
thereof to form the polyurethane.
Group E
[0086] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0087] (a) about 1 equivalent of at least one
polyisocyanate; [0088] (b) about 0.3 to about 1 equivalents of at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; and [0089] (c) about 0.01 to about 0.3
equivalents of at least one polycarbonate diol, wherein the
reaction product components are essentially free of polyether
polyol and amine curing agent and wherein the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes.
[0090] In other non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
consisting of: [0091] (a) about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); [0092] (b) about 0.3
equivalents of trimethylolpropane; [0093] (c) about 0.5 to about
0.55 equivalents of butanediol or pentanediol; and [0094] (d) about
0.15 to about 0.2 equivalents of polyhexylene carbonate diol
wherein the reaction components are maintained at a temperature of
at least about 100.degree. C. for at least about 10 minutes.
[0095] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the step of
reacting in a one-potprocess components comprising: [0096] (a)
about 1 equivalent of at least one polyisocyanate; [0097] (b) about
0.3 to about 1 equivalents of at least one branched polyol having 4
to 18 carbon atoms and at least 3 hydroxyl groups; and [0098] (c)
about 0.01 to about 0.3 equivalents of at least one polycarbonate
diol, wherein the reaction product components are essentially free
of polyether polyol and amine curing agent and wherein the reaction
components are maintained at a temperature of at least about
100.degree. C. for at least about 10 minutes.
[0099] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the steps of:
[0100] (a) reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and [0101] (b) reacting
the polyurethane prepolymer with at least one polycarbonate diol to
form the polyurethane.
Group F
[0102] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0103] (a) about 1 equivalent of at least one
polyisocyanate; [0104] (b) about 0.05 to about 1 equivalents of at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; [0105] (c) about 0.01 to about 0.3 equivalents
of at least one polycarbonate diol; and [0106] (d) about 0.1 to
about 0.9 equivalents of at least one polyol different from the
branched polyol having 2 to 18 carbon atoms, wherein the reaction
product components are essentially free of polyether polyol and the
reaction components are maintained at a temperature of at least
about 100.degree. C. for at least about 10 minutes.
[0107] In some non-limiting embodiments, the present invention
provides methods comprising reacting in a one-potprocess reaction
components comprising: [0108] (a) about 1 equivalent of at least
one polyisocyanate; [0109] (b) about 0.05 to about 1 equivalents of
at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups; [0110] (c) about 0.01 to about 0.3
equivalents of at least one polycarbonate diol; and [0111] (d)
about 0.1 to about 0.9 equivalents of at least one polyol different
from the branched polyol having 2 to 18 carbon atoms, wherein the
reaction product components are essentially free of polyether
polyol and the reaction components are maintained at a temperature
of at least about 100.degree. C. for at least about 10 minutes.
[0112] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0113] (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: [0114] (i)
about 1 equivalent of at least one polyisocyanate; and [0115] (ii)
about 0.3 to about 0.4 equivalents of butanediol or cyclohexane
dimethanol; and [0116] (b) about 0.1 to about 0.3 equivalents of
trimethylolpropane; [0117] (c) about 0.4 to about 0.5 equivalents
of butanediol or cyclohexane dimethanol; and [0118] (d) about 0.01
to about 0.3 equivalents of at least one polycarbonate diol,
wherein the reaction product components are essentially free of
polyether polyol.
[0119] In some non-limiting embodiments, the present invention
provides methods for preparing polyurethanes from reaction
components comprising: [0120] (a) reacting about 1 equivalent of at
least one polyisocyanate and about 0.3 to about 0.4 equivalents of
butanediol or cyclohexane dimethanol to form an isocyanate
functional urethane prepolymer; and [0121] (b) reacting the
isocyanate functional urethane prepolymer, about 0.1 to about 0.3
equivalents of trimethylolpropane, about 0.4 to about 0.5
equivalents of butanediol or cyclohexane dimethanol; and about 0.01
to about 0.3 equivalents of at least one polycarbonate diol,
wherein the reaction product components are essentially free of
polyether polyol.
[0122] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0123] (a) about 1 equivalent of at least one
polyisocyanate; [0124] (b) about 0.3 to about 1 equivalents of at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; [0125] (c) about 0.01 to about 0.3 equivalents
of at least one polycarbonate diol; and [0126] (d) about 0.1 to
about 0.9 equivalents of at least one diol having 2 to 18 carbon
atoms, wherein the reaction product components are essentially free
of polyether polyol and wherein the reaction components are
maintained at a temperature of at least about 100.degree. C. for at
least about 10 minutes.
[0127] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the step of
reacting in a one-potprocess components comprising: [0128] (a)
about 1 equivalent of at least one polyisocyanate; [0129] (b) about
0.3 to about 1 equivalents of at least one branched polyol having 4
to 18 carbon atoms and at least 3 hydroxyl groups; [0130] (c) about
0.01 to about 0.3 equivalents of at least one polycarbonate diol;
and [0131] (d) about 0.1 to about 0.9 equivalents of at least one
diol having 2 to 18 carbon atoms, wherein the reaction product
components are essentially free of polyether polyol and wherein the
reaction components are maintained at a temperature of at least
about 100.degree. C. for at least about 10 minutes.
[0132] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the steps of:
[0133] (a) reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and [0134] (b) reacting
the polyurethane prepolymer with at least one polycarbonate diol
and at least one diol having 2 to 18 carbon atoms to form the
polyurethane wherein the reaction product components are
essentially free of polyether polyol.
Group G
[0135] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0136] (a) about 1 equivalent of at least one
polyisocyanate; [0137] (b) about 0.3 to about 1 equivalents of at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; [0138] (c) about 0.01 to about 0.3 equivalents
of at least one polyol selected from the group consisting of
polyester polyol, polycaprolactone polyol and mixtures thereof; and
[0139] (d) about 0.1 to about 0.7 equivalents of at least one
aliphatic diol, wherein the reaction product components are
essentially free of polyether polyol and amine curing agent and
wherein the reaction components are maintained at a temperature of
at least about 100.degree. C. for at least about 10 minutes.
[0140] In other non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
consisting of: [0141] (a) about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); [0142] (b) about 0.3
equivalents of trimethylolpropane; [0143] (c) about 0.5 equivalents
of decanediol; and [0144] (d) about 0.2 equivalents of
polycaprolactone polyol, wherein the reaction components are
maintained at a temperature of at least about 100.degree. C. for at
least about 10 minutes.
[0145] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the step of
reacting in a one-potprocess components comprising: [0146] (a)
about 1 equivalent of at least one polyisocyanate; [0147] (b) about
0.3 to about 1 equivalents of at least one branched polyol having 4
to 18 carbon atoms and at least 3 hydroxyl groups; and [0148] (c)
about 0.01 to about 0.3 equivalents of at least one polyol selected
from the group consisting of polyester polyol, polycaprolactone
polyol and mixtures thereof; and [0149] (d) about 0.1 to about 0.7
equivalents of at least one aliphatic diol, wherein the reaction
product components are essentially free of polyether polyol and
amine curing agent.
[0150] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the steps of:
[0151] (a) reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and [0152] (b) reacting
the polyurethane prepolymer with at least one polyol selected from
the group consisting of polyester polyol, polycaprolactone polyol
and mixtures thereof and about 0.1 to about 0.7 equivalents of at
least one aliphatic diol to form the polyurethane.
Group H
[0153] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0154] (a) a prepolymer which is the reaction product
of components comprising: [0155] (1) at least one polyisocyanate;
[0156] (2) at least one polycaprolactone polyol; and [0157] (3) at
least one polyol selected from the group consisting of polyalkylene
polyol, polyether polyol and mixtures thereof; and [0158] (b) at
least one diol having 2 to 18 carbon atoms.
[0159] In other non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0160] (a) a prepolymer which is the reaction product
of components comprising: [0161] (1) aliphatic or cycloaliphatic
diisocyanate; [0162] (2) polycaprolactone diol; [0163] (3)
polyethylene glycol; and [0164] (4) polyoxyethylene and
polyoxypropylene copolymer; and [0165] (b) at least one diol having
2 to 18 carbon atoms.
[0166] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethane comprising the steps of:
[0167] (a) reacting components comprising: [0168] 1) at least one
polyisocyanate; [0169] 2) at least one polycaprolactone polyol; and
[0170] 3) at least one polyol selected from the group consisting of
polyalkylene polyol, polyether polyol and mixtures thereof, [0171]
to form a polyurethane prepolymer; and [0172] (b) reacting the
prepolymer with at least one diol having 2 to 18 carbon atoms to
form the polyurethane.
Group I
[0173] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s comprising a reaction product of
components comprising: [0174] (a) at least one isocyanate
functional urea prepolymer comprising a reaction product of: [0175]
(1) at least one polyisocyanate; and [0176] (2) water; and [0177]
(b) at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups, wherein the reaction product components
are essentially free of amine curing agent.
[0178] In some non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane) comprising the
steps of: [0179] (a) reacting at least one polyisocyanate and water
to form an isocyanate functional urea prepolymer; and [0180] (b)
reacting reaction product components comprising the isocyanate
functional urea prepolymer with at least one branched polyol having
4 to 18 carbon atoms and at least 3 hydroxyl groups, wherein the
reaction product components are essentially free of amine curing
agent.
Group J
[0181] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s comprising a reaction product of
components comprising: [0182] (a) at least one isocyanate
functional urea prepolymer comprising a reaction product of: [0183]
(1) at least one polyisocyanate selected from the group consisting
of polyisocyanate trimers and branched polyisocyanates, the
polyisocyanate having at least three isocyanate functional groups;
and [0184] (2) water; and [0185] (b) at least one aliphatic polyol
having 4 to 18 carbon atoms and at least 2 hydroxyl groups.
[0186] In some non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane)s comprising the
steps of: [0187] (a) reacting at least one polyisocyanate selected
from the group consisting of polyisocyanate trimers and branched
polyisocyanates and water to form an isocyanate functional urea
prepolymer; and [0188] (b) reacting reaction product components
comprising the isocyanate functional urea prepolymer with at least
one aliphatic polyol having 4 to 18 carbon atoms and at least 2
hydroxyl groups, wherein the reaction product components are
essentially free of amine curing agent.
Group K
[0189] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s comprising a reaction product of
components comprising: [0190] (a) at least one isocyanate
functional ureaurethane prepolymer comprising the reaction product
of: [0191] (1) at least one isocyanate functional urethane
prepolymer comprising the reaction product of: [0192] (i) a first
amount of at least one polyisocyanate; and [0193] (ii) a first
amount of at least one branched polyol; and [0194] (2) water,
[0195] to form an isocyanate functional ureaurethane prepolymer;
and [0196] (b) a second amount of at least one polyisocyanate and a
second amount of at least one branched polyol.
[0197] In some non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane)s comprising the
steps of: [0198] (a) reacting at least one polyisocyanate and at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups to form an isocyanate functional urethane
prepolymer; [0199] (b) reacting the isocyanate functional urethane
prepolymer with water and polyisocyanate to form an isocyanate
functional ureaurethane prepolymer; and [0200] (c) reacting
reaction product components comprising the isocyanate functional
ureaurethane prepolymer with at least one aliphatic polyol having 4
to 18 carbon atoms and at least 2 hydroxyl groups, wherein the
reaction product components are essentially free of amine curing
agent.
Group L
[0201] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s comprising a reaction product of
components comprising: [0202] (a) at least one isocyanate
functional ureaurethane prepolymer comprising the reaction product
of: [0203] (1) at least one isocyanate functional urethane
prepolymer comprising the reaction product of: [0204] (i) a first
amount of at least one polyisocyanate selected from the group
consisting of polyisocyanate trimers and branched polyisocyanates,
the polyisocyanate having at least three isocyanate functional
groups; and [0205] (ii) a first amount of at least one aliphatic
polyol; and [0206] (2) water, [0207] to form an isocyanate
functional ureaurethane prepolymer; and [0208] (b) a second amount
of at least one polyisocyanate and a second amount of at least one
aliphatic polyol.
[0209] In some non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane)s comprising the
steps of: [0210] (a) reacting at least one polyisocyanate selected
from the group consisting of polyisocyanate trimers and branched
polyisocyanates and at least one aliphatic polyol having 4 to 18
carbon atoms and at least 2 hydroxyl groups to form an isocyanate
functional urethane prepolymer; [0211] (b) reacting the isocyanate
functional urethane prepolymer with water and polyisocyanate to
form an isocyanate functional ureaurethane prepolymer; and [0212]
(c) reacting reaction product components comprising the isocyanate
functional ureaurethane prepolymer with at least one aliphatic
polyol having 4 to 18 carbon atoms and at least 2 hydroxyl groups,
wherein the reaction product components are essentially free of
amine curing agent.
Group M
[0213] In other non-limiting embodiments, the present invention
provides poly(ureaurethane)s comprising a reaction product of
components comprising: [0214] (a) about 1 equivalent of at least
one polyisocyanate; [0215] (b) about 0.1 to about 0.9 equivalents
of at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups; [0216] (c) about 0.1 to about 0.9
equivalents of at least one aliphatic diol having 2 to 18 carbon
atoms; and [0217] (d) at least one amine curing agent, wherein the
reaction product components are essentially free of polyester
polyol and polyether polyol.
[0218] In other non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane) comprising the
step of reacting in a one-potprocess components comprising: [0219]
(a) at least one polyisocyanate; [0220] (b) at least one branched
polyol having 4 to 18 carbon atoms and at least 3 hydroxyl groups;
[0221] (c) at least one aliphatic diol having 2 to 18 carbon atoms;
and [0222] (d) amine curing agent, wherein the reaction product
components are essentially free of polyester polyol and polyether
polyol.
Group N
[0223] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s comprising a reaction product of
components comprising: [0224] (a) at least one polyisocyanate
selected from the group consisting of polyisocyanate trimers and
branched polyisocyanates, the polyisocyanate having at least three
isocyanate functional groups; [0225] (b) about 0.1 to about 0.9
equivalents of at least one polyol having 4 to 18 carbon atoms and
at least 2 hydroxyl groups; and [0226] (c) at least one amine
curing agent, wherein the reaction product components are
essentially free of polyester polyol and polyether polyol.
[0227] In some non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane) comprising the
step of reacting in a one-potprocess components comprising: [0228]
(a) at least one polyisocyanate selected from the group consisting
of polyisocyanate trimers and branched polyisocyanates; [0229] (b)
at least one aliphatic polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups; [0230] (c) at least one aliphatic diol
having 2 to 18 carbon atoms; and [0231] (d) amine curing agent,
wherein the reaction product components are essentially free of
polyester polyol and polyether polyol.
Group O
[0232] In some non-limiting embodiments, the present invention
provides polyurethane materials comprising a first portion of
crystalline particles having self-orientation and bonded together
to fix their orientation along a first crystallographic direction
and a second portion of crystalline particles having
self-orientation and bonded together to fix their orientation along
a second crystallographic direction, the first crystallographic
direction being different from the second crystallographic
direction, wherein said crystalline particles comprise at least
about 30% of the total volume of the polyurethane material.
Group P
[0233] In some non-limiting embodiments, the present invention
provides methods of preparing a polyurethane powder coating
composition comprising the steps of: reacting at least one
polyisocyanate with at least one aliphatic polyol to form a
generally solid, hydroxy functional prepolymer; melting the hydroxy
functional prepolymer; melting at least one generally solid
polyisocyanate to form a melted polyisocyanate; mixing the hydroxy
functional prepolymer and melted polyisocyanate to form a mixture;
and solidifying the mixture to form a generally solid powder
coating composition.
[0234] In other non-limiting embodiments, the present invention
provides methods of preparing a polyurethane powder coating
composition comprising the steps of: reacting at least one
polyisocyanate with at least one aliphatic polyol to form a
generally solid, hydroxy functional prepolymer; dissolving the
hydroxy functional prepolymer in a first solvent to form a first
solution; dissolving at least one generally solid polyisocyanate in
a second solvent that is the same as or compatible with the first
solvent to form a second solution; mixing the first and second
solutions; and removing substantially all of the solvent to form a
generally solid powder coating composition.
Group Q
[0235] In some non-limiting embodiments, the present invention
provides polyurethane compositions comprising: at least one
polyurethane comprising a reaction product of components
comprising: [0236] (a) (i) at least one polyisocyanate; [0237] (ii)
at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups; and [0238] (iii) at least one diol having
2 to 18 carbon atoms; and [0239] (b) at least one reinforcement
material selected from the group consisting of polymeric inorganic
materials, nonpolymeric inorganic materials, polymeric organic
materials, nonpolymeric organic materials, composites thereof, and
combinations thereof.
[0240] In other non-limiting embodiments, the present invention
provides polyurethane compositions comprising: [0241] (a) at least
one polyurethane comprising a reaction product of components
comprising: [0242] (i) at least one polyisocyanate; [0243] (ii) at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; and [0244] (iii) at least one polyol having one
or more bromine atoms, one or more phosphorus atoms or combinations
thereof; and [0245] (b) at least one reinforcement material
selected from the group consisting of polymeric inorganic
materials, nonpolymeric inorganic materials, polymeric organic
materials, nonpolymeric organic materials, composites thereof, and
mixtures thereof.
[0246] In other non-limiting embodiments, the present invention
provides polyurethane compositions comprising: [0247] (a) a
polyurethane comprising a reaction product of components
comprising: [0248] (i) a prepolymer which is the reaction product
of components comprising: [0249] (1) at least one polyisocyanate;
[0250] (2) at least one polycaprolactone polyol; and [0251] (3) at
least one polyol selected from the group consisting of polyalkylene
polyol, polyether polyol and mixtures thereof; [0252] and [0253]
(ii) at least one diol having 2 to 18 carbon atoms; and [0254] (b)
at least one reinforcement material selected from the group
consisting of polymeric inorganic materials, nonpolymeric inorganic
materials, polymeric organic materials, nonpolymeric organic
materials, composites thereof, and mixtures thereof.
[0255] In other non-limiting embodiments, the present invention
provides polyurethane compositions comprising: [0256] (a) at least
one polyurethane comprising a reaction product of components
comprising: [0257] (i) at least one polyisocyanate selected from
the group consisting of polyisocyanate trimers or branched
polyisocyanates, the polyisocyanate having at least three
isocyanate functional groups; and [0258] (ii) at least one
aliphatic polyol having 4 to 18 carbon atoms and at least two
hydroxyl groups; and [0259] (b) at least one reinforcement material
selected from the group consisting of polymeric inorganic
materials, nonpolymeric inorganic materials, polymeric organic
materials, nonpolymeric organic materials, composites thereof, and
mixtures thereof.
[0260] In other non-limiting embodiments, the present invention
provides poly(ureaurethane)s compositions comprising: [0261] (a) at
least one poly(ureaurethane) comprising a reaction product of
components comprising: [0262] (i) at least one isocyanate
functional prepolymer comprising a reaction product of: [0263] 1.
at least one polyisocyanate; and [0264] 2. water; and [0265] (ii)
at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups, wherein the reaction product components
are essentially free of amine curing agent; and [0266] (b) at least
one reinforcement material selected from the group consisting of
polymeric inorganic materials, nonpolymeric inorganic materials,
polymeric organic materials, nonpolymeric organic materials,
composites thereof, and mixtures thereof.
[0267] In other non-limiting embodiments, the present invention
provides poly(ureaurethane)s compositions comprising: [0268] (a) at
least one poly(ureaurethane) comprising a reaction product of
components comprising: [0269] (i) at least one isocyanate
functional urethane prepolymer comprising a reaction product of:
[0270] 1. a first amount of at least one polyisocyanate; and [0271]
2. a first amount of at least one branched polyol; and [0272] (ii)
water, [0273] to form an isocyanate functional ureaurethane
prepolymer; and [0274] (b) a second amount of at least one
polyisocyanate and a second amount of at least one branched polyol;
and [0275] (c) at least one reinforcement material selected from
the group consisting of polymeric inorganic materials, nonpolymeric
inorganic materials, polymeric organic materials, nonpolymeric
organic materials, composites thereof, and mixtures thereof.
[0276] In some non-limiting embodiments, the present invention
provides methods for forming a reinforced polyurethane composition,
comprising the steps of: mixing a precursor solution of the
reaction product components of the above polyurethane or
poly(ureaurethane) with a precursor for the nanostructures; forming
the nanostructures from the precursor of the nanostructures in the
polyurethane matrix; and polymerizing the precursor of the reaction
product components to form the polyurethane.
Group R
[0277] In some non-limiting embodiments, the present invention
provides a laminate comprising: [0278] (a) at least one layer of at
least one polyurethane comprising a reaction product of components
comprising: [0279] (i) at least one polyisocyanate; [0280] (ii) at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; and [0281] (iii) at least one diol having 2 to
18 carbon atoms; and [0282] (b) at least one layer of a substrate
selected from the group consisting of paper, glass, ceramic, wood,
masonry, textile, metal or organic polymeric material and
combinations thereof.
[0283] In other non-limiting embodiments, the present invention
provides a laminate comprising: [0284] (a) at least one layer of at
least one polyurethane comprising a reaction product of components
comprising: [0285] (i) at least one polyisocyanate; [0286] (ii) at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups; and [0287] (iii) at least one polyol having one
or more bromine atoms, one or more phosphorus atoms or combinations
thereof; and [0288] (b) at least one layer of a substrate selected
from the group consisting of paper, glass, ceramic, wood, masonry,
textile, metal or organic polymeric material and combinations
thereof.
[0289] In other non-limiting embodiments, the present invention
provides a laminate comprising: [0290] (a) at least one layer of at
least one polyurethane comprising a reaction product of components
comprising: [0291] (i) a prepolymer which is the reaction product
of components comprising: [0292] (1) at least one polyisocyanate;
[0293] (2) at least one polycaprolactone polyol; and [0294] (3) at
least one polyol selected from the group consisting of polyalkylene
polyol, polyether polyol and mixtures thereof; and [0295] (ii) at
least one diol having 2 to 18 carbon atoms; and [0296] (b) at least
one layer of a substrate selected from the group consisting of
paper, glass, ceramic, wood, masonry, textile, metal or organic
polymeric material and combinations thereof.
[0297] In other non-limiting embodiments, the present invention
provides a laminate comprising: [0298] (a) at least one layer of at
least one polyurethane comprising a reaction product of components
comprising: [0299] (i) at least one polyisocyanate selected from
the group consisting of polyisocyanate trimers or branched
polyisocyanates, the polyisocyanate having at least three
isocyanate functional groups; and [0300] (ii) at least one
aliphatic polyol having 4 to 18 carbon atoms and at least two
hydroxyl groups; and [0301] (b) at least one layer of a substrate
selected from the group consisting of paper, glass, ceramic, wood,
masonry, textile, metal or organic polymeric material and
combinations thereof.
[0302] In other non-limiting embodiments, the present invention
provides a laminate comprising: [0303] (a) at least one layer of at
least one poly(ureaurethane) comprising a reaction product of
components comprising: [0304] (i) at least one isocyanate
functional prepolymer comprising a reaction product of: [0305] 1.
at least one polyisocyanate; and [0306] 2. water; and [0307] (ii)
at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups, wherein the reaction product components
are essentially free of amine curing agent; and [0308] (b) at least
one layer of a substrate selected from the group consisting of
paper, glass, ceramic, wood, masonry, textile, metal or organic
polymeric material and combinations thereof.
[0309] In other non-limiting embodiments, the present invention
provides a laminate comprising:
[0310] (A) at least one layer of at least one poly(ureaurethane)
comprising a reaction product of components comprising: [0311] (a)
at least one isocyanate functional ureaurethane prepolymer
comprising a reaction product of components comprising [0312] (1)
at least one isocyanate functional urethane prepolymer comprising a
reaction product of: [0313] a. a first amount of at least one
polyisocyanate; and [0314] b. a first amount of at least one
branched polyol; and [0315] (2) water, [0316] to form an isocyanate
functional ureaurethane prepolymer; and [0317] (b) a second amount
of at least one polyisocyanate and a second amount of at least one
branched polyol; and
[0318] (B) at least one layer of a substrate selected from the
group consisting of paper, glass, ceramic, wood, masonry, textile,
metal or organic polymeric material and combinations thereof.
[0319] Cured compositions, articles, laminates and methods of
making and using the same comprising the above polyurethanes and
poly(ureaurethane)s are also provided by the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0320] The foregoing summary, as well as the following detailed
description, will be better understood when read in conjunction
with the appended drawings. In the drawings:
[0321] FIG. 1 is a graph of G' and G'' as a function of temperature
measured using Dynamic Mechanical Analysis (DMA) showing storage
modulus, loss modulus and tan Delta for a casting of a polyurethane
according to Example A, Formulation 1 of the present invention;
[0322] FIG. 2 is a graph of G' and G'' as a function of temperature
measured using Dynamic Mechanical Analysis (DMA) showing storage
modulus, loss modulus and tan Delta for a casting of a polyurethane
according to Example A, Formulation 2 of the present invention;
[0323] FIG. 3 is a graph of G' and G'' as a function of temperature
measured using Dynamic Mechanical Analysis (DMA) showing storage
modulus, loss modulus and tan Delta for a casting of a polyurethane
according to Example A, Formulation 40 of the present
invention;
[0324] FIG. 4 is a TEM photomicrograph showing a casting of a
polyurethane according to Example A, Formulation 2 analyzed two
weeks after formation according to the present invention;
[0325] FIG. 5 is a TEM photomicrograph showing a casting of a
polyurethane according to Example A, Formulation 2 analyzed about
three weeks after formation according to the present invention;
[0326] FIG. 6 is a TEM photomicrograph showing a first portion of a
casting of a polyurethane according to Example A, Formulation 2
analyzed about seven months after formation according to the
present invention;
[0327] FIG. 7 is an electron diffraction pattern of a casting of
the polyurethane of Example A, Formulation 2 of FIG. 6;
[0328] FIG. 8 is a TEM photomicrograph showing a second portion of
the casting of the polyurethane of FIG. 6 according to Example A,
Formulation 2 prepared after aging at ambient conditions for about
seven months according to the present invention;
[0329] FIG. 9 is a TEM photomicrograph showing a first portion of a
casting of a polyurethane according to Example A, Formulation 2
prepared after aging at ambient temperature for about two to four
weeks;
[0330] FIG. 10 is a TEM photomicrograph showing a second portion of
the casting of the polyurethane according to Example A, Formulation
2 shown in FIG. 9;
[0331] FIG. 11 is a TEM photomicrograph showing a casting of a
polyurethane according to Example A, Formulation 2;
[0332] FIG. 12 is a TEM photomicrograph showing a first portion of
a casting of a polyurethane according to Example A, Formulation 2
prepared after aging at ambient temperature for about seven
months;
[0333] FIG. 13 is a TEM photomicrograph showing a second portion of
a casting of a polyurethane according to Example A, Formulation 2
shown in FIG. 12;
[0334] FIG. 14 is a graph of heat flow as a function of temperature
measured using Differential Scanning Calorimetry (DSC) for castings
of a polyurethane according to Example A, Formulation 2 measured
after aging at ambient conditions for two weeks, three months and
seven months, respectively, according to the present invention;
[0335] FIG. 15 is a graph of Gardner Impact as a function of
Young's Modulus for castings of a polyurethane according to Example
A, Formulations 1 and 2 measured after aging at ambient conditions
for seven months and one year, respectively, according to the
present invention;
[0336] FIG. 16 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example A, Formulation 114,
according to the present invention;
[0337] FIG. 17 is a photograph of a perspective view of a test
sample of Formulation 2, Example A after shooting of the sample
with .40 caliber bullets from 30 feet (9.2 m) at a velocity of 987
ft/sec (300.8 m/sec);
[0338] FIG. 18 is a photograph of a front elevational view of a
test sample of Formulation 2, Example A after shooting of the
sample with a 12-gauge shotgun shot from 20 feet (6.1 m) at a
velocity of 1290 ft/sec (393.2 m/sec) using heavy game lead shot
pellets;
[0339] FIG. 19 is a photograph of a front elevational view of a
test sample of Formulation 93, Example A is a photograph of a front
elevational view of a test sample of 9 mm bullets shot from 20 feet
(6.1 m) at a velocity of 1350 ft/sec (411.5 m/sec);
[0340] FIG. 20 is a photograph of a perspective view of a test
sample of Formulation 94, Example A after shooting of the sample
with a 9 mm bullet shot from 20 feet (6.1 m) at an initial velocity
of 1350 ft/sec (411.5 m/sec);
[0341] FIG. 21 is a side elevational view of the sample shown in
FIG. 20;
[0342] FIG. 22 is front elevational view of a portion of a
composite according to the present invention after shooting of the
sample with four 7.62.times.39 mm bullets having a steel core shot
from an AK-47 rifle from a distance of 30 yards (27.4 m) at an
initial velocity of 2700 ft/sec (823 m/sec);
[0343] FIG. 23 is a rear perspective view of the sample of FIG.
22.
[0344] FIG. 24 is a graph of heat flow as a function of temperature
measured using Differential Scanning Calorimetry (DSC) for a
casting of a polyurethane prepared according to Example A,
Formulation 2 of the present invention;
[0345] FIG. 25 is a graph of heat flow as a function of temperature
measured using (DSC) for a casting of a polyurethane prepared
according to Example A, Formulation 136 of the present
invention;
[0346] FIG. 26 is a graph of weight loss as a function of
temperature measured using Thermogravimetric Analysis (TGA) for a
casting of a polyurethane prepared according to Example A,
Formulation 136 of the present invention;
[0347] FIG. 27 is a graph of Gardner Impact strength as a function
of residence time in the mix head for selected samples according to
the present invention;
[0348] FIG. 28 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #2,
Sample 19, according to the present invention;
[0349] FIG. 29 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #2,
Sample 21, according to the present invention;
[0350] FIG. 30 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #2,
Sample 31, according to the present invention;
[0351] FIG. 31 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #2,
Sample 46, according to the present invention;
[0352] FIG. 32 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #2,
Sample 48, according to the present invention;
[0353] FIG. 33 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #2,
Sample 49, according to the present invention;
[0354] FIG. 34 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #2,
Sample 52, according to the present invention;
[0355] FIG. 35 is a graph of Young's Modulus (psi) as a function of
residence time in the mix head (sec) for selected polyurethane
samples prepared according to Example L3, Trial #2, according to
the present invention;
[0356] FIG. 36 is a graph of Gardner Impact strength as a function
of residence time in the mix head for selected samples according to
the present invention;
[0357] FIG. 37 is a graph of Gardner Impact strength as a function
of residence time in the mix head for selected samples according to
the present invention;
[0358] FIG. 38 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Example L3, Trial #4,
Sample 11, according to the present invention;
[0359] FIG. 39 is a graph of nominal strain in mm as a function of
test time for samples of conventional stretched acrylic and a
sample #1 (Formulation 3) Trial A according to the present
invention; and
[0360] FIG. 40 is a bar chart of average K-factor in
lb.sub.f/in.sup.3/2 and deflection in mm for selected samples
according to the present invention.
DETAILED DESCRIPTION
[0361] As used herein, spatial or directional terms, such as
"inner", "left", "right", "up", "down", "horizontal", "vertical"
and the like, relate to the invention as it is described herein.
However, it is to be understood that the invention can assume
various alternative orientations and, accordingly, such terms are
not to be considered as limiting. For the purposes of this
specification, unless otherwise indicated, all numbers expressing
quantities of ingredients, reaction conditions, dimensions,
physical characteristics, and so forth used in the specification
and claims are to be understood as being modified in all instances
by the term "about." Accordingly, unless indicated to the contrary,
the numerical parameters set forth in the following specification
and attached claims are approximations that may vary depending upon
the desired properties sought to be obtained by the present
invention. At the very least, and not as an attempt to limit the
application of the doctrine of equivalents to the scope of the
claims, each numerical parameter should at least be construed in
light of the number of reported significant digits and by applying
ordinary rounding techniques.
[0362] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the invention are approximations,
the numerical values set forth in the specific examples are
reported as precisely as possible. Any numerical value, however,
inherently contain certain errors necessarily resulting from the
standard deviation found in their respective testing
measurements.
[0363] Also, it should be understood that any numerical range
recited herein is intended to include all sub-ranges subsumed
therein. For example, a range of "1 to 10" is intended to include
any and all sub-ranges between and including the recited minimum
value of 1 and the recited maximum value of 10, that is, all
subranges beginning with a minimum value equal to or greater than 1
and ending with a maximum value equal to or less than 10, and all
subranges in between, e.g., 1 to 6.3, or 5.5 to 10, or 2.7 to
6.1.
[0364] "Alkyl" means an aliphatic hydrocarbon group which may be
straight or branched and comprising about 1 to about 20 carbon
atoms in the chain. Non-limiting examples of suitable alkyl groups
contain about 1 to about 18 carbon atoms in the chain, or about 1
to about 6 carbon atoms in the chain. Branched means that one or
more lower alkyl groups such as methyl, ethyl or propyl, are
attached to a linear alkyl chain. "Lower alkyl" or "short chain
alkyl" means a group having about 1 to about 6 carbon atoms in the
chain which may be straight or branched. "Alkyl" may be
unsubstituted or optionally substituted by one or more substituents
which may be the same or different, each substituent being
independently selected from the group consisting of halo, alkyl,
aryl, cycloalkyl, cyano, hydroxy, alkoxy, alkylthio, amino,
--NH(alkyl), --NH(cycloalkyl), --N(alkyl).sub.2, carboxy and
--C(O)O-alkyl. Non-limiting examples of suitable alkyl groups
include methyl, ethyl, n-propyl, isopropyl and t-butyl.
[0365] "Alkylene" means a difunctional group obtained by removal of
a hydrogen atom from an alkyl group that is defined above.
Non-limiting examples of alkylene include methylene, ethylene and
propylene.
[0366] "Aryl" means an aromatic monocyclic or multicyclic ring
system comprising about 6 to about 14 carbon atoms, or about 6 to
about 10 carbon atoms. The aryl group can be optionally substituted
with one or more "ring system substituents" which may be the same
or different, and are as defined herein. Non-limiting examples of
suitable aryl groups include phenyl and naphthyl.
[0367] "Heteroaryl" means an aromatic monocyclic or multicyclic
ring system comprising about 5 to about 14 ring atoms, or about 5
to about 10 ring atoms, in which one or more of the ring atoms is
an element other than carbon, for example nitrogen, oxygen or
sulfur, alone or in combination. In some non-limiting embodiments,
the heteroaryls contain about 5 to about 6 ring atoms. The
"heteroaryl" can be optionally substituted by one or more "ring
system substituents" which may be the same or different, and are as
defined herein. The prefix aza, oxa or thia before the heteroaryl
root name means that at least one of a nitrogen, oxygen or sulfur
atom respectively, is present as a ring atom. A nitrogen atom of a
heteroaryl can be optionally oxidized to the corresponding N-oxide.
Non-limiting examples of suitable heteroaryls include pyridyl,
pyrazinyl, furanyl, thienyl, pyrimidinyl, pyridone (including
N-substituted pyridones), isoxazolyl, isothiazolyl, oxazolyl,
thiazolyl, pyrazolyl, furazanyl, pyrrolyl, pyrazolyl, triazolyl,
1,2,4-thiadiazolyl, pyrazinyl, pyridazinyl, quinoxalinyl,
phthalazinyl, oxindolyl, imidazo[1,2-a]pyridinyl,
imidazo[2,1-b]thiazolyl, benzofurazanyl, indolyl, azaindolyl,
benzimidazolyl, benzothienyl, quinolinyl, imidazolyl,
thienopyridyl, quinazolinyl, thienopyrimidyl, pyrrolopyridyl,
imidazopyridyl, isoquinolinyl, benzoazaindolyl, 1,2,4-triazinyl,
benzothiazolyl and the like. The term "heteroaryl" also refers to
partially saturated heteroaryl moieties such as, for example,
tetrahydroisoquinolyl, tetrahydroquinolyl and the like.
[0368] "Aralkyl" or "arylalkyl" means an aryl-alkyl- group in which
the aryl and alkyl are as previously described. In some
non-limiting embodiments, the aralkyls comprise a lower alkyl
group. Non-limiting examples of suitable aralkyl groups include
benzyl, 2-phenethyl and naphthalenylmethyl. The bond to the parent
moiety is through the alkyl.
[0369] "Alkylaryl" means an alkyl-aryl- group in which the alkyl
and aryl are as previously described. In some non-limiting
embodiments, the alkylaryls comprise a lower alkyl group. A
non-limiting example of a suitable alkylaryl group is tolyl. The
bond to the parent moiety is through the aryl.
[0370] "Cycloalkyl" means a non-aromatic mono- or multicyclic ring
system comprising about 3 to about 10 carbon atoms, or about 5 to
about 10 carbon atoms. In some non-limiting embodiments, the
cycloalkyl ring contains about 5 to about 7 ring atoms. The
cycloalkyl can be optionally substituted with one or more "ring
system substituents" which may be the same or different, and are as
defined above. Non-limiting examples of suitable monocyclic
cycloalkyls include cyclopropyl, cyclopentyl, cyclohexyl,
cycloheptyl and the like. Non-limiting examples of suitable
multicyclic cycloalkyls include 1-decalinyl, norbornyl, adamantyl
and the like.
[0371] "Halogen" or "halo" means fluorine, chlorine, bromine, or
iodine. In some non-limiting embodiments, the halogen groups are
fluorine, chlorine or bromine.
[0372] "Ring system substituent" means a substituent attached to an
aromatic or non-aromatic ring system which, for example, replaces
an available hydrogen on the ring system. Ring system substituents
may be the same or different, each being independently selected
from the group consisting of alkyl, alkenyl, alkynyl, aryl,
heteroaryl, aralkyl, alkylaryl, heteroaralkyl, heteroarylalkenyl,
heteroarylalkynyl, alkylheteroaryl, hydroxy, hydroxyalkyl, alkoxy,
aryloxy, aralkoxy, acyl, aroyl, halo, nitro, cyano, carboxy,
alkoxycarbonyl, aryloxycarbonyl, aralkoxycarbonyl, alkylsulfonyl,
arylsulfonyl, heteroarylsulfonyl, alkylthio, arylthio,
heteroarylthio, aralkylthio, heteroaralkylthio, cycloalkyl,
heterocyclyl, --C(.dbd.N--CN)--NH.sub.2, --C(.dbd.NH)--NH.sub.2,
--C(.dbd.NH)--NH(alkyl), Y.sub.1Y.sub.2N--, Y.sub.1Y.sub.2N-alkyl-,
Y.sub.1Y.sub.2NC(O)--, Y.sub.1Y.sub.2NSO.sub.2-- and
--SO.sub.2NY.sub.1Y.sub.2, wherein Y.sub.1 and Y.sub.2 can be the
same or different and are independently selected from the group
consisting of hydrogen, alkyl, aryl, cycloalkyl, and aralkyl. "Ring
system substituent" may also mean a single moiety which
simultaneously replaces two available hydrogens on two adjacent
carbon atoms (one H on each carbon) on a ring system. Examples of
such moieties are methylene dioxy, ethylenedioxy,
--C(CH.sub.3).sub.2-- and the like which form moieties such as, for
example:
##STR00001##
[0373] "Heterocyclyl" means a non-aromatic saturated monocyclic or
multicyclic ring system comprising about 3 to about 10 ring atoms,
or about 5 to about 10 ring atoms, in which one or more of the
atoms in the ring system is an element other than carbon, for
example nitrogen, oxygen or sulfur, alone or in combination. There
are no adjacent oxygen and/or sulfur atoms present in the ring
system. In some non-limiting embodiments, the heterocyclyl contains
about 5 to about 6 ring atoms. The prefix aza, oxa or thia before
the heterocyclyl root name means that at least a nitrogen, oxygen
or sulfur atom respectively is present as a ring atom. Any --NH in
a heterocyclyl ring may exist protected such as, for example, as an
--N(Boc), --N(CBz), --N(Tos) group and the like; such protections
are also considered part of this invention. The heterocyclyl can be
optionally substituted by one or more "ring system substituents"
which may be the same or different, and are as defined herein. The
nitrogen or sulfur atom of the heterocyclyl can be optionally
oxidized to the corresponding N-oxide, S-oxide or S,S-dioxide.
Non-limiting examples of suitable monocyclic heterocyclyl rings
include piperidyl, pyrrolidinyl, piperazinyl, morpholinyl,
thiomorpholinyl, thiazolidinyl, 1,4-dioxanyl, tetrahydrofuranyl,
tetrahydrothiophenyl, lactam, lactone, and the like.
[0374] It should be noted that in hetero-atom containing ring
systems of this invention, there are no hydroxyl groups on carbon
atoms adjacent to a N, O or S, as well as there are no N or S
groups on carbon adjacent to another heteroatom. Thus, for example,
in the ring:
##STR00002##
there is no --OH attached directly to carbons marked 2 and 5.
[0375] It should also be noted that tautomeric forms such as, for
example, the moieties:
##STR00003##
are considered equivalent in certain embodiments of this
invention.
[0376] "Heteroaralkyl" means a heteroaryl-alkyl- group in which the
heteroaryl and alkyl are as previously described. In some
non-limiting embodiments, the heteroaralkyl contains a lower alkyl
group. Non-limiting examples of suitable heteroaralkyl groups
include pyridylmethyl, and quinolin-3-ylmethyl. The bond to the
parent moiety is through the alkyl.
[0377] "Hydroxyalkyl" means a HO-alkyl- group in which alkyl is as
previously defined. In some non-limiting embodiments, the
hydroxyalkyl contains a lower alkyl group. Non-limiting examples of
suitable hydroxyalkyl groups include hydroxymethyl and
2-hydroxyethyl.
[0378] "Alkoxy" means an alkyl-O-- group in which the alkyl group
is as previously described. Non-limiting examples of suitable
alkoxy groups include methoxy, ethoxy, n-propoxy, isopropoxy and
n-butoxy. The bond to the parent moiety is through the ether
oxygen.
[0379] "Aryloxy" means an aryl-O-- group in which the aryl group is
as previously described. Non-limiting examples of suitable aryloxy
groups include phenoxy and naphthoxy. The bond to the parent moiety
is through the ether oxygen.
[0380] "Alkylthio" means an alkyl-S-- group in which the alkyl
group is as previously described. Non-limiting examples of suitable
alkylthio groups include methylthio and ethylthio. The bond to the
parent moiety is through the sulfur.
[0381] "Arylthio" means an aryl-S-- group in which the aryl group
is as previously described. Non-limiting examples of suitable
arylthio groups include phenylthio and naphthylthio. The bond to
the parent moiety is through the sulfur.
[0382] "Aralkylthio" means an aralkyl-S-- group in which the
aralkyl group is as previously described. A non-limiting example of
a suitable aralkylthio group is benzylthio. The bond to the parent
moiety is through the sulfur.
[0383] "Alkoxycarbonyl" means an alkyl-O--CO-- group. Non-limiting
examples of suitable alkoxycarbonyl groups include methoxycarbonyl
and ethoxycarbonyl. The bond to the parent moiety is through the
carbonyl.
[0384] "Aryloxycarbonyl" means an aryl-O--C(O)-- group.
Non-limiting examples of suitable aryloxycarbonyl groups include
phenoxycarbonyl and naphthoxycarbonyl. The bond to the parent
moiety is through the carbonyl.
[0385] "Aralkoxycarbonyl" means an aralkyl-O--C(O)-- group. A
non-limiting example of a suitable aralkoxycarbonyl group is
benzyloxycarbonyl. The bond to the parent moiety is through the
carbonyl.
[0386] "Alkylsulfonyl" means an alkyl-S(O.sub.2)-- group. In some
non-limiting embodiments, the alkylsulfonyl group includes a lower
alkyl group. The bond to the parent moiety is through the
sulfonyl.
[0387] "Arylsulfonyl" means an aryl-S(O.sub.2)-- group. The bond to
the parent moiety is through the sulfonyl.
[0388] The term "substituted" means that one or more hydrogens on
the designated atom is replaced with a selection from the indicated
group, provided that the designated atom's normal valency under the
existing circumstances is not exceeded, and that the substitution
results in a stable compound. Combinations of substituents and/or
variables are permissible only if such combinations result in
stable compounds.
[0389] The term "optionally substituted" means optional
substitution with the specified groups, radicals or moieties.
[0390] It should also be noted that any carbon as well as
heteroatom with unsatisfied valences in the text, schemes, examples
and Tables herein is assumed to have the sufficient number of
hydrogen atom(s) to satisfy the valences.
[0391] When a functional group in a compound is termed "protected",
this means that the group is in modified form to preclude undesired
side reactions at the protected site when the compound is subjected
to a reaction. Suitable protecting groups will be recognized by
those with ordinary skill in the art as well as by reference to
standard textbooks such as, for example, T. W. Greene et al.,
Protective Groups in Organic Synthesis (1991), Wiley, New York.
[0392] When any variable (e.g., aryl, heterocycle, R.sup.2, etc.)
occurs more than one time in any constituent, its definition on
each occurrence is independent of its definition at every other
occurrence.
[0393] As used herein, the term "composition" is intended to
encompass a product comprising the specified ingredients in the
specified amounts, as well as any product which results, directly
or indirectly, from combination of the specified ingredients in the
specified amounts.
[0394] As used herein, "formed from" or "prepared from" denotes
open, e.g., "comprising," claim language. As such, it is intended
that a composition "formed from" or "prepared from" a list of
recited components be a composition comprising at least these
recited components or the reaction product of at least these
recited components, and can further comprise other, non-recited
components, during the composition's formation or preparation. As
used herein, the phrase "reaction product of" means chemical
reaction product(s) of the recited components, and can include
partial reaction products as well as fully reacted products.
[0395] As used herein, the term "polymer" is meant to encompass
oligomers, and includes without limitation both homopolymers and
copolymers. The term "prepolymer" means a compound, monomer or
oligomer used to prepare a polymer, and includes without limitation
both homopolymer and copolymer oligomers.
[0396] The phrase "thermoplastic polymer" means a polymer that
undergoes liquid flow upon heating and can be soluble in
solvents.
[0397] The phrase "thermoset polymer" means a polymer that
solidifies or "sets" irreversibly upon curing or crosslinking. Once
cured, a crosslinked thermoset polymer will not melt upon the
application of heat and is generally insoluble in solvents.
[0398] As used herein, the term "cure" or "cured" as used in
connection with a composition, e.g., "composition when cured" or a
"cured composition", shall mean that any curable or crosslinkable
components of the composition are at least partially cured or
crosslinked. In some non-limiting embodiments of the present
invention, the crosslink density of the crosslinkable components,
i.e., the degree of crosslinking, ranges from about 5% to about
100% of complete crosslinking. In other non-limiting embodiments,
the crosslink density ranges from about 35% to about 85% of full
crosslinking. In other non-limiting embodiments, the crosslink
density ranges from about 50% to about 85% of full crosslinking.
One skilled in the art will understand that the presence and degree
of crosslinking, i.e., the crosslink density, can be determined by
a variety of methods, such as dynamic mechanical thermal analysis
(DMA) using a TA Instruments DMA 2980 DMA analyzer over a
temperature range of -65.degree. F. (-18.degree. C.) to 350.degree.
F. (177.degree. C.) conducted under nitrogen according to ASTM D
4065-01. This method determines the glass transition temperature
and crosslink density of free films of coatings or polymers. These
physical properties of a cured material are related to the
structure of the crosslinked network. In an embodiment of the
present invention, the sufficiency of cure is evaluated relative to
the solvent resistance of a cured film of the polymer. For example,
solvent resistance can be measured by determining the number of
double acetone rubs. For purposes of the present invention, a
coating is deemed to be "cured" when the film can withstand a
minimum of 100 double acetone rubs without substantial softening of
the film and no removal of the film.
[0399] Curing of a polymerizable composition can be obtained by
subjecting the composition to curing conditions, such as but not
limited to thermal curing, irradiation, etc., leading to the
reaction of reactive groups of the composition and resulting in
polymerization and formation of a solid polymerizate. When a
polymerizable composition is subjected to curing conditions,
following polymerization and after reaction of most of the reactive
groups occurs, the rate of reaction of the remaining unreacted
reactive groups becomes progressively slower. In some non-limiting
embodiments, the polymerizable composition can be subjected to
curing conditions until it is at least partially cured. The term
"at least partially cured" means subjecting the polymerizable
composition to curing conditions, wherein reaction of at least a
portion of the reactive groups of the composition occurs, to form a
solid polymerizate. The at least partially cured polymerizate can
be demolded and, for example, used to prepare articles such as
windows, cut into test pieces or subjected to machining operations,
such as optical lens processing. In some non-limiting embodiments,
the polymerizable composition can be subjected to curing conditions
such that a substantially complete cure is attained and wherein
further exposure to curing conditions results in no significant
further improvement in polymer properties, such as strength or
hardness.
[0400] The term "polyurethane" is intended to include not only
polyurethanes that are formed from the reaction of polyisocyanates
and polyols but also poly(ureaurethane)(s) that are prepared from
the reaction of polyisocyanates with polyols and water and/or
polyamines.
[0401] The polyurethanes and poly(ureaurethane)s of the present
invention can be useful in applications in which one or more of the
following properties are desired: transparency, high optical
quality, high Abbe number, low color, energy-absorption, stiffness,
moisture stability, ultraviolet light stability, weathering
resistance, low water absorption, hydrolytic stability and bullet
or explosive resistance.
[0402] In some embodiments, cured articles prepared from the
polyurethanes and poly(ureaurethane)s of the present invention are
generally clear, can have a luminous transmittance of at least
about 80 percent, less than about 2 percent haze and show no visual
change after 1,000 hours of light and water exposure according to
ASTM D-1499-64.
[0403] Polyurethanes and poly(ureaurethane)s of the present
invention can be formed into articles having a variety of shapes
and dimensions, such as flat sheets or curved shapes. Non-limiting
examples of useful methods for forming articles include heat
treatment, pressure casting, or pouring liquid polyurethane or
poly(ureaurethane) into a mold and curing the product to form a
molded article.
[0404] Generally, the polyurethanes and poly(ureaurethane)s of the
present invention comprise a reaction product of components
comprising at least one polyisocyanate and at least one aliphatic
polyol having 4 to 18 carbon atoms and at least 2 or at least 3
hydroxyl groups, wherein at least one of the polyisocyanate(s)
and/or the aliphatic polyol(s) is branched.
[0405] In the present invention, at least one of the isocyanate
and/or at least one of the polyols is branched. As used herein,
"branched" means a chain of atoms with one or more side chains
attached to it. Branching occurs by the replacement of a
substituent, e.g, a hydrogen atom, with a covalently bonded
substituent or moiety, e.g, an alkyl group. While not intending to
be bound by any theory, it is believed that branching of the
polyisocyanate and/or polyol can increase the free volume within
the polymer matrix, thereby providing room for the molecules to
move. The molecules can orient and rotate into configurations and
alignments having favorable energy states which can provide good
impact properties and/or high modulus of elasticity for the cured
polymer matrix. As shown in FIGS. 1, 2 and 3, Dynamic Mechanical
Analysis (DMA) of polyurethane castings prepared according to
Examples 1, 2 and 40, respectively, for loss modulus as a function
of temperature show a low temperature transition at about
-70.degree. C. DMA analysis was conducted over a temperature range
of -65.degree. F. (-18.degree. C.) to 350.degree. F. (177.degree.
C.) under nitrogen according to ASTM D 4065-01. While not intending
to be bound by any theory, it is believed that this low temperature
transition is due to molecular torsional mobility at that
temperature and is believed to contribute to the high impact
strength of these polymers.
[0406] When a viscoelastic material is subjected to an oscillatory
vibration, some energy is stored in the polymer, which is
proportional to the elastic component of the modulus G', or storage
modulus, and some of the energy is converted to heat through
internal friction, or viscous dissipation of the energy, which is
termed the loss modulus G''. The maximum in the loss modulus is
termed tan Delta, which is the maximum in internal friction,
damping, or viscous energy dissipation.
[0407] High light transmittance, glassy polymers rarely exhibit
high impact strength. Polycarbonate plastics such as LEXAN can
exhibit a similar low temperature transition, but can have lower
impact strength and lower Young's Modulus.
[0408] The physical properties of the polyurethanes and
poly(ureaurethane)s of the present invention are derived from their
molecular structure and are determined by the selection of building
blocks, e.g., the selection of the reactants, the ratio of the hard
crystalline and soft amorphous segments, and the supra-molecular
structures caused by atomic interactions between chains.
[0409] Hard segments, i.e., the crystalline or semi-crystalline
region of the urethane polymer, result from the reaction of the
isocyanate and a chain extender, such as an aliphatic polyol having
4 to 18 carbon atoms or a low molecular weight polyol having a
molecular weight of less than about 200 discussed herein.
Generally, the soft segment, i.e., the amorphous, rubbery region of
the urethane polymer, results from the reaction of the isocyanate
and a polymer backbone component, for example a polyester polyol
(such as a polycarbonate polyol) or a polyether polyol or short
chain diols that have not formed crystalline regions.
[0410] The qualitative contribution of a particular organic polyol
to either the hard or soft segment when mixed and reacted with
other polyurethane-forming components can be readily determined by
measuring the Fischer microhardness of the resulting cured
polyurethane according to ISO 14577-1:2002.
[0411] In some non-limiting embodiments, the hard segment content
of the polyurethane ranges from about 10 to about 100 weight
percent, or about 50 to about 100 weight percent, or about 70 to
about 100 weight percent. The hard segment content is the
percentage by weight of the hard segment linkages present in the
polymer and can be calculated by determining the total number of
equivalents, and from this the total weight of all reactants, and
dividing the total weight of the hard segment linkages obtainable
from these reactants by the total weight of the reactants
themselves. The following example will further explain the
calculation. In Example I, Formulation 1 which follows, a
polyurethane article according to the invention was prepared by
reacting 0.7 equivalents of 1,4-butanediol, 0.3 equivalents of
trimethylolpropane and one equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate) (DESMODUR W). The
equivalent weight of the 1,4-butanediol is 45 g/eq., the equivalent
weight of the trimethylolpropane is 44.7 g/eq. (corrected for
impurities) and the equivalent weight of the DESMODUR W is 131.2
g/eq. Therefore, the actual weight of ingredients used is 31.54
parts by weight of 1,4-butanediol, 13.2 parts by weight of
trimethylolpropane and 131.2 parts by weight of DESMODUR W or a
total reactant weight of 175. parts by weight. One equivalent of
1,4-butanediol will yield one equivalent of hard segment linkage,
where the hard segment linkage is 1,4-butanediol/DESMODUR W dimer.
The equivalent weight of a 1,4-butanediol/DESMODUR W dimer linkage
is 176 g/eq. so that the total weight of the hard segment linkages
determined by multiplying the equivalent weight of the hard segment
dimer by the number of equivalents of 1,4-butanediol would be 123.2
g/eq. Thus, the total weight of the 1,4-butanediol/DESMODUR W dimer
linkage, 123.2, divided by the total weight of the reactants,
175.7, multiplied by 100 to convert to percentages would give a
percentage by weight of hard segment linkage of 70 percent by
weight.
[0412] Both Plexiglas and stretched acrylic absorb quite a bit of
water from the atmosphere. In accelerated tests such as QUV-B or
soaking in water at room temperature, surprisingly, polyurethanes
according to the present invention including short chain diols such
as butanediol and pentanediol, absorbed essentially no water in
water vapor transmission rate studies and after soaking in water
for about 24 hours. While not intending to be bound by any theory,
it is believed that even though these plastics are very polar, the
hydrogen bonding in the hard segment domains is strong enough to
block water vapor transmission and uptake of water. In comparison,
stretched acrylic will absorb enough water to cause severe swelling
of the plastic, to the point that it cracks in-plane, like layers
of onion skin separating until it falls apart. The low water
absorption can also mitigate any hydrolysis degradation of the
urethane groups in the polymer.
[0413] Discussion of the various aspects and embodiments of
polyurethanes and poly(ureaurethanes) of the present invention have
been grouped generally in groups A-Q below. As stated above, these
groupings are not intended to limit the scope of the invention and
aspects of one grouping may be relevant to the subject matter of
other groupings. Also, limitations as to amounts of reactants in
one grouping are not necessarily intended to limit amounts of the
same component in other groupings, although appropriate amounts may
be the same for a different grouping unless otherwise
indicated.
Group A
[0414] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: [0415] (a) about 1 equivalent of at least one
polyisocyanate; [0416] (b) about 0.05 to about 0.9 equivalents of
at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups; and [0417] (c) about 0.1 to about 0.95
equivalents of at least one diol having 2 to 18 carbon atoms,
wherein the reaction product components are essentially free of
polyester polyol and polyether polyol and wherein the reaction
components are maintained at a temperature of at least about
100.degree. C. for at least about 10 minutes.
[0418] As used herein, the term "equivalent" means the mass in
grams of a substance which will react with one mole
(6.022.times.10.sup.23 electrons) of another substance. As used
herein, "equivalent weight" is effectively equal to the amount of a
substance in moles, divided by the valence or number of functional
reactive groups of the substance.
[0419] As used herein, the term "isocyanate" includes compounds,
monomers, oligomers and polymers comprising at least one or at
least two --N.dbd.C.dbd.O functional groups and/or at least one or
at least two --N.dbd.C.dbd.S (isothiocyanate) groups.
Monofunctional isocyanates can be used as chain terminators or to
provide terminal groups during polymerization. As used herein,
"polyisocyanate" means an isocyanate comprising at least two
--N.dbd.C.dbd.O functional groups and/or at least two
--N.dbd.C.dbd.S (isothiocyanate) groups, such as diisocyanates or
triisocyanates, as well as dimers and trimers or biurets of the
isocyanates discussed herein. Suitable isocyanates are capable of
forming a covalent bond with a reactive group such as hydroxyl,
thiol or amine functional group. Isocyanates useful in the present
invention can be branched or unbranched. As discussed above, use of
branched isocyanates may be desirable to increase the free volume
within the polymer matrix to provide space for the molecules to
move.
[0420] Isocyanates useful in the present invention include
"modified", "unmodified" and mixtures of "modified" and
"unmodified" isocyanates. The isocyanates can have "free",
"blocked" or partially blocked isocyanate groups. The term
"modified" means that the aforementioned isocyanates are changed in
a known manner to introduce biuret, urea, carbodiimide, urethane or
isocyanurate groups or blocking groups. In some non-limiting
embodiments, the "modified" isocyanate is obtained by cycloaddition
processes to yield dimers and trimers of the isocyanate, i.e.,
polyisocyanates. Free isocyanate groups are extremely reactive. In
order to control the reactivity of isocyanate group-containing
components, the NCO groups may be blocked with certain selected
organic compounds that render the isocyanate group inert to
reactive hydrogen compounds at room temperature. When heated to
elevated temperatures, e.g., ranging from about 90.degree. C. to
about 200.degree. C., the blocked isocyanates release the blocking
agent and react in the same way as the original unblocked or free
isocyanate.
[0421] Generally, compounds used to block isocyanates are organic
compounds that have active hydrogen atoms, e.g., volatile alcohols,
epsilon-caprolactam or ketoxime compounds. Non-limiting examples of
suitable blocking compounds include phenol, cresol, nonylphenol,
epsilon-caprolactam and methyl ethyl ketoxime.
[0422] As used herein, the NCO in the NCO:OH ratio represents the
free isocyanate of free isocyanate-containing materials, and of
blocked or partially blocked isocyanate-containing materials after
the release of the blocking agent. In some cases, it is not
possible to remove all of the blocking agent. In those situations,
more of the blocked isocyanate-containing material would be used to
attain the desired level of free NCO.
[0423] The molecular weight of the isocyanate and isothiocyanate
can vary widely. In alternate non-limiting embodiments, the number
average molecular weight (Mn) of each can be at least about 100
grams/mole, or at least about 150 grams/mole, or less than about
15,000 grams/mole, or less than about 5,000 grams/mole. The number
average molecular weight can be determined using known methods,
such as by gel permeation chromatography (GPC) using polystyrene
standards.
[0424] Non-limiting examples of suitable isocyanates include
aliphatic, cycloaliphatic, aromatic and heterocyclic isocyanates,
dimers and trimers thereof and mixtures thereof. Useful
cycloaliphatic isocyanates include those in which one or more of
the isocyanato groups are attached directly to the cycloaliphatic
ring and cycloaliphatic isocyanates in which one or more of the
isocyanato groups are not attached directly to the cycloaliphatic
ring. Useful aromatic isocyanates include those in which one or
more of the isocyanato groups are attached directly to the aromatic
ring, and aromatic isocyanates in which one or more of the
isocyanato groups are not attached directly to the aromatic ring.
Useful heterocyclic isocyanates include those in which one or more
of the isocyanato groups are attached directly to the heterocyclic
ring and heterocyclic isocyanates in which one or more of the
isocyanato groups are not attached directly to the heterocyclic
ring.
[0425] Cycloaliphatic diisocyanates are desirable for use in the
present invention because they are not adversely affected by
ultraviolet light and can yield polyurethanes having high impact
energy absorption levels, which make them desirable for glass
replacements and bilayer safety glass applications. Also,
polyurethanes prepared with cycloaliphatic diisocyanates are not
adversely affected by conventional processing temperatures. When an
aromatic polyisocyanate is used, generally, care should be taken to
select a material that does not cause the polyurethane to color
(e.g., yellow).
[0426] In some non-limiting embodiments, the aliphatic and
cycloaliphatic diisocyanates can comprise about 6 to about 100
carbon atoms linked in a straight chain or cyclized and having two
isocyanate reactive end groups.
[0427] Non-limiting examples of suitable aliphatic isocyanates
include straight chain isocyanates such as ethylene diisocyanate,
trimethylene diisocyanate, 1,6-hexamethylene diisocyanate (HDI),
tetramethylene diisocyanate, hexamethylene diisocyanate,
octamethylene diisocyanate, nonamethylene diisocyanate,
decamethylene diisocyanate, 1,6,11-undecanetriisocyanate,
1,3,6-hexamethylene triisocyanate, bis(isocyanatoethyl)-carbonate,
bis(isocyanatoethyl)ether.
[0428] Other non-limiting examples of suitable aliphatic
isocyanates include branched isocyanates such as trimethylhexane
diisocyanate, trimethylhexamethylene diisocyanate (TMDI),
2,2'-dimethylpentane diisocyanate, 2,2,4-trimethylhexane
diisocyanate, 2,4,4,-trimethylhexamethylene diisocyanate,
1,8-diisocyanato-4-(isocyanatomethyl)octane,
2,5,7-trimethyl-1,8-diisocyanato-5-(isocyanatomethyl) octane,
2-isocyanatopropyl-2,6-diisocyanatohexanoate, lysinediisocyanate
methyl ester and lysinetriisocyanate methyl ester.
[0429] Non-limiting examples of suitable cycloaliphatic isocyanates
include dinuclear compounds bridged by an isopropylidene group or
an alkylene group of 1 to 3 carbon atoms. Non-limiting examples of
suitable cycloaliphatic isocyanates include
1,1'-methylene-bis-(4-isocyanatocyclohexane) or
4,4'-methylene-bis-(cyclohexyl isocyanate) (such as DESMODUR W
commercially available from Bayer Corp. of Pittsburgh, Pa.),
4,4'-isopropylidene-bis-(cyclohexyl isocyanate), 1,4-cyclohexyl
diisocyanate (CHDI), 4,4'-dicyclohexylmethane diisocyanate,
3-isocyanato methyl-3,5,5-trimethylcyclohexyl isocyanate (a
branched isocyanate also known as isophorone diisocyanate or IPDI)
which is commercially available from Arco Chemical Co. of Newtown
Square, Pa. and meta-tetramethylxylylene diisocyanate (a branched
isocyanate also known as
1,3-bis(1-isocyanato-1-methylethyl)-benzene which is commercially
available from Cytec Industries Inc. of West Patterson, N.J. under
the tradename TMXDI.RTM. (Meta) Aliphatic Isocyanate) and mixtures
thereof.
[0430] Other useful dinuclear cycloaliphatic diisocyanates include
those formed through an alkylene group of from 1 to 3 carbon atoms
inclusive, and which can be substituted with nitro, chlorine,
alkyl, alkoxy and other groups that are not reactive with hydroxyl
groups (or active hydrogens) providing they are not positioned so
as to render the isocyanate group unreactive. Also, hydrogenated
aromatic diisocyanates such as hydrogenated toluene diisocyanate
may be used. Dinuclear diisocyanates in which one of the rings is
saturated and the other unsaturated, which are prepared by
partially hydrogenating aromatic diisocyanates such as diphenyl
methane diisocyanates, diphenyl isopropylidene diisocyanate and
diphenylene diisocyanate, may also be used.
[0431] Mixtures of cycloaliphatic diisocyanates with aliphatic
diisocyanates and/or aromatic diisocyanates may also be used. An
example is 4,4'-methylene-bis-(cyclohexyl isocyanate) with
commercial isomer mixtures of toluene diisocyanate or
meta-phenylene diisocyanate.
[0432] Thioisocyanates corresponding to the above diisocyanates can
be used, as well as mixed compounds containing both an isocyanate
and a thioisocyanate group.
[0433] Non-limiting examples of suitable isocyanates can include
but are not limited to DESMODUR W, DESMODUR N 3300 (hexamethylene
diisocyanate trimer), DESMODUR N 3400 (60% hexamethylene
diisocyanate dimer and 40% hexamethylene diisocyanate trimer),
which are commercially available from Bayer Corp.
[0434] In some non-limiting embodiments, the isocyanate can include
1,1'-methylene-bis-(4-isocyanatocyclohexane) (also known as
4,4'-methylene-bis-(cyclohexyl isocyanate)) and isomeric mixtures
thereof. As used herein, the term "isomeric mixtures" refers to a
mixture of the cis-cis, trans-trans, and cis-trans isomers of the
isocyanate. Non-limiting examples of isomeric mixtures suitable for
use in the present invention can include the trans-trans isomer of
4,4'-methylenebis(cyclohexyl isocyanate), hereinafter referred to
as "PICM" (paraisocyanato cyclohexylmethane), the cis-trans isomer
of PICM, the cis-cis isomer of PICM, and mixtures thereof. Three
suitable isomers of 4,4'-methylenebis(cyclohexyl isocyanate) (also
known as 1,1'-methylenebis(4-isocyanatocyclohexane) for use in the
present invention are shown below.
##STR00004##
[0435] In some non-limiting embodiments, the PICM used in this
invention can be prepared by phosgenating the
4,4'-methylenebis(cyclohexyl amine) (PACM) by procedures well-known
in the art such as the procedures disclosed in U.S. Pat. Nos.
2,644,007 and 2,680,127, which are incorporated herein by
reference. The PACM isomer mixtures, upon phosgenation, can produce
PICM in a liquid phase, a partially liquid phase, or a solid phase
at room temperature. The PACM isomer mixtures can be obtained by
the hydrogenation of methylenedianiline and/or by fractional
crystallization of PACM isomer mixtures in the presence of water
and alcohols such as methanol and ethanol.
[0436] In some non-limiting embodiments, the isomeric mixture can
comprise from about 10 to about 100 weight percent of the trans,
trans isomer of 4,4'-methylenebis(cyclohexyl isocyanate) (PICM), or
about 30 to about 100 weight percent, or about 50 to about 100
weight percent, or about 75 to about 100 weight percent. In other
non-limiting embodiments, the cycloaliphatic isocyanate can consist
essentially of the trans, trans isomer of
1,1'-methylene-bis-(4-isocyanatocyclohexane) (also known as
4,4'-methylene-bis-(cyclohexyl isocyanate)), e.g., at least about
80 weight percent of the trans, trans isomer of
1,1'-methylene-bis-(4-isocyanatocyclohexane), or at least about 90
weight percent of the trans, trans isomer of
1,1'-methylene-bis-(4-isocyanatocyclohexane), or at least about 95
weight percent of the trans, trans isomer of
1,1'-methylene-bis-(4-isocyanatocyclohexane) and in other
non-limiting embodiments consists of about 100 weight percent of
the trans, trans isomer of
1,1'-methylene-bis-(4-isocyanatocyclohexane).
[0437] Non-limiting examples of suitable polyisocyanates for use in
the present invention include polyisocyanates and
polyisothiocyanates having backbone linkages such as urethane
linkages (--NH--C(O)--O--), thiourethane linkages
(--NH--C(O)--S--), thiocarbamate linkages (--NH--C(S)--O--),
dithiourethane linkages (--NH--C(S)--S--), polyamide linkages, and
combinations thereof.
[0438] Other non-limiting examples of suitable polyisocyanates
include ethylenically unsaturated polyisocyanates and
polyisothiocyanates; alicyclic polyisocyanates and
polyisothiocyanates; aromatic polyisocyanates and
polyisothiocyanates wherein the isocyanate groups are not bonded
directly to the aromatic ring, e.g., .alpha.,.alpha.'-xylylene
diisocyanate; aromatic polyisocyanates and polyisothiocyanates
wherein the isocyanate groups are bonded directly to the aromatic
ring, e.g., benzene diisocyanate; aliphatic polyisocyanates and
polyisothiocyanates containing sulfide linkages; aromatic
polyisocyanates and polyisothiocyanates containing sulfide or
disulfide linkages; aromatic polyisocyanates and
polyisothiocyanates containing sulfone linkages; sulfonic
ester-type polyisocyanates and polyisothiocyanates, e.g.,
4-methyl-3-isocyanatobenzenesulfonyl-4'-isocyanato-phenol ester;
aromatic sulfonic amide-type polyisocyanates and
polyisothiocyanates; sulfur-containing heterocyclic polyisocyanates
and polyisothiocyanates, e.g., thiophene-2,5-diisocyanate;
halogenated, alkylated, alkoxylated, nitrated, carbodiimide
modified, urea modified and biuret modified derivatives of
isocyanates; and dimerized and trimerized products of
isocyanates.
[0439] Non-limiting examples of suitable ethylenically unsaturated
polyisocyanates include butene diisocyanate and
1,3-butadiene-1,4-diisocyanate. Non-limiting examples of suitable
alicyclic polyisocyanates include isophorone diisocyanate,
cyclohexane diisocyanate, methylcyclohexane diisocyanate,
bis(isocyanatomethyl)cyclohexane, bis(isocyanatocyclohexyl)methane,
bis(isocyanatocyclohexyl)-2,2-propane,
bis(isocyanatocyclohexyl)-1,2-ethane,
2-isocyanatomethyl-3-(3-isocyanatopropyl)-5-isocyanatomethyl-bicyclo[2.2.-
1]-heptane,
2-isocyanatomethyl-3-(3-isocyanatopropyl)-6-isocyanatomethyl-bicyclo[2.2.-
1]-heptane,
2-isocyanatomethyl-2-(3-isocyanatopropyl)-5-isocyanatomethyl-bicyclo[2.2.-
1]-heptane,
2-isocyanatomethyl-2-(3-isocyanatopropyl)-6-isocyanatomethyl-bicyclo[2.2.-
1]-heptane,
2-isocyanatomethyl-3-(3-isocyanatopropyl)-6-(2-isocyanatoethyl)-bicyclo[2-
.2.1]-heptane,
2-isocyanatomethyl-2-(3-isocyanatopropyl)-5-(2-isocyanatoethyl)-bicyclo[2-
.2.1]-heptane and
2-isocyanatomethyl-2-(3-isocyanatopropyl)-6-(2-isocyanatoethyl)-bicyclo[2-
.2.1]-heptane.
[0440] Non-limiting examples of suitable aromatic polyisocyanates
wherein the isocyanate groups are not bonded directly to the
aromatic ring include .alpha.,.alpha.'-xylene diisocyanate,
bis(isocyanatoethyl)benzene,
.alpha.,.alpha.,.alpha.',.alpha.'-tetramethylxylene diisocyanate,
1,3-bis(1-isocyanato-1-methylethyl)benzene,
bis(isocyanatobutyl)benzene, bis(isocyanatomethyl)naphthalene,
bis(isocyanatomethyl)diphenyl ether, bis(isocyanatoethyl)
phthalate, mesitylene triisocyanate and
2,5-di(isocyanatomethyl)furan.
[0441] Non-limiting examples of suitable aromatic polyisocyanates
having isocyanate groups bonded directly to the aromatic ring
include phenylene diisocyanate, ethylphenylene diisocyanate,
isopropylphenylene diisocyanate, dimethylphenylene diisocyanate,
diethylphenylene diisocyanate, diisopropylphenylene diisocyanate,
trimethylbenzene triisocyanate, benzene diisocyanate, benzene
triisocyanate, naphthalene diisocyanate, methylnaphthalene
diisocyanate, biphenyl diisocyanate, ortho-toluidine diisocyanate,
ortho-tolylidine diisocyanate, ortho-tolylene diisocyanate,
4,4'-diphenylmethane diisocyanate,
bis(3-methyl-4-isocyanatophenyl)methane,
bis(isocyanatophenyl)ethylene,
3,3'-dimethoxy-biphenyl-4,4'-diisocyanate, triphenylmethane
triisocyanate, polymeric 4,4'-diphenylmethane diisocyanate,
naphthalene triisocyanate, diphenylmethane-2,4,4'-triisocyanate,
4-methyldiphenylmethane-3,5,2',4',6'-pentaisocyanate, diphenylether
diisocyanate, bis(isocyanatophenylether)ethyleneglycol,
bis(isocyanatophenylether)-1,3-propyleneglycol, benzophenone
diisocyanate, carbazole diisocyanate, ethylcarbazole diisocyanate
and dichlorocarbazole diisocyanate.
[0442] In some non-limiting embodiments, sulfur-containing
isocyanates of the following general formula (I) can be used:
##STR00005##
wherein R.sub.10 and R.sub.11 are each independently C.sub.1 to
C.sub.3 alkyl.
[0443] Non-limiting examples of suitable aliphatic polyisocyanates
containing sulfide linkages include thiodiethyl diisocyanate,
thiodipropyl diisocyanate, dithiodihexyl diisocyanate,
dimethylsulfone diisocyanate, dithiodimethyl diisocyanate,
dithiodiethyl diisocyanate, dithiodipropyl diisocyanate and
dicyclohexylsulfide-4,4'-diisocyanate. Non-limiting examples of
aromatic polyisocyanates containing sulfide or disulfide linkages
include but are not limited to diphenylsulfide-2,4'-diisocyanate,
diphenylsulfide-4,4'-diisocyanate,
3,3'-dimethoxy-4,4'-diisocyanatodibenzyl thioether,
bis(4-isocyanatomethylbenzene)-sulfide,
diphenyldisulfide-4,4'-diisocyanate,
2,2'-dimethyldiphenyldisulfide-5,5'-diisocyanate,
3,3'-dimethyldiphenyldisulfide-5,5'-diisocyanate,
3,3'-dimethyldiphenyldisulfide-6,6'-diisocyanate,
4,4'-dimethyldiphenyldisulfide-5,5'-diisocyanate,
3,3'-dimethoxydiphenyldisulfide-4,4'-diisocyanate and
4,4'-dimethoxydiphenyldisulfide-3,3'-diisocyanate.
[0444] Non-limiting examples of suitable aromatic polyisocyanates
containing sulfone linkages include
diphenylsulfone-4,4'-diisocyanate,
diphenylsulfone-3,3'-diisocyanate,
benzidinesulfone-4,4'-diisocyanate,
diphenylmethanesulfone-4,4'-diisocyanate,
4-methyldiphenylmethanesulfone-2,4'-diisocyanate,
4,4'-dimethoxydiphenylsulfone-3,3'-diisocyanate,
3,3'-dimethoxy-4,4'-diisocyanatodibenzylsulfone,
4,4'-dimethyldiphenylsulfone-3,3'-diisocyanate,
4,4'-di-tert-butyl-diphenylsulfone-3,3'-diisocyanate and
4,4'-dichlorodiphenylsulfone-3,3'-diisocyanate.
[0445] Non-limiting examples of aromatic sulfonic amide-type
polyisocyanates include
4-methyl-3-isocyanato-benzene-sulfonylanilide-3'-methyl-4'-isocyanate,
dibenzenesulfonyl-ethylenediamine-4,4'-diisocyanate,
4,4'-methoxybenzenesulfonyl-ethylenediamine-3,3'-diisocyanate and
4-methyl-3-isocyanato-benzene-sulfonylanilide-4-ethyl-3'-isocyanate.
[0446] Non-limiting examples of suitable isothiocyanates include
cyclohexane diisothiocyanates; aromatic isothiocyanates wherein the
isothiocyanate group(s) are not bonded directly to the aromatic
ring; aromatic isothiocyanates wherein the isothiocyanate group(s)
are bonded directly to the aromatic ring; heterocyclic
isothiocyanates; carbonyl polyisothiocyanates; aliphatic
polyisothiocyanates containing sulfide linkages; and mixtures
thereof.
[0447] Other non-limiting examples of suitable isothiocyanates
include aromatic polyisothiocyanates wherein the isothiocyanate
groups are bonded directly to the aromatic ring, such as phenylene
diisothiocyanate; heterocyclic polyisothiocyanates, such as
2,4,6-triisothicyanato-1,3,5-triazine and
thiophene-2,5-diisothiocyanate; carbonyl polyisothiocyanates;
aliphatic polyisothiocyanates containing sulfide linkages, such as
thiobis(3-isothiocyanatopropane); aromatic polyisothiocyanates
containing sulfur atoms in addition to those of the isothiocyanate
groups; halogenated, alkylated, alkoxylated, nitrated, carbodiimide
modified, urea modified and biuret modified derivatives of these
polyisothiocyanates; and dimerized and trimerized products of these
isothiocyanates.
[0448] Non-limiting examples of suitable aliphatic
polyisothiocyanates include 1,2-diisothiocyanatoethane,
1,3-diisothiocyanatopropane, 1,4-diisothiocyanatobutane and
1,6-diisothiocyanatohexane. Non-limiting examples of aromatic
polyisothiocyanates having isothiocyanate groups bonded directly to
the aromatic ring include 1,2-diisothiocyanatobenzene,
1,3-diisothiocyanatobenzene, 1,4-diisothiocyanatobenzene,
2,4-diisothiocyanatotoluene, 2,5-diisothiocyanato-m-xylene,
4,4'-diisothiocyanato-1,1'-biphenyl,
1,1'-methylenebis(4-isothiocyanatobenzene),
1,1'-methylenebis(4-isothiocyanato-2-methylbenzene),
1,1'-methylenebis(4-isothiocyanato-3-methylbenzene),
1,1'-(1,2-ethanediyl)bis(4-isothiocyanatobenzene),
4,4'-diisothiocyanatobenzophenenone,
4,4'-diisothiocyanato-3,3'-dimethylbenzophenone,
benzanilide-3,4'-diisothiocyanate,
diphenylether-4,4'-diisothiocyanate and
diphenylamine-4,4'-diisothiocyanate.
[0449] Non-limiting examples of suitable carbonyl isothiocyanates
include hexane-dioyl diisothiocyanate, nonanedioyl
diisothiocyanate, carbonic diisothiocyanate, 1,3-benzenedicarbonyl
diisothiocyanate, 1,4-benzenedicarbonyl diisothiocyanate and
(2,2'-bipyridine)-4,4'-dicarbonyl diisothiocyanate. Non-limiting
examples of suitable aromatic polyisothiocyanates containing sulfur
atoms in addition to those of the isothiocyanate groups, include
1-isothiocyanato-4-[(2-isothiocyanato)sulfonyl]benzene,
thiobis(4-isothiocyanatobenzene),
sulfonylbis(4-isothiocyanatobenzene),
sulfinylbis(4-isothiocyanatobenzene),
dithiobis(4-isothiocyanatobenzene),
4-isothiocyanato-1-[(4-isothiocyanatophenyl)-sulfonyl]-2-methoxybenzene,
4-methyl-3-isothicyanatobenzene-sulfonyl-4'-isothiocyanate phenyl
ester and
4-methyl-3-isothiocyanatobenzene-sulfonylanilide-3'-methyl-4'-isothio-
cyanate.
[0450] Other non-limiting examples of isocyanates having isocyanate
and isothiocyanate groups include materials having aliphatic,
alicyclic, aromatic or heterocyclic groups and which optionally can
contain sulfur atoms in addition to those of the isothiocyanate
groups. Non-limiting examples of such materials include
1-isocyanato-3-isothiocyanatopropane,
1-isocyanato-5-isothiocyanatopentane,
1-isocyanato-6-isothiocyanatohexane, isocyanatocarbonyl
isothiocyanate, 1-isocyanato-4-isothiocyanatocyclohexane,
1-isocyanato-4-isothiocyanatobenzene,
4-methyl-3-isocyanato-1-isothiocyanatobenzene,
2-isocyanato-4,6-diisothiocyanato-1,3,5-triazine,
4-isocyanato-4'-isothiocyanato-diphenyl sulfide and
2-isocyanato-2'-isothiocyanatodiethyl disulfide.
[0451] In some non-limiting embodiments, the isocyanate comprises
at least one triisocyanate or at least one polyisocyanate trimer.
Non-limiting examples of such isocyanates include aromatic
triisocyanates such as tris(4-iso-cyanatophenyl)methane (DESMODUR
R),
1,3,5-tris(3-isocyanato-4-methylphenyl)-2,3,6-trioxohexahydro-1,3,5
triazine (DESMODUR IL); adducts of aromatic diisocyanates such as
the adduct of 2,4-tolylene diisocyanate (TDI,
2,4-diisocyanatotoluene) and trimethylolpropane (DESMODUR L); and
from aliphatic triisocyanates such as
N-isocyanatohexylaminocarbonyl-N,N'-bis(isocyanatohexyl)urea
(DESMODUR N),
2,4,6-trioxo-1,3,5-tris(6-isocyanatohexyl)hexahydro-1,3,5-triazine
(DESMODUR N3390),
2,4,6-trioxo-1,3,5-tris(5-isocyanato-1,3,3-trimethylcyclo-hexylmethyl)hex-
ahydro-1,3,5-triazine (DESMODUR Z4370), and
4-(isocyanatomethyl)-1,8-octane diisocyanate. The above DESMODUR
products are commercially available from Bayer Corp. Also useful
are the biuret of hexanediisocyanate, polymeric methane
diisocyanate, and polymeric isophorone diisocyanate, and trimers of
hexamethylene diisocyanate, isophorone diisocyanate and
tetramethylxylylene diisocyanate.
[0452] In some non-limiting embodiments, the polyisocyanate used to
make a polyurethane polyol prepolymer as a precursor is a
cycloaliphatic compound, such as a dinuclear compound bridged by an
isopropylidene group or an alkylene group of 1 to 3 carbon
atoms.
[0453] The reaction components for preparing the polyurethane of
Group A also comprise about 0.1 to about 0.9 equivalents of at
least one branched polyol having 4 to 18 carbon atoms and at least
3 hydroxyl groups. As discussed above, the branched polyol may
increase the free volume within the polymer matrix to provide space
for the molecules to move or rotate when impacted.
[0454] As used herein, the term "polyol" includes compounds,
monomers, oligomers and polymers comprising at least two hydroxyl
groups (such as diols) or at least three hydroxyl groups (such as
triols), higher functional polyols and mixtures thereof. Suitable
polyols are capable of forming a covalent bond with a reactive
group such as an isocyanate functional group.
[0455] Non-limiting examples of suitable polyols include aliphatic,
cycloaliphatic, aromatic, heterocyclic, oligomeric, and polymeric
polyols and mixtures thereof. In some embodiments, such as for
transparencies or windows exposed to sunlight, aliphatic or
cycloaliphatic polyols can be used.
[0456] The number of carbon atoms in the polyol described above for
Group A can range from 4 to 18, or from 4 to 12, or from 4 to 10,
or from 4 to 8, or from 4 to 6 carbon atoms. In some non-limiting
embodiments, one or more carbon atoms in the polyol can be replaced
with one or more heteroatoms, such as N, S, or O.
[0457] As discussed above, the branched polyol useful as a reaction
product for preparing the polyurethane of Group A has 4 to 18
carbon atoms and at least 3 hydroxyl groups. Non-limiting examples
of trifunctional, tetrafunctional or higher polyols suitable for
use as the branched polyol include branched chain alkane polyols
such as glycerol or glycerin, tetramethylolmethane,
trimethylolethane (for example 1,1,1-trimethylolethane),
trimethylolpropane (TMP) (for example 1,1,1-trimethylolpropane),
erythritol, pentaerythritol, dipentaerythritol, tripentaerythritol,
sorbitan, alkoxylated derivatives thereof (discussed below) and
mixtures thereof.
[0458] In some non-limiting embodiments, the polyol can be a
cycloalkane polyol, such as trimethylene
bis(1,3,5-cyclohexanetriol).
[0459] In some non-limiting embodiments, the polyol can be an
aromatic polyol, such as trimethylene bis(1,3,5-benzenetriol).
[0460] Further non-limiting examples of suitable polyols include
the aforementioned polyols which can be alkoxylated derivatives,
such as ethoxylated, propoxylated and butoxylated. In alternate
non-limiting embodiments, the following polyols can be alkoxylated
with from 1 to 10 alkoxy groups: glycerol, trimethylolethane,
trimethylolpropane, benzenetriol, cyclohexanetriol, erythritol,
pentaerythritol, sorbitol, mannitol, sorbitan, dipentaeryltritol
and tripentaerythritol. In alternate non-limiting embodiments,
alkoxylated, ethoxylated and propoxylated polyols and mixtures
thereof can be used alone or in combination with unalkoxylated,
unethoxylated and unpropoxylated polyols having at least three
hydroxyl groups and mixtures thereof. The number of alkoxy groups
can be from 1 to 10, or from 2 to 8 or any rational number between
1 and 10. In a non-limiting embodiment, the alkoxy group can be
ethoxy and the number of ethoxy groups can be 1 to 5 units. In
another non-limiting embodiment, the polyol can be
trimethylolpropane having up to 2 ethoxy groups. Non-limiting
examples of suitable alkoxylated polyols include ethoxylated
trimethylolpropane, propoxylated trimethylolpropane, ethoxylated
trimethylolethane, and mixtures thereof.
[0461] Mixtures of any of the above polyols can be used.
[0462] In some embodiments, the polyurethanes of the present
invention can be thermoplastics, for example those polyurethanes
having a molecular weight per crosslink of at least about 6000
g/mole.
[0463] In some non-limiting embodiments, the branched polyol having
4 to 18 carbon atoms can have a number average molecular weight of
about 100 to about 500 grams/mole. In some non-limiting
embodiments, the polyol can have a number average molecular weight
of less than about 450 grams/mole. In other non-limiting
embodiments, the polyol can have a number average molecular weight
of less than about 200 grams/mole.
[0464] The reaction components for preparing the polyurethane of
Group A also comprise about 0.1 to about 0.9 equivalents of at
least one diol having 2 to 18 carbon atoms, or from about 2 to
about 14 carbon atoms, or from 2 to 10 carbon atoms, or from 2 to 6
carbon atoms. In some non-limiting embodiments, one or more carbon
atoms in the diol can be replaced with one or more heteroatoms,
such as N, S, or O.
[0465] Non-limiting examples of suitable diols include straight
chain alkane diols such as ethylene glycol, diethylene glycol,
triethylene glycol, tetraethylene glycol, 1,2-ethanediol, propane
diols such as 1,2-propanediol and 1,3-propanediol, butane diols
such as 1,2-butanediol, 1,3-butanediol, and 1,4-butanediol, pentane
diols such as 1,5-pentanediol, 1,3-pentanediol and 2,4-pentanediol,
hexane diols such as 1,6-hexanediol and 2,5-hexanediol, heptane
diols such as 2,4-heptanediol, octane diols such as 1,8-octanediol,
nonane diols such as 1,9-nonanediol, decane diols such as
1,10-decanediol, dodecane diols such as 1,12-dodecanediol,
octadecanediols such as 1,18-octadecanediol, sorbitol, mannitol,
and mixtures thereof. In some non-limiting embodiments, the diol is
a propane diol such as 1,2-propanediol and 1,3-propanediol, or
butane diol such as 1,2-butanediol, 1,3-butanediol, and
1,4-butanediol. In some non-limiting embodiments, one or more
carbon atoms in the polyol can be replaced with one or more
heteroatoms, such as N, S, or O, for example sulfonated polyols,
such as dithio-octane bis diol, thiodiethanol such as
2,2-thiodiethanol, or 3,6-dithia-1,2-octanediol.
[0466] Other non-limiting examples of suitable diols include those
represented by the following formula:
##STR00006##
wherein R represents C.sub.0 to C.sub.18 divalent linear or
branched aliphatic, cycloaliphatic, aromatic, heterocyclic, or
oligomeric saturated alkylene radical or mixtures thereof; C.sub.2
to C.sub.18 divalent organic radical containing at least one
element selected from the group consisting of sulfur, oxygen and
silicon in addition to carbon and hydrogen atoms; C.sub.5 to
C.sub.18 divalent saturated cycloalkylene radical; or C.sub.5 to
C.sub.18 divalent saturated heterocycloalkylene radical; and R' and
R'' can be present or absent and, if present, each independently
represent C.sub.1 to C.sub.18 divalent linear or branched
aliphatic, cycloaliphatic, aromatic, heterocyclic, polymeric, or
oligomeric saturated alkylene radical or mixtures thereof.
[0467] Other non-limiting examples of suitable diols include
branched chain alkane diols, such as propylene glycol, dipropylene
glycol, tripropylene glycol, neopentyl glycol, 2-methyl-butanediol.
2,2,4-trimethyl-1,3-pentanediol, 2-methyl-1,3-pentanediol,
2-ethyl-1,3-hexanediol, 2-methyl-1,3-propanediol,
2,2-dimethyl-1,3-propanediol, dibutyl 1,3-propanediol, polyalkylene
glycols such as polyethylene glycols, and mixtures thereof.
[0468] In some non-limiting embodiments, the diol can be a
cycloalkane diol, such as cyclopentanediol, 1,4-cyclohexanediol,
cyclohexanedimethanols (CHDM), such as 1,4-cyclohexanedimethanol,
cyclododecanediol, 4,4'-isopropylidene-biscyclohexanol,
hydroxypropylcyclohexanol, cyclohexanediethanol,
1,2-bis(hydroxymethyl)-cyclohexane,
1,2-bis(hydroxyethyl)-cyclohexane,
4,4'-isopropylidene-biscyclohexanol,
bis(4-hydroxycyclohexanol)methane and mixtures thereof.
[0469] In some non-limiting embodiments, the diol can be an
aromatic diol, such as dihydroxybenzene, 1,4-benzenedimethanol,
xylene glycol, hydroxybenzyl alcohol and dihydroxytoluene;
bisphenols, such as, 4,4'-isopropylidenediphenol,
4,4'-oxybisphenol, 4,4'-dihydroxybenzophenone, 4,4'-thiobisphenol,
phenolphthalein, bis(4-hydroxyphenyl)methane,
4,4'-(1,2-ethenediyl)bisphenol and 4,4'-sulfonylbisphenol;
halogenated bisphenols, such as
4,4'-isopropylidenebis(2,6-dibromophenol),
4,4'-isopropylidenebis(2,6-dichlorophenol) and
4,4'-isopropylidenebis(2,3,5,6-tetrachlorophenol); alkoxylated
bisphenols, which can have, for example, ethoxy, propoxy,
.alpha.-butoxy and .beta.-butoxy groups; and biscyclohexanols,
which can be prepared by hydrogenating the corresponding
bisphenols, such as 4,4'-isopropylidene-biscyclohexanol,
4,4'-oxybiscyclohexanol, 4,4'-thiobiscyclohexanol and
bis(4-hydroxycyclohexanol)methane, the alkoxylation product of 1
mole of 2,2-bis(4-hydroxyphenyl)propane (i.e., bisphenol-A) and 2
moles of propylene oxide, hydroxyalkyl terephthalates such as meta
or para bis(2-hydroxyethyl) terephthalate, bis(hydroxyethyl)
hydroquinone and mixtures thereof.
[0470] In some non-limiting embodiments, the diol can be an
heterocyclic diol, for example a dihydroxy piperidine such as
1,4-bis(hydroxyethyl)piperazine.
[0471] In some non-limiting embodiments, the diol can be a diol of
an amide or alkane amide (such as ethanediamide (oxamide)), for
example N,N',bis(2-hydroxyethyl)oxamide.
[0472] In some non-limiting embodiments, the diol can be a diol of
a propionate, such as
2,2-dimethyl-3-hydroxypropyl-2,2-dimethyl-3-hydroxypropionate.
[0473] In some non-limiting embodiments, the diol can be a diol of
a hydantoin, such as bishydroxypropyl hydantoin.
[0474] In some non-limiting embodiments, the diol can be a diol of
a phthalate, such as meta or para bis(2-hydroxyethyl)
terephthalate.
[0475] In some non-limiting embodiments, the diol can be a diol of
a hydroquinone, such as a dihydroxyethylhydroquinone.
[0476] In some non-limiting embodiments, the diol can be a diol of
an isocyanurate, such as dihydroxyethyl isocyanurate.
[0477] In some non-limiting embodiments, the diol for use in the
present invention can be an SH-containing material, such as
polythiols having at least three thiol groups and 4 to 18 carbon
atoms. Non-limiting examples of suitable polythiols can include but
are not limited to aliphatic polythiols, cycloaliphatic polythiols,
aromatic polythiols, heterocyclic polythiols, polymeric polythiols,
oligomeric polythiols and mixtures thereof. The sulfur-containing
active hydrogen-containing material can have linkages including but
not limited to ether linkages (--O--), sulfide linkages (--S--),
polysulfide linkages (--S.sub.x--, wherein x is at least 2, or from
2 to 4) and combinations of such linkages. As used herein, the
terms "thiol," "thiol group," "mercapto" or "mercapto group" refer
to an --SH group which is capable of forming a thiourethane
linkage, (i.e., --NH--C(O)--S--) with an isocyanate group or a
dithioruethane linkage (i.e., --NH--C(S)--S--) with an
isothiocyanate group.
[0478] In some non-limiting embodiments, the components of the
polyurethane are essentially free of SH-containing materials, i.e.,
comprise less than about 5 weight percent of SH-containing
materials, in other non-limiting embodiments the components
comprise less than about 2 weight percent of SH-containing
materials, and in other non-limiting embodiments are free of
SH-containing materials.
[0479] In some non-limiting embodiments, the diol having 4 to 18
carbon atoms can have a number average molecular weight of about
200 to about 10,000 grams/mole, or less than about 500 grams/mole,
or less than about 200 grams/mole.
[0480] Mixtures of any of the above diols can be used.
[0481] In some non-limiting embodiments, the reaction components
for preparing the polyurethane of Group A can further comprise one
or more non-branched triols and/or one or more non-branched higher
functional polyols.
[0482] Non-limiting examples of suitable non-branched triols and
non-branched higher functional polyols include aliphatic,
cycloaliphatic, aromatic, heterocyclic, oligomeric, and polymeric
polyols and mixtures thereof.
[0483] In some non-limiting embodiments, the polyol can be a
cycloalkane polyol, such as cyclohexanetriol (for example
1,3,5-cyclohexanetriol).
[0484] In some non-limiting embodiments, the polyol can be an
aromatic polyol, such as benzenetriol (for example
1,2,3-benzenetriol, 1,2,4-benzenetriol, and 1,3,5-benzenetriol) and
phenolphthalein.
[0485] In some non-limiting embodiments, the polyol can be a polyol
of an isocyanurate, such as tris hydroxyethyl isocyanurate.
[0486] In some non-limiting embodiments, the reaction components
for preparing the polyurethane of Group A can further comprise one
or more branched or unbranched polyols (diols, triols, and/or
higher functional polyols) having more than 18 carbon atoms.
[0487] Non-limiting examples of suitable polyols having more than
18 carbon atoms include straight or branched chain aliphatic
polyols, cycloaliphatic polyols, cycloaliphatic polyols, aromatic
polyols, heterocyclic polyols, oligomeric polyols, polymeric
polyols and mixtures thereof.
[0488] Non-limiting examples of suitable straight or branched chain
aliphatic polyols having more than 18 carbon atoms include
1,18-icosanediol and 1,24-tetracosanediol.
[0489] Other non-limiting examples of suitable polyols having more
than 18 carbon atoms include those represented by the following
formula:
##STR00007##
[0490] wherein R represents C.sub.0 to C.sub.30 divalent linear or
branched aliphatic, cycloaliphatic, aromatic, heterocyclic, or
oligomeric saturated alkylene radical or mixtures thereof; C.sub.2
to C.sub.30 divalent organic radical containing at least one
element selected from the group consisting of sulfur, oxygen and
silicon in addition to carbon and hydrogen atoms; C.sub.5 to
C.sub.30 divalent saturated cycloalkylene radical; or C.sub.5 to
C.sub.30 divalent saturated heterocycloalkylene radical; and R' and
R'' can be present or absent and, if present, each independently
represent C.sub.1 to C.sub.30 divalent linear or branched
aliphatic, cycloaliphatic, aromatic, heterocyclic, polymeric, or
oligomeric saturated alkylene radical or mixtures thereof.
[0491] Non-limiting examples of suitable cycloaliphatic polyols
having more than 18 carbon atoms include biscyclohexanols having
more than 18 carbon atoms, which can be prepared by hydrogenating
the corresponding bisphenols.
[0492] Non-limiting examples of suitable aromatic polyols having
more than 18 carbon atoms include bisphenols, and alkoxylated
bisphenols, such as alkoxylated 4,4'-isopropylidenediphenol which
can have from 3 to 70 alkoxy groups.
[0493] Other non-limiting examples of suitable oligomeric or
polymeric polyols having more than 18 carbon atoms include higher
polyalkylene glycols such as polyethylene glycols having number
average molecular weights ranging from about 200 grams/mole to
about 2,000 grams/mole, and mixtures thereof.
[0494] In some non-limiting embodiments, the polyol for use in the
present invention can be an SH-containing material, such as
polythiols having at least two thiol groups or at least three thiol
groups and at least 18 carbon atoms. Non-limiting examples of
suitable polythiols can include but are not limited to aliphatic
polythiols, cycloaliphatic polythiols, aromatic polythiols,
heterocyclic polythiols, polymeric polythiols, oligomeric
polythiols and mixtures thereof. The sulfur-containing active
hydrogen-containing material can have linkages including but not
limited to ether linkages (--O--), sulfide linkages (--S--),
polysulfide linkages (--S.sub.x--, wherein x is at least 2, or from
2 to 4) and combinations of such linkages. As used herein, the
terms "thiol," "thiol group," "mercapto" or "mercapto group" refer
to an --SH group which is capable of forming a thiourethane
linkage, (i.e., --NH--C(O)--S--) with an isocyanate group or a
dithioruethane linkage (i.e., --NH--C(S)--S--) with an
isothiocyanate group.
[0495] In some non-limiting embodiments, the components of the
polyurethane are essentially free of SH-containing materials, e.g.,
contain less than about 5 weight percent of SH-containing
materials, in other non-limiting embodiments the components contain
less than about 2 weight percent of SH-containing materials, and in
other non-limiting embodiments are free of SH-containing
materials.
[0496] In some non-limiting embodiments, the polyol having at least
18 carbon atoms can have a number average molecular weight of about
200 to about 5,000 grams/mole, or about 200 to about 4,000
grams/mole, or at least about 200 grams/mole, or at least about 400
grams/mole, or at least about 1000 grams/mole, or at least about
2000 grams/mole. In some non-limiting embodiments, the polyol can
have a number average molecular weight of less than about 5,000
grams/mole, or less than about 4,000 grams/mole, or less than about
3,000 grams/mole, or less than about 2,000 grams/mole, or less than
about 1,000 grams/mole, or less than about 500 grams/mole.
[0497] Mixtures of any of the above polyols can be used. For
example, the polyol can comprise trimethylolpropane and the diol
can comprise butanediol and/or pentanediol.
[0498] As discussed above, the amount of branched polyol used to
form the polyurethane of Group A is about 0.1 to about 0.9
equivalents. In some non-limiting embodiments, the amount of
branched polyol used to form the polyurethane is about 0.3 to about
0.9 equivalents. In other non-limiting embodiments, the amount of
branched polyol used to form the polyurethane is about 0.3
equivalents.
[0499] As discussed above, the amount of diol used to form the
polyurethane of Group A is about 0.1 to about 0.9 equivalents. In
some non-limiting embodiments, the amount of diol used to form the
polyurethane is about 0.3 to about 0.9 equivalents. In other
non-limiting embodiments, the amount of diol used to form the
polyurethane is about 0.3 equivalents.
[0500] In some non-limiting embodiments of the polyurethane of
Group A, the reaction components comprise about 0.1 to about 0.9
equivalents of at least one branched polyol having 4 to 18 carbon
atoms and at least 3 hydroxyl groups and about 0.1 to about 0.9
equivalents of at least one diol having 2 to 18 carbon atoms, per 1
equivalent of at least one polyisocyanate, wherein the reaction
product components are essentially free of polyester polyol and
polyether polyol and wherein the reaction components are maintained
at a temperature of at least about 100.degree. C. for at least
about 10 minutes.
[0501] In some non-limiting embodiments, the polyurethane comprises
a reaction product of components consisting of: about 1 equivalent
of 4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 to about
0.5 equivalents of trimethylolpropane; and about 0.3 to about 0.7
equivalents of butanediol or pentanediol, or about 0.7 equivalents
of butanediol or pentanediol, wherein the reaction components are
maintained at a temperature of at least about 100.degree. C. for at
least about 10 minutes.
[0502] In another embodiment, the present invention provides
polyurethanes of Group A comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 equivalents
of trimethylolpropane; and about 0.7 equivalents of
1,10-dodecanediol, wherein the reaction components are maintained
at a temperature of at least about 100.degree. C. for at least
about 10 minutes.
[0503] In another embodiment, the present invention provides
polyurethanes of Group A comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 equivalents
of trimethylolpropane; and about 0.7 equivalents of
1,5-pentanediol, wherein the reaction components are maintained at
a temperature of at least about 100.degree. C. for at least about
10 minutes.
[0504] In another embodiment, the present invention provides
polyurethanes of Group A comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 equivalents
of trimethylolpropane; about 0.7 equivalents of 1,4-butanediol,
wherein the reaction components are maintained at a temperature of
at least about 100.degree. C. for at least about 10 minutes.
[0505] In another embodiment, the present invention provides
polyurethanes of Group A comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.4 equivalents
of trimethylolpropane; about 0.6 equivalents of
1,18-octadecanediol, wherein the reaction components are maintained
at a temperature of at least about 100.degree. C. for at least
about 10 minutes.
[0506] The polyurethanes of Group A can exhibit good ballistics
resistance, e.g., resistance to perforation, penetration or
cracking due to impact from a projectile such as a bullet or shot
which is shot from a handgun, shotgun, rifle, AK-47, or other
shooting device or explosives. In some embodiments, the
polyurethanes of Group A of 0.75'' (1.9 cm) thickness or greater
will stop or deflect: a 9 mm, 125 grain bullet shot at an initial
velocity of 1350 ft/sec (411.5 m/sec) from 20 feet; a .40 caliber
bullet shot at an initial velocity of 987 ft/sec (300.8 m/sec)
bullet from 20 feet (6.1 m); and/or a 12-gauge shotgun shot at an
initial velocity of 1290 ft/sec (393.2 m/sec) from 20 feet (6.1
m).
Group B
[0507] In some non-limiting embodiments, the present invention
provides polyurethanes of Group B comprising a reaction product of
components comprising: (a) an isocyanate functional urethane
prepolymer comprising a reaction product of components comprising:
(i) about 1 equivalent of at least one polyisocyanate; and (ii)
about 0.1 to about 0.5 equivalents of at least one diol having 2 to
18 carbon atoms; and (b) about 0.05 to about 0.9 equivalents of at
least one polyol having 4 to 18 carbon atoms and at least 3
hydroxyl groups; and (c) up to about 0.45 equivalents of at least
one diol having 2 to 18 carbon atoms, wherein the reaction product
components are essentially free of polyester polyol and polyether
polyol.
[0508] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: (i) about 1
equivalent of at least one polyisocyanate; and (ii) about 0.1 to
about 0.5 equivalents of at least one polyol having 2 to 18 carbon
atoms; and (b) about 0.05 to about 1.0 equivalents of at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups; and (c) up to about 0.9 equivalents of at least one polyol
different from branched polyol (b) and having 2 to 18 carbon atoms,
wherein the reaction product components are essentially free of
polyester polyol and polyether polyol.
[0509] In some non-limiting embodiments, the reaction product for
forming the isocyanate functional urethane prepolymer can comprise
about 0.2 to about 0.3 equivalents of the at least one polyol
having 2 to 18 carbon atoms, or about 0.21, about 0.3, about 0.35,
or about 0.4 equivalents. In some non-limiting embodiments, the
equivalent ratio of polyisocyanate to polyol having 2 to 18 carbon
atoms for preparing the isocyanate functional urethane prepolymer
is about 1:0.3 to about 1:0.4, or about 1:0.35.
[0510] Additional components can be used to prepare the isocyanate
functional urethane prepolymer, such as a small amount of at least
one branched polyol having 4 to 18 carbon atoms and at least 3
hydroxyl groups, for example about 0.05 to about 0.3 equivalents of
a branched polyol such as trimethylolpropane.
[0511] The "at least one polyol different from branched polyol (b)
and having 2 to 18 carbon atoms" mentioned above can be any polyol
having 2 to 18 carbon atoms discussed above or below which is not a
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups. For example, the polyol different from branched polyol (b)
can be the same as polyol (ii) having 2 to 18 carbon atoms, for
example a butanediol or pentanediol. If present, the amount of
polyol different from branched polyol (b) can range from about 0.01
to about 0.9 equivalents, or about 0.1 to about 0.5 equivalents, or
about 0.1 to about 0.3 equivalents, or about 0.15 equivalents, or
about 0.2 equivalents.
[0512] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: (i) about 1
equivalent of at least one polyisocyanate; and (ii) about 0.3 to
about 0.4 equivalents of butanediol or pentanediol; and (b) about
0.3 to about 0.6 equivalents of trimethylolpropane; and (c) about
0.1 to about 0.4 equivalents of butanediol or pentanediol, wherein
the reaction product components are essentially free of polyester
polyol and polyether polyol.
[0513] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: (i) about 1
equivalent of at least one polyisocyanate; and (ii) about 0.3 to
about 0.4 equivalents of butanediol or pentanediol; and (b) about
0.3 to about 0.7 equivalents of trimethylolpropane; and (c) up to
about 0.4 equivalents of butanediol or pentanediol, wherein the
reaction product components are essentially free of polyester
polyol and polyether polyol.
[0514] In some non-limiting embodiments, the polyurethanes can be
essentially free of polyester polyol and/or polyether polyol, as
discussed in detail below, for example less than about 0.1
equivalents of polyester polyol or polyether polyol.
[0515] In some non-limiting embodiments, the polyurethanes can be
essentially free of amine curing agent, as discussed in detail
below. As used herein, "essentially free of amine curing agent"
means that the reaction product components comprise less than about
10 weight percent of amine curing agent, or less than about 5
weight percent of amine curing agent, or less than about 2 weight
percent of amine curing agent, or in other non-limiting embodiments
are free of amine curing agent.
[0516] In some non-limiting embodiments, the polyurethane has a
hard segment content of about 10 to about 100 weight percent, or
about 30 to about 70 weight percent. In some non-limiting
embodiments, the polyurethane has a urethane content of about 20 to
about 40 weight percent, or about 30 to about 43 weight percent. In
some non-limiting embodiments, the polyurethane has a cyclic
content of about 10 to about 80 weight percent, or about 30 to
about 46 weight percent. In some non-limiting embodiments, the
polyurethane has a molecular weight per crosslink of at least about
500 grams per mole, or about 1700 grams per mole.
[0517] Non-limiting examples and amounts of suitable
polyisocyanates, diols and polyols for use as reaction products for
preparing the polyurethanes of Group B are discussed in detail
above with respect to Group A. Methods for preparing polyurethanes
of Group B are discussed in detail below. In some non-limiting
embodiments, the components are maintained at a temperature of at
least about 100.degree. C., or at least about 105.degree. C., or at
least about 110.degree. C. for at least about 10 minutes or at
least about 20 minutes
[0518] The polyurethanes of Group B can be useful for any of the
applications or uses described herein. In some non-limiting
embodiments, the present invention provides polyurethanes suitable
for use as transparencies or windows. Polyurethanes of Group B
having good creep resistance (or low deflection) and high fracture
toughness (K-factor) can be useful for airplane windows. Airplane
windows typically deflect or deform over time due to extremes in
temperature and pressure, which can increase interior cabin noise
and decrease gas mileage due to increased drag. Therefore,
resistance to creep or low deflection is a desirable
characteristic. In some non-limiting embodiments, the maximum
average deflection of the transparency or window is about 0.5 inch
(about 1.3 mm). A flexural test (discussed in the Examples below)
was developed to simulate the creep phenomenon under 3,294 psig
(300 times the service pressure at 3,500 feet altitude) for 3 hrs.
In some non-limiting embodiments for aircraft window applications,
the values of Young's Modulus can be at least about 350,000 (about
2413 MPa). Thus, in some non-limiting embodiments, the present
invention provides polyurethanes suitable for use as
transparencies, such as airplane windows, which can have one or
more of the following desirable properties: good deflection
resistance, high fracture toughness (K-factor), lower weight than
conventional airplane transparencies, and good abrasion
resistance.
[0519] In some non-limiting embodiments in which articles having
good optical properties are desired, such as low striation or no
visible striation, the equivalent ratio of the prepolymer
components of isocyanate functional material(s) (such as
4,4'-methylene-bis-(cyclohexyl isocyanate) to the polyol(s) having
2 to 18 carbon atoms (such as 1,5-pentane diol) can range from
about 1.0:0.3 to about 1.0:0.4, or about 1.0:0.35. While not
intending to be bound by any theory, it is believed that the
formation of striations in a molded article may be related to the
viscosity of the prepolymer. The higher viscosity prepolymer can
wet the release-coated glass mold better so that flow into the
casting cell is more uniform and smooth, and the urethane content
is higher, making compatibility of the components occur faster. The
striation of an article can be determined by forming a molded
article, for example having a thickness of about one inch (2.54
cm), and holding the molded article in front of a white-coated
board or substrate, and visually observing for the presence of
striations when a light source is shined upon the molded
article.
Group C
[0520] In some non-limiting embodiments, the present invention
provides polyurethanes of Group C comprising a reaction product of
components comprising: at least one polyisocyanate selected from
the group consisting of polyisocyanate trimers and branched
polyisocyanates, the polyisocyanate having at least three
isocyanate functional groups; and at least one aliphatic polyol
having 4 to 18 carbon atoms and at least two hydroxyl groups,
wherein the reaction product components are essentially free of
polyester polyol and polyether polyol.
[0521] In other non-limiting embodiments, the present invention
provides polyurethanes of Group C comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 1.1 equivalents
of butanediol; and about 0.1 equivalents of isophorone diisocyanate
trimer.
[0522] Non-limiting examples of suitable polyisocyanate trimers,
branched polyisocyanates and aliphatic polyols (including but not
limited to straight chain, branched or cycloaliphatic polyols) for
use in as reaction products for preparing the polyurethanes of
Group C are discussed in detail above with respect to Group A.
Similar amounts of polyisocyanate trimer(s) and/or branched
polyisocyanate(s) can be used as described for the polyisocyanate
of Group A above. Also, mixtures of polyisocyanate trimer(s) and/or
branched polyisocyanate(s) with other non-branched and non-trimer
polyisocyanates described above can be used to form the
polyurethanes of Group C.
[0523] In some non-limiting embodiments of the polyurethane of
Group C, the reaction components comprise about 0.1 to about 0.9
equivalents of at least one branched polyol having 4 to 18 carbon
atoms and at least 2 hydroxyl groups per 1 equivalent of at least
one polyisocyanate, and in other non-limiting embodiments about 0.3
to about 0.9 equivalents of at least one aliphatic polyol having 2
to 18 carbon atoms, wherein the reaction product components are
essentially free of polyester polyol and polyether polyol.
[0524] As discussed above, in some non-limiting embodiments of
Group A, Group B and Group C, the reaction product components are
essentially free of polyester polyol and polyether polyol. As used
herein, "essentially free of" polyester polyol and/or polyether
polyol means that the reaction product components comprise less
than about 10 weight percent of polyester polyol and/or polyether
polyol, or less than about 5 weight percent of polyester polyol
and/or polyether polyol, or less than about 2 weight percent of
polyester polyol and/or polyether polyol, or is free of polyester
polyol and/or polyether polyol, or less than about 0.1 equivalents
of polyester polyol or polyether polyol.
[0525] Non-limiting examples of such polyester polyols include
polyester glycols, polycaprolactone polyols, polycarbonate polyols
and mixtures thereof. Polyester glycols can include the
esterification products of one or more dicarboxylic acids having
from four to ten carbon atoms, such as but not limited to adipic,
succinic or sebacic acids, with one or more low molecular weight
glycols having from two to ten carbon atoms, such as but not
limited to ethylene glycol, propylene glycol, diethylene glycol,
1,4-butanediol, neopentyl glycol, 1,6-hexanediol and
1,10-decanediol. Esterification procedures for producing polyester
polyols are described, for example, in the article by D. M. Young,
F. Hostettler et al., "Polyesters from Lactone," Union Carbide
F-40, p. 147.
[0526] Non-limiting examples of polycaprolactone polyols include
those prepared by condensing caprolactone in the presence of
difunctional active hydrogen material such as water or low
molecular weight glycols, for example ethylene glycol and propylene
glycol. Non-limiting examples of suitable polycaprolactone polyols
can include commercially available materials designated as the CAPA
series from Solvay Chemical of Houston, Tex.; such as CAPA 2047A
and CAPA 2077A, and the TONE series from Dow Chemical of Midland,
Mich., such as TONE 0201, 0210, 0230 & 0241. In some
non-limiting embodiments, the polycaprolactone polyol has a
molecular weight ranging from about 500 to about 2000 grams per
mole, or about 500 to about 1000 grams per mole.
[0527] Non-limiting examples of polycarbonate polyols include
aliphatic polycarbonate diols, for example those based upon
alkylene glycols, ether glycols, alicyclic glycols or mixtures
thereof. In some embodiments, the alkylene groups for preparing the
polycarbonate polyol can comprise from 5 to 10 carbon atoms and can
be straight chain, cycloalkylene or combinations thereof.
Non-limiting examples of such alkylene groups include hexylene,
octylene, decylene, cyclohexylene and cyclohexyldimethylene.
Suitable polycarbonate polyols can be prepared, in non-limiting
examples, by reacting a hydroxy terminated alkylene glycol with a
dialkyl carbonate, such as methyl, ethyl, n-propyl or n-butyl
carbonate, or diaryl carbonate, such as diphenyl or dinaphthyl
carbonate, or by reacting of a hydroxy-terminated alkylene diol
with phosgene or bischoloroformate, in a manner well-known to those
skilled in the art. Non-limiting examples of such polycarbonate
polyols include those commercially available as Ravecarb.TM. 107
from Enichem S.p.A. (Polimeri Europa) of Italy, and polyhexylene
carbonate diols, about 1000 number average molecular weight, such
as KM10-1733 polycarbonate diol prepared from hexanediol, available
from Stahl. Examples of other suitable polycarbonate polyols that
are commercially available include KM10-1122, KM10-1667 (prepared
from a 50/50 weight percent mixture of cyclohexane dimethanol and
hexanediol) (commercially available from Stahl U.S.A. Inc. of
Peabody, Mass.) and DESMOPHEN 2020E (commercially available from
Bayer Corp).
[0528] The polycarbonate polyol can be produced by reacting diol,
such as described herein, and a dialkyl carbonate, such as
described in U.S. Pat. No. 4,160,853. The polycarbonate polyol can
include polyhexamethylene carbonate such as
HO--(CH.sub.2).sub.6--[O--C(O)--O--(CH.sub.2).sub.6].sub.n--OH,
wherein n is an integer from 4 to 24, or from 4 to 10, or from 5 to
7.
[0529] Non-limiting examples of polyether polyols include
poly(oxyalkylene) polyols or polyalkoxylated polyols.
Poly(oxyalkylene) polyols can be prepared in accordance with known
methods. In a non-limiting embodiment, a poly(oxyalkylene) polyol
can be prepared by condensing an alkylene oxide, or a mixture of
alkylene oxides, using acid- or base-catalyzed addition with a
polyhydric initiator or a mixture of polyhydric initiators, such as
ethylene glycol, propylene glycol, glycerol, and sorbitol.
Compatible mixtures of polyether polyols can also be used. As used
herein, "compatible" means that two or more materials are mutually
soluble in each other so as to essentially form a single phase.
Non-limiting examples of alkylene oxides can include ethylene
oxide, propylene oxide, butylene oxide, amylene oxide, aralkylene
oxides, such as styrene oxide, mixtures of ethylene oxide and
propylene oxide. In some non-limiting embodiments, polyoxyalkylene
polyols can be prepared with mixtures of alkylene oxide using
random or step-wise oxyalkylation. Non-limiting examples of such
poly(oxyalkylene) polyols include polyoxyethylene polyols, such as
polyethylene glycol, and polyoxypropylene polyols, such as
polypropylene glycol.
[0530] Other polyether polyols include block polymers such as those
having blocks of ethylene oxide-propylene oxide and/or ethylene
oxide-butylene oxide. In some non-limiting embodiments, the
polyether polyol comprises a block copolymer of the following
formula:
HO--(CHR.sub.1CHR.sub.2--O).sub.a--(CHR.sub.3CHR.sub.4--O).sub.b--(CHR.s-
ub.5CHR.sub.6--O).sub.c--H
wherein R.sub.1 through R.sub.6 can each independently represent
hydrogen or methyl; and a, b, and c can each be independently
selected from an integer from 0 to 300, wherein a, b and c are
selected such that the number average molecular weight of the
polyol is less than about 32,000 grams/mole, or less than about
10,000 grams/mole, as determined by GPC. In other non-limiting
embodiments a, b, and c each can be independently an integer from 1
to 300. In other non-limiting embodiments, R.sub.1, R.sub.2,
R.sub.5, and R.sub.6 can be hydrogen, and R.sub.3 and R.sub.4 each
can be independently selected from hydrogen and methyl, with the
proviso that R.sub.3 and R.sub.4 are different from one another. In
other non-limiting embodiments, R.sub.3 and R.sub.4 can be
hydrogen, and R.sub.1 and R.sub.2 each can be independently
selected from hydrogen and methyl, with the proviso that R.sub.1
and R.sub.2 are different from one another, and R.sub.5 and R.sub.6
each can be independently selected from hydrogen and methyl, with
the proviso that R.sub.5 and R.sub.6 are different from one
another.
[0531] In some non-limiting embodiments, polyalkoxylated polyols
can be represented by the following general formula:
##STR00008##
wherein m and n can each be a positive integer, the sum of m and n
being from 5 to 70; R.sub.1 and R.sub.2 are each hydrogen, methyl
or ethyl; and A is a divalent linking group such as a straight or
branched chain alkylene which can contain from 1 to 8 carbon atoms,
phenylene, and C.sub.1 to C.sub.9 alkyl-substituted phenylene. The
values of m and n can, in combination with the selected divalent
linking group, determine the molecular weight of the polyol.
Polyalkoxylated polyols can be prepared by methods that are known
in the art. In a non-limiting embodiment, a polyol such as
4,4'-isopropylidenediphenol can be reacted with an
oxirane-containing material such as ethylene oxide, propylene oxide
or butylene oxide, to form what is commonly referred to as an
ethoxylated, propoxylated or butoxylated polyol having hydroxyl
functionality. Non-limiting examples of polyols suitable for use in
preparing polyalkoxylated polyols can include those polyols
described in U.S. Pat. No. 6,187,444 B1 at column 10, lines 1-20,
incorporated herein by reference.
[0532] In some non-limiting embodiments, the polyether polyol can
be PLURONIC ethylene oxide/propylene oxide block copolymers, such
as PLURONIC R and PLURONIC L62D, and/or TETRONIC tetra-functional
block copolymers based on ethylene oxide and propylene oxide, such
as TETRONIC R, which are commercially available from BASF Corp. of
Parsippany, N.J.
[0533] As used herein, the phrase "polyether polyols" also can
include poly(oxytetramethylene) diols prepared by the
polymerization of tetrahydrofuran in the presence of Lewis acid
catalysts such as, but not limited to, boron trifluoride, tin (IV)
chloride and sulfonyl chloride.
Group D
[0534] In some non-limiting embodiments, the present invention
provides polyurethanes of Group D comprising a reaction product of
components comprising: at least one polyisocyanate; at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups; and at least one polyol having one or more bromine atoms,
one or more phosphorus atoms or combinations thereof. Brominated or
phosphonated polyols can provide the polyurethane with enhanced
flame retardancy. The flame retardancy of polyurethanes of the
present invention can be determined simply by exposure to flame to
determine if the polymer is self-extinguishing or burns more slowly
than a polymer without the brominated or phosphonated polyol, or
according to Underwriter's Laboratory Test UL-94, incorporated by
reference herein. Alternatively, horizontal and vertical burning
rate can be determined according to EC Directive 95/28/EC, Annexes
IV and VI respectively, incorporated by reference herein. Federal
Aviation Regulation (FAR) 25.853 (a)(1)(ii) permits a burn length
of 8 inches and flame time of 15 seconds.
[0535] In other non-limiting embodiments, the present invention
provides polyurethanes of Group D comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 to about 0.5
equivalents of trimethylolpropane; about 0.2 to about 0.5
equivalents of bis(4-(2-hydroxyethoxy)-3,5-dibromophenyl) sulfone;
about 0.2 to about 0.5 equivalents of 1,4-cyclohexane dimethanol;
and about 0.2 to about 0.5 equivalents of
3,6-dithia-1,2-octanediol.
[0536] Non-limiting examples of suitable polyisocyanates and
branched polyols having 4 to 18 carbon atoms and at least 3
hydroxyl groups for use as reaction products for preparing the
polyurethanes of Group D are discussed in detail above with respect
to Group A.
[0537] Non-limiting examples of suitable polyols having one or more
bromine atoms, one or more phosphorus atoms or combinations thereof
include 4,4'-isopropylidene bis(2,6-dibromophenol), isopropylidene
bis[2-(2,6-dibromo-phenoxy)ethanol],
bis(4-(2-hydroxyethoxy)-3,5-dibromophenyl) sulfone
heptakis(dipropylene glycol) triphosphite, tris(dipropylene glycol)
phosphate, diethyl-N,N-bis(2-hydroxyethyl)aminoethanol phosphonate
and mixtures thereof. Non-limiting examples of suitable
phosphonated polyols include those of the formula
HO--Y--O[POOR--O--Y--O][POOR--O--Y--OH, wherein each R is
independently selected from an alkylene group having 1 to 10 repeat
units, such as CH.sub.2 to (CH.sub.2).sub.10 and each Y is
independently selected from an alkylene group having 1 to 6 repeat
units, such as CH.sub.2 to (CH.sub.2).sub.6.
[0538] The amount of brominated polyols and/or phosphonated polyols
used to form the polyurethane of Group D can be about 0.1 to about
0.9 equivalents, or about 0.3 to about 0.9 equivalents, or about
0.3 equivalents.
[0539] In some non-limiting embodiments, the reaction components
can further comprise one or more of the polyether polyols and/or
polyester polyols discussed above. If present, the amount of
polyether polyols and/or polyester polyols used to form the
polyurethane of Group D can be about 0.1 to about 0.9 equivalents,
or about 0.3 to about 0.9 equivalents, or about 0.3
equivalents.
Groups A-D
[0540] In some non-limiting embodiments of the polyurethanes of
Groups A-D, the reaction products can further comprise one or more
of the following: polyurethane polyols, (meth)acrylamides,
hydroxy(meth)acrylamides, polyvinyl alcohols, polymers containing
hydroxy functional (meth)acrylates, polymers containing allyl
alcohols, dihydroxy oxamides, dihydroxyamides,
dihydroxypiperidines, dihydroxy phthalates, dihydroxyethyl
hydroquinones, polyesteramides and mixtures thereof. In some
embodiments, polymerization with acrylamides can form an
interpenetrating network having high transparency, good impact
strength, and high Young's Modulus.
[0541] Non-limiting examples of suitable polyurethane polyols
include the reaction product of an excess of polyisocyanate and a
branched or straight chain polyol. The equivalent ratio of
polyisocyanate to polyol can range from about 1.0:0.05 to about
1.0:3, or about 1.0:0.7. The amount of polyurethane polyols used
can range from about 1 to about 90 weight percent, about 5 to about
70 weight percent, or about 20 to about 50 weight percent on a
basis of total weight of the components.
[0542] Non-limiting examples of suitable acrylamides include
acrylamide, methacrylamide and dimethylacrylamide. The acrylamide
can be added with all of the other reaction components, or it can
be dissolved in the diol and then mixed with the other reaction
components. The amount of acrylamide used can range from about 5 to
about 70 weight percent, about 10 to about 50 weight percent, or
about 10 to about 30 weight percent on a basis of total weight of
the components.
[0543] Non-limiting examples of suitable polyvinyl alcohols include
polyvinyl alcohol. The amount of polyvinyl alcohol used can range
from about 5 to about 90 weight percent, about 10 to about 70
weight percent, or about 10 to about 40 weight percent on a basis
of total weight of the components.
[0544] Non-limiting examples of suitable polymers containing
hydroxy functional (meth)acrylates include hydroxypropylacrylate;
hydroxyethylacrylate; hydroxypropylmethacrylate;
hydroxyethylmethacrylate; and copolymers of hydroxy functional
(meth)acrylates with acrylamides, cyanoethyl(meth)acrylates,
methylmethacrylates, methacrylates, ethacrylates, propylacrylates
and vinylpyrrolidinone. The amount of hydroxy functional
(meth)acrylates used can range from about 10 to about 90 weight
percent, about 10 to about 70 weight percent, or about 10 to about
30 weight percent on a basis of total weight of the components.
[0545] Non-limiting examples of suitable polymers containing allyl
alcohols include diethylene glycol bis(allylcarbonate),
allyloxytrimethylsilane, and diallylcarbonate. The amount of allyl
alcohols used can range from about 5 to about 70 weight percent,
about 10 to about 50 weight percent, or about 10 to about 30 weight
percent.
[0546] Non-limiting examples of suitable polyesteramides include
esteramide polymers obtained by the reaction of bis-oxamidodiols
such as N,N'-bis(omega-hydroxyalkylene)oxamide with a dicarboxylic
acid or diester such as diethyl oxalate, diethyl succinates,
diethyl suberate, or dimethyl terephthalate. The amount of
polyesteramides used can range from about 10 to about 80 weight
percent, about 20 to about 60 weight percent, or about 30 to about
50 weight percent on a basis of total weight of the components.
[0547] In some non-limiting embodiments of the polyurethanes of
Groups A-C, the reaction products can further comprise one or more
amine curing agents. The amine curing agent, if present, can act as
a catalyst in the polymerization reaction, be incorporated into the
resulting polymerizate and can form poly(ureaurethane)s. The amount
of amine curing agent used can range from about 0.05 to about 0.9
equivalents, about 0.1 to about 0.7 equivalents, or about 0.3 to
about 0.5 equivalents.
[0548] Non-limiting examples of such amine curing agents include
aliphatic polyamines, cycloaliphatic polyamines, aromatic
polyamines and mixtures thereof. In some non-limiting embodiments,
the amine curing agent can have at least two functional groups
selected from primary amine (--NH.sub.2), secondary amine (--NH--)
and combinations thereof. In some non-limiting embodiments, the
amine curing agent can have at least two primary amine groups. In
some non-limiting embodiments, the amino groups are all primary
groups.
[0549] Examples of such amine curing agents include compounds
having the following formula:
##STR00009##
wherein R.sub.1 and R.sub.2 are each independently selected from
methyl, ethyl, propyl, and isopropyl groups, and R.sub.3 is
selected from hydrogen and chlorine, such as the following
compounds manufactured by Lonza Ltd. (Basel, Switzerland):
LONZACURE.RTM. M-DMA, in which R.sub.1=C.sub.3H.sub.7;
R.sub.2=C.sub.3H.sub.7; R.sub.3=H; LONZACURE.RTM. M-DMA, in which
R.sub.1=CH.sub.3; R.sub.2=CH.sub.3; R.sub.3=H; LONZACURE.RTM.
M-MEA, in which R.sub.1=CH.sub.3; R.sub.2=C.sub.2H.sub.5;
R.sub.3=H; LONZACURE.RTM. M-DEA, in which R.sub.1=C.sub.2H.sub.5;
R.sub.2=C.sub.2H.sub.5; R.sub.3=H; LONZACURE.RTM. M-MIPA: in which
R.sub.1=CH.sub.3; R.sub.2=C.sub.3H.sub.7; R.sub.3=H; and
LONZACURE.RTM. M-CDEA, in which R.sub.1=C.sub.2H.sub.5;
R.sub.2=C.sub.2H.sub.5; R.sub.3=Cl, each of which is commercially
available from Air Products and Chemicals, Inc. of Allentown,
Pa.
[0550] Such amine curing agents can include a diamine curing agent
such as 4,4'-methylenebis(3-chloro-2,6-diethylaniline),
(LONZACURE.RTM. M-CDEA); 2,4-diamino-3,5-diethyl-toluene,
2,6-diamino-3,5-diethyl-toluene and mixtures thereof (collectively
"diethyltoluenediamine" or "DETDA"), which is commercially
available from Albemarle Corporation under the trade name ETHACURE
100; dimethylthiotoluenediamine (DMTDA) (commercially available as
ETHACURE 300); the color stabilized version of ETHACURE 100 (i.e.,
formulation which contains an additive to reduce yellow color),
which is available under the name ETHACURE 100S;
4,4'-methylene-bis-(2-chloroaniline) (commercially available from
Kingyorker Chemicals under the trade name MOCA). DETDA can be a
liquid at room temperature with a viscosity of 156 centipoise (cp)
at 25.degree. C. DETDA can be isomeric, with the 2,4-isomer amount
being from 75 to 81 percent while the 2,6-isomer amount can be from
18 to 24 percent.
[0551] Other non-limiting examples of amine curing agents include
ethyleneamines, such as ethylenediamine (EDA), diethylenetriamine
(DETA), triethylenetetramine (TETA), tetraethylenepentamine (TEPA),
pentaethylenehexamine (PEHA), piperazine, morpholine, substituted
morpholine, piperidine, substituted piperidine, diethylenediamine
(DEDA), and 2-amino-1-ethylpiperazine. In some non-limiting
embodiments, the amine curing agent can be selected from one or
more isomers of C.sub.1-C.sub.3 dialkyl toluenediamine, such as
3,5-dimethyl-2,4-toluenediamine, 3,5-dimethyl-2,6-toluenediamine,
3,5-diethyl-2,4-toluenediamine, 3,5-diethyl-2,6-toluenediamine,
3,5-diisopropyl-2,4-toluenediamine,
3,5-diisopropyl-2,6-toluenediamine, and mixtures thereof. In some
non-limiting embodiments, the amine curing agent can be methylene
dianiline or trimethyleneglycol di(para-aminobenzoate).
[0552] Other non-limiting examples of amine curing agents include
compounds of the following general structures (XIII-XV):
##STR00010##
[0553] Other non-limiting examples of amine curing agents include
one or more methylene bis anilines represented by the general
formulas XVI-XX, one or more aniline sulfides represented by the
general formulas XXI-XXV, and/or one or more bianilines represented
by the general formulas XXVI-XXVIX,
##STR00011## ##STR00012##
wherein R.sub.3 and R.sub.4 are each independently C.sub.1-C.sub.3
alkyl, and R.sub.5 is selected from hydrogen and halogen, such as
chlorine or bromine. The diamine represented by general formula XV
can be described generally as a 4,4'-methylene-bis(dialkylaniline).
Suitable non-limiting examples of diamines which can be represented
by general formula XV include but are not limited to
4,4'-methylene-bis(2,6-dimethylaniline),
4,4'-methylene-bis(2,6-diethylaniline),
4,4'-methylene-bis(2-ethyl-6-methylaniline),
4,4'-methylene-bis(2,6-diisopropylaniline),
4,4'-methylene-bis(2-isopropyl-6-methylaniline) and
4,4'-methylene-bis(2,6-diethyl-3-chloroaniline).
[0554] The amine curing agent includes compounds represented by the
following general structure (XXX):
##STR00013##
where R.sub.20, R.sub.21, R.sub.22, and R.sub.23 are each
independently selected from H, C.sub.1-C.sub.3 alkyl, CH.sub.3--S--
and halogen, such as chlorine or bromine. The amine curing agent
represented by general formula XXX can include diethyl toluene
diamine (DETDA) wherein R.sub.23 is methyl, R.sub.20 and R.sub.21
are each ethyl and R.sub.22 is hydrogen. Also, the amine curing
agent can include 4,4'-methylenedianiline.
[0555] In an embodiment wherein it is desirable to produce a
poly(ureaurethane) having low color, the amine curing agent can be
selected such that it has relatively low color and/or it can be
manufactured and/or stored in a manner as to prevent the amine from
developing a color (e.g., yellow).
[0556] In some non-limiting embodiments of the polyurethanes of
Groups A-D, the reaction products can be essentially free of amine
curing agent. As used herein, "essentially free of amine curing
agent" means that the reaction product components comprise less
than about 10 weight percent of amine curing agent, or less than
about 5 weight percent of amine curing agent, or less than about 2
weight percent of amine curing agent, or in other non-limiting
embodiments are free of amine curing agent.
Group E
[0557] In some non-limiting embodiments, the present invention
provides polyurethanes of Group E comprising a reaction product of
components comprising: about 1 equivalent of at least one
polyisocyanate; about 0.3 to about 1 equivalents of at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups; and about 0.01 to about 0.3 equivalents of at least one
polycarbonate diol, wherein the reaction product components are
essentially free of polyether polyol and amine curing agent and
wherein the reaction components are maintained at a temperature of
at least about 100.degree. C. for at least about 10 minutes.
[0558] Non-limiting examples of suitable polyisocyanates, branched
polyols having 4 to 18 carbon atoms and at least 3 hydroxyl groups,
polycarbonate diols and diol having 2 to 18 carbon atoms for use in
as reaction products for preparing the polyurethanes of Group E are
discussed in detail above with respect to Group A.
[0559] In some non-limiting embodiments, the amount of branched
polyol used to form the polyurethane of Group E can range from
about 0.3 to about 0.98 equivalents, or about 0.5 to about 0.98
equivalents, or about 0.3 equivalents or about 0.9 to about 0.98
equivalents.
[0560] In some non-limiting embodiments, the amount of
polycarbonate diol used to form the polyurethane of Group E can
range from about 0.01 to about 0.1 equivalents, or about 0.05 to
about 0.1 equivalents, or about 0.1 equivalents.
[0561] In another embodiment, the present invention provides
polyurethanes of Group E comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 equivalents
of trimethylolpropane; about 0.55 equivalents of 1,5-pentanediol
and about 0.15 equivalents of KM10-1733 polycarbonate diol prepared
from hexanediol, available from Stahl, wherein the reaction
components are maintained at a temperature of at least about
100.degree. C. for at least about 10 minutes.
[0562] In another embodiment, the present invention provides
polyurethanes of Group E comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 equivalents
of trimethylolpropane; about 0.5 equivalents of 1,5-pentanediol and
about 0.2 equivalents of KM10-1733 polycarbonate diol prepared from
hexanediol, available from Stahl, wherein the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes.
[0563] The polyurethanes of Group E can exhibit good ballistics
resistance.
[0564] The polyurethanes of Group E are essentially free of
polyether polyol and amine curing agent, the types and amounts of
polyether polyol and amine curing agent being described above with
respect to Groups A-D.
[0565] In some non-limiting embodiments of the polyurethanes of
Group E, the reaction products can further comprise one or more of
the following: polyurethane polyols, acrylamides, polyvinyl
alcohols, polymers containing hydroxy functional (meth)acrylates,
polymers containing allyl alcohols, polyesteramides and mixtures
thereof, as described and in amounts as above with respect to
Groups A-D.
Group F
[0566] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: (a) about 1 equivalent of at least one polyisocyanate;
(b) about 0.05 to about 1 equivalents of at least one branched
polyol having 4 to 18 carbon atoms and at least 3 hydroxyl groups;
(c) about 0.01 to about 0.3 equivalents of at least one
polycarbonate diol; and (d) about 0.1 to about 0.9 equivalents of
at least one polyol different from the branched polyol (b) and
having 2 to 18 carbon atoms, wherein the reaction product
components are essentially free of polyether polyol and the
reaction components are maintained at a temperature of at least
about 100.degree. C. for at least about 10 minutes.
[0567] In some non-limiting embodiments, an isocyanate functional
prepolymer can be prepared from at least one polyisocyanate and a
portion of the polyol (d) prior to reaction with the branched
polyol and polycarbonate diol. Preparation of isocyanate functional
prepolymers from polyisocyanate(s) and polyols are discussed
herein.
[0568] In some non-limiting embodiments, the equivalents of
branched polyol can range from about 0.1 to about 0.9 equivalents,
or about 0.1 to about 0.5 equivalents, or about 0.1 to about 0.3
equivalents, or about 0.1 equivalents, or about 0.15 equivalents,
or about 0.2 equivalents, or about 0.3 equivalents.
[0569] In some non-limiting embodiments, the equivalents of
polycarbonate diol can range from about 0.5 to about 0.15
equivalents, or about 0.07 to about 0.15 equivalents, or about 0.07
equivalents, or about 0.1 equivalents, or about 0.15
equivalents.
[0570] In some non-limiting embodiments, the equivalents of polyol
different from the branched polyol (b) and having 2 to 18 carbon
atoms can range from about 0.5 to about 0.9 equivalents, or about
0.6 to about 0.8 equivalents, or about 0.63 equivalents, or about
0.7 equivalents, or about 0.8 equivalents. In some non-limiting
embodiments, the polyol different from the branched polyol (b) and
having 2 to 18 carbon atoms can be butanediol, pentanedoil or
cyclohexanedimethanol.
[0571] In some non-limiting embodiments, the present invention
provides polyurethanes comprising a reaction product of components
comprising: (a) an isocyanate functional urethane prepolymer
comprising a reaction product of components comprising: (i) about 1
equivalent of at least one polyisocyanate; and (ii) about 0.3 to
about 0.4 (or about 0.35) equivalents of butanediol or cyclohexane
dimethanol; and (b) about 0.1 to about 0.3 equivalents of
trimethylolpropane; (c) about 0.4 to about 0.5 equivalents of
butanediol or cyclohexane dimethanol; and (d) about 0.01 to about
0.3 equivalents of at least one polycarbonate diol, wherein the
reaction product components are essentially free of polyether
polyol.
[0572] In some non-limiting embodiments, the present invention
provides polyurethanes of Group F comprising a reaction product of
components comprising: (a) about 1 equivalent of at least one
polyisocyanate; (b) about 0.3 to about 1 equivalents of at least
one branched polyol having 4 to 18 carbon atoms and at least 3
hydroxyl groups; (c) about 0.01 to about 0.3 equivalents of at
least one polycarbonate diol; and (d) about 0.1 to about 0.9
equivalents of at least one diol having 2 to 18 carbon atoms,
wherein the reaction product components are essentially free of
polyether polyol and wherein the reaction components are maintained
at a temperature of at least about 100.degree. C. for at least
about 10 minutes. The diol having 2 to 18 carbon atoms is
chemically different from the polycarbonate diol, e.g., the diol
has at least one different atom or a different arrangement of atoms
compared to the polycarbonate diol.
[0573] Non-limiting examples of suitable polyisocyanates, branched
polyols having 4 to 18 carbon atoms and at least 3 hydroxyl groups,
polycarbonate diols, diols having 2 to 18 carbon atoms, and polyols
different from the branched polyol (b) and having 2 to 18 carbon
atoms for use in as reaction products for preparing the
polyurethanes of Group F are discussed in detail above with respect
to Groups A and B. In some non-limiting embodiments, the
polyisocyanate can be dicyclohexylmethane diisocyanate.
[0574] In some non-limiting embodiments, the diol (d) is an
aliphatic diol selected from the group consisting of ethylene
glycol, diethylene glycol, triethylene glycol, tetraethylene
glycol, 1,2-ethanediol, propanediol, butanediol, pentanediol,
hexanediol, heptanediol, octanediol, nonanediol, decanediol,
dodecane diol, sorbitol, mannitol, cyclopentanediol,
1,4-cyclohexanediol, cyclohexanedimethanol, 1,4-benzenedimethanol,
xylene glycol, hydroxybenzyl alcohol, dihydroxytoluene
bis(2-hydroxyethyl) terephthalate, 1,4-bis(hydroxyethyl)piperazine,
N,N',bis(2-hydroxyethyl)oxamide and mixtures thereof.
[0575] In some non-limiting embodiments, the amount of branched
polyol used to form the polyurethane of Group F can range from
about 0.3 to about 0.98 equivalents, or about 0.5 to about 0.98
equivalents, or about 0.9 to about 0.98 equivalents.
[0576] In some non-limiting embodiments, the amount of
polycarbonate diol used to form the polyurethane of Group F can
range from about 0.01 to about 0.1 equivalents, or about 0.05 to
about 0.1 equivalents, or about 0.1 equivalents.
[0577] In some non-limiting embodiments, the amount of diol used to
form the polyurethane of Group F can range from about 0.01 to about
0.1 equivalents, or about 0.05 to about 0.1 equivalents, or about
0.1 equivalents.
[0578] The polyurethanes of Group F are essentially free of
polyether polyol, the types and amounts of polyether polyol being
described above with respect to Groups A-D.
[0579] In some non-limiting embodiments of the polyurethanes of
Group F, the reaction products can further comprise one or more of
the following: polyurethane polyols, acrylamides, polyvinyl
alcohols, polymers containing hydroxy functional (meth)acrylates,
polymers containing allyl alcohols, dihydroxy oxamides,
dihydroxyamides, dihydroxy piperidines, dihydroxy phthalates,
dihydroxyethyl hydroquinones, polyesteramides and mixtures thereof,
as described and in amounts as above with respect to Groups
A-D.
[0580] In some non-limiting embodiments of the polyurethanes of
Group F, the reaction products can further comprise one or more
amine curing agents as discussed above with respect to Group E. In
other non-limiting embodiments, the reaction products for preparing
the polyurethanes of Group F can be essentially free of or free of
amine curing agent as discussed above with respect to Groups A-D.
In other non-limiting embodiments, the reaction products for
preparing the polyurethanes of Group F can be essentially free of
or free of polyether polyol as discussed above with respect to
Groups A-D, or in some embodiments comprise less than abo0ut 0.1
equivalents of polyether polyol.
[0581] The polyurethanes of Group F can be useful for any of the
applications or uses described herein. In some non-limiting
embodiments, the present invention provides polyurethanes suitable
for use as transparencies or windows. Polyurethanes of Group F
having good creep resistance (or low deflection) and high fracture
toughness (K-factor) can be useful for airplane windows. Desirable
properties for airplane windows are discussed above with respect to
Group B.
Group G
[0582] In some non-limiting embodiments, the present invention
provides polyurethanes of Group G comprising a reaction product of
components comprising: about 1 equivalent of at least one
polyisocyanate; about 0.3 to about 1 equivalents of at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups; about 0.01 to about 0.3 equivalents of at least one polyol
selected from the group consisting of polyester polyol,
polycaprolactone polyol and mixtures thereof; and about 0.1 to
about 0.7 equivalents of at least one aliphatic diol, wherein the
reaction product components are essentially free of polyether
polyol and amine curing agent and wherein the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes, wherein the reaction components are
maintained at a temperature of at least about 100.degree. C. for at
least about 10 minutes.
[0583] Non-limiting examples of suitable polyisocyanates, branched
polyols having 4 to 18 carbon atoms and at least 3 hydroxyl groups,
polyester polyols, polycaprolactone polyols and aliphatic diols for
use as reaction products for preparing the polyurethanes of Group G
are discussed in detail above with respect to Group A. The
aliphatic diol is chemically different from the polyester polyol
and polycaprolactone polyol, e.g., the diol has at least one
different atom or a different arrangement of atoms compared to the
polyester polyol and polycaprolactone polyol.
[0584] In some non-limiting embodiments, the amount of branched
polyol used to form the polyurethane of Group G can range from
about 0.3 to about 0.9 equivalents, or about 0.3 to about 0.7
equivalents, or about 0.4 equivalents to about 0.6 equivalent, or
about 0.7 equivalents.
[0585] In some non-limiting embodiments, the amount of polyester
and/or polycaprolactone polyol used to form the polyurethane of
Group G can range from about 0.01 to about 0.1 equivalents, or
about 0.05 to about 0.1 equivalents, or about 0.1 equivalents.
[0586] In some non-limiting embodiments, the amount of aliphatic
diol used to form the polyurethane of Group G can range from about
0.1 to about 0.6 equivalents, or about 0.1 to about 0.5
equivalents, or about 0.5 equivalents.
[0587] The polyurethanes of Group G are essentially free of or free
of polyether polyol and/or amine curing agent, the types and
amounts of polyether polyol and amine curing agent being described
above with respect to Groups A-D.
[0588] In some non-limiting embodiments of the polyurethanes of
Group G, the reaction products can further comprise one or more of
the following: polyurethane polyols, acrylamides, polyvinyl
alcohols, polymers containing hydroxy functional (meth)acrylates,
polymers containing allyl alcohols, polyesteramides and mixtures
thereof, as described and in amounts as above with respect to
Groups A-D.
[0589] In other non-limiting embodiments, the present invention
provides polyurethanes of Group G comprising a reaction product of
components consisting of: about 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate); about 0.3 equivalents
of trimethylolpropane; about 0.5 equivalents of decanediol; and
about 0.2 equivalents of polycaprolactone polyol, such as Dow TONE
0210 polycaprolactone polyol having a number average molecular
weight of about 1000 grams/mole, wherein the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes.
[0590] In other non-limiting embodiments, the present invention
provides polyurethanes of Group G prepared from a prepolymer which
is the reaction product of components comprising: (1) about 0.4
equivalents of 4,4'-methylene-bis-(cyclohexyl isocyanate) (such as
DESMODUR W); (2) about 0.3 equivalents of polycaprolactone diol
(such as CAPA 2047 and CAPA 2077A polycaprolactone diols prepared
from hexanediol); (3) about 0.05 equivalents of trimethylolpropane.
The prepolymer is reacted with at least one aliphatic diol having 2
to 18 carbon atoms as described above, such as butanediol or
pentanediol.
Group H
[0591] In other non-limiting embodiments, the present invention
provides polyurethanes of Group H comprising a reaction product of
components comprising: (a) a prepolymer which is the reaction
product of components comprising: (1) at least one polyisocyanate;
(2) at least one polycaprolactone polyol; and (3) at least one
polyol selected from the group consisting of polyalkylene polyol,
polyether polyol and mixtures thereof; and (b) at least one diol
having 2 to 18 carbon atoms.
[0592] Non-limiting examples of suitable polyisocyanates,
polycaprolactone polyols, polyalkylene polyols, polyether polyols
and diols having 2 to 18 carbon atoms for use as reaction products
for preparing the polyurethanes of Group H are discussed in detail
above with respect to Group A. Non-limiting examples of suitable
polyalkylene polyols include polyethylene glycols, polypropylene
glycols and mixtures thereof. The polyalkylene glycol can have a
number average molecular weight ranging from about 200 to about
1000 grams/mole, or from about 200 grams/mole to about 4,000
grams/mole.
[0593] The diol is chemically different from the polyalkylene
polyol and polyether polyol, e.g., the diol has at least one
different atom or a different arrangement of atoms compared to the
polyalkylene polyol and polyether polyol.
[0594] In some non-limiting embodiments, the amount of branched
polycaprolactone polyol used to form the polyurethane of Group H
can range from about 0.05 to about 0.8 equivalents, or about 0.1 to
about 0.6 equivalents, or about 0.1 equivalents to about 0.4
equivalents, or about 0.3 equivalents.
[0595] In some non-limiting embodiments, the amount of polyalkylene
polyol and/or polyether polyol used to form the polyurethane of
Group H can range from about 0.1 to about 0.9 equivalents, or about
0.2 to about 0.6 equivalents, or about 0.4 equivalents.
[0596] In some non-limiting embodiments, the amount of diol used to
form the polyurethane of Group H can range from about 0.1 to about
0.9 equivalents, or about 0.3 to about 0.8 equivalents, or about
0.7 equivalents.
[0597] The polyurethanes of Group H are prepared by reacting
reaction product components comprising: (1) at least one
polyisocyanate; (2) at least one polycaprolactone polyol; and (3)
at least one polyol selected from the group consisting of
polyalkylene polyol, polyether polyol and mixtures thereof to form
a prepolymer. The prepolymer is then reacted with at least one diol
having 2 to 18 carbon atoms and any other optional reaction
components as described below.
[0598] In some non-limiting embodiments of the polyurethanes of
Group H, the reaction products can further comprise one or more of
the following: branched polyols having at least three hydroxyl
groups, polyurethane polyols, acrylamides, polyvinyl alcohols,
polymers containing hydroxy functional (meth)acrylates, polymers
containing allyl alcohols, polyesteramides and mixtures thereof, as
described and in amounts as above with respect to Groups A-D.
[0599] In some non-limiting embodiments of the polyurethanes of
Group H, the reaction products can further comprise one or more
amine curing agents as discussed above with respect to Group E. In
other non-limiting embodiments, the reaction products for preparing
the polyurethanes of Group H can be essentially free of or free of
amine curing agent as discussed above with respect to Groups
A-D.
[0600] In other non-limiting embodiments, the present invention
provides polyurethanes of Group H comprising a reaction product of
components comprising: (a) a prepolymer which is the reaction
product of components comprising: (1) aliphatic or cycloaliphatic
diisocyanate; (2) polycaprolactone diol; (3) polyethylene glycol;
and (4) polyoxyethylene and polyoxypropylene copolymer and (b) at
least one diol having 2 to 18 carbon atoms.
[0601] In other non-limiting embodiments, the present invention
provides polyurethanes of Group H prepared from a prepolymer which
is the reaction product of components comprising: (1) about 0.4
equivalents of 4,4'-methylene-bis-(cyclohexyl isocyanate) (such as
DESMODUR W); (2) about 0.003 equivalents of polycaprolactone diol
(such as CAPA 2077A polycaprolactone diol prepared from
hexanediol); (3) about 0.025 equivalents of polyethylene glycol
(such as PLURACOL E400NF); (4) about 0.029 equivalents of
polyoxyethylene and polyoxypropylene copolymer (such as PLURONIC
L62D ethylene oxide/propylene oxide block copolymer); (5) about
0.05 equivalents of trimethylolpropane; and additives such as
catalyst (for example dibutyltin dilaurate), antioxidant (such as
IRGANOX 1010 and IRGANOX MD 1024), and ultraviolet light
stabilizer(s) such as CYASORB UV 5411 and TINUVIN 328 (each
described below).
[0602] The isocyanate-terminated prepolymer is reacted with at
least one diol having 2 to 18 carbon atoms, such as 1,4-butanediol
and/or 1,4-cyclohexane dimethanol in an equivalent ratio of about
0.75:0.25 1,4-butanediol to 1,4-cyclohexane dimethanol. The
equivalent ratio of prepolymer to diol is about 1:1.
Groups A-H
[0603] Referring now to the inventions of Groups A-H, the
polyurethanes of the present invention can be polymerized using a
variety of techniques. In some non-limiting embodiments described
in further detail below, polyisocyanate and polyol can be reacted
together in a one-pot process to form the polyurethane.
Sulfur-containing polyurethanes of the present invention can be
produced by combining isocyanate and/or isothiocyanate and polyol
and/or polythiol.
[0604] In other non-limiting embodiments, the polyurethane can be
prepared by reacting polyisocyanate(s) and polyol(s) to form a
polyurethane prepolymer and then introducing diol(s), and
optionally catalyst and other optional reaction components.
[0605] In other non-limiting embodiments such as Group B, the
polyurethane can be prepared by reacting polyisocyanate(s) and
diol(s) to form an isocyanate functional urethane prepolymer and
then introducing diol(s), polyols and optionally catalyst and other
optional reaction components. In some non-limiting embodiments, the
isocyanate functional urethane prepolymer, polyol and second
portion of diol reaction components are maintained at a temperature
of at least about 100.degree. C. for at least about 10 minutes, or
at least about 110.degree. C., or at least about 120.degree. C.,
for at least about 10 minutes or at least about 20 minutes.
[0606] In some non-limiting embodiments, the prepolymer and
polyurethane can be prepared using a Max Urethane Processing System
having a dynamic pin mixer, such as a Max Urethane Processing
System Model No. 601-000-282 or Model No. 601-000-333 available
from Max Machinery, Inc. of Healdsburg, Calif. The mixing head or
chamber volume can be varied as desired, for example 62 cc, 70 cc,
140 cc, 205 cc or 250 cc. In some embodiments, increased residence
time of the reactants in the mix head can provide improved physical
properties, such as Young's Modulus and Gardner Impact strength.
For some embodiments, a residence time of about 4 seconds to about
30 minutes, or about 4 seconds to about 15 minutes, or about 4
seconds to about 1 minute, or about 4 to about 30 seconds, or about
4 to about 15 seconds, or about 4 to about 8 seconds can be
desirable.
[0607] Whether prepared in a one-shot process or in a multi-stage
process using a prepolymer, in some non-limiting embodiments, the
aforementioned ingredients each can be degassed prior to reaction.
In some non-limiting embodiments, the prepolymer can be degassed,
the difunctional material can be degassed, and then these two
materials can be combined. One or more of the reactants can be
preheated to a temperature of at least about 100.degree. C., at
least about 110.degree. C., or at least about 120.degree. C., prior
to reaction.
[0608] In the "one shot", "one pot" or bulk polymerization method,
all of the ingredients, that is, isocyanate, polyol and diol are
mixed simultaneously. This method is generally satisfactory when
all active hydrogens react at about the same rate such as when all
contain hydroxyl groups as the only reactive sites. The urethane
reaction can be conducted under anhydrous conditions with dry
reactants such as in a nitrogen atmosphere of atmospheric pressure
and at a temperature ranging from about 75.degree. C. to about
140.degree. C. If polycarbonate polyols or any hydroxy functional
compounds are used, they are typically dried before reaction,
usually to a moisture content ranging from about 0.01 to about 0.05
percent.
[0609] To obtain the randomness desired and a generally clear
polymer, the diol, for example, anhydrous 1,4-butanediol
(containing a maximum of 0.04 percent water) can be added to the
polyol under a nitrogen atmosphere to exclude moisture and the
temperature maintained sufficiently high so that there is no phase
separation and a homogeneous mixture is obtained. The
polyisocyanate, for example, 4,4'-methylene-bis-(cyclohexyl
isocyanate), can be added rapidly and the mixture can be maintained
at a temperature of at least about 75.degree. C., or at least about
85.degree. C., or at least about 90.degree. C., or at least about
95.degree. C. for at least about 10 minutes or at least about 20
minutes. In some embodiments, the mixture is maintained at a
temperature of at least about 100.degree. C., or at least about
105.degree. C., or at least about 110.degree. C. for at least about
10 minutes or at least about 20 minutes, so that there is no phase
separation and the mixture remains homogeneous. The mixture can be
maintained at a pressure of ranging from about 2 to about 6 mm Hg
(about 266.6 to about 800 Pascal (Pa)), or about 266.6 Pa for a
time period of about 10 minutes to about 24 hours, or about 10
minutes to about 4 hours.
[0610] In some non-limiting embodiments, the mixture can be
vigorously agitated at a temperature of at least about 75.degree.
C., or at least about 85.degree. C., or at least about 90.degree.
C., or at least about 95.degree. C., or at least about 100.degree.
C., or at least about 105.degree. C., or at least about 110.degree.
C., and degassed for a period of at least about 3 minutes during
which time the pressure is reduced from atmospheric to about 3
millimeters of mercury. The reduction in pressure facilitates the
removal of the dissolved gases such as nitrogen and carbon dioxide
and then the ingredients can be reacted at a temperature ranging
from about 100.degree. C. to about 140.degree. C., or about
110.degree. C. to about 140.degree. C., in the presence of a
catalyst and the reaction continued until there are substantially
no isocyanate groups present, in some embodiments for at least
about 6 hours. In the absence of a catalyst, the reaction can be
conducted for at least about 24 hours, such as under a nitrogen
atmosphere.
[0611] In some non-limiting embodiments, wherein a window can be
formed, the polymerizable mixture which can be optionally degassed
can be introduced into a mold and the mold can be heated (i.e.,
thermal cure cycle) using a variety of conventional techniques
known in the art. The thermal cure cycle can vary depending on the
reactivity and molar ratio of the reactants. In a non-limiting
embodiment, the thermal cure cycle can include heating the mixture
of prepolymer and diol and optionally diol and dithiol; or heating
the mixture of polyisocyanate, polyol and/or polythiol and diol or
diol/dithiol, from room temperature to a temperature of about
200.degree. C. over a period of from about 0.5 hour to about 72
hours; or from about 80.degree. C. to about 150.degree. C. for a
period of from about 5 hours to about 48 hours.
[0612] In other non-limiting embodiments described in further
detail below, isocyanate and polyol can be reacted together to form
a polyurethane prepolymer and the prepolymer can be reacted with
more of the same or a different polyol(s) and/or diol(s) to form a
polyurethane or sulfur-containing polyurethane. When the prepolymer
method is employed, the prepolymer and diol(s) can be heated so as
to reduce the prepolymer viscosity to about 200 cp or at most a few
thousand centipoise so as to aid in mixing. As in the bulk
polymerization, reaction should be conducted under anhydrous
conditions with dry reactants. The reactants can be preheated to a
temperature of at least about 100.degree. C., at least about
110.degree. C., or at least about 120.degree. C. prior to reaction.
The reactants can be maintained at a temperature of at least about
100.degree. C., at least about 110.degree. C. or at least about
120.degree. C. for at least about 10 minutes, or at least about 2
hours, to facilitate reaction. The mixture can be maintained at a
pressure of ranging from about 2 to about 6 mm Hg (about 266.6 to
about 800 Pascal (Pa)), or about 266.6 Pa for a time period of
about 10 minutes to about 24 hours, or about 10 minutes to about 4
hours.
[0613] The polyurethane prepolymer can have a number average
molecular weight (Mn) of less than about 50,000 grams/mole, or less
than about 20,000 grams/mole, or less than about 10,000 grams/mole,
or less than about 5,000 grams/mole, or at least about 1,000
grams/mole or at least about 2,000 grams/mole, inclusive of any
range in between.
[0614] When polyurethane-forming components, such as polyols and
isocyanates, are combined to produce polyurethanes, the relative
amounts of the ingredients are typically expressed as a ratio of
the available number of reactive isocyanate groups to the available
number of reactive hydroxyl groups, i.e., an equivalent ratio of
NCO:OH. For example, a ratio of NCO:OH of 1.0:1.0 is obtained when
the weight of one NCO equivalent of the supplied form of the
isocyanate component is reacted with the weight of one OH
equivalent of the supplied form of the organic polyol component.
The polyurethanes of the present invention can have an equivalent
ratio of NCO:OH ranging from about 0.9:1.0 to about 1.1:1.0, or
about 1.0:1.0.
[0615] In some non-limiting embodiments, when the isocyanate and
polyol are reacted to form a prepolymer, the isocyanate is present
in excess, for example the amount of isocyanate and the amount of
polyol in the isocyanate prepolymer can be selected such that the
equivalent ratio of (NCO):(OH) can range from about 1.0:0.05 to
about 1.0:0.7.
[0616] In some non-limiting embodiments, the amount of isocyanate
and the amount of polyol used to prepare isocyanate-terminated
polyurethane prepolymer or isocyanate-terminated sulfur-containing
polyurethane prepolymer can be selected such that the equivalent
ratio of (NCO):(SH+OH) can be at least about 1.0:1.0, or at least
about 2.0:1.0, or at least about 2.5:1.0, or less than about
4.5:1.0, or less than about 5.5:1.0; or the amount of
isothiocyanate and the amount of polyol used to prepare
isothiocyanate-terminated sulfur-containing polyurethane prepolymer
can be selected such that the equivalent ratio of (NCS):(SH+OH) can
be at least about 1.0:1.0, or at least about 2.0:1.0, or at least
about 2.5:1.0, or less than about 4.5:1.0, or less than about
5.5:1.0; or the amount of a combination of isothiocyanate and
isocyanate and the amount of polyol used to prepare
isothiocyanate/isocyanate terminated sulfur-containing polyurethane
prepolymer can be selected such that the equivalent ratio of
(NCS+NCO):(SH+OH) can be at least about 1.0:1.0, or at least about
2.0:1.0, or at least about 2.5:1.0, or less than about 4.5:1.0, or
less than about 5.5:1.0
[0617] The ratio and proportions of the diol and the polyol can
affect the viscosity of the prepolymer. The viscosity of such
prepolymers can be important, for example when they are intended
for use with coating compositions, such as those for flow coating
processes. The solids content of such prepolymers, however, also
can be important, in that higher solids content can achieve desired
properties from the coating, such as weatherability, scratch
resistance, etc. In conventional coatings, coating compositions
with higher solids content typically require greater amounts of
solvent material to dilute the coating in order to reduce the
viscosity for appropriate flow coating processes. The use of such
solvents, however, can adversely affect the substrate surface,
particularly when the substrate surface is a polymeric material. In
the present invention, the viscosity of the prepolymer can be
appropriately tailored to provide a material with lower viscosity
levels at higher solids content, thereby providing an effective
coating without the need for excessive amounts of solvents which
can deleteriously affect the substrate surface.
[0618] In some non-limiting embodiments in which optional amine
curing agent is used, the amount of isocyanate-terminated
polyurethane prepolymer or sulfur-containing isocyanate-terminated
polyurethane prepolymer and the amount of amine curing agent used
to prepare sulfur-containing polyurethane can be selected such that
the equivalent ratio of (NH+SH+OH):(NCO) can range from about
0.80:1.0 to about 1.1:1.0, or from about 0.85:1.0 to about 1.0:1.0,
or from about 0.90:1.0 to about 1.0:1.0, or from about 0.90:1.0 to
about 0.95:1.0, or from about 0.95:1.0 to about 1.0:1.0.
[0619] In some non-limiting embodiments, the amount of
isothiocyanate or isothiocyanate/isocyanate terminated
sulfur-containing polyurethane prepolymer and the amount of amine
curing agent used to prepare sulfur-containing polyureaurethane can
be selected such that the equivalent ratio of (NH+SH+OH):(NCO+NCS)
can range from about 0.80:1.0 to about 1.1:1.0, or from about
0.85:1.0 to about 1.0:1.0, or from about 0.90:1.0 to about 1.0:1.0,
or from about 0.90:1.0 to about 0.95:1.0, or from about 0.95:1.0 to
about 1.0:1.0.
[0620] It is believed that the unusual energy absorption properties
and transparency of the polyurethanes of the present invention may
not only be dependent upon the urethane ingredients and
proportions, but also may be dependent on the method of
preparation. More particularly, it is believed that the presence of
polyurethane regular block segments may adversely affect the
polyurethane transparency and energy absorption properties and,
consequently, it is believed that random segments within the
polymer can provide optimal results. Consequently, whether the
urethane contains random or regular block segments depends upon the
particular reagents and their relative reactivity as well as the
conditions of reaction. Generally speaking, the polyisocyanate will
be more reactive with a low molecular weight diol or polyol, for
example, 1,4-butanediol, than with a polymeric polyol and, hence,
in some non-limiting embodiments, it is desirable to inhibit the
preferential reaction between the low molecular weight diol or
polyol and the polyisocyanate such as by rapidly adding the
polyisocyanate to an intimate mixture of the low molecular weight
diol or polyol and polymeric polyol with vigorous agitation, such
as at a temperature of at least about 75.degree. C. when no
catalyst is employed, and then maintained at temperature of
reaction of at least about 100.degree. C. or about 110.degree. C.
after the exotherm has subsided. When a catalyst is employed, the
initial mixing temperature can be lower, such as about 60.degree.
C., so that the exotherm does not carry the temperature of the
mixture substantially above the reaction temperature desired.
Inasmuch as the polyurethanes are thermally stable, however,
reaction temperatures can reach as high as about 200.degree. C. and
as low as about 60.degree. C., and in some non-limiting
embodiments, ranging from about 75.degree. C. to about 130.degree.
C. when a catalyst is employed, or ranging from about 80.degree. C.
to about 100.degree. C. When no catalyst is employed, in some
non-limiting embodiments the reaction temperature can range from
about 130.degree. C. to about 150.degree. C.
[0621] It is also desirable to rapidly attain reaction temperatures
after a homogeneous mixture is obtained when a catalyst is not
employed, so that the polymer does not become hazy due to phase
separation. For example, some mixtures can become hazy in less than
one-half hour at less than 80.degree. C. without catalyst. Thus, it
can be desirable either to use a catalyst or introduce the
reactants to rapidly reach a reaction temperature above about
100.degree. C., or about 110.degree. C. or about 130.degree. C.,
for example by the use of a high-speed shear mixing head, so that
the polymer does not become hazy. Suitable catalysts can be
selected from those known in the art. In some non-limiting
embodiments, degassing can take place prior to or following
addition of catalyst.
[0622] In some non-limiting embodiments, a urethane-forming
catalyst can be used in the present invention to enhance the
reaction of the polyurethane-forming materials. Suitable
urethane-forming catalysts include those catalysts that are useful
for the formation of urethane by reaction of the NCO and
OH-containing materials, and which have little tendency to
accelerate side reactions leading to allophonate and isocyanate
formation. Non-limiting examples of suitable catalysts are selected
from the group of Lewis bases, Lewis acids and insertion catalysts
as described in Ullmann's Encyclopedia of Industrial Chemistry,
5.sup.th Edition, 1992, Volume A21, pp. 673 to 674.
[0623] In some non-limiting embodiments, the catalyst can be a
stannous salt of an organic acid, such as stannous octoate or butyl
stannoic acid. Other non-limiting examples of suitable catalysts
include tertiary amine catalysts, tertiary ammonium salts, tin
catalysts, phosphines or mixtures thereof. In some non-limiting
embodiments, the catalysts can be dimethyl cyclohexylamine, dibutyl
tin dilaurate, dibutyltin diacetate, dibutyltin mercaptide,
dibutyltin diacetate, dibutyl tin dimaleate, dimethyl tin
diacetate, dimethyl tin dilaurate, 1,4-diazabicyclo[2.2.2]octane,
bismuth carboxylates, zirconium carboxylates, zinc octoate, ferric
acetylacetonate and mixtures thereof. The amount of catalyst used
can vary depending on the amount of components, for example about
10 ppm to about 600 ppm.
[0624] In alternate non-limiting embodiments, various additives can
be included in compositions comprising the polyurethane(s) of the
present invention. Such additives include light stabilizers, heat
stabilizers, antioxidants, colorants, fire retardants, ultraviolet
light absorbers, light stabilizers such as hindered amine light
stabilizers, mold release agents, static (non-photochromic) dyes,
fluorescent agents, pigments, surfactants, flexibilizing additives,
such as but not limited to alkoxylated phenol benzoates and
poly(alkylene glycol) dibenzoates, and mixtures thereof.
Non-limiting examples of anti-yellowing additives include
3-methyl-2-butenol, organo pyrocarbonates and triphenyl phosphite
(CAS Registry No. 101-02-0). Examples of useful antioxidants
include IRGANOX 1010, IRGANOX 1076, and IRGANOX MD 1024, each
commercially available from Ciba Specialty Chemicals of Tarrytown,
N.Y. Examples of useful UV absorbers include CYASORB UV 5411,
TINUVIN 130 and TINUVIN 328 commercially available Ciba Specialty
Chemicals, and SANDOVAR 3206 commercially available from Clariant
Corp. of Charlotte, N.C. Examples of useful hindered amine light
stabilizers include SANDOVAR 3056 commercially available from
Clariant Corp. of Charlotte, N.C. Examples of useful surfactants
include BYK 306 commercially available from BYK Chemie of Wesel,
Germany.
[0625] Such additives can be present in an amount such that the
additive constitutes less than about 30 percent by weight, or less
than about 15 percent by weight, or less than about 5 percent by
weight, or less than about 3 percent by weight, based on the total
weight of the polymer. In some non-limiting embodiments, the
aforementioned optional additives can be pre-mixed with the
polyisocyanate(s) or isocyanate functional prepolymer. In other
non-limiting embodiments, the optional additives can be pre-mixed
with the polyol(s) or urethane prepolymer.
[0626] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group A comprising
the step of reacting in a one-potprocess components comprising:
about 1 equivalent of at least one polyisocyanate; about 0.1 to
about 0.9 equivalents of at least one branched polyol having 4 to
18 carbon atoms and at least 3 hydroxyl groups; and about 0.1 to
about 0.9 equivalents of at least one diol having 2 to 18 carbon
atoms, wherein the components are essentially free of polyester
polyol and polyether polyol.
[0627] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group A comprising
the steps of: reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and reacting the
polyurethane prepolymer with at least one diol having 2 to 18
carbon atoms to form the polyurethane.
[0628] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group B comprising
the steps of: (a) reacting (i) about 1 equivalent of at least one
polyisocyanate; and (ii) about 0.1 to about 0.5 equivalents of at
least one diol having 2 to 18 carbon atoms to form an isocyanate
functional urethane prepolymer; (b) reacting the isocyanate
functional urethane prepolymer with about 0.05 to about 0.9
equivalents of at least one branched polyol having 4 to 18 carbon
atoms and at least 3 hydroxyl groups and up to about 0.45
equivalents of at least one diol having 2 to 18 carbon atoms,
wherein the reaction product components are essentially free of
polyester polyol and polyether polyol.
[0629] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group B comprising
reacting components comprising: (a) an isocyanate functional
urethane prepolymer comprising a reaction product of components
comprising: (i) about 1 equivalent of at least one polyisocyanate;
and (ii) about 0.1 to about 0.5 equivalents of at least one polyol
having 2 to 18 carbon atoms; and (b) about 0.05 to about 1.0
equivalents of at least one branched polyol having 4 to 18 carbon
atoms and at least 3 hydroxyl groups; and (c) up to about 0.9
equivalents of at least one polyol different from branched polyol
(b) and having 2 to 18 carbon atoms, wherein the reaction product
components are essentially free of polyester polyol and polyether
polyol.
[0630] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group C comprising
the step of reacting in a one-pot process components comprising: at
least one polyisocyanate trimer or branched polyisocyanate, the
polyisocyanate having at least three isocyanate functional groups;
and at least one aliphatic polyol having 4 to 18 carbon atoms and
at least two hydroxyl groups, wherein the reaction product
components are essentially free of polyester polyol and polyether
polyol.
[0631] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group D comprising
the step of reacting in a one-pot process components comprising: at
least one polyisocyanate; at least one branched polyol having 4 to
18 carbon atoms and at least 3 hydroxyl groups; and at least one
polyol having one or more bromine atoms, one or more phosphorus
atoms or combinations thereof.
[0632] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group D comprising
the steps of: reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and reacting the
polyurethane prepolymer with at least one polyol having one or more
bromine atoms, one or more phosphorus atoms or combinations thereof
to form the polyurethane. In some non-limiting embodiments, about
0.1 to about 0.15 equivalents of the branched polyol are reacted
with about 1 equivalent of polyisocyanate in step (a) and step (b)
further comprises reacting the polyurethane prepolymer with the
polyol and about 0.15 to about 0.9 equivalents of the branched
polyol to form the polyurethane.
[0633] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group E comprising
the step of reacting in a one-pot process components comprising:
about 1 equivalent of at least one polyisocyanate; about 0.3 to
about 1 equivalents of at least one branched polyol having 4 to 18
carbon atoms and at least 3 hydroxyl groups; and about 0.01 to
about 0.3 equivalents of at least one polycarbonate diol, wherein
the reaction product components are essentially free of polyether
polyol and amine curing agent.
[0634] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group E comprising
the steps of: reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and reacting the
polyurethane prepolymer with at least one polycarbonate diol to
form the polyurethane.
[0635] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group F comprising
the step of reacting in a one-potprocess components comprising: (a)
about 1 equivalent of at least one polyisocyanate; (b) about 0.3 to
about 1 equivalents of at least one branched polyol having 4 to 18
carbon atoms and at least 3 hydroxyl groups; (c) about 0.01 to
about 0.3 equivalents of at least one polycarbonate diol; and (d)
about 0.1 to about 0.9 equivalents of at least one diol having 2 to
18 carbon atoms, wherein the reaction product components are
essentially free of polyether polyol.
[0636] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group F comprising
the steps of:(a) reacting at least one polyisocyanate and at least
one branched polyol having 4 to 18 carbon atoms and at least 3
hydroxyl groups to form a polyurethane prepolymer; and (b) reacting
the polyurethane prepolymer with at least one polycarbonate diol
and at least one diol having 2 to 18 carbon atoms to form the
polyurethane, wherein the reaction product components are
essentially free of polyether polyol.
[0637] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group F comprising A
polyurethane comprising a reaction product of components
comprising: (a) about 1 equivalent of at least one polyisocyanate;
(b) about 0.05 to about 1 equivalents of at least one branched
polyol having 4 to 18 carbon atoms and at least 3 hydroxyl groups;
(c) about 0.01 to about 0.3 equivalents of at least one
polycarbonate diol; and (d) about 0.1 to about 0.9 equivalents of
at least one polyol different from the branched polyol and having 2
to 18 carbon atoms, wherein the reaction product components are
essentially free of polyether polyol and the reaction components
are maintained at a temperature of at least about 100.degree. C.
for at least about 10 minutes.
[0638] In other non-limiting embodiments, the present invention
provides methods of preparing a polyurethane from reaction
components comprising: (a) reacting about 1 equivalent of at least
one polyisocyanate and about 0.3 to about 0.4 equivalents of
butanediol or cyclohexane dimethanol to form an isocyanate
functional urethane prepolymer; and (b) reacting the isocyanate
functional urethane prepolymer, about 0.1 to about 0.3 equivalents
of trimethylolpropane, about 0.4 to about 0.5 equivalents of
butanediol or cyclohexane dimethanol; and about 0.01 to about 0.3
equivalents of at least one polycarbonate diol, wherein the
reaction product components are essentially free of polyether
polyol.
[0639] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group G comprising
the step of reacting in a one-pot process components comprising:
about 1 equivalent of at least one polyisocyanate; about 0.3 to
about 1 equivalents of at least one branched polyol having 4 to 18
carbon atoms and at least 3 hydroxyl groups; and about 0.01 to
about 0.3 equivalents of at least one polyol selected from the
group consisting of polyester polyol, polycaprolactone polyol and
mixtures thereof; and about 0.1 to about 0.7 equivalents of at
least one aliphatic diol, wherein the reaction product components
are essentially free of polyether polyol and amine curing
agent.
[0640] In other non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group G comprising
the steps of: reacting at least one polyisocyanate and at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups to form a polyurethane prepolymer; and reacting the
polyurethane prepolymer with at least one polyol selected from the
group consisting of polyester polyol, polycaprolactone polyol and
mixtures thereof and about 0.1 to about 0.7 equivalents of at least
one aliphatic diol to form the polyurethane.
[0641] In some non-limiting embodiments, the present invention
provides methods of preparing polyurethanes of Group H comprising
the steps of: reacting components comprising: at least one
polyisocyanate; at least one polycaprolactone polyol; and at least
one polyol selected from the group consisting of polyalkylene
polyol, polyether polyol and mixtures thereof, to form a
polyurethane prepolymer; and reacting the prepolymer with at least
one diol having 2 to 18 carbon atoms to form the polyurethane.
Poly(ureaurethanes)
[0642] Poly(ureaurethane)s can be prepared from any of the above
polyurethanes of Groups A-H by including one or more amine curing
agents in the reaction components. The amine functionality of the
amine curing agent can react with isocyanate groups to form urea
linkages or units within the polyurethane matrix. Suitable amounts
of amine curing agents and reaction conditions are discussed in
detail above.
Poly(ureaurethane) Synthesis A
[0643] Alternatively or additionally, urea linkages or units can be
formed within the polyurethane matrix to the extent desired by
reacting isocyanate functional groups of the polyisocyanate with
water. As shown in Step 1 of the reaction scheme of
Poly(ureaurethane) Synthesis A below, isocyanate functional groups
are converted to carbamate functional groups by the reaction with
water. In some non-limiting embodiments, the equivalent ratio of
NCO:water ranges from about 10:1 to about 2:1, or about 5:1 to
about 2:1, or about 3:1 to about 2:1.
[0644] The isocyanate shown in Step 1 is a diisocyanate in which R
is any linking group, such as aliphatic, cycloaliphatic, aromatic,
heterocycle, etc. as described in detail above. However, one
skilled in the art would understand that the isocyanate can have
one or more, two or more, three or more or a higher number of
isocyanate functional groups, as desired. Examples of suitable
isocyanates can be any of the isocyanates discussed above. In some
non-limiting embodiments, the polyisocyanate is one or more
aliphatic polyisocyanates. In some non-limiting embodiments, the
polyisocyanate is 4,4'-methylene-bis-(cyclohexyl isocyanate) (such
as DESMODUR W).
[0645] Removal of carbon dioxide facilitates conversion of the
carbamate groups into amine groups. Excess isocyanate is desirable
to ensure essentially complete consumption of the water. Also, it
is desirable to remove essentially all of the carbon dioxide
generated to facilitate conversion to amine groups. The water can
be reacted with the polyisocyanate or polyurethane polyisocyanate
prepolymer at a temperature of up to about 60.degree. C. under
vacuum. The vacuum pressure should be low enough so as not to
remove water from the system, and can range for example from about
10 to about 20 mm Hg (about 1333 to about 2666 Pa) for a time
period of about 10 to about 30 minutes. After the reaction is
essentially complete, i.e., no further carbon dioxide is formed,
the temperature can be increased to at least about 100.degree. C.
or about 110.degree. C. and heated for about 2 to about 24 hours,
or about 2 hours, using 10 ppm or more of catalyst such as
dibutyltin diacetate. After substantially all of the water reacts
with the excess isocyanate, the amine that is formed reacts
essentially instantaneously with the isocyanate.
##STR00014##
[0646] As is well known to those skilled in the art, certain amine
curing agents (such as aliphatic amine curing agents having 2 to 18
carbon atoms, e.g., ethylene diamine, diethylenediamine,
diaminobutane, PACM, diamine hexane, 1,10-decanediamine) are highly
reactive and impractical to use under normal production conditions
because the amine functionality begins to react with oxygen present
in the ambient air very quickly to discolor the polymerizate.
Aliphatic amine curing agents are typically very hygroscopic and
difficult to keep dry. Generally, aliphatic amines are so reactive
as to be impractical for making 100% solids, transparent, low color
and low haze plastics.
[0647] By forming the amine in situ as discussed above and shown in
Step 2, amines can be generated in situ that normally are not
practical to use under normal production conditions without
formation of undesirable side products, color or haze. Also, the
rate of reaction can be more easily regulated. This reaction can be
used for any type of polyisocyanate described above, but is
especially useful for converting aliphatic polyisocyanates to
amines as described above.
[0648] As shown in Step 2 above, the amine formed in situ reacts
with another isocyanate to form a urea group. Use of excess
polyisocyanate permits formation of an isocyanate functional urea
prepolymer. In some non-limiting embodiments, the equivalent ratio
of NCO:amine functional groups ranges from about 1:0.05 to about
1:0.7, or about 1:0.05 to about 1:0.5, or about 1:0.05 to about
1:0.3. Suitable reaction temperatures can range from about
25.degree. C. to about 60.degree. C. with a catalyst such as a tin
catalyst. After the water is reacted and the carbon dioxide
removed, the reaction temperature can be increased up to about
90.degree. C. for about 2 to about 4 hours. Alternatively, the
reaction can proceed at about 25.degree. C. for up to about 8 hours
until complete. Optionally, one or more polyols or diols as
described above can be included in this reaction to form isocyanate
functional urethane prepolymers, as shown in Poly(ureaurethane)
Synthesis B, described in further detail below.
[0649] As shown in Step 3 of the reaction scheme of
Poly(ureaurethane) Synthesis A above, the polyol and/or diol can be
reacted with the isocyanate functional urea prepolymer(s) to form
poly(ureaurethane)s of the present invention. The polyol shown in
Step 3 can be a diol (m=2), triol (m=3) or higher hydroxyl
functional material (m=4 or more) as described above in which R is
any linking group, such as aliphatic, cycloaliphatic, aromatic,
heterocycle, etc. as described in detail above with respect to the
polyols. Examples of suitable polyols can be any of the polyols
discussed above. In some non-limiting embodiments, the polyol can
be trimethylolpropane and butanediol and/or pentanediol. Suitable
amounts of polyols for reacting with the isocyanate functional urea
prepolymer as polyisocyanate are discussed in detail above. In the
above poly(ureaurethane), x can range from 1 to about 100, or about
1 to about 20.
[0650] In some non-limiting embodiments, to form the
poly(ureaurethane) the isocyanate functional prepolymer is heated
to a temperature of about 90.degree. C., the polyol(s) are added
and heated to about 90.degree. C. The temperature can be increased
to about 100.degree. C. or about 110.degree. C. to facilitate
compatibilization, then about 2 to about 4 mm of vacuum can be
applied for about 3 to about 5 minutes.
[0651] To prepare an article, for example, the mixture can be
poured or pressure cast into a release-coated glass casting mold to
form an article of desired thickness and dimensions. In some
embodiments, the casting mold is preheated to a temperature of
about 200.degree. F. (93.3.degree. C.). The filled mold or cell can
be placed in an oven at a temperature of about 250.degree. F.
(121.degree. C.) to about 320.degree. F. (160.degree. C.) and cured
for about 24 to about 48 hours, for example. The cell can be
removed from the oven and cooled to a temperature of about
25.degree. C. and the cured polymer released from the casting
mold.
Group I
[0652] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s of Group I comprising a reaction
product of components comprising: (a) at least one isocyanate
functional urea prepolymer comprising a reaction product of: (1) at
least one polyisocyanate; and (2) water; and (b) at least one
branched polyol having 4 to 18 carbon atoms and at least 3 hydroxyl
groups, wherein the reaction product components are essentially
free or free of amine curing agents. Suitable polyisocyanates and
branched polyol(s) having 4 to 18 carbon atoms are described in
detail above. If present, the amine curing agent(s) can be present
in an amount as defined above as essentially free. Any of the other
optional polyols, catalysts or other additives described above can
be included as reaction components in amounts as described above
with respect to the foregoing Groups A-H.
[0653] In some non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane)s of Group I
comprising the steps of: (a) reacting at least one polyisocyanate
and water to form an isocyanate functional urea prepolymer; and (b)
reacting reaction product components comprising the isocyanate
functional urea prepolymer with at least one branched polyol having
4 to 18 carbon atoms and at least 3 hydroxyl groups, wherein the
reaction product components are essentially free of amine curing
agent. The reaction synthesis can be as described above with
respect to Poly(ureaurethane) Synthesis A. Optionally, a portion of
one or more polyols or diols as described above can be included in
this reaction to form isocyanate functional urethane prepolymer
which is then further reacted with another portion of polyol and/or
diol, as shown in Poly(ureaurethane) Synthesis B, described in
further detail below.
Group J
[0654] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s of Group J comprising a reaction
product of components comprising: (a) at least one isocyanate
functional urea prepolymer comprising a reaction product of: (1) at
least one polyisocyanate selected from the group consisting of
polyisocyanate trimers and branched polyisocyanates, the
polyisocyanate having at least three isocyanate functional groups;
and (2) water; and (b) at least one aliphatic polyol having 4 to 18
carbon atoms and at least 2 hydroxyl groups.
[0655] Examples of suitable polyisocyanate trimers and branched
polyisocyanates and polyol(s) are discussed above. Any of the other
optional polyols, amine curing agent, catalysts or other additives
described above can be included as reaction components in amounts
as described above with respect to the foregoing Groups A-H. In
some non-limiting embodiments, the reaction components are
essentially free or free of amine curing agents as described
above.
[0656] In other non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane) comprising the
steps of: (a) reacting at least one polyisocyanate selected from
the group consisting of polyisocyanate trimers and branched
polyisocyanates and water to form an isocyanate functional urea
prepolymer; and (b) reacting reaction product components comprising
the isocyanate functional urea prepolymer with at least one
aliphatic polyol having 4 to 18 carbon atoms and at least 2
hydroxyl groups, wherein the reaction product components are
essentially free of amine curing agent.
[0657] The reaction synthesis can be as described above with
respect to Poly(ureaurethane) Synthesis A. Optionally, a portion of
one or more polyols or diols as described above can be included in
this reaction to form isocyanate functional urethane prepolymer
which is then further reacted with another portion of polyol and/or
diol, as shown in Poly(ureaurethane) Synthesis B, described in
further detail below.
Poly(ureaurethane) Synthesis B
[0658] As shown generally in Poly(ureaurethane) Synthesis B below,
in other non-limiting embodiments urea linkages or units can be
formed within the polyurethane matrix to the extent desired by
reacting polyisocyanate(s) and a portion of the polyol(s) to form
at least one isocyanate functional urethane prepolymer, and then
reacting the isocyanate functional urethane prepolymer(s) with
water. As shown in Step 1 of the reaction scheme of
Poly(ureaurethane) Synthesis B below, a portion of the polyol(s)
and/or diol(s) can be reacted with polyisocyanate(s) to form the at
least one isocyanate functional urethane prepolymer. In some
non-limiting embodiments, the equivalent ratio of NCO:OH functional
groups ranges from about 1:0.05 to about 1:0.7, or about 1:0.05 to
about 1:0.5, or about 1:0.05 to about 1:0.3. It is desirable to use
excess isocyanate to ensure essentially complete conversion of the
hydroxyl groups to urethane groups.
[0659] The isocyanate shown in Step 1 is a diisocyanate in which R
is any linking group, such as aliphatic, cycloaliphatic, aromatic,
heterocycle, etc. as described in detail above. However, one
skilled in the art would understand that the isocyanate can have
one or more, two or more, three or more or a higher number of
isocyanate functional groups, as desired. Examples of suitable
isocyanates can be any of the polyisocyanates discussed above. In
some non-limiting embodiments, the polyisocyanate is one or more
aliphatic polyisocyanates. In some non-limiting embodiments, the
polyisocyanate is 4,4'-methylene-bis-(cyclohexyl isocyanate) (such
as DESMODUR W).
[0660] The polyol shown in Step 1 can be a diol (m=2), triol (m=3)
or higher hydroxyl functional material (m=4 or more) as described
above in which R is any linking group, such as aliphatic,
cycloaliphatic, aromatic, heterocycle, etc. as described in detail
above with respect to the polyols. Examples of suitable polyols can
be any of the polyols discussed above. In some non-limiting
embodiments, the polyol can be trimethylolpropane and butanediol
and/or pentanediol. Optionally, one or more catalysts such as are
described above can be used to facilitate the reaction. The
polyisocyanate can be reacted with the polyol to form the
isocyanate functional urethane prepolymer by charging the reactants
into a kettle and adding about 10 ppm or more of catalyst, such as
a tin, bismuth or zirconium catalyst. The mixture can be heated to
a temperature of about. 100.degree. C. or about 110.degree. C. for
about 2 to about 4 hours until all of the hydroxyl functionality is
reacted. FTIR spectroscopy can be used to determine the extent of
reaction.
[0661] Urea linkages or units can be formed within the polyurethane
matrix to the extent desired by reacting isocyanate functional
groups of the isocyanate functional urethane prepolymer with water.
As shown in Step 2 of the reaction scheme of Poly(ureaurethane)
Synthesis B below, isocyanate functional groups are converted to
carbamate functional groups by the reaction with water. In some
non-limiting embodiments, the equivalent ratio of NCO: water ranges
from about 1:0.05 to about 1:0.7, or about 1:0.05 to about 1:0.5,
or about 1:0.05 to about 1:0.3.
[0662] Removal of carbon dioxide facilitates conversion of the
carbamate groups into amine groups. Excess isocyanate is desirable
to ensure essentially complete consumption of the water. Also, it
is desirable to remove essentially all of the carbon dioxide
generated to facilitate conversion to amine groups. To prevent the
removal of water under vacuum, the reaction can be started at a
temperature of about 25.degree. C., then raised to a temperature of
about 60.degree. C. while applying vacuum to remove the carbon
dioxide. After cessation of carbon dioxide formation, the reaction
temperature can be increased to about 100.degree. C. or about
110.degree. C. for about 2 to about 4 hours.
[0663] As discussed above, certain amine curing agents (such as
aliphatic amine curing agents) are highly reactive and impractical
to use under normal production conditions. By forming the amine in
situ as discussed above and shown in Step 2, amines can be
generated in situ that normally are not practical to use under
normal production conditions without formation of undesirable side
products. Also, the rate of reaction can be more easily regulated.
This reaction can be used for any type of polyisocyanate described
above, but is especially useful for converting aliphatic
polyisocyanates to amines as described above.
[0664] As shown in Step 3 below, the amine formed in situ reacts
with another isocyanate to form a urea group. Use of excess
polyisocyanate permits formation of an isocyanate functional
ureaurethane prepolymer. The isocyanate functional ureaurethane
prepolymer can be prepared by reacting a stoichiometric excess of
the polyisocyanate with the amine under substantially anhydrous
conditions at a temperature ranging from about 25.degree. C. and
about 150.degree. C. or about 110.degree. C. until the reaction
between the isocyanate groups and the amine groups is substantially
complete. The polyisocyanate and amine components are suitably
reacted in such proportions that the ratio of number of isocyanate
groups to the number of amine groups is in the range of about
1:0.05 to about 1:0.7, or within the range of about 1:0.05 to
1:0.3.
[0665] As shown in Step 4 of the reaction scheme of
Poly(ureaurethane) Synthesis B below, the isocyanate functional
ureaurethane prepolymer can be reacted with another portion of
polyol and/or diol to form the poly(ureaurethane)s of the present
invention. The polyol shown in Step 4 can be a diol, triol or
higher hydroxyl functional material as described above in which R
is any linking group, such as aliphatic, cycloaliphatic, aromatic,
heterocycle, etc. as described in detail above with respect to the
polyols. Examples of suitable polyols can be any of the polyols
discussed above. In some non-limiting embodiments, the polyol can
be trimethylolpropane and butanediol and/or pentanediol. Suitable
amounts of polyols for reacting with the isocyanate functional
ureaurethane prepolymer as polyisocyanate are discussed in detail
above.
[0666] The isocyanate functional ureaurethane prepolymer can be
reacted with the other portion of polyol and/or diol (n=2 or more)
under substantially anhydrous conditions at a temperature ranging
from about 120.degree. C. to about 160.degree. C. until the
reaction between the isocyanate groups and the hydroxyl groups is
substantially complete. The isocyanate functional ureaurethane
prepolymer and polyol(s) and/or diol(s) components are suitably
reacted in such proportions that the ratio of number of isocyanate
groups to the number of hydroxyl groups is in the range of about
1.05:1 to about 1:1 In the poly(ureaurethane) of Group K, y can
range from 1 to about 500 or higher, or about 1 to about 200.
[0667] The cure temperature depends upon the glass transition
temperature of the final polymer. In some embodiments, for complete
cure the cure temperature should be greater than the glass
transition temperature. For example, the cure temperature can range
from about 140.degree. C. to about 180.degree. C. or about
143.degree. C. to about 180.degree. C.
##STR00015##
Group K
[0668] In some non-limiting embodiments, the present invention
provides poly(ureaurethane)s of Group K comprising a reaction
product of components comprising: (a) at least one isocyanate
functional ureaurethane prepolymer comprising the reaction product
of: (1) at least one isocyanate functional urethane prepolymer
comprising the reaction product of: (i) a first amount of at least
one polyisocyanate; and (ii) a first amount of at least one
branched polyol; and (2) water, to form an isocyanate functional
ureaurethane prepolymer; and (b) a second amount of at least one
polyisocyanate and a second amount of at least one branched
polyol.
[0669] Examples of suitable polyisocyanates and polyol(s) are
discussed above. Any of the other optional polyols, amine curing
agents, catalysts or other additives described above can be
included as reaction components in amounts as described above with
respect to the foregoing Groups A-G. In some non-limiting
embodiments, the reaction components are essentially free or free
of amine curing agent as described above, or free of amine curing
agent.
[0670] In other non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane)s of Group K
comprising the steps of: (a) reacting at least one polyisocyanate
and at least one branched polyol having 4 to 18 carbon atoms and at
least 3 hydroxyl groups to form an isocyanate functional urethane
prepolymer; (b) reacting the isocyanate functional urethane
prepolymer with water and polyisocyanate to form an isocyanate
functional ureaurethane prepolymer; and (c) reacting reaction
product components comprising the isocyanate functional
ureaurethane prepolymer with at least one aliphatic polyol having 4
to 18 carbon atoms and at least 2 hydroxyl groups, wherein the
reaction product components are essentially free of amine curing
agent. The reaction synthesis can be as described above with
respect to Poly(ureaurethane) Synthesis B.
Group L
[0671] In other non-limiting embodiments, the present invention
provides poly(ureaurethane)s of Group L comprising a reaction
product of components comprising: (a) at least one isocyanate
functional ureaurethane prepolymer comprising the reaction product
of: (a) (1) at least one isocyanate functional urethane prepolymer
comprising the reaction product of: (i) a first amount of at least
one polyisocyanate selected from the group consisting of
polyisocyanate trimers and branched polyisocyanates, the
polyisocyanate having at least three isocyanate functional groups;
and (ii) a first amount of at least one aliphatic polyol; and (2)
water, to form an isocyanate functional ureaurethane prepolymer;
and (b) a second amount of at least one polyisocyanate and a second
amount of at least one aliphatic polyol.
[0672] Examples of suitable polyisocyanate trimers and branched
polyisocyanates having at least three isocyanate functional groups
and polyol(s) are discussed above. Any of the other optional
polyols, amine curing agent, catalysts or other additives described
above can be included as reaction components in amounts as
described above with respect to the foregoing Groups A-G. In some
non-limiting embodiments, the reaction components are essentially
free or free of amine curing agent as described above.
[0673] In other non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane)s of Group L
comprising the steps of: (a) reacting at least one polyisocyanate
selected from the group consisting of polyisocyanate trimers and
branched polyisocyanates and at least one aliphatic polyol having 4
to 18 carbon atoms and at least 2 hydroxyl groups to form an
isocyanate functional urethane prepolymer; (b) reacting the
isocyanate functional urethane prepolymer with water and
polyisocyanate to form an isocyanate functional ureaurethane
prepolymer; and (c) reacting reaction product components comprising
the isocyanate functional ureaurethane prepolymer with at least one
aliphatic polyol having 4 to 18 carbon atoms and at least 2
hydroxyl groups, wherein the reaction product components are
essentially free or free of amine curing agent. The reaction
synthesis can be as described above with respect to
Poly(ureaurethane) Synthesis B.
[0674] As discussed above, poly(ureaurethane)s can be prepared by
including one or more amine curing agents in the reaction
components. The amine functionality of the amine curing agent can
react with isocyanate groups to form urea linkages or units within
the polyurethane matrix.
Group M
[0675] In other non-limiting embodiments, the present invention
provides poly(ureaurethane)s of Group M comprising a reaction
product of components comprising: about 1 equivalent of at least
one polyisocyanate; about 0.1 to about 0.9 equivalents of at least
one branched polyol having 4 to 18 carbon atoms and at least 3
hydroxyl groups; about 0.1 to about 0.9 equivalents of at least one
aliphatic diol having 2 to 18 carbon atoms; and at least one amine
curing agent, wherein the reaction product components are
essentially free or free of polyester polyol and polyether
polyol.
[0676] Non-limiting examples of suitable polyisocyanates, branched
polyols having 4 to 18 carbon atoms and at least 3 hydroxyl groups,
aliphatic diols and amine curing agents for use as reaction
components for preparing the polyurethanes of Group M are discussed
in detail above with respect to Group A.
[0677] In some non-limiting embodiments, the amount of branched
polyol used to form the polyurethane of Group M can be about 0.3 to
about 0.98 equivalents, in other non-limiting embodiments about 0.5
to about 0.98 equivalents, and in other non-limiting embodiments
about 0.3 equivalents or about 0.9 or about 0.98 equivalents.
[0678] In some non-limiting embodiments, the amount of aliphatic
diols used to form the polyurethane of Group M can be about 0.1 to
about 0.7 equivalents, in other non-limiting embodiments about 0.1
to about 0.5 equivalents, and in other non-limiting embodiments
about 0.3 equivalents.
[0679] In some non-limiting embodiments, the amount of amine curing
agent used to form the polyurethane of Group M can be about 0.1 to
about 0.9 equivalents, in other non-limiting embodiments about 0.1
to about 0.7 equivalents, and in other non-limiting embodiments
about 0.3 equivalents.
[0680] With respect to poly(ureaurethane)s of Group M, essentially
free of polyester polyol and polyether polyol means that the
polyester polyol and polyether polyol can be present as reaction
components in respective amounts as described for the polyurethane
of Group A above, or the reaction components can be free of one or
both of polyester polyol and polyether polyol.
[0681] Any of the other optional polyols, catalysts or other
additives described above can be included as reaction components in
amounts as described above with respect to the foregoing Groups
A-H.
[0682] In other non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane) comprising the
step of reacting in a one-potprocess components comprising: at
least one polyisocyanate; at least one branched polyol having 4 to
18 carbon atoms and at least 3 hydroxyl groups; at least one
aliphatic diol having 2 to 18 carbon atoms; and amine curing agent,
wherein the reaction product components are essentially free or
free of polyester polyol and polyether polyol.
Group N
[0683] In other non-limiting embodiments, the present invention
provides poly(ureaurethane)s of Group N comprising a reaction
product of components comprising: (a) at least one polyisocyanate
selected from the group consisting of polyisocyanate trimers and
branched polyisocyanates, the polyisocyanate having at least three
isocyanate functional groups; (b) about 0.1 to about 0.9
equivalents of at least one polyol having 4 to 18 carbon atoms and
at least 2 hydroxyl groups; and (c) at least one amine curing
agent, wherein the reaction product components are essentially free
or free of polyester polyol and polyether polyol.
[0684] Non-limiting examples of suitable polyisocyanates, branched
polyols having 4 to 18 carbon atoms and at least 3 hydroxyl groups,
aliphatic diols and amine curing agents for use as reaction
components for preparing the polyurethanes of Group N are discussed
in detail above with respect to Groups A-C.
[0685] In some non-limiting embodiments, the amount of branched
polyol used to form the polyurethane of Group N can be about 0.3 to
about 0.98 equivalents, in other non-limiting embodiments about 0.5
to about 0.98 equivalents, and in other non-limiting embodiments
about 0.3 equivalents or about 0.9 or about 0.98 equivalents.
[0686] In some non-limiting embodiments, the amount of aliphatic
diols used to form the polyurethane of Group N can be about 0.1 to
about 0.7 equivalents, in other non-limiting embodiments about 0.1
to about 0.5 equivalents, and in other non-limiting embodiments
about 0.3 equivalents.
[0687] In some non-limiting embodiments, the amount of amine curing
agent used to form the polyurethane of Group N can be about 0.1 to
about 0.7 equivalents, in other non-limiting embodiments about 0.1
to about 0.5 equivalents, and in other non-limiting embodiments
about 0.3 equivalents.
[0688] With respect to poly(ureaurethane)s of Group N, essentially
free of polyester polyol and polyether polyol means that the
polyester polyol and polyether polyol can be present as reaction
components in respective amounts as described for the polyurethane
of Group A above, or the reaction components can be free of one or
both of polyester polyol and polyether polyol.
[0689] Any of the other optional polyols, catalysts or other
additives described above can be included as reaction components in
amounts as described above with respect to the foregoing Groups
A-H.
[0690] In other non-limiting embodiments, the present invention
provides methods of preparing poly(ureaurethane) comprising the
step of reacting in a one-potprocess components comprising: at
least one polyisocyanate selected from the group consisting of
polyisocyanate trimers and branched polyisocyanates; at least one
aliphatic polyol having 4 to 18 carbon atoms and at least 3
hydroxyl groups; at least one aliphatic diol having 2 to 18 carbon
atoms; and amine curing agent, wherein the reaction product
components are essentially free or free of polyester polyol and
polyether polyol.
[0691] In some embodiments, the poly(ureaurethanes) of Groups I-N
of the present invention can be thermosetting.
Group O
[0692] In some non-limiting embodiments, the present invention
provides polyurethane materials comprising a first portion of
crystalline particles having self-orientation and bonded together
to fix their orientation along a first crystallographic direction
and a second portion of crystalline particles having
self-orientation and bonded together to fix their orientation along
a second crystallographic direction, the first crystallographic
direction being different from the second crystallographic
direction, wherein said crystalline particles comprise at least
about 30% of the total volume of the polyurethane material.
[0693] The particles interact with one another or with a substrate
surface to align their crystallographic axes in one, two or three
dimensions. As used herein, "align" or "aligned" with respect to
the crystalline particles means that the particles of that
crystalline portion are arranged in an array of generally fixed
position and orientation. The preferred degree of alignment will
depend on the intended application for the material. For purposes
of alignment, it is desirable that the particles have uniform
shapes with dominant planar surfaces in a suitable orientation,
such as perpendicular to or parallel to, with respect to the
desired direction of alignment.
[0694] In some non-limiting embodiments, the first portion of the
crystalline particles is aligned in two dimensions. In some
non-limiting embodiments, the first portion of the crystalline
particles is aligned in three dimensions. In some embodiments, the
crystalline particles are aligned along a distance ranging from
about 1 nm to about 50 nm along any direction.
[0695] In some non-limiting embodiments, the second portion of the
crystalline particles is aligned in two dimensions. In some
non-limiting embodiments, the second portion of the crystalline
particles is aligned in three dimensions.
[0696] The crystalline particles of the present invention have at
least "Self-Aligning" morphologies. As used herein, "Self-Aligning"
morphologies include any particles that are capable of
self-organizing to form a polycrystalline structure wherein the
single particles are aligned along at least one crystallographic
direction into areas of higher density and order, for example like
lamellae. Examples of crystal particle morphologies with
Self-Aligning morphologies include cubic particles, hexagonal
platelets, hexagonal fibers, rectangular platelets, rectangular
particles, triangular platelets, square platelets, tetrahedral,
cube, octahedron and mixtures thereof.
[0697] Self-Aligning morphologies may establish an orientation that
could be up to about 10 degrees from the desired alignment
direction, yet still sufficiently capture the desired properties.
Thus, particles having such morphologies include particles that
essentially have the desired morphology. For instance, for
particles that are cubes, the particles need not be perfect cubes.
The axes need not be at perfect 90 degree angles, nor exactly equal
in length. Corners may also be cut off of the particles.
Furthermore, "cube" or "cubic" is intended to refer to morphology,
and is not intended to limit the particles to cubic crystal
systems. Instead, single crystal particles that have orthorhombic,
tetragonal or rhombohedral crystal structure may also be employed
as cubes if they possess the defined cubic morphology. In other
words, any essentially orthogonal single crystal particles in which
the faces are essentially square, essentially rectangular, or both,
that possess an essentially cubic morphology are considered cubes
for purposes of the present invention.
[0698] The crystalline particles can be aligned in monolithic
structures consisting of a single layer of crystals or multiple
layers of crystals. The layer or layers are generally planar,
although the layers can conform to curved surfaces or complex
geometries depending on the shape of the supporting substrate
material during formation and curing of the polyurethane.
[0699] The polycrystalline materials of the present invention are
prepared by packing and aligning a plurality of single crystal
particles into an aligned array to achieve one, two and
three-dimensional alignment. In some non-limiting embodiments, the
particles can self-assemble into arrays upon aging or heat
treatment. In some non-limiting embodiments, to obtain a level of
solid state diffusion sufficient to bind together adjacent
particles, a temperature above about half of the melting
temperature is required, which is most generally in the range of
about 35.degree. C. to about 100.degree. C. The temperature range
selected will depend upon the material being bonded, but can be
readily determined by those of ordinary skill in the art without
undue experimentation within the defined range. The preparation
steps may be repeated to form a polycrystalline material having
multiple layers of aligned particles. The resulting material is
essentially a three-dimensional object with one, two, or three
dimensional alignment of single crystal particles within.
[0700] FIG. 4 is a TEM photomicrograph showing a casting prepared
from a polyurethane according to Example A, Formulation 2. This
casting was analyzed, using TEM, two weeks after polymerization of
the polyurethane. The casting had been stored at ambient
temperature (about 25.degree. C.) for the two-week period. As shown
in FIG. 4, no discernible regions of aligned crystals were
observed.
[0701] FIG. 5 is a TEM photomicrograph showing a casting of a
polyurethane according to Example A, Formulation 2. This casting
was analyzed, using TEM, three weeks after polymerization of the
polyurethane. The casting had been stored at ambient temperature
(about 25.degree. C.) for the three-week period. As shown in FIG.
5, initial formation of crystalline domains is observed.
[0702] FIG. 6 is a TEM photomicrograph showing a casting of a
polyurethane according to Example A, Formulation 2. This casting
was analyzed, using TEM, seven months after polymerization of the
polyurethane. The casting had been stored at ambient temperature
(about 25.degree. C.) for the seven-month period. In the
photomicrograph FIG. 6, a region of aligned crystals generally
parallel to the arrows is shown.
[0703] FIG. 7 is an electron diffraction pattern of the
polyurethane Example A, Formulation 2 stored at ambient temperature
(about 25.degree. C.) for seven months. The bright spots in the
pattern are reflections from the crystalline lattice planes, which
are about 8 nanometers by about 4 nanometers in size.
[0704] FIG. 8 is a TEM photomicrograph showing a casting of a
polyurethane according to Example A, Formulation 2 prepared after
aging at ambient temperature for about 7 months. In this
photomicrograph, FIG. 8, many regions or domains of aligned
crystals generally parallel to the arrows are shown, the domains
being oriented in different directions and showing a higher density
of domains than the samples aged for three weeks.
[0705] FIG. 9 is a TEM photomicrograph showing a first portion of a
casting of a polyurethane according to Example A, Formulation 2
prepared after aging at ambient temperature for about two to four
weeks. The casting had been stored at ambient temperature for the
two- to four-week period. As shown in FIG. 9, no discernible
regions of aligned crystals were observed.
[0706] FIG. 10 is a TEM photomicrograph showing a second portion of
the casting of the polyurethane according to Example A, Formulation
2 shown in FIG. 9. As shown in the circled area in FIG. 10, initial
formation of crystalline domains is observed.
[0707] The sample shown in FIGS. 9 and 10 had a Gardner Impact
Strength of 180 in-lbs.
[0708] FIG. 11 is a TEM photomicrograph showing a casting of a
polyurethane according to Example A, Formulation 2. This casting
was analyzed, using TEM, about two to about four weeks after
polymerization of the polyurethane. The casting had been stored at
ambient temperature for the two- to four-week period. In the
photomicrograph, FIG. 11, regions of aligned crystals in the
circled areas are shown.
[0709] FIG. 12 is a TEM photomicrograph showing a first portion of
a casting of a polyurethane according to Example A, Formulation 2
prepared after aging at ambient temperature for about 7 months. In
this photomicrograph FIG. 12, a large region or domain of aligned
crystals is shown.
[0710] FIG. 13 is a TEM photomicrograph showing a second portion of
a casting of a polyurethane according to Example A, Formulation 2
shown in FIG. 12. In this photomicrograph FIG. 13, many regions or
domains of aligned crystals are shown, the domains being oriented
in different directions and showing a higher density of domains
than the samples aged for a shorter period of time.
[0711] The sample shown in FIGS. 12 and 13 had a Gardner Impact
Strength of 640 in-lbs.
[0712] FIG. 14 is a graph of heat flow as a function of temperature
measured using Differential Scanning Calorimetry (DSC) for castings
of a polyurethane according to Example A, Formulation 2 measured
after aging at ambient conditions for two weeks, three months and
seven months, respectively. The melting endotherm enthalpy of the
crystalline domains increases with time, showing a change in
polymer morphology and microstructure with time, even though the
polymer is glassy and highly crosslinked with a glass transition
temperature of 235.degree. F. (113.degree. C.). As the number and
size of the crystalline domains increases, the melting enthalpy
increases. The Gardner Impact Strength increased over time. At two
weeks, the Gardner Impact Strength was 180 in-lbs. At three months,
the Gardner Impact Strength was 380 in-lbs. At seven months, the
Gardner Impact Strength was 640 in-lbs.
[0713] FIG. 15 is a graph of Gardner Impact strength as a function
of Young's Modulus for castings of a polyurethane according to
Example A, Formulations 2 and 1, respectively, measured after aging
at ambient conditions for seven months and one year, respectively.
At seven months for Formulation 2, the Gardner Impact strength was
640 in-lbs. At one year for Formulation 1, the Gardner Impact
Strength was 400 in-lbs.
[0714] In some non-limiting embodiments, the polyurethane material
comprises a monolithic agglomerate of the first portion of the
crystalline particles with low-angle grain boundaries therebetween
bonded together by a polymer phase.
[0715] In some non-limiting embodiments, the polyurethane material
comprises a monolithic agglomerate of the second portion of the
crystalline particles with low-angle grain boundaries therebetween
bonded together by a polymer phase.
[0716] In some non-limiting embodiments, the polyurethane material
comprises a monolithic agglomerate of the first portion of the
crystalline particles with low-angle grain boundaries and a
generally amorphous phase therebetween.
[0717] In some non-limiting embodiments, the polyurethane material
comprises a monolithic agglomerate of the second portion of the
crystalline particles with low-angle grain boundaries and a
generally amorphous phase therebetween.
[0718] In some non-limiting embodiments, the thickness of the first
portion of crystalline particles is less than about 50 nanometers.
In some non-limiting embodiments, the thickness of the second
portion of crystalline particles is less than about 50 nanometers.
The length and width, respectively, of the first portion can vary,
for example about 4 nm by about 8 nm.
[0719] In some non-limiting embodiments, the thickness of the first
portion of crystalline particles can range from about 10 nanometers
to about 100 nanometers. In some non-limiting embodiments, the
thickness of the second portion of crystalline particles can range
from about 4 nanometers to about 50 nanometers. The length and
width, respectively, of the second portion can vary, for example
about 4 nm by about 8 nm.
[0720] In some non-limiting embodiments, the crystalline particles
comprise at least about 30% of the total volume of the material. In
other non-limiting embodiments, the crystalline particles comprise
at least about 40%, or at least about 50%, or at least about 60%,
or at least about 70%, or at least about 80%, or at least about 90%
of the total volume of the material. The percentage of crystalline
particles can be determined using DSC. For example, an article
prepared from Formulation 2 as described below, aged at ambient
conditions (about 25.degree. C.) for about 7 months had a
crystallinity of about 43% by volume.
[0721] In some non-limiting embodiments, the polyurethane comprises
a reaction product of components consisting of: (a) about 1
equivalent of 4,4'-methylene-bis-(cyclohexyl isocyanate); (b) about
0.3 equivalents of trimethylolpropane; and (c) about 0.7
equivalents of butanediol or pentanediol. In some non-limiting
embodiments, the butanediol is 1,4-butanediol. In some non-limiting
embodiments, the pentanediol is 1,5-pentanediol.
[0722] In some non-limiting embodiments, the impact resistance of
polyurethanes and poly(ureaurethane)s of Groups A-M above according
to the present invention can be improved by aging or heat
treatment.
[0723] In some non-limiting embodiments, the polyurethane material
can be aged for at least about 2 weeks after formation. In some
non-limiting embodiments, the polyurethane material can be aged for
at least about 2 months after formation. In some non-limiting
embodiments, the polyurethane material has been aged for at least
about 7 months after formation.
[0724] In some non-limiting embodiments, the polyurethane material
has been heated to a temperature of about 90.degree. C. to about
150.degree. C. or about 200.degree. F. (about 93.degree. C.) to
about 290.degree. F. (about 143.degree. C.) for about 1 to about 24
hours after formation. In some non-limiting embodiments, the
polyurethane is heated at a temperature sufficient to induce grain
boundary mobility, so that the particles grow until impingement of
adjacent crystal grain boundaries prevent further growth. The net
result is a polycrystalline microstructure, the grains of which for
all practical purposes are aligned in two or three dimensions so
that it performs like a single crystal with respect to some desired
property.
[0725] Impact resistance or flexibility can be measured using a
variety of conventional methods known to those skilled in the art.
The flexibility of the materials can be measured by the Gardner
Impact Test using a Gardner Variable Impact Tester in accordance
with ASTM-D 5420-04, which consists of a 40-inch (101.6 cm)
aluminum tube in which an 8- or 16-lb (17.6- or 35.2-kg) weight is
dropped from various heights onto a metal dart resting onto the
substrate being tested (2 inch by 2 inch by 1/8 inch (5.1 cm by 5.1
cm by 0.3 cm) specimen size. In a non-limiting embodiment, the
impact strength results of the Gardner Impact Test of at least
about 65 in-lb (7.3 Joules) or from about 65 in-lb (7.3 Joules) to
about 640 in-lb (72 joules).
[0726] In another embodiment, the impact resistance can be measured
using the Dynatup Test in accordance with ASTM-D 3763-02, which
consists of a high velocity test with a load cell which measures
total energy absorption in the first microseconds of the impact.
The impact strength can be measured in Joules. In a non-limiting
embodiment, the substrate can have an impact strength of at least
about 35 Joules or from about 35 to about 105 Joules.
Group P
[0727] In some non-limiting embodiments, the present invention
provides polyurethane powder coating compositions. The powder
coating compositions can be prepared from any of the polyurethanes
or poly(ureaurethane)s of Groups A-N discussed in detail above.
[0728] In some non-limiting embodiments, the present invention
provides methods of preparing a polyurethane powder coating
composition comprising the steps of: reacting at least one
polyisocyanate with at least one aliphatic polyol to form a
generally solid, hydroxy functional prepolymer; melting the hydroxy
functional prepolymer; melting at least one generally solid
polyisocyanate to form a melted polyisocyanate; mixing the melted
hydroxy functional prepolymer and melted polyisocyanate to form a
mixture; and solidifying the mixture to form a generally solid
powder coating composition.
[0729] The generally solid, hydroxy functional prepolymer can be
prepared by reacting the polyisocyanate(s) with excess aliphatic
polyol(s) and catalyst in amounts as described above and heating
the prepolymer to a temperature of about 140.degree. C. or about
150.degree. C. to about 180.degree. C. for about 1 to about 24
hours to facilitate essentially complete reaction of the components
and formation of a generally solid prepolymer.
[0730] In some non-limiting embodiments, the polyisocyanate is
branched or a trimer as discussed above and the aliphatic polyol is
an aliphatic diol having from 4 to 18 carbon atoms, or 4 or 5
carbon atoms, such as propanediol, butanediol, cyclohexane
dimethanol, 1,10-decanediol and/or 1,12-dodecanediol. In other
non-limiting embodiments, the polyisocyanate can be any
polyisocyanate as discussed above and the aliphatic polyol can be a
branched diol having from 4 to 18 carbon atoms, such as
trimethylolpropane.
[0731] The equivalent ratio of isocyanate functional groups to
hydroxyl functional groups can range from about 1:0.9 to about
1:1.1, or about 1:1.
[0732] The generally solid polyisocyanate can be melted by, for
example, heating at a temperature of about 35.degree. C. to about
150.degree. C. for about 2 to about 24 hours to form the melted
polyisocyanate. The melted hydroxy functional prepolymer and melted
polyisocyanate can be mixed and solidified to form a generally
homogeneous mixture suitable for forming a powder coating, as
discussed below. The equivalent ratio of isocyanate functional
groups of the polyisocyanate to hydroxyl functional groups of the
hydroxy functional prepolymer can range from about 1.05:1 to about
0.95:1, or about 1:1.
[0733] In other non-limiting embodiments, the present invention
provides methods of preparing a polyurethane powder coating
composition comprising the steps of: reacting at least one
polyisocyanate with at least one aliphatic polyol to form a
generally solid, hydroxy functional prepolymer; dissolving the
hydroxy functional prepolymer in a first solvent to form a first
solution; dissolving at least one generally solid polyisocyanate in
a second solvent that is the same as or compatible with the first
solvent to form a second solution; mixing the first and second
solutions; and removing substantially all of the solvent to form a
generally solid powder coating composition.
[0734] In some non-limiting embodiments, the polyisocyanate(s) are
branched or a trimer as discussed above and the aliphatic polyol is
an aliphatic diol having from 4 to 18 carbon atoms, or 4 or 5
carbon atoms, such as propanediol and/or butanediol. In other
non-limiting embodiments, the polyisocyanate can be any
polyisocyanate as discussed above and the aliphatic polyol can be a
branched diol having from 4 to 18 carbon atoms, such as
trimethylolpropane.
[0735] The generally solid, hydroxy functional prepolymer can be
prepared by reacting the polyisocyanate(s) with excess aliphatic
polyol(s) and catalyst in types and amounts as described above. The
hydroxy functional prepolymer is dissolved in a first solvent to
form a first solution. The solvent can be any solvent capable of
dissolving the hydroxy functional prepolymer, such as a dipolar
aprotic solvent, for example m-pyrrole (N-methyl-2-pyrrolidone),
N,N-dimethylformamide, N,N-dimethylacetamide, dimethyl sulfoxide
(DMSO), methylene chloride, dichlorobutane, cyclohexanone, dimethyl
formamide and/or acetonitrile solvent. The amount of solvent can
range from about 20 to about 95 weight percent based upon weight of
solids of the hydroxy functional prepolymer.
[0736] The generally solid polyisocyanate in a second solvent that
is the same as or compatible with the first solvent to form a
second solution. The solvent can be any solvent capable of
dissolving the generally solid polyisocyanate, such as a dipolar
aprotic solvent, for example m-pyrrole (N-methyl-2-pyrrolidone),
N,N-dimethylformamide, N,N-dimethylacetamide, dimethyl sulfoxide
(DMSO), methylene chloride, dimethyl formamide and/or acetonitrile
solvent. The amount of solvent can range from about 20 to about 95
weight percent based upon weight of the solids of
polyisocyanate.
[0737] The first and second solutions are mixed and substantially
all of the solvent is removed, for example by vacuum in an oven, to
form a generally solid powder suitable for use as a coating
composition. The powder can be milled or micronized, if
desired.
[0738] Curable powder coating compositions useful in the present
invention are typically prepared by first dry blending the polymer,
e.g., polyurethane or poly(ureaurethane) polymer, the crosslinking
agent (if present), the particles and additives, such as degassing
agents, flow control agents and catalysts, in a blender, e.g., a
Henshel blade blender. The blender is operated for a period of time
sufficient to result in a homogenous dry blend of the materials
charged thereto. The homogeneous dry blend is then melt blended in
an extruder, e.g., a twin screw co-rotating extruder, operated
within a temperature range sufficient to melt but not gel the
components.
[0739] Optionally, curable powder coating compositions of the
present invention may be melt blended in two or more steps. For
example, a first melt blend is prepared in the absence of a cure
catalyst. A second melt blend is prepared at a lower temperature,
from a dry blend of the first melt blend and the cure catalyst. The
melt blended curable powder coating composition is typically milled
to an average particle size of from, for example, 15 to 30
microns.
[0740] Alternatively, the powder coating compositions of the
present invention can be prepared by blending and extruding the
ingredients as described above, but without the particles. The
particles can be added as a post-additive to the formulation by
simply mixing the particles into the milled powder coating
composition, such as by mixing using a Henschel mixer. In some
non-limiting embodiments, the powder coating composition is
slurried in a liquid medium, such as water, which may be spray
applied.
Group Q
[0741] In some non-limiting embodiments, the compositions of the
present invention can further comprise one or more types of
reinforcing materials. These reinforcing materials can be present
in any physical form desired, for example as particles, including
but not limited to nanoparticles, agglomerates, fibers, chopped
fibers, mats, etc.
[0742] The reinforcing materials can be formed from materials
selected from the group consisting of polymeric inorganic
materials, nonpolymeric inorganic materials, polymeric organic
materials, nonpolymeric organic materials, composites thereof and
mixtures thereof that are chemically different from the
polyurethane or poly(ureaurethane). As used herein, "chemically
different" from the polyurethane or poly(ureaurethane) means that
the reinforcing material has at least one different atom or has a
different arrangement of atoms compared to the polyurethane or
poly(ureaurethane).
[0743] As used herein, the term "polymeric inorganic material"
means a polymeric material having a backbone repeat unit based on
an element or elements other than carbon. See James Mark et al.,
Inorganic Polymers, Prentice Hall Polymer Science and Engineering
Series, (1992) at page 5, incorporated by reference herein.
Moreover, as used herein, the term "polymeric organic materials"
means synthetic polymeric materials, semisynthetic polymeric
materials and natural polymeric materials, all of which have a
backbone repeat unit based on carbon.
[0744] An "organic material," as used herein, means
carbon-containing compounds wherein the carbon is typically bonded
to itself and to hydrogen, and often to other elements as well, and
excludes binary compounds such as the carbon oxides, the carbides,
carbon disulfide, etc.; such ternary compounds as the metallic
cyanides, metallic carbonyls, phosgene, carbonyl sulfide, etc.; and
carbon-containing ionic compounds such as metallic carbonates, for
example calcium carbonate and sodium carbonate. See R. Lewis, Sr.,
Hawley's Condensed Chemical Dictionary, (12th Ed. 1993) at pages
761-762, and M. Silberberg, Chemistry The Molecular Nature of
Matter and Change (1996) at page 586, which are incorporated by
reference herein.
[0745] As used herein, the term "inorganic material" means any
material that is not an organic material.
[0746] As used herein, the term "composite material" means a
combination of two or more differing materials. For example a
composite particle can be formed from a primary material that is
coated, clad or encapsulated with one or more secondary materials
to form a composite particle that has a softer surface. In some
non-limiting embodiments, particles formed from composite materials
can be formed from a primary material that is coated, clad or
encapsulated with a different form of the primary material. For
more information on particles useful in the present invention, see
G. Wypych, Handbook of Fillers, 2nd Ed. (1999) at pages 15-202,
incorporated by reference herein.
[0747] The reinforcing materials suitable for use in the
compositions of the invention can comprise inorganic elements or
compounds known in the art. Suitable nonpolymeric, inorganic
reinforcing materials can be formed from ceramic materials,
metallic materials, and mixtures of any of the foregoing.
Nonpolymeric, inorganic materials useful in forming the reinforcing
materials of the present invention comprise inorganic materials
selected from the group consisting of graphite, metals, oxides,
carbides, nitrides, borides, sulfides, silicates, carbonates,
sulfates, and hydroxides. Suitable ceramic materials comprise metal
oxides, metal nitrides, metal carbides, metal sulfides, metal
silicates, metal borides, metal carbonates, and mixtures of any of
the foregoing. Non-limiting examples of suitable metals include
molybdenum, platinum, palladium, nickel, aluminum, copper, gold,
iron, silver, alloys, and mixtures of any of the foregoing.
Non-limiting examples of metal nitrides are, for example, boron
nitride; non-limiting examples of metal oxides are, for example,
zinc oxide; non-limiting examples of suitable metal sulfides are,
for example, molybdenum disulfide, tantalum disulfide, tungsten
disulfide, and zinc sulfide; non-limiting examples of metal
silicates are, for example aluminum silicates and magnesium
silicates such as vermiculite. In some non-limiting embodiments,
the reinforcing material is essentially free of (less than 5 weight
percent or less than 1 weight percent) or free of fillers such as
sodium carbonate, calcium carbonate, silicates, alginates, carbon
black, and metal oxides such as titanium dioxide, silica, and zinc
oxide.
[0748] In some non-limiting embodiments, the reinforcing materials
can comprise a core of essentially a single inorganic oxide such as
silica in colloidal, fumed, or amorphous form, alumina or colloidal
alumina, titanium dioxide, cesium oxide, yttrium oxide, colloidal
yttria, zirconia, e.g., colloidal or amorphous zirconia, and
mixtures of any of the foregoing; or an inorganic oxide of one type
upon which is deposited an organic oxide of another type. In some
non-limiting embodiments, the reinforcing materials should not
seriously interfere with the optical properties of the cured
composition. As used herein, "transparent" means that the cured
coating has a BYK Haze index of less than 50 as measured using a
BYK/Haze Gloss instrument.
[0749] The composition can comprise precursors suitable for forming
silica particles in situ by a sol-gel process. The composition
according to the present invention can comprise alkoxy silanes
which can be hydrolyzed to form silica particles in situ. For
example tetraethylortho silicate can be hydrolyzed with an acid
such as hydrochloric acid and condensed to form silica particles.
Other useful particles include surface-modified silicas such as are
described in U.S. Pat. No. 5,853,809 at column 6, line 51 to column
8, line 43, incorporated herein by reference.
[0750] Sols, such as an organosols, of reinforcement particles can
be used in the present invention. These sols can be of a wide
variety of small-particle, colloidal silicas having an average
particle size in ranges such as are described below. The colloidal
silicas can be surface modified during or after the particles are
initially formed. These surface modified silicas may contain on
their surface chemically bonded carbon-containing moieties, as well
as such groups as anhydrous SiO.sub.2 groups and SiOH groups,
various ionic groups physically associated or chemically bonded
within the surface of the silica, adsorbed organic groups, or
combinations of any of the foregoing, depending on the
characteristics of the particular silica desired. Such surface
modified silicas are described in detail in U.S. Pat. No.
4,680,204, incorporated by reference herein. Such small particle
colloidal silicas are readily available, are essentially colorless
and have refractive indices which permit their inclusion in
compositions that, without additional pigments or components known
in the art to color and/or decrease the transparency of such
compositions, result in colorless, transparent compositions or
coatings.
[0751] Other suitable non-limiting examples of reinforcing
materials include colloidal silicas, such as those commercially
available from Nissan Chemical Company under the trademark
ORGANOSILICASOLS.TM. such as ORGANOSILICASOL.TM. MT-ST, and from
Clariant Corporation as HIGHLNK.TM.; colloidal aluminas, such as
those commercially available from Nalco Chemical under the
trademark NALCO 8676.RTM.; and colloidal zirconias, such as those
commercially available from Nissan Chemical Company under the
trademark HIT-32M.RTM..
[0752] In some non-limiting embodiments of the present invention,
the reinforcing material is a nanostructure. As used herein, the
term "nanostructure" refers to a three dimensional object wherein
the length of the longest dimension ranges from 1 nm to 1000 nm,
for example, from 1 nm to 500 nm, or from 1 nm to 100 nm, or from 1
to 40 nm.
[0753] Nanostructural reinforcing materials can be incorporated
into the matrix of a polymer by dispersing pre-made nanostructures,
such as for example nanoclays, into the polymer solution.
Alternatively or additionally, nanostructural reinforcement
materials can be incorporated into the polymer matrix by forming
the nanostructures in situ. For example, the nanostructural
reinforcement materials can be formed in situ by mixing a precursor
solution for the polyurethane or poly(ureaurethane) with a
precursor for the nanostructures to form a mixture, forming
nanostructures in the matrix of the polymer from the precursor of
the nanostructures, and forming a polymer from the precursor
solution of the polymer.
[0754] As used herein, the phrase "precursor solution for the
polyurethane or poly(ureaurethane)" refers to any material that can
be used as a starting material to form the polyurethane or
poly(ureaurethane), as discussed above. For example, if the desired
end product is an aliphatic polyurethane, suitable precursors for
the polymer include, but are not limited to, 1,4-butanediol,
trimethylolpropane, and bis(4-isocyanatocyclohexyl)methane and
thiodiethanol.
[0755] As used herein, the phrase "precursor for the
nanostructures" refers to any material that can be used as a
starting material to form the nanostructures.
[0756] In some non-limiting embodiments of the invention, a solvent
such as water, ethanol, iso-propanol, butanol, etc. is added to the
mixture.
[0757] The nanostructures are formed while the viscosity of the
polymer is low so that the nanostructures can incorporate
themselves into the matrix of the polymer. The formation of the
nanostructures can be initiated using various techniques. In a
non-limiting embodiment of the invention, the nanostructures are
formed by adjusting the pH of the mixture. An acid or base, such as
ammonia, can be used to adjust the pH of the solution. Depending on
the exact precursor solution of the polymer and the exact precursor
for the nanostructures, there is an optimum pH range in which the
nanostructures will form. One of ordinary skill in the art would
know what the optimum pH range is based on both precursors.
[0758] In another non-limiting embodiment, the mixture can be
heated to initiate the formation of the nanoparticles. The mixture
can be heated to any temperature provided the mixture is not heated
to a temperature above that at which the precursor solution would
break down. For example, a precursor solution comprising
polyurethane or poly(ureaurethane) cannot be heated above
200.degree. C. because that is the temperature at which
polyurethane or poly(ureaurethane) begins to decompose. Similarly
to the pH range, the optimum temperature range at which the
particles will form depends on the exact precursor solution of the
polyurethane or poly(ureaurethane) and the exact precursor for the
nanostructures. One of ordinary skill in the art would know what
the optimum temperature range is based on both precursors.
Generally, the higher the temperature to which the mixture is
heated and/or the longer the mixture is heated, the larger the size
of the nanostructures that will be formed.
[0759] In yet another non-limiting embodiment of the invention,
forming the nanostructures is accomplished by heating the mixture
after the pH of the mixture is adjusted. In a further non-limiting
embodiment of the invention, forming the nanostructures is
accomplished by heating the mixture and then adjusting the pH of
the mixture.
[0760] In various other non-limiting embodiments of the invention,
the nanostructures can be formed by using one or more of the
following: increasing the pressure on the mixture; by changing the
concentration of the precursor solution for the polyurethane or
poly(ureaurethane); by using an initiator for nanostructure
formation; and by seeding (adding no greater than 5% of the desired
nanostructure material based on the projected weight of the formed
nanostructures as is well known in the art).
[0761] The formed nanostructures are charged species. If the pH of
the solution was adjusted to cause the formation of the
nanostructures, the charge is a result of the pH adjustment. If no
pH adjustment was performed during the nanostructure formation
step, a polymeric stabilizer such as, but not limited to, sodium
polymethacrylate in water and ammonium polymethacrylate in water,
which are both commercially available as Darvan.RTM. 7 and as
Darvan.RTM. C, respectively, from R.T. Vanderbilt Company, Inc. in
Norwalk, Conn. can be added to the solution to create the
charge.
[0762] The third step involves forming the polyurethane or
poly(ureaurethane) from a mixture including the precursor solution
of the polyurethane or poly(ureaurethane). The formation of the
polyurethane or poly(ureaurethane) can be initiated using various
techniques (as discussed in detail above) based on the precursor
solution of the polyurethane or poly(ureaurethane) and the
precursor for the nanostructures.
[0763] In another embodiment of the present invention, the second
and third steps described above are switched.
[0764] The method of making polymers having nanostructures
incorporated into the matrix of the polymer according to the
present invention is referred to as an "in-situ" process. This
means the nanostructures are formed during the same process that
produces the polymer as opposed to pre-formed nanostructures being
dispersed into a polymer solution.
[0765] During some methods of the present invention, ions (cations
and/or anions) can form in the mixture. The formed ions and other
process variables, such as the pressure of the system in which the
mixture is held, can affect the final polymer. For example, the
amount of nanostructure formation and the morphology of the
nanostructures will vary depending on the types and amount of ions
present in the solution.
[0766] In the polymer matrix, the nanostructures typically
continually approach one another and collide because they possess
kinetic energy. Under normal circumstances, some of the
nanostructures would become bound together and agglomerate due to
various forces such as Van der Waals forces. As discussed above,
agglomeration is not desirable because the nanostructures can
effectively become regular sized particles and the desired effect
of incorporating the nanostructures is reduced.
[0767] However, the methods described above can produce polymers
having nanostructures in the matrix of the polymer that do not
agglomerate to the extent that the performance of the polymer is
compromised, for example to improve the thermal stability of the
polymer and/or to decrease the chemical activity of the polymer.
The nanostructures do not agglomerate because they are stabilized.
The stabilization can occur via electrostatic stabilization and/or
steric stabilization.
[0768] Because the nanostructures in the polymer matrix are
similarly charged species, they repel each other. This prevents the
nanostructures from coming so close together that they agglomerate.
This phenomenon is referred to as electrostatic stabilization.
[0769] Because the nanostructures are surrounded by polymer
precursor solution when they are formed, the nanostructures lose a
degree of freedom which they would otherwise possess as the
nanostructures approach each other. This loss of freedom is
expressed, in thermodynamic terms, as a reduction in entropy, which
provides the necessary barrier to hinder agglomeration. This
phenomenon is referred to as steric stabilization. The same
principle applies when the method involves forming the polymer
before forming the nanostructures.
[0770] The concentration of the nanostructures in the polymer
matrix can range from 0.1% to 90%, for example from 3% to 85% or
from 15% to 80% based on total volume. The nanostructures in the
polymer matrix can have the following shapes: spherical,
polyhedral-like cubic, triangular, pentagonal, diamond shaped,
needle shaped, rod shaped, disc shaped etc. The nanostructures in
the polymer matrix can have an aspect ratio of 1:1 to 1:1,000, for
example 1:1 to 1:100.
[0771] Non-limiting examples of suitable nanostructure materials
include titania, alumina, indium tin oxide (ITO), antimony tin
oxide (ATO), monobutyl tin tri-chloride, indium acetate, and
antimony tri-chloride nanostructures incorporated into the polymer
matrix is formed. Suitable precursors for titania nanostructures
include, but are not limited to, titanium iso-propoxide, titanium
(IV) chloride and potassium titanyl oxalate. Suitable precursors
for alumina nanostructures include, but are not limited to,
aluminum iso-propoxide, aluminum tri-tert-butoxide, aluminum
tri-sec-butoxide, aluminum triethoxide, and aluminum
pentanedionate. Suitable precursors for zirconia nanostructures
include, but are not limited to, zirconium iso-propoxide, zirconium
tert-butoxide, zirconium butoxide, zirconium ethoxide, zirconium
2,4-pentanedionate, and zirconium trifluoropentane-dionate.
[0772] In the first step, a precursor solution for polyurethane or
poly(ureaurethane) is mixed with a precursor for the
nanostructures.
[0773] In the second step, nanostructures are formed from the
precursor of the nanostructures in the polymer matrix. The
nanostructure formation can be caused by adjusting the pH of the
mixture followed by heating. The pH can be adjusted by introducing
an agent, such as ammonia, into the mixture. For ITO nanostructures
in a urethane or ureaurethane aqueous solution, the nanostructures
begin to form at a pH>8. After the pH is adjusted, the mixture
is heated to a temperature of up to 100.degree. C. Heating the
solution to a temperature greater than 100.degree. C. may cause the
polymer matrix to decompose. As discussed above, heating the
mixture for a longer time period can increase the size of the
nanostructures.
[0774] In the third step, the precursor solution for the polymer is
converted to the polymer, as discussed above for forming the
polyurethane and poly(ureaurethane).
[0775] In a non-limiting embodiment of the invention, the final
reinforced polymer is used as an interlayer in a laminated glass
transparency for automotive and architectural applications. As is
well known in the art, a laminated glass transparency can be
manufactured by interposing an interlayer between at least two
transparent glass sheets.
[0776] In this particular embodiment of the invention, a laminated
glass transparency for an automotive and architectural applications
embodiment, it is important that the nanostructures do not
agglomerate. If the nanostructures were to agglomerate and
effectively achieve a diameter of greater than 200 nm, the
nanostructures would scatter visible light rays to such an extent
that transmittance through the interlayer would be insufficient for
the application. A polymer with nanostructures having an acceptable
size for the application, can be determined using a "haze value".
The haze value is associated with the degree to which transparency
is prevented. The larger the nanostructures present in the polymer
matrix, the higher the haze value. According to the present
invention, laminated glass for automotive and architectural
applications has a haze value of less than or equal to about 1%,
for example, less than or equal to about 0.3%, or less than or
equal to about 0.2%, as measured using a Hazeguard System from
BYK-Gardner in Columbia, Md.
[0777] In the embodiment where a polyurethane or poly(ureaurethane)
is being formed having titania nanostructures incorporated into the
polymer matrix, the first step can comprise mixing titanium
iso-propoxide with a 1-10 wt % H.sub.2O.sub.2 solution and suitable
polyurethane or poly(ureaurethane) precursors as discussed above.
The H.sub.2O.sub.2 acts as an initiator for titania nanostructures;
particularly, titania nanostructures in the anatase form.
Optionally, polymers such as polyoxyethylene (20) sorbitan
monooleate commercially available as Tween.RTM. 80 from ICI Ltd.
(Bridgewater, N.J.) can be added to the solution to help stabilize
the titania nanostructures.
[0778] In the second step, the titania nanostructures are formed
from the precursor by heating the mixture to a temperature of up to
100.degree. C.
[0779] In the third step, the precursor solution for the polymer is
converted into polyurethane or poly(ureaurethane) as discussed in
detail above.
[0780] In a non-limiting embodiment of the invention, polyurethane
or poly(ureaurethane) having titania, alumina, or zirconia
nanostructures incorporated into the matrix of the polymer can be
used as an optical lens. A polymer with nanostructures having an
acceptable size for optical lens applications can be determined
using a "haze value". According to the present invention, an
optical lens has a haze value of less than or equal to 0.5%, for
example less than or equal to 0.2%, as measured using a Hazeguard
System from BYK Gardner.
[0781] In a non-limiting embodiment of the invention, a
polyurethane having ITO or ATO nanostructures incorporated into the
polymer matrix is formed. Such a polymer can be formed in the
following manner. In the first step, a precursor solution for the
trimethylol propane, methylene bis(4-cyclohexylisocyanate) and
thiodiethanol is mixed with a precursor for ITO or ATO
nanostructures.
[0782] A suitable precursor solution for the polyurethane is
trimethylol propane, methylene bis(4-cyclohexylisocyanate),
thiodiethanol and 1,4-butanediol. Suitable precursors for ITO
nanostructures include monobutyl tin tri-chloride and indium
acetate. A suitable precursor for ATO nanostructures is antimony
tri-chloride.
[0783] In the second step, ITO or ATO nanostructures are formed
from the precursor. The nanostructure formation can be caused by
adjusting the pH of the solution by introducing an agent, such as
ammonia, into the mixture followed by heating the mixture. For ITO
nanostructures, the ITO nanostructures start to form at pH>8.
After the pH is adjusted, the mixture is heated to a temperature of
up to 100.degree. C. As discussed above, heating the mixture for a
longer time period can increase the size of the nanostructures.
[0784] In the third step, the 1,4-butanediol is mixed into
trimethylol propane, methylene bis(4-cyclohexylisocyanate),
thiodiethanol as is well known in the art. For example, 1,4
butanediol, thiodiethanol, trimethylol propane (TMP), and
DESMODUR.RTM. W can all be mixed into a vessel and heated to
180.degree. F. The mixture is mixed under vacuum for approximately
15 minutes, and then a tin catalyst, such as dibutyltindilaurate or
bismuth carboxylate, is added to the mixture in a 25 ppm
concentration. The mixture is then cast into a glass mold and cured
for at least 20 hours at 250.degree. F. (121.degree. C.) to form
the polyurethane.
[0785] In a non-limiting embodiment, trimethylol propane, methylene
bis(4-cyclohexylisocyanate), thiodiethanol having ITO or ATO
nanostructures incorporated into the polymer matrix is used to form
an anti-static coating for aircraft windows. The polymer with the
nanostructures has an elastic modulus that is greater than that of
the standard trimethylol propane, methylene
bis(4-cyclohexylisocyanate) thiodiethanol without ITO/ATO
nanoparticles.
[0786] In other non-limiting embodiments, the reinforcement
material is a nanostructural reinforcement material formed in situ
by swelling the polyurethane in a solvent comprising a precursor
for the nanostructures, and forming nanostructures in the matrix of
the polyurethane from the precursor of the nanostructures.
Non-limiting examples of suitable solvents for mild swelling of the
polymer include methanol, propylene glycol methyl ether such as
DOWANOL PM (commercially available from Dow Chemical Co. of
Midland, Mich.), diacetone alcohol, 2-propanol, 1-propanol and
acetylpropanol.
[0787] A polymer with nanostructures having an acceptable size for
the aircraft window application can be determined using a "haze
value". According to the present invention, a laminated aircraft
window has a haze value of less than or equal to about 1%, for
example less than or equal to about 0.5%, as measured using a
Hazeguard System from BYK Gardner.
[0788] In some non-limiting embodiments of the present invention,
the reinforcing materials have a hardness value greater than the
hardness value of materials that can abrade a polymeric coating or
a polymeric substrate. Examples of materials that can abrade the
polymeric coating or polymeric substrate include, but are not
limited to, dirt, sand, rocks, glass, carwash brushes, and the
like. The hardness values of the particles and the materials that
can abrade the polymeric coating or polymeric substrate can be
determined by any conventional hardness measurement method, such as
Vickers or Brinell hardness, or can be determined according to the
original Mohs' hardness scale which indicates the relative scratch
resistance of the surface of a material on a scale of one to ten.
The Mohs' hardness values of several nonlimiting examples of
particles formed from inorganic materials suitable for use in the
present invention are given in Table 1 below.
TABLE-US-00001 TABLE A Particle material Mohs' hardness (original
scale) Boron nitride 2.sup.1 Graphite 0.5-1.sup.2 Molybdenum
disulfide 1.sup.3 Talc 1-1.5.sup.4 Mica 2.8-3.2.sup.5 Kaolinite
2.0-2.5.sup.6 Gypsum 1.6-2.sup.7 Calcite (calcium carbonate)
3.sup.8 Calcium fluoride 4.sup.9 Zinc oxide 4.5.sup.10 Aluminum
2.5.sup.11 Copper 2.5-3.sup.12 Iron 4-5.sup.13 Gold 2.5-3.sup.14
Nickel 5.sup.15 Palladium 4.8.sup.16 Platinum 4.3.sup.17 Silver
2.5-4.sup.18 Zinc sulfide 3.5-4.sup.19 .sup.1K. Ludema, Friction,
Wear, Lubrication, (1996) at page 27, incorporated by reference
herein. .sup.2R. Weast (Ed.), Handbook of Chemistry and Physics,
CRC Press (1975) at page F-22. .sup.3R. Lewis, Sr., Hawley's
Condensed Chemical Dictionary, (12th Ed. 1993) at page
793,incorporated by reference herein. .sup.4Hawley's Condensed
Chemical Dictionary, (12th Ed. 1993) at page 1113, incorporated by
reference herein. .sup.5Hawley's Condensed Chemical Dictionary,
(12th Ed. 1993) at page 784, incorporated by reference herein.
.sup.6Handbook of Chemistry and Physics at page F-22.
.sup.7Handbook of Chemistry and Physics at page F-22.
.sup.8Friction, Wear, Lubrication at page 27. .sup.9Friction, Wear,
Lubrication at page 27. .sup.10Friction, Wear, Lubrication at page
27. .sup.11Friction, Wear, Lubrication at page 27. .sup.12Handbook
of Chemistry and Physics at page F-22. .sup.13Handbook of Chemistry
and Physics at page F-22. .sup.14Handbook of Chemistry and Physics
at page F-22. .sup.15Handbook of Chemistry and Physics at page
F-22. .sup.16Handbook of Chemistry and Physics at page F-22.
.sup.17Handbook of Chemistry and Physics at page F-22.
.sup.18Handbook of Chemistry and Physics at page F-22. .sup.19R.
Weast (Ed.), Handbook of Chemistry Physics, CRC Press (71.sup.st
Ed. 1990) at page 4-158
[0789] In some non-limiting embodiments, the reinforcing material
can be formed from a primary material that is coated, clad or
encapsulated with one or more secondary materials to form a
composite material that has a harder surface. In other non-limiting
embodiments, reinforcement particles can be formed from a primary
material that is coated, clad or encapsulated with a differing form
of the primary material to form a composite material that has a
harder surface.
[0790] In some non-limiting examples, inorganic particles formed
from an inorganic material such as silicon carbide or aluminum
nitride can be provided with a silica, carbonate or nanoclay
coating to form a useful composite particle. In other nonlimiting
examples, a silane coupling agent with alkyl side chains can
interact with the surface of an inorganic particle formed from an
inorganic oxide to provide a useful composite particle having a
"softer" surface. Other examples include cladding, encapsulating or
coating particles formed from nonpolymeric or polymeric materials
with differing nonpolymeric or polymeric materials. One
non-limiting example of such composite particles is DUALITE.TM.,
which is a synthetic polymeric particle coated with calcium
carbonate that is commercially available from Pierce and Stevens
Corporation of Buffalo, N.Y.
[0791] In some non-limiting embodiments, the particles are formed
from solid lubricant materials. As used herein, the term "solid
lubricant" means any solid used between two surfaces to provide
protection from damage during relative movement and/or to reduce
friction and wear. In some non-limiting embodiments, the solid
lubricants are inorganic solid lubricants. As used herein,
"inorganic solid lubricant" means that the solid lubricants have a
characteristic crystalline habit which causes them to shear into
thin, flat plates which readily slide over one another and thus
produce an antifriction lubricating effect. See R. Lewis, Sr.,
Hawley's Condensed Chemical Dictionary, (12th Ed. 1993) at page
712, incorporated by reference herein. Friction is the resistance
to sliding one solid over another. F. Clauss, Solid Lubricants and
Self-Lubricating Solids (1972) at page 1, incorporated by reference
herein.
[0792] In some non-limiting embodiments, the particles have a
lamellar structure. Particles having a lamellar structure are
composed of sheets or plates of atoms in hexagonal array, with
strong bonding within the sheet and weak van der Waals bonding
between sheets, providing low shear strength between sheets. A
non-limiting example of a lamellar structure is a hexagonal crystal
structure. Inorganic solid particles having a lamellar fullerene
(i.e., buckyball) structure can also be useful in the present
invention.
[0793] Non-limiting examples of suitable materials having a
lamellar structure that are useful in forming the particles of the
present invention include boron nitride, graphite, metal
dichalcogenides, mica, talc, gypsum, kaolinite, calcite, cadmium
iodide, silver sulfide, and mixtures of any of the foregoing.
Suitable metal dichalcogenides include molybdenum disulfide,
molybdenum diselenide, tantalum disulfide, tantalum diselenide,
tungsten disulfide, tungsten diselenide, and mixtures of any of the
foregoing.
[0794] In some non-limiting embodiments, the reinforcing material
can be glass fiber strands. The glass fiber strands are formed from
glass filaments, a class of filaments generally accepted to be
based upon oxide compositions such as silicates selectively
modified with other oxide and non-oxide compositions. Useful glass
filaments can be formed from any type of fiberizable glass
composition known to those skilled in the art, and include those
prepared from fiberizable glass compositions such as "E-glass",
"A-glass", "C-glass", "D-glass", "R-glass", "S-glass", and E-glass
derivatives that are fluorine-free and/or boron-free. As used
herein, the term "fiberizable" means a material capable of being
formed into a generally continuous filament, fiber, strand or yarn.
As used herein, "E-glass derivatives" means glass compositions that
include minor amounts of fluorine and/or boron or can be
fluorine-free and/or boron-free. Furthermore, as used herein,
"minor amounts of fluorine" means less than 0.5 weight percent
fluorine, or less than 0.1 weight percent fluorine, and "minor
amounts of boron" means less than 5 weight percent boron, or less
than 2 weight percent boron. Basalt and mineral wool are examples
of other fiberizable glass materials useful in the present
invention. Non-limiting examples of suitable non-glass fiberizable
inorganic materials include ceramic materials such as silicon
carbide, carbon, quartz, graphite, mullite, aluminum oxide and
piezoelectric ceramic materials. In some non-limiting embodiments,
the glass filaments are formed from E-glass. Such compositions and
methods of making glass filaments therefrom are well known to those
skilled in the art such glass compositions and fiberization methods
are disclosed in K. Loewenstein, The Manufacturing Technology of
Continuous Glass Fibres, (3d Ed. 1993) at pages 30-44, 47-60,
115-122 and 126-135, incorporated by reference herein.
[0795] The glass fibers can have a nominal filament diameter
ranging from about 5.0 to about 30.0 micrometers (corresponding to
a filament designation of D through Y). Typically, the glass fiber
strands have a strand coating composition which is compatible with
the composition applied to at least a portion of surfaces of the
glass fiber strands, such as an essentially dried residue. The
glass fiber strand reinforcements can be used in chopped form,
generally continuous strands, mats, etc.
[0796] The particles also can be hollow particles formed from
materials selected from polymeric and nonpolymeric inorganic
materials, polymeric and nonpolymeric organic materials, composite
materials, and mixtures of any of the foregoing. Non-limiting
examples of suitable materials from which the hollow particles can
be formed are described above. In some embodiments, the hollow
particles are hollow glass spheres.
[0797] In some non-limiting embodiments, the reinforcing materials
can be formed from nonpolymeric, organic materials. Nonlimiting
examples of nonpolymeric, organic materials useful in the present
invention include, but are not limited to, stearates (such as zinc
stearate and aluminum stearate), diamond, carbon black, and
stearamide.
[0798] In some non-limiting embodiments, the particles can be
formed from inorganic polymeric materials. Nonlimiting examples of
useful inorganic polymeric materials include polyphosphazenes,
polysilanes, polysiloxane, polygeremanes, polymeric sulfur,
polymeric selenium, silicones, and mixtures of any of the
foregoing. A non-limiting example of a particle formed from an
inorganic polymeric material suitable for use in the present
invention is TOSPEARL.sup.1, which is a particle formed from
cross-linked siloxanes and is commercially available from Toshiba
Silicones Company, Ltd. of Japan. .sup.1 See R. J. Perry
"Applications for Cross-Linked Siloxane Particles" Chemtech.
February 1999 at pp. 39-44.
[0799] The particles can be formed from synthetic, organic
polymeric materials that are chemically different from the
polyurethane or poly(ureaurethane). Nonlimiting examples of
suitable organic polymeric materials include, but are not limited
to, thermoset materials and thermoplastic materials. Nonlimiting
examples of suitable thermoplastic materials include thermoplastic
polyesters such as polyethylene terephthalate, polybutylene
terephthalate, and polyethylene naphthalate, polycarbonates,
polyolefins such as polyethylene, polypropylene, and polyisobutene,
acrylic polymers such as copolymers of styrene and an acrylic acid
monomer, and polymers containing methacrylate, polyamides,
thermoplastic polyurethanes, vinyl polymers, and mixtures of any of
the foregoing.
[0800] In some non-limiting embodiments, the polymeric organic
material is a (meth)acrylic polymer or copolymer comprising at
least one functional group selected from the group consisting of
silane groups, carboxyl groups, hydroxyl groups and amide groups.
In some non-limiting embodiments, these (meth)acrylic polymer or
copolymers can be present as nanofibers having a diameter up to
about 5000 nm, such as about 5 to about 5000 nm, or less than the
wavelength of visible light, for example 700 nanometers or less,
such as about 50 to about 700 nanometers. The fibers may have a
ribbon shape and, in this case, diameter is intended to mean the
largest dimension of the fiber. Typically the width of the ribbon
shaped fibers can be up to about 5000 nanometers, such as about 500
to about 5000 nm and the thickness up to about 200 nm, such as
about 5 to about 200 nm. The fibers can be prepared by
electrospinning a ceramic melt, a polymer melt or a polymer
solution.
[0801] Suitable (meth)acrylic polymers can be made by addition
polymerization of unsaturated polymerizable materials that contain
silane groups, carboxyl groups, hydroxyl groups and amine or amide
groups. Non-limiting examples of useful silane groups include
groups that have the structure Si--X.sub.n (wherein n is an integer
having a value ranging from 1 to 3 and X is selected from chlorine,
alkoxy esters, and/or acyloxy esters). Such groups hydrolyze in the
presence of water including moisture in the air to form silanol
groups that condense to form --Si--O--Si-- groups. The
(meth)acrylic polymer can contain hydroxyl functionality, for
example by using a hydroxyl functional ethylenically unsaturated
polymerizable monomer such as hydroxyalkyl esters of (meth)acrylic
acids having from 2 to 4 carbon atoms in the hydroxyalkyl group.
The (meth)acrylic polymer optionally contains nitrogen
functionality introduced from nitrogen-containing ethylenically
unsaturated monomers, such as amines, amides, ureas, imidazoles and
pyrrolidones. Further discussion of such (meth)acrylic polymers and
fiberizing methods are disclosed in U.S. patent application Ser.
No. 11/610,755 entitled "Transparent Composite Articles" and U.S.
patent application Ser. No. 11/610,651 entitled "Organic-Inorganic
Polymer Composites and Their Preparation by Liquid Infusion", each
filed on Dec. 14, 2006, and incorporated by reference herein.
[0802] Non-limiting examples of suitable fiberizable organic
materials include cotton, cellulose, natural rubber, flax, ramie,
hemp, sisal and wool. Non-limiting examples of suitable fiberizable
organic polymeric materials include those formed from polyamides
(such as nylon and aramids), (such as KEVLAR.TM. aramid fibers),
thermoplastic polyesters (such as polyethylene terephthalate and
polybutylene terephthalate), acrylics (such as polyacrylonitriles),
polyolefins, polyurethanes and vinyl polymers (such as polyvinyl
alcohol). Non-glass fiberizable materials useful in the present
invention and methods for preparing and processing such fibers are
discussed at length in the Encyclopedia of Polymer Science and
Technology, Vol. 6 (1967) at pages 505-712, which is specifically
incorporated by reference herein.
[0803] It is understood that blends or copolymers of any of the
above materials and combinations of fibers formed from any of the
above materials can be used in the present invention, if desired.
Moreover, the term "strand" can encompass at least two different
fibers made from differing fiberizable materials. As used herein,
the term "fiberizable" means a material capable of being formed
into a generally continuous filament, fiber, strand or yarn.
[0804] Suitable thermoplastic fibers can be formed by a variety of
polymer extrusion and fiber formation methods, such as for example
drawing, melt spinning, dry spinning, wet spinning and gap
spinning. Such methods are well known to those skilled in the art
and further discussion thereof is not believed to be necessary in
view of the present disclosure. If additional information is
needed, such methods are disclosed in Encyclopedia of Polymer
Science and Technology, Vol. 6 at 507-508.
[0805] Non-limiting examples of useful polyamide fibers include
nylon fibers such as nylon 6 (a polymer of caprolactam), nylon 6,6
(a condensation product of adipic acid and hexamethylenediamine),
nylon 12 (which can be made from butadiene) and nylon 10,
polyhexamethylene adipamide, polyamide-imides and aramids such as
KEVLAR.TM., which is commercially available from E. I. duPont de
Nemours, Inc. of Wilmington, Del.
[0806] Non-limiting examples of useful thermoplastic polyester
fibers include those composed of polyethylene terephthalate and
polybutylene terephthalate.
[0807] Non-limiting examples of useful fibers formed from acrylic
polymers include polyacrylonitriles having at least about 35% by
weight acrylonitrile units, or at least about 85% by weight, which
can be copolymerized with other vinyl monomers such as vinyl
acetate, vinyl chloride, styrene, vinylpyridine, acrylic esters or
acrylamide. See Encyclopedia of Polymer Science and Technology,
Vol. 6 at 559-561.
[0808] Non-limiting examples of useful polyolefin fibers are
generally composed of at least 85% by weight of ethylene,
propylene, or other olefins. See Encyclopedia of Polymer Science
and Technology, Vol. 6 at 561-564.
[0809] Non-limiting examples of useful fibers formed from vinyl
polymers can be formed from polyvinyl chloride, polyvinylidene
chloride, polytetrafluoroethylene, and polyvinyl alcohol.
[0810] Further non-limiting examples of thermoplastic fiberizable
materials believed to be useful in the present invention include
fiberizable polyimides, polyether sulfones, polyphenyl sulfones,
polyetherketones, polyphenylene oxides, polyphenylene sulfides and
polyacetals.
[0811] It is understood that blends or copolymers of any of the
above materials and combinations of fibers formed from any of the
above materials can be used in the present invention, if desired.
Also, the thermoplastic fibers can have an antistatic agent coated
thereon.
[0812] Suitable reinforcing materials can include mats or fabrics
comprised of any of the fibers discussed above. An increasingly
popular process for forming composites is by compression molding or
stamping a moldable sheet of a thermoplastic resin reinforced with
fibers such as a glass fiber mat, often referred to as glass mat
thermoplastics or "GMT". These composite sheets can be used to form
articles such as automobile components and housings for computers.
An example of a commercially successful GMT sheet is the AZDEL.RTM.
moldable composite sheet which is formed by extruding layers of
polypropylene resin sheet with needled mats of continuous glass
fiber strand. The AZDEL.RTM. composite sheet is commercially
available from Azdel, Inc. of Shelby, N.C.
[0813] For reinforcing a resin matrix material, U.S. Pat. Nos.
3,664,909, 3,713,962 and 3,850,723 disclose fibrous mats of
unstranded filaments which can be layered with reinforcing mats of
fiber strands.
[0814] U.S. Pat. No. 4,847,140 discloses an insulation medium
formed by needling a loose layer of inorganic fibers, such as
glass, bonded together by a carrier web which is a blend of
inorganic and organic fibers, with the carrier web comprising up to
about 10% by weight organic fibers.
[0815] U.S. Pat. Nos. 4,948,661, 5,011,737, 5,071,608 and 5,098,624
disclose fiber reinforced thermoplastic molded products produced by
intimately blending reinforcing glass fibers and thermoplastic
fibers into a web and heating the web to the melting point of the
thermoplastic fibers while applying pressure to the web to press
the web into a consolidated structure.
[0816] A non-limiting example of a useful polypropylene spun-bonded
fiber mat is commercially available from Fiberweb N.A., Inc. of
Simpsonville, S.C.
[0817] Nonlimiting examples of suitable thermoset reinforcement
materials include thermoset polyesters, vinyl esters, epoxy
materials, phenolics, aminoplasts, thermoset polyurethanes, and
mixtures of any of the foregoing. A specific, nonlimiting example
of a synthetic polymeric particle formed from an epoxy material is
an epoxy microgel particle.
[0818] The concentration of reinforcement particles present in the
cured article or coating can be determined, if desired, by a
variety of analysis techniques well known in the art, such as
Transmission Electron Microscopy ("TEM"), Surface Scanning Electron
Microscopy ("X-SEM"), Atomic Force Microscopy ("AFM"), and X-ray
Photoelectron Spectroscopy.
[0819] In some non-limiting embodiments, the present invention is
directed to cured compositions as previously described wherein the
reinforcement particles have an average particle size of less than
about 100 microns prior to incorporation into the composition, or
less than about 50 microns prior to incorporation into the
composition. In other non-limiting embodiments, the present
invention is directed to cured compositions as previously described
wherein the reinforcement particles have an average particle size
ranging from about 1 to less than about 1000 nanometers prior to
incorporation into the composition, or about 1 to about 100
nanometers prior to incorporation into the composition.
[0820] In other non-limiting embodiments, the present invention is
directed to cured compositions as previously described wherein the
particles have an average particle size ranging from about 5 to
about 50 nanometers prior to incorporation into the composition, or
about 5 to about 25 nanometers prior to incorporation into the
composition.
[0821] In an embodiment where the average particle size of the
particles is at least about one micron, the average particle size
can be measured according to known laser scattering techniques. For
example the average particle size of such particles is measured
using a Horiba Model LA 900 laser diffraction particle size
instrument, which uses a helium-neon laser with a wave length of
633 nm to measure the size of the particles and assumes the
particle has a spherical shape, i.e., the "particle size" refers to
the smallest sphere that will completely enclose the particle.
[0822] In an embodiment of the present invention wherein the size
of the particles is less than or equal to one micron, the average
particle size can be determined by visually examining an electron
micrograph of a transmission electron microscopy ("TEM") image,
measuring the diameter of the particles in the image, and
calculating the average particle size based on the magnification of
the TEM image. One of ordinary skill in the art will understand how
to prepare such a TEM image, and a description of one such method
is disclosed in the examples set forth below. In one nonlimiting
embodiment of the present invention, a TEM image with
105,000.times. magnification is produced, and a conversion factor
is obtained by dividing the magnification by 1000. Upon visual
inspection, the diameter of the particles is measured in
millimeters, and the measurement is converted to nanometers using
the conversion factor. The diameter of the particle refers to the
smallest diameter sphere that will completely enclose the
particle.
[0823] The shape (or morphology) of the reinforcing material can
vary depending upon the specific embodiment of the present
invention and its intended application. For example generally
spherical morphologies (such as solid beads, microbeads, or hollow
spheres), can be used, as well as particles that are cubic, platy,
or acicular (elongated or fibrous). Additionally, the particles can
have an internal structure that is hollow, porous or void free, or
a combination of any of the foregoing, e.g., a hollow center with
porous or solid walls. For more information on suitable particle
characteristics see H. Katz et al. (Ed.), Handbook of Fillers and
Plastics (1987) at pages 9-10, incorporated by reference
herein.
[0824] It will be recognized by one skilled in the art that
mixtures of one or more particles having different average particle
sizes can be incorporated into the compositions in accordance with
the present invention to impart the desired properties and
characteristics to the compositions. For example particles of
varying particle sizes can be used in the compositions according to
the present invention.
[0825] In some non-limiting embodiments, the reinforcing
material(s) are present in the composition in an amount ranging
from about 0.01 to about 75 weight percent, or about 25 to about 50
weight percent, based on total weight of the components which form
the composition.
[0826] Reinforcement particles can be present in a dispersion,
suspension or emulsion in a carrier. Nonlimiting examples of
suitable carriers include, but are not limited to, water, solvents,
surfactants, or a mixture of any of the foregoing. Nonlimiting
examples of suitable solvents include, but are not limited to,
mineral oil, alcohols such as methanol or butanol, ketones such as
methyl amyl ketone, aromatic hydrocarbons such as xylene, glycol
ethers such as ethylene glycol monobutyl ether, esters, aliphatics,
and mixtures of any of the foregoing.
[0827] Dispersion techniques such as grinding, milling,
microfluidizing, ultrasounding, or any other dispersing techniques
well known in the art of coatings or molded article formulation can
be used. Alternatively, the particles can be dispersed by any other
dispersion techniques known in the art. If desired, the particles
in other than colloidal form can be post-added to an admixture of
other composition components and dispersed therein using any
dispersing techniques known in the art.
[0828] A further embodiment of the present invention is directed to
a coated automobile substrate comprising an automobile substrate
and a cured composition coated over at least a portion of the
automobile substrate, wherein the cured composition is selected
from any of the foregoing compositions. In yet another embodiment,
the present invention is directed to a method of making a coated
automobile substrate comprising providing an automobile substrate
and applying over at least a portion of the automotive substrate a
coating composition selected from any of the foregoing
compositions. Again, the components used to form the cured
compositions in these embodiments can be selected from the
components discussed above, and additional components also can be
selected from those recited above.
[0829] Suitable flexible elastomeric substrates can include any of
the thermoplastic or thermoset synthetic materials well known in
the art. Nonlimiting examples of suitable flexible elastomeric
substrate materials include polyethylene, polypropylene,
thermoplastic polyolefin ("TPO"), reaction injected molded
polyurethane ("RIM"), and thermoplastic polyurethane ("TPU").
[0830] Nonlimiting examples of thermoset materials useful as
substrates for coating with compositions of the present invention
include polyesters, epoxides, phenolics, polyurethanes such as
"RIM" thermoset materials, and mixtures of any of the foregoing.
Nonlimiting examples of suitable thermoplastic materials include
thermoplastic polyolefins such as polyethylene, polypropylene,
polyamides such as nylon, thermoplastic polyurethanes,
thermoplastic polyesters, acrylic polymers, vinyl polymers,
polycarbonates, acrylonitrile-butadiene-styrene ("ABS") copolymers,
ethylene propylene diene terpolymer ("EPDM") rubber, copolymers,
and mixtures of any of the foregoing.
[0831] Nonlimiting examples of suitable metal substrates useful as
substrates for coatings with compositions of the present invention
include ferrous metals (e.g., iron, steel, and alloys thereof),
nonferrous metals (e.g., aluminum, zinc, magnesium, and alloys
thereof), and mixtures of any of the foregoing. In the particular
use of automobile components, the substrate can be formed from cold
rolled steel, electrogalvanized steel such as hot dip
electrogalvanized steel, electrogalvanized iron-zinc steel,
aluminum, and magnesium.
[0832] When the substrates are used as components to fabricate
automotive vehicles (including, but not limited to, automobiles,
trucks and tractors) they can have any shape, and can be selected
from the metallic and flexible substrates described above. Typical
shapes of automotive body components can include bodies (frames),
hoods, doors, fenders, mirror housings, bumpers, and trim for
automotive vehicles.
[0833] In embodiments of the present invention directed to
automotive applications, the cured compositions can be, for
example, the electrodeposition coating, the primer coating, the
basecoat and/or the topcoat. Suitable topcoats include monocoats
and basecoat/clearcoat composites. Monocoats are formed from one or
more layers of a colored coating composition.
[0834] In some non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of Groups A-P can be reinforced with fiberglass
to form a composite article, such as for example a windmill blade,
blast-resistant panels, bullet resistant panels and radomes.
Group R
[0835] In some non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of Groups A-Q can be useful as one or more
layers in a multilayer article. If desired, the multilayered
article can be laminated.
[0836] In some non-limiting embodiments, the polymer is cut while
warm, granulated, extruded and/or milled and calendered to sheets
and assembled into laminates and aged for several days, a week, or
longer at ambient temperature (about 25.degree. C.).
[0837] In some non-limiting embodiments, the present invention
provides articles having multiple layers of polyurethanes and/or
poly(ureaurethanes) of the present invention. The thickness of each
layer and overall thickness of the article can vary as desired.
Non-limiting examples of suitable thicknesses of the layers and
articles are discussed below. The layers can be laminated together,
if desired.
[0838] In some non-limiting embodiments, the present invention
provides multilayered articles or laminates comprising: (a) at
least one layer of the polyurethane(s) or poly(ureaurethane)s of
the present invention as discussed above; and (b) at least one
layer of a substrate selected from the group consisting of paper,
glass, ceramic, wood, masonry, textile, metal or organic polymeric
material and combinations thereof. In some non-limiting
embodiments, the layer (a) of polyurethane(s) or
poly(ureaurethane)s of the present invention is chemically or
physically different from the organic polymeric material of layer
(b), i.e., it has at least one different atom, arrangement of atoms
or configuration. In other embodiments, two or more layers of the
same or similar polyurethane(s) or poly(ureaurethane)s of the
present invention can be used.
[0839] In some non-limiting embodiments, the substrate is an
optically clear polymerized organic material prepared from a
thermoplastic polycarbonate resin, such as the carbonate-linked
resin derived from bisphenol A and phosgene, which is sold under
the trademark LEXAN.RTM. by GE Plastics of Pittsfield, Mass.; a
polyester, such as the material sold under the trademark MYLAR by
E.I. duPont de Nemours Co. of Wilmington, Del.; a poly(methyl
methacrylate), such as the material sold under the trademark
PLEXIGLAS by Altuglas International of Philadelphia, Pa.;
polyhexylene-polycarbonate-based polyurethanes; polymerizates of a
polyol(allyl carbonate) monomer, especially diethylene glycol
bis(allyl carbonate), which monomer is sold under the trademark
CR-39 by PPG Industries, Inc., and polymerizates of copolymers of a
polyol (allyl carbonate), e.g., diethylene glycol bis(allyl
carbonate), with other copolymerizable monomeric materials, such as
copolymers with vinyl acetate, and copolymers with a polyurethane
having terminal diacrylate functionality, as described in U.S. Pat.
Nos. 4,360,653 and 4,994,208; and copolymers with aliphatic
urethanes, the terminal portion of which contain allyl or acrylyl
functional groups, as described in U.S. Pat. No. 5,200,483;
poly(vinyl acetate), polyvinylbutyral, polyurethane, polymers of
members of the group consisting of diethylene glycol dimethacrylate
monomers, diisopropenyl benzene monomers, and ethoxylated
trimethylol propane triacrylate monomers; cellulose acetate,
cellulose propionate, cellulose butyrate, cellulose acetate
butyrate, polystyrene and copolymers of styrene with methyl
methacrylate, vinyl acetate and acrylonitrile. In some non-limiting
embodiments, the article comprises at least one layer of
polyurethane or polyureaurethane of the present invention and at
least one layer of polycarbonate.
[0840] A non-limiting example of a suitable
polyhexylene-polycarbonate-based polyurethane can be prepared as
follows: a hydroxyl-terminated prepolymer is made from 0.2
equivalents of a 1000 molecular weight hexanediol-based carbonate
diol (PC-1733 commercially available from Stahl), 0.8 equivalents
of 1,5 pentanediol, and 1.0 equivalents of
trimethylhexanediisocyanate. The components are heated to
180.degree. F. (82.degree. C.) and using 100 ppm of dibutyltin
dilaurate as a catalyst. The prepolymer has an equivalent weight of
218 grams/equivalent. The trimeric hydroxyl terminated prepolymer
is dissolved into cyclohexanone solvent and 1 equivalent of
Desmodur 3390 (triisocyanurate trimer of hexanediisocyanate) is
added as a crosslinker and mixed. The coating solution is 95%
solids with a viscosity of 3000 centipoise. The solution can be
flow-coated onto any bisphenol A polycarbonate such as Lexan and
cured in an oven at 250.degree. F. (121.degree. C.) for 4 hours.
The coating thickness can range from 2 to 5 mils thick and is
elastomeric.
[0841] The number and thickness of the layers can vary as desired.
For example, the thickness of a single layer can range from about
0.1 mm to about 60 cm, or about 2 mm to about 60 cm, or about 0.3
cm to about 2.5 cm. The number of layers can range from 2 to 10, or
2 to 4, as desired. The overall thickness of the multilayer article
or laminate can range from about 2 mm to about 15 cm or more, or
about 2 mm to about 5 cm. For ballistics applications, the overall
thickness of the polyurethane or poly(ureaurethane) of the present
invention can range from about 2 mm to about 15 cm or more, or
about 2 mm to about 5 cm. Also, for ballistics applications
suitable substrates for layering with the polyurethane(s) and/or
poly(ureaurethane)s of the present invention include polyesters,
polycarbonates, or polyether thermoplastic elastomers, for example.
The layer(s) of polyurethane or poly(ureaurethane) of the present
invention can be positioned on the outside of the laminate (facing
the potential ballistic impact), on the inside of the laminate, or
elsewhere in between.
Groups A-R
[0842] In some non-limiting embodiments, polyurethanes and
poly(ureaurethane)s of the present invention can have a hard
segment content of about 10 to about 100 weight percent, or about
20 to about 80 weight percent, or about 30 to about 75 weight
percent. Hard segment calculation is discussed in detail above.
[0843] In some non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of the present invention generally have a
urethane content (Wu) of about 20 to about 40 weight percent, or
about 21 to about 36 weight percent, or about 30 to about 40 weight
percent. The urethane content is the percentage by weight of the
urethane linkages present in the polymer and can be calculated by
determining the total number of equivalents, and from this the
total weight of all reactants, and dividing the total weight of the
urethane linkages obtainable from these reactants by the total
weight of the reactants themselves. The following example will
further explain the calculation. In Example I, Formulation 1 which
follows, a polyurethane article according to the invention was
prepared by reacting 0.7 equivalents of 1,4-butanediol, 0.3
equivalents of trimethylolpropane and one equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate) (DESMODUR W). The
equivalent weight of the 1,4-butanediol is 45, the equivalent
weight of the trimethylolpropane is 44.7 (corrected for impurities)
and the equivalent weight of the DESMODUR W is 131.2. Therefore,
the actual weight of ingredients used is 31.54 parts by weight of
1,4-butanediol, 13.2 parts by weight of trimethylolpropane and
131.2 parts by weight of DESMODUR W or a total reactant weight of
175.9 parts by weight. One equivalent of DESMODUR W will yield one
equivalent of urethane linkage. The equivalent weight of a urethane
linkage is 59 so that the total weight of the urethane linkages
determined by multiplying the equivalent weight by the number of
equivalents would also be 59. Thus, the total weight of the
urethane linkage, 59, divided by the total weight of the reactants,
175.9, multiplied by 100 to convert to percentages would give a
percentage by weight of urethane linkage of 33.49 percent by
weight.
[0844] In an analogous manner, the percentage by weight of cyclic
structures (W.sub.c) (such as for example cyclohexyl) can be
calculated. In Example I, Formulation 1, the only material
contributing cyclohexyl moieties is the DESMODUR W. One equivalent
of DESMODUR W would yield one equivalent of cyclohexyl moiety which
has an equivalent weight of 81. Thus, the total weight of
cyclohexyl moiety would be equal to 81 and this divided by the
total weight of reactants or 175.9 would yield a W.sub.c of 46
percent. In some non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of the present invention can have a cyclic
content of about 10 to about 80 weight percent, about 20 to about
70 weight percent, about 30 to about 70 weight percent, or about 30
to about 60 weight percent.
[0845] In some non-limiting embodiments, the resulting
polyurethanes or poly(ureaurethane)s of the present invention when
cured can be solid, and essentially transparent. In some
non-limiting embodiments, the polyurethane can be partially cured
or fully cured such that essentially no further reaction
occurs.
[0846] In some non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of the present invention generally have a
number average molecular weight, as estimated from inherent
viscosity measurements, of at least about 20,000 grams/mole, or
ranging from about 20,000 to about 1,000,000 grams/mole, or ranging
from about 20,000 to about 800,000 grams/mole. The polyurethanes
and poly(ureaurethane)s of the present invention generally have an
average molecular weight per crosslink of at least about 500 grams
per mole, in some embodiments ranging from about 500 and about
15,000 grams/mole, or ranging from about 1800 and about 15,000
grams/mole. The polyurethanes and poly(ureaurethane)s of the
present invention generally have a crosslink density of at least
about 11,000 grams per mole.
[0847] In some non-limiting embodiments, the polyurethane(s) and
poly(ureaurethane)s of the present invention when cured can have
low density. In some non-limiting embodiments, the density can be
from at least 0.9 to less than 1.25 grams/cm.sup.3, or from at
least 1.0 to less than 1.45 grams/cm.sup.3, or from 1.08 to 1.37
grams/cm.sup.3, or from 1.08 to 1.13. In some non-limiting
embodiments, the density of polyurethanes and poly(ureaurethane)s
of the present invention can be less than LEXAN (density about 1.21
g/cm.sup.3) and conventional stretched acrylic (density about 1.18
g/cm.sup.3). The density can be measured using a DensiTECH
instrument manufactured by Tech Pro, Incorporated. In some
non-limiting embodiments, the density is measured in accordance
with ASTM D 792-00.
[0848] Also, some optically clear polyurethanes and
poly(ureaurethane)s upon heating can exhibit a low temperature
exotherm at about -70.degree. C. (differential thermal analysis can
be determined using a du Pont 900 thermal analyzer), and about
11.degree. C., indicating that the polymers are generally
amorphous.
[0849] In some non-limiting embodiments, softening points of about
65.degree. C. to about 200.degree. C., melting points of about
80.degree. C. to about 220.degree. C., and decomposition
temperatures of about 280.degree. C. to about 330.degree. C. under
nitrogen atmosphere are typical.
[0850] The polyurethanes and poly(ureaurethane)s of the present
invention can be used to form articles having good impact
resistance or flexibility, high impact strength, high tensile
strength, resistance to heat distortion, resistance to deflection
under pressure, good hardness, high Young's Modulus, high K factor,
good solvent resistance, good clarity or transparency, high light
transmittance, low haze, good weatherability, good energy
absorption, good moisture stability, good ultraviolet light
stability, and/or good ballistics resistance.
[0851] In some non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of the present invention can be used to form
articles having a Gardner Impact strength of at least about 100
in-lb, or at least about 200 in-lb, or at least about 400 in-lb (45
Joules), or at least about 500 in-lb or at least about 600 in-lb,
according to ASTM-D 5420-04. Non-limiting examples of suitable
methods and equipment for measuring impact resistance and impact
strength are discussed in detail above.
[0852] In some embodiments, the heat distortion temperature of
cured articles of the invention can be at least about 190.degree.
F. (88.degree. C.) or above about 200.degree. F. (93.degree. C.),
as determined according to ASTM-D-648.
[0853] Hardness of the polyurethanes and poly(ureaurethanes) can be
determined by the Shore hardness and, accordingly, in some
embodiments articles of the invention have a Shore D hardness at
room temperature (25.degree. C.) using a Shore D durometer of at
least about 75 or at least about 80.
[0854] Tensile strength at yield or break can be measured according
to ASTM-D 638-03. In some non-limiting embodiments, the tensile
strength at yield is at least about 6,800 lb/in.sup.2 (47 MPa)
according to ASTM-D 638-03, or about 6,800 to about 20,000
lb/in.sup.2 (about 47 to about 138 MPa), or about 12,000 to about
20,000 lb/in.sup.2 (about 83 to about 138 MPa).
[0855] Young's Modulus can be measured according to ASTM-D 638-03.
In some non-limiting embodiments, the Young's Modulus is at least
about 215,000 lb/in.sup.2 (about 1482 MPa), or about 215,000 (about
1482 MPa) to about 600,000 lb/in.sup.2 (about 4137 MPa), or about
350,000 (about 2413 MPa) to about 600,000 lb/in.sup.2 (about 4137
MPa). For commercial airplane cabin window applications, when the
cabin pressure is 10 psi (0.07 MPa) or more greater than the
external pressure, the cabin windows can deflect into the
airstream, thereby increasing noise and decreasing fuel efficiency.
Higher values of Young's Modulus indicate increased stiffness and
less tendency for the window to deflect into the airstream. In some
non-limiting embodiments for aircraft window applications, the
values of Young's Modulus can be at least about 350,000 (about 2413
MPa). In typical ballistics applications, the outer plies are
glass, which is hard enough to deform a bullet by spreading the
impact stress over a large area before it penetrates the underlying
plies. A poly(ureaurethane) prepared according to Example A,
Formulation 125, according to the present invention, having a
thickness of about 0.125 inches (0.3 cm) flattened a 9 mm bullet
fired at 1350 ft/sec (411 m/sec) from a distance of 20 feet (6.1
m). Though the ply broke into two cracked areas, it did not shatter
over a large area like glass, which would provide greater
visibility for an occupant to escape attack on a vehicle.
[0856] K factor is a measure of crack propagation. Crack
propagation can be measured according to U.S. Dept. of Defense
MIL-PRF-25690B (Jan. 29, 1993). In some non-limiting embodiments,
the polyurethanes and poly(ureaurethane)s of the present invention
have a K-Factor crack propagation resistance of at least about 1000
lb/in.sup.3/2 (1,098,800 N/m.sup.3/2), or about 1000 lb/in.sup.3/2
(1,098,800 N/m.sup.3/2) to about 4000 lb/in.sup.3/2 (4,395,200
N/m.sup.3/2), or about 2000 lb/in.sup.3/2 (2,197,600 N/m.sup.3/2)
to about 4000 lb/in.sup.3/2 (4,395,200 N/m.sup.3/2).
[0857] Compositions suitable for use in automobile windshields meet
the standard requirement of minimum light transmission of 70
percent or 86.5 percent or above (Illuminant A. Tungsten lamp
2,840.degree. K.) and less than 2 percent haze (ANSI CODE Z-26.1,
1966, Test No. 18). The percent light transmission and percent haze
can be measured by a Hunter Pivotable Sphere Haze Meter according
to ASTM E903-82.
[0858] The polyurethanes and poly(ureaurethane)s of the present
invention can have outstanding weather characteristics as measured
by UV light stability and hydrolytic stability. Fade-O-Meter.RTM.
exposure can be conducted according to ASTM G-25-70, Method A using
a Fade-O-Meter, Type FDA-R, Serial No. F02951, manufactured by
Atlas Electric Devices Co., Chicago, Ill. The light source can be a
carbon arc lamp enclosed in a fused silica globe. The operating
temperature of the Fade-O-Meter (black panel) can be 140.degree. F.
(60.degree. C.) and the instrument operated with no water in the
atomizing unit. Sample sizes are 21/2 inches by 6 inches by 1/8
inch (6.35 cm by 15.24 cm by 0.32 cm). Weather-O-Meter.RTM.
exposure can be conducted according to ASTM D-1499-64 using a
Weather-O-Meter, Type DMC, Serial No. WO-1305. The type of light
source can be a twin carbon arc lamp enclosed in a fused silica
globe. The operating black panel temperature can be 140.degree. F.
(60.degree. C.). The spray of water is deionized water at a
temperature of about 70.degree. F. (21.degree. C.). The number and
type of water spray nozzles which are used are four No. 50 nozzles.
Alternatively, the UV resistance can be determined using QUV at
1000 hours according to ASTM G-53.
[0859] Abrasion resistance can be measured using a Taber Abrader
having a CS-10F abrasion wheel with 500 grams of weight, for a
sample size 3 inches by 3 inches by 1/8 inch (7.62 cm by 7.62 cm by
0.32 cm) according to ASTM D 1044-99. In some non-limiting
embodiments, 100 cycles of Taber can result in 30% haze for
stretched acrylic and from 5% to 40%, or from 10% to 15% or less
than about 5% for the polyurethanes and poly(ureaurethane)s of the
present invention.
[0860] The polyurethanes and poly(ureaurethane)s of the present
invention can have good craze resistance to solvents and acids.
Craze resistance can be measured according to U.S. Dept. of Defense
MIL-PRF-25690B (Jan. 29, 1993). Non-limiting examples of solvents
and acids for Stress Craze Testing include methanol, isopropanol,
ethylene glycol, propylene glycol, ethyl acetate, acetone, toluene,
isobutyl acetate, Skydrol (hydraulic fluid), jet fuel such as JP-4,
and 75% aqueous solution of sulfuric acid. In some non-limiting
embodiments, uncoated articles prepared from the polyurethanes and
poly(ureaurethane)s of the present invention have a stress craze
resistance in organic solvent and 75% by weight aqueous solution of
sulfuric acid of at least about 1000 psi (6.9 MPa) tensile stress,
or about 1000 psi (6.9 MPa) to about 4000 psi (27.6 MPa), or about
2000 psi (13.8 MPa) to about 4000 psi (27.6 MPa). In some
non-limiting embodiments, the polyurethanes and poly(ureaurethane)s
of the present invention when uncoated can withstand 75% sulfuric
acid for up to thirty days or any organic solvent at between 1000
psi (6.9 MPa) and 4000 psi (27.6 MPa) membrane stress.
[0861] In some non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of the present invention when polymerized can
produce a polymerizate having a refractive index of at least 1.55,
or at least 1.56, or at least 1.57, or at least 1.58, or at least
1.59, or at least 1.60, or at least 1.62, or at least 1.65. In
other non-limiting embodiments, the poly(ureaurethane)s of the
present invention when polymerized can produce a polymerizate
having an Abbe number of at least 32, or at least 35, or at least
38, or at least 39, or at least 40, or at least 44, or at least 59,
or having an Abbe number of 59. The refractive index and Abbe
number can be determined by methods known in the art such as
American Standard Test Method (ASTM) Number D 542-00. Further, the
refractive index and Abbe number can be determined using various
known instruments. In a non-limiting embodiment of the present
invention, the refractive index and Abbe number can be measured in
accordance with ASTM D 542-00 with the following exceptions: (i)
test one to two samples/specimens instead of the minimum of three
specimens specified in Section 7.3; and (ii) test the samples
unconditioned instead of conditioning the samples/specimens prior
to testing as specified in Section 8.1. Further, in a non-limiting
embodiment, an Atago, model DR-M2 Multi-Wavelength Digital Abbe
Refractometer can be used to measure the refractive index and Abbe
number of the samples/specimens.
[0862] Solid articles that can be prepared using the polyurethanes
or poly(ureaurethanes) of the present invention include but are not
limited to optical articles or lenses, photochromic articles or
lenses, windows, transparencies, such as generally transparent
windows, windshields, sidelights and backlights, aircraft or
airplane transparencies, ballistic resistant articles, windmill
components such as blades, and glazings.
[0863] In some non-limiting embodiments, the polymeric substrate
material, including the coating composition applied thereto, may be
in the form of optical elements such as windows, plano and vision
correcting ophthalmic lenses, exterior viewing surfaces of liquid
crystal displays, cathode ray tubes, e.g., video display tubes for
televisions and computers, clear polymeric films, transparencies,
e.g., windshields, aircraft transparencies, plastic sheeting,
etc.
[0864] The polyurethanes and poly(ureaurethane)s of the present
invention are desirable for a wide variety of uses. They are
particularly useful as glazing materials for aircraft safety glass
windows. Besides aircraft glazing, the polyurethanes and
poly(ureaurethane)s of the invention in sheet form can be used in
architectural applications and can be tinted or made opaque by
pigmenting if desired. In such applications, the polyurethanes and
poly(ureaurethane)s of the invention can be in sheet form and may
be used alone or laminated to other materials as discussed above.
The layers in the composite can have the same or different modulus
values, as desired. Also, in some embodiments the polyurethanes and
poly(ureaurethane)s of the invention can be used for optical lenses
since they can be optically clear, unaffected by ultraviolet light
and humidity exposure and abrasion resistant.
[0865] In other non-limiting embodiments, the polyurethanes and
poly(ureaurethane)s of the present invention can be used as low
thermal expansion substrates for deposition of conductive films for
electrochromic applications, microwave absorbing films or low
resistance films. In other non-limiting embodiments, a stretched
acrylic substrate can be coated with a cyanoethyl acrylate/acrylic
copolymer and further coated with the polyurethanes and
poly(ureaurethane)s of the present invention.
[0866] The polyurethanes and poly(ureaurethane)s of the invention
can be used in sheet form and can vary in thickness from about 2 to
500 mils, although somewhat thinner and thicker sheets can be used,
depending upon the application. For aircraft use, in some
embodiments the thickness can vary between 1/8 inch and 1/2 inch
(0.32 cm to 1.27 cm).
[0867] In some non-limiting embodiments, an automobile window can
be prepared from a thermoplastic polycarbonate resin, such as that
sold under the trademark LEXAN, with the coating composition of the
present invention applied as a weather layer on the outboard side
of the window to increase the weatherability of the window.
Alternatively, an automobile window can be prepared as a
glass/LEXAN laminate, with the glass as the outboard layer and the
coating composition of the present invention applied as a layer on
the inboard side of the laminate.
[0868] The coating composition of the present invention can be
applied to the substrate surface using any known coating
procedures. Desirably, the coating composition is flow coated over
the substrate surface by an automated flow-coating system in which
the surface tension of the liquid pulls a coherent sheet of liquid
across the substrate surface as the mechanical flow-coating device
traverses across the substrate sheet. An automatic flow-coating
device typically consists of an articulating arm that holds a
nozzle connected to a pressure pot where the resin solution is
held. The arm runs on a track above the sheet to be coated. The
rate of flow of the liquid is adjusted using the pressure pot. The
rate of traverse of the articulating arm is set using a
potentiometer. The nozzle distance from the sheet is optimized and
kept constant, via the articulating arm. This is particularly
important for curved sheets. The thickness of the coating is
determined by the initial viscosity of the resin solution and the
rate of solvent evaporation. The evaporation rate is mainly
controlled by the solvent choice and the cubic feet/minute airflow
in the ventilated coating booth. Alternatively, the coating
compositions can be prepared and cast in an appropriate mold to
form a desired structure, which can then be applied as a layer to a
suitable substrate, such as through a lamination process, or may
used as a monolithic structure.
[0869] The coating composition generally may be applied to a
substrate by itself as a transparent or pigmented monocoat, or as
the pigmented base coat and/or transparent topcoat in a
color-plus-clear composite coating as known to those skilled in the
art. In some embodiments, the coating can be applied before the
isocyanate and hydroxyl groups are fully reacted, for example by
spraying the isocyanate and hydroxyl components separately through
a mixing nozzle to apply the coating to the substrate.
Alternatively, the coating can be partially cured in an oven and
then subjected to a high moisture environment, such as high
humidity or water spray, to further react and cure the coating. If
desired, the coating composition may contain additional materials
well known in the art of formulated surface coatings, such as
surfactants, flow control agents, thixotropic agents, fillers,
antigassing agents, organic cosolvents, catalysts, and other
customary auxiliaries. These materials can constitute up to 40
percent by weight of the total weight of the coating
composition.
[0870] As aforementioned, although the cured compositions can be
formed from liquid coating compositions, they also can be formed
from coating compositions formulated as powder coating
compositions.
[0871] In another non-limiting embodiment, the cured compositions
of the present invention also can be useful as decorative or
protective coatings for pigmented plastic (elastomeric) substrates
or mold-in-color ("MIC") plastic substrates. In these applications,
the compositions can be applied directly to the plastic substrate
or included in the molding matrix. Optionally, an adhesion promoter
can first be applied directly to the plastic or elastomeric
substrate and the composition applied as a topcoat thereover.
[0872] In another non-limiting embodiment, the compositions of the
present invention also can be useful as a spalling shield layer, an
anti-lacerative coating layer or a break-in resistant coating layer
for glass or other substrates.
[0873] In a non-limiting embodiment, the polyurethane polymerizate
of the present invention can be used to prepare photochromic
articles. In a further embodiment, the polymerizate can be
transparent to that portion of the electromagnetic spectrum which
activates the photochromic substance(s), i.e., that wavelength of
ultraviolet (UV) light that produces the colored or open form of
the photochromic substance and that portion of the visible spectrum
that includes the absorption maximum wavelength of the photochromic
substance in its UV activated form, i.e., the open form.
[0874] Photochromic compounds exhibit a reversible change in color
when exposed to light radiation involving ultraviolet rays, such as
the ultraviolet radiation in sunlight or the light of a mercury
lamp. Various classes of photochromic compounds have been
synthesized and suggested for use in applications in which a
sunlight-induced reversible color change or darkening is desired.
The most widely described classes of photochromic compounds are
oxazines, pyrans and fulgides.
[0875] The general mechanism responsible for the reversible change
in color, i.e., a change in the absorption spectrum in the visible
range of light (400-700 nm), exhibited by different types of
photochromic compounds has been described and categorized. See John
C. Crano, "Chromogenic Materials (Photochromic)", Kirk-Othmer
Encyclopedia of Chemical Technology, Fourth Edition, 1993, pp.
321-332. The general mechanism for the most common classes of
photochromic compounds, e.g., indolino spiropyrans and indolino
spirooxazines, involves an electrocyclic mechanism. When exposed to
activating radiation, these compounds transform from a colorless
closed ring compound into a colored open ring species. In contrast,
the colored form of fulgide photochromic compounds is produced by
an electrocyclic mechanism involving the transformation of a
colorless open ring form into a colored closed ring form.
[0876] A wide variety of photochromic substances can be used in the
present invention. In a non-limiting embodiment, organic
photochromic compounds or substances can be used. In alternate
non-limiting embodiments, the photochromic substance can be
incorporated, e.g., dissolved, dispersed or diffused into the
polymerizate, or applied as a coating thereto.
[0877] In a non-limiting embodiment, the organic photochromic
substance can have an activated absorption maximum within the
visible range of greater than 590 nanometers. In a further
non-limiting embodiment, the activated absorption maximum within
the visible range can be from at least 590 to 700 nanometers. These
materials can exhibit a blue, bluish-green, or bluish-purple color
when exposed to ultraviolet light in an appropriate solvent or
matrix. Non-limiting examples of such substances that are useful in
the present invention include but are not limited to
spiro(indoline)naphthoxazines and spiro(indoline)benzoxazines.
These and other suitable photochromic substances are described in
U.S. Pat. Nos. 3,562,172; 3,578,602; 4,215,010; 4,342,668;
5,405,958; 4,637,698; 4,931,219; 4,816,584; 4,880,667;
4,818,096.
[0878] In another non-limiting embodiment, the organic photochromic
substances can have at least one absorption maximum within the
visible range ranging from 400 and less than 500 nanometers. In a
further non-limiting embodiment, the substance can have two
absorption maxima within this visible range. These materials can
exhibit a yellow-orange color when exposed to ultraviolet light in
an appropriate solvent or matrix. Non-limiting examples of such
materials can include certain chromenes, such as but not limited to
benzopyrans and naphthopyrans. Many of such chromenes are described
in U.S. Pat. Nos. 3,567,605; 4,826,977; 5,066,818; 4,826,977;
5,066,818; 5,466,398; 5,384,077; 5,238,931; and 5,274,132.
[0879] In another non-limiting embodiment, the photochromic
substance can have an absorption maximum within the visible range
ranging from 400 to 500 nanometers and an absorption maximum within
the visible range ranging from 500 to 700 nanometers. These
materials can exhibit color(s) ranging from yellow/brown to
purple/gray when exposed to ultraviolet light in an appropriate
solvent or matrix. Non-limiting examples of these substances can
include certain benzopyran compounds having substituents at the
2-position of the pyran ring and a substituted or unsubstituted
heterocyclic ring, such as a benzothieno or benzofurano ring fused
to the benzene portion of the benzopyran. Further non-limiting
examples of such materials are disclosed in U.S. Pat. No.
5,429,774.
[0880] In some non-limiting embodiments, the photochromic substance
for use in the present invention can include photochromic
organo-metal dithizonates, such as, but not limited to
(arylazo)-thioformic arylhydrazidates, such as, but not limited to
mercury dithizonates which are described, for example, in U.S. Pat.
No. 3,361,706. Fulgides and fulgimides, such as, but not limited to
3-furyl and 3-thienyl fulgides and fulgimides which are described
in U.S. Pat. No. 4,931,220 at column 20, line 5 through column 21,
line 38, can be used in the present invention. The relevant
portions of the aforedescribed patents are incorporated herein by
reference.
[0881] In other non-limiting embodiments, the photochromic articles
of the present invention can include one photochromic substance or
a mixture of more than one photochromic substances. In other
non-limiting embodiments, various mixtures of photochromic
substances can be used to attain activated colors such as a near
neutral gray or brown.
[0882] The amount of photochromic substance employed can vary. In
some non-limiting embodiments, the amount of photochromic substance
and the ratio of substances (for example, when mixtures are used)
can be such that the polymerizate to which the substance is
applied, or in which it is incorporated, exhibits a desired
resultant color, e.g., a substantially neutral color such as shades
of gray or brown when activated with unfiltered sunlight, i.e., as
near a neutral color as possible given the colors of the activated
photochromic substances. In some non-limiting embodiments, the
amount of photochromic substance used can depend upon the intensity
of the color of the activated species and the ultimate color
desired.
[0883] In some non-limiting embodiments, the photochromic substance
can be applied to or incorporated into the polymerizate by various
methods known in the art. In a non-limiting embodiment, the
photochromic substance can be dissolved or dispersed within the
polymerizate. In other non-limiting embodiments, the photochromic
substance can be imbibed into the polymerizate by methods known in
the art. The term "imbibition" or "imbibe" includes permeation of
the photochromic substance alone into the polymerizate, solvent
assisted transfer absorption of the photochromic substance into a
porous polymer, vapor phase transfer, and other such transfer
mechanisms. In a non-limiting embodiment, the imbibing method can
include coating the photochromic article with the photochromic
substance; heating the surface of the photochromic article; and
removing the residual coating from the surface of the photochromic
article. In alternate non-limiting embodiments, the imbibition
process can include immersing the polymerizate in a hot solution of
the photochromic substance or by thermal transfer.
[0884] In some non-limiting embodiments, the photochromic substance
can be a separate layer between adjacent layers of the
polymerizate, e.g., as a part of a polymer film; or the
photochromic substance can be applied as a coating or as part of a
coating placed on the surface of the polymerizate.
[0885] The amount of photochromic substance or composition
containing the same applied to or incorporated into the
polymerizate can vary. In some non-limiting embodiments, the amount
can be such that a photochromic effect discernible to the naked eye
upon activation is produced. Such an amount can be described in
general as a photochromic amount. In some non-limiting embodiments,
the amount used can depend upon the intensity of color desired upon
irradiation thereof and the method used to incorporate or apply the
photochromic substance. In general, the more photochromic substance
applied or incorporated, the greater the color intensity. In some
non-limiting embodiments, the amount of photochromic substance
incorporated into or applied onto a photochromic optical
polymerizate can be from 0.15 to 0.35 milligrams per square
centimeter of surface to which the photochromic substance is
incorporated or applied.
[0886] In another embodiment, the photochromic substance can be
added to the polyurethane prior to polymerizing and/or cast curing
the material. In this embodiment, the photochromic substance used
can be chosen such that it is resistant to potentially adverse
interactions with, for example, the isocyanate present. Such
adverse interactions can result in deactivation of the photochromic
substance, for example, by trapping them in either an open or
closed form.
[0887] Further non-limiting examples of suitable photochromic
substances for use in the present invention can include
photochromic pigments and organic photochromic substances
encapsulated in metal oxides such as those disclosed in U.S. Pat.
Nos. 4,166,043 and 4,367,170; organic photochromic substances
encapsulated in an organic polymerizate such as those disclosed in
U.S. Pat. No. 4,931,220.
[0888] The invention will be further described by reference to the
following examples. Unless otherwise indicated, all parts and
percentages are by weight.
EXAMPLES
[0889] The physical properties set forth below were measured as
follows:
[0890] Light Transmittance (%) was measured according to ASTM
E903-82;
[0891] Yellowness Index was measured according to ASTM D
1925-70;
[0892] Refractive index was measured on a multiple wavelength Abbe
Refractometer Model DR-M2 manufactured by ATAGO Co., Ltd.; the
refractive index of liquids were measured in accordance with ASTM-D
1218; and the refractive index of solids were measured in
accordance with ASTM-D 542;
[0893] Density (grams/cm.sup.3) of solids was measured in
accordance with ASTM-D 792-00;
[0894] Taber Abrasion (% haze) was measured for up to 100 cycles
using a Taber Abrader having a CS-10F abrasion wheel with 500 grams
of weight, for a sample size 3 inches by 3 inches by 1/8 inch (7.62
cm by 7.62 cm by 0.32 cm) according to ASTM D 1044-99;
[0895] Bayer Abrasion (% haze) was measured for according to ASTM F
735-94 (Reapproved 2001);
[0896] K-Factor crack propagation resistance was measured according
to U.S. Dept. of Defense MIL-PRF-25690B (Jan. 29, 1993).
[0897] Tensile strength at yield, percent elongation at yield, and
Young's Modulus were measured at about 25.degree. C. in accordance
with ASTM-D 638-03;
[0898] Gardner Impact Strength was measured in accordance with
ASTM-D 5420-04;
[0899] Dynatup Multiaxial Impact Strength was measured in
accordance with ASTM-D 3763-02;
[0900] Shore D Hardness was measured in accordance with a Shore D
durometer;
[0901] QUV-B testing was conducted for 333 hours or 1000 hours (as
specified) according to ASTM G-53;
[0902] Glass transition temperature (Tg) was measured using Dynamic
Mechanical Analysis; and
[0903] Linear Coefficient of Thermal Expansion was measured using a
duPont Thermomechanical analyzer (TMA) according to ASTM E
228-95.
[0904] The following abbreviations were used herein:
[0905] CHDM: 1,4-cyclohexane dimethanol;
[0906] Des N 3400: 60% hexamethylene diisocyanate dimer and 40%
hexamethylene diisocyanate trimer commercially available from
Bayer;
[0907] Des W or DESMODUR W: 4,4'-methylene-bis-(cyclohexyl
isocyanate) commercially available from Bayer;
[0908] MDI: Methylene diphenyl 4,4'-diisocyanate;
[0909] PDO: 1,5-pentanediol;
[0910] Polycaprolactone diol: Tone 0210 polycaprolactone diol
having a molecular weight of 1000 g/mol commercially available from
Solvay;
[0911] Polycarbonate diol 1: KM-10-1733 polycarbonate diol prepared
from hexanediol having a molecular weight of 1000 g/mol
commercially available from Stahl (also known as PC-1733);
[0912] Polycarbonate diol 2: KM10-1667 polycarbonate diol prepared
from hexanediol having a molecular weight of 1000 g/mol
commercially available from Stabl;
[0913] TMDI: trimethylhexamethylene diisocyanate;
[0914] TMP: trimethylolpropane; and
[0915] TMXDI: meta-tetramethylxylylene diisocyanate.
Example A
[0916] Polyurethanes and poly(ureaurethane)s of Formulations 1
through 133 were prepared from the components in amounts listed in
Tables 1-18.
[0917] The polyurethanes (formulations not including water) were
prepared in a glass kettle under nitrogen blanket with stirring.
The polyisocyanate was preheated to a temperature of about
100.degree. C. before addition of the other components. The mixture
was heated to a temperature of about 110.degree. C. over about 10
minutes and maintained at this temperature for about 30
minutes.
[0918] The poly(ureaurethane)s (formulations including water) also
were prepared in a glass kettle under nitrogen blanket with
stirring. The polyisocyanate was preheated to a temperature of
about 60.degree. C.
[0919] For Formulations 123-127, 131, 132 and 133, the water was
added to the polyisocyanate and the temperature was maintained for
about 30 minutes to form an isocyanate functional urea prepolymer.
The other components were added and the mixture was heated to a
temperature of about 90.degree. C. over about 10 minutes and
maintained at this temperature for about 30 minutes.
[0920] For Formulations 128-130, about 0.15 equivalents of
trimethylolpropane was added to the polyisocyanate and the
temperature was maintained for about 120 minutes to form an
isocyanate functional ureaurethane prepolymer. The other components
were added and the mixture was heated to a temperature of about
110.degree. C. over about 120 minutes and maintained at this
temperature for about four hours.
[0921] Each of the polyurethane and poly(ureaurethane) mixtures was
degassed to remove carbon dioxide and cast into a
12''.times.13''.times.0.125'' (30.5 cm.times.33 cm.times.0.3 cm)
casting cell which had been preheated to a temperature of about
121.degree. C. The filled cell was then cured in an oven for a
period of about 48 hours at about 121.degree. C.
TABLE-US-00002 TABLE 1 Molecular Hard Formu- Urethane Cyclic Weight
per Segment lation Polyisocyanate Branched Polyol Diol Content
Content Crosslink Content No. Type Equivalents Type Equivalents
Type Equivalents (wt. %) (wt. %) (g/mole) (wt. %) 1 Des W 1.00 TMP
0.3 1,4-butanediol 0.7 33.49 45.98 1762 70.00 2 Des W 1.00 TMP 0.3
1,5-pentanediol 0.7 32.59 44.74 1810 71.00 3 Des W 1.00 TMP 0.6
1,5-pentanediol 0.4 32.99 45.29 1788 41.00 4 Des W 1.00 TMP 0.3
1,6-hexanediol 0.7 31.73 43.56 1860 71.00 5 Des W 1.00 TMP 0.3
Xylene glycol 0.35 30.41 76.00 1940 71.00 CHDM 0.35 6 Des W 1.00
TMP 0.3 1,5-pentanediol 0.35 31.37 58.00 1881 72.00 CHDM 0.35 7 Des
W 1.00 TMP 0.3 1,6-hexanediol 0.35 30.97 57.34 1905 72.00 CHDM 0.35
8 Des W 1.00 TMP 0.3 1,8-octanediol 0.7 30.14 41.37 1958 73.00 9
Des W 1.00 TMP 0.3 1,10-decanediol 0.7 28.70 39.40 2056 74.00 10
Des W 1.00 TMP 0.3 1,8-octanediol 0.35 29.40 40.36 2007 74.00
1,10-decanediol 0.35 11 Des W 1.00 TMP 0.8 CHDM 0.2 32.53 53.60
1814 22.00 12 Des W 1.00 TMP 0.3 CHDM 0.7 30.24 70.50 1951 73.00 13
Des W 1.00 TMP 0.8 1,5-pentanediol 0.2 33.26 45.67 1774 21.00 14
Des W 1.00 TMP 0.3 1,7-heptanediol 0.7 30.91 42.44 1909 72.00 15
Des 1.00 TMP 0.3 1,9-nonanediol 0.7 29.40 40.36 2007 73.00 16 Des W
1.00 TMP 0.3 1,12-dodecanediol 0.7 27.39 37.60 2154 75.60 17 Des W
1.00 TMP 0.6 1,10-decanediol 0.4 30.59 42.00 1929 45.00 18 Des W
1.00 TMP 0.4 1,10-decanediol 0.4 29.75 40.84 1983 45.00 CHDM 0.2 19
Des W 1.00 TMP 0.3 1,10-decanediol 0.65 26.52 36.40 2225 63.00
Polycarbonate diol 1 0.05 20 TMDI 1.00 TMP 0.3 CHDM 0.7 34.91 47.92
1690 73.00
TABLE-US-00003 TABLE 2 Molecular Hard Formu- Urethane Cyclic Weight
per Segment lation Polyisocyanate Branched Polyol Diol Content
Content Crosslink Content No. Type Equivalents Type Equivalents
Type Equivalents (wt. %) (wt. %) (g/mole) (wt. %) 21 Des W 1.00 TMP
0.3 1,4-butanediol 0.6 27.54 37.81 2142 49.00 Polycarbonate diol 1
0.1 22 Des W 1.00 TMP 0.3 Isopropylidene 0.7 25.79 35.41 2287 77.00
dicyclohexanol 23 Des W 1.00 TMP 0.4 1,10-decanediol 0.5 25.08
34.44 2352 46.00 Polycarbonate diol 1 0.1 24 Des W 1.00 TMP 0.3
1,10-decanediol 0.6 24.64 33.83 2395 46.00 Polycarbonate diol 1 0.1
25 Des W 1.00 TMP 0.3 1,4-butanediol 0.5 23.38 32.10 2523 54.00
Polycarbonate diol 1 0.2 26 Des W 1.00 TMP 0.4 1,10-decanediol 0.6
29.30 40.23 2013 65.00 27 Des W 0.5 TMP 0.3 1,10-decanediol 0.7
29.13 39.99 2025 MDI 0.5 28 Des W 1.00 TMP 0.3 1,12- 0.7 27.48
37.72 2147 cyclododecanediol 29 TMDI 1.00 TMP 0.2 CHDM 0.8 34.35
47.16 1718 73.00 30 1.00 TMP 0.3 Decanediol 0.45 29.34 40.28 2011
Xylene Glycol 0.25 31 Des W 0.3 TMP 0.3 1,10-decanediol 0.7 31.50
43.24 1873 TMDI 0.7 32 Des W 0.8 TMP 0.3 1,10-decanediol 0.5 27.62
37.92 2136 75.00 Bis(2-hydroxyethyl) 0.2 terephthalate 34 Des W
0.75 TMP 0.3 1,10-decanediol 0.7 28.91 39.69 2041 MDI 0.25
TABLE-US-00004 TABLE 3 Molecular Hard Urethane Cyclic Weight per
Segment Formulation Polyisocyanate Branched Polyol Diol Content
Content Crosslink Content No. Type Equivalents Type Equivalents
Type Equivalents (wt. %) (wt. %) (g/mole) (wt. %) 35 Des W 0.85 TMP
0.3 1,10-decanediol 0.7 28.83 39.58 2047 MDI 0.15 36 TMXDI 1.00 TMP
0.3 1,4-butanediol 0.7 35.31 48.47 1671 37 Des W 1.00 TMP 0.3
1,10-decanediol 0.6 28.91 39.69 2041 75.00 1,4-cyclohexane 0.1
dimethanol 38 Des W 1.00 TMP 0.3 1,10-decanediol 0.6 28.24 38.78
2089 74.00 Isopropylidene 0.10 Dicyclohexanol 39 Des W 1.00 TMP 0.3
1,8-octanediol 0.45 29.61 40.65 1993 70.00 1,10-decanediol 0.25 40
Des W 1.00 TMP 0.35 1,10-decanediol 0.65 29.00 39.81 2035 74.00 41
Des W 1.00 TMP 0.3 1,8-octanediol 0.4 29.50 40.50 2000
1,10-decanediol 0.30 42 Des W 1.00 TMP 0.3 1,8-octanediol 0.5 29.71
40.79 1986 73.00 1,10-decanediol 0.20 43 Des W 1.00 TMP 0.3
1,4-butanediol 0.1 28.12 38.61 2098 75.00 1,12-dodecanediol 0.60 44
Des W 1.00 TMP 0.3 1,10-decanediol 0.35 26.60 36.52 2218 76.00
Isopropylidene 0.35 dicyclohexanol 45 Des N 3400 1.00
1,10-decanediol 1. 20.93 28.73 2820 46 Des N 3400 1.00
1,10-decanediol 0.8 21.15 29.04 2790 CHDM 0.20 47 Prepolymer 1.00
1,4-butanediol 0.75 13.29 18.24 4441 CHDM 0.25
TABLE-US-00005 TABLE 4 Molecular Hard Formu- Urethane Cyclic Weight
per Segment lation Polyisocyanate Branched Polyol Diol Content
Content Crosslink Content No. Type Equivalents Type Equivalents
Type Equivalents (wt. %) (wt. %) (g/mole) (wt. %) 48 Des W 1.00 TMP
0.3 1,4-butanediol 0.35 33.04 45.35 1786 70.00 1,5-pentanediol 0.35
49 Des W 1.00 TMP 0.3 1,5-pentanediol 0.6 32.22 44.23 1831 71.00
1,8-octanediol 0.10 50 Des W 1.00 TMP 0.3 1,5-pentanediol 0.6 31.97
43.89 1845 71.00 1,10-decanediol 0.10 51 Des W 1.00 TMP 0.3
1,4-butanediol 0.2 32.84 45.09 1796 71.00 1,5-pentanediol 0.50 52
Des W 1.00 TMP 0.3 1,4-butanediol 0.5 33.23 45.62 1775 70.00
1,5-pentanediol 0.20 53 Des W 1.00 TMP 0.3 1,4-butanediol 0.6 32.99
45.29 1789 70.00 CHDM 0.10 54 Des W 1.00 TMP 0.3 1,5-pentanediol
0.6 32.23 44.25 1830 71.00 CHDM 0.10 55 Des W 1.00 TMP 0.3
1,5-pentanediol 0.5 31.88 43.77 1850 71.00 CHDM 0.20 56 Des W 1.00
TMP 0.3 1,5-pentanediol 0.5 30.09 41.32 1960 71.00
Bis(2-hydroxyethyl) 0.20 terephthalate 57 Des W 1.00 TMP 0.3
1,5-pentanediol 0.6 31.19 42.82 1892 73.00 Isopropylidene 0.10
dicyclohexanol 58 Des W 1.00 TMP 0.3 1,5-pentanediol 0.5 22.99
31.56 2566 35.00 Polycarbonate diol 1 0.2 59 Des W 1.00 TMP 0.3
1,5-pentanediol 0.6 26.96 37.01 2188 50.00 Polycarbonate diol 1 0.1
60 Des W 1.00 TMP 0.3 1,5-pentanediol 0.3 26.25 36.04 2247 64.00
CHDM 0.3 Polycarbonate diol 1 0.10 61 Des W 1.00 TMP 0.4
1,5-pentanediol 0.1 22.55 30.95 2617 37.00 CHDM 0.3 Polycarbonate
diol 1 0.20
TABLE-US-00006 TABLE 5 Molecular Hard Urethane Cyclic Weight per
Segment Formulation Polyisocyanate Branched Polyol Diol Content
Content Crosslink Content No. Type Equivalents Type Equivalents
Type Equivalents (wt. %) (wt. %) (g/mole) (wt. %) 62 Des W 1.00 TMP
1.0 Polycarbonate diol 1 0.05 30.24 41.52 616 0.00 63 Des W 1.00
TMP 1.0 Polycarbonate diol 1 0.25 31.81 43.67 560 0.00 64 Des W
1.00 TMP 0.9 Polycarbonate diol 1 0.1 27.53 37.80 716 0.00 65 Des W
1.00 TMP 1.0 Polycarbonate diol 1 0.01 32.82 45.06 543 0.00 66 Des
W 1.00 TMP 1.00 33.54 46.05 1759 0.00 67 Des W 1.00 TMP 0.35
1,5-pentanediol 0.65 32.66 44.83 1562 66.00 68 Des W 1.00 TMP 0.40
1,5-pentanediol 0.6 32.72 44.93 1363 61.00 69 Des W 1.00 TMP 0.70
1,5-pentanediol 0.3 33.13 45.48 770 31.00 70 Des W 1.00 TMP 0.65
1,5-pentanediol 0.35 33.06 45.39 1785 36.00 71 Des W 1.00 TMP 0.55
1,5-pentanediol 0.45 32.92 45.20 1792 46.00 72 Des W 1.00 TMP 0.50
1,5-pentanediol 0.5 32.86 45.11 1796 51.00 73 Des W 1.00 TMP 0.45
1,5-pentanediol 0.55 32.79 45.02 1799 56.00 74 Des W 1.00 TMP 0.70
1,10-decanediol 0.3 31.28 42.94 1886 35.00 75 Des W 1.00 TMP 0.65
1,10-decanediol 0.35 30.93 42.47 1907 76 Des W 1.00 TMP 0.55
1,10-decanediol 0.45 30.26 41.54 1950 51.00 77 Des W 1.00 TMP 0.50
1,10-decanediol 0.5 29.93 41.10 1971 55.00 78 Des W 1.00 TMP 0.45
1,10-decanediol 0.55 30.26 41.54 1950 79 Des W 1.00 TMP 0.25
1,10-decanediol 0.75 28.41 39.00 2077 79.00 80 Des W 1.00 TMP 0.20
1,10-decanediol 0.8 28.12 38.60 2098 83.00 81 Des W 1.00 TMP 0.15
1,10-decanediol 0.85 27.84 38.22 2119 88.00 82 Des W 1.00 TMP 0.10
1,10-decanediol 0.9 27.56 37.84 2141 61.00 83 Prepolymer 1.00
1,4-butanediol 1.00 20.12 27.62 2933 84 Prepolymer 1.00
1,4-butanediol 0.75 19.66 27.00 3001 CHDM 0.25 85 Des W 0.41 PEG
0.03 1,4-butanediol 0.3565 56.78 77.95 1039 Polycaprolactone diol
0.003 Pluronic 0.03 86 Des W 1.00 TMP 0.30 1,5-pentanediol 0.46
21.71 29.80 2718 31.00 Polycarbonate diol 1 0.24 87 Des W 1.00 TMP
0.30 1,5-pentanediol 0.47 22.02 30.22 2680 Polycarbonate diol 1
0.23 88 Des W 1.00 TMP 0.30 1,5-pentanediol 0.48 22.33 30.66 2642
Polycarbonate diol 1 0.22
TABLE-US-00007 TABLE 6 Urethane Cyclic Molecular Wt. Hard Segmt
Formulation Polyisocyanate Branched Polyol Diol Content Content per
Crosslink Content No. Type Equivalents Type Equivalents Type
Equivalents (wt. %) (wt. %) (g/mole) (wt. %) 89 Des W 1.00 TMP 0.30
1,5-pentanediol 0.49 22.65 31.10 2604 Polycarbonate diol 1 0.21 90
Des W 1.00 TMP 0.30 1,5-pentanediol 0.51 23.33 32.03 2529
Polycarbonate diol 1 0.19 91 Des W 1.00 TMP 0.30 1,5-pentanediol
0.52 23.69 32.52 2491 Polycarbonate diol 1 0.18 92 Des W 1.00 TMP
0.30 1,5-pentanediol 0.53 24.05 33.02 2453 Polycarbonate diol 1
0.17 93 Des W 1.00 TMP 0.30 1,5-pentanediol 0.54 24.43 33.54 2415
Polycarbonate diol 1 0.16 94 Des W 1.00 TMP 0.30 1,5-pentanediol
0.55 24.82 34.07 2377 42.00 Polycarbonate diol 1 0.15 95 Des W 1.00
TMP 0.3 1,5-pentanediol 0.5 22.80 31.30 2020 Polycarbonate diol 2
0.2 96 Des W 1.00 TMP 0.3 1,5-pentanediol 0.65 29.43 40.41 2005
59.00 Polycarbonate diol 2 0.05 97 Des W 1.00 TMP 0.3
1,4-butanediol 0.65 30.11 41.34 1959 Polycarbonate diol 2 0.05 98
Des W 1.00 TMP 0.3 1,5-pentanediol 0.6 26.83 36.84 2199
Polycarbonate diol 2 0.1 99 Des W 1.00 TMP 0.3 1,4-butanediol 0.5
23.31 32.00 2532 Polycarbonate diol 1 0.2 100 Des W 1.00 TMP 0.3
1,4-butanediol 0.6 27.49 37.73 2147 Polycarbonate diol 1 0.1 101
Des W 1.00 TMP 0.30 1,4-butanediol 0.46 21.97 30.16 2686
Polycarbonate diol 1 0.24 102 Des W 1.00 TMP 0.30 1,4-butanediol
0.47 22.29 30.60 2647 Polycarbonate diol 1 0.23 103 Des W 1.00 TMP
0.30 1,4-butanediol 0.48 22.62 31.05 2609 Polycarbonate diol 1 0.22
104 Des W 1.00 TMP 0.30 1,4-butanediol 0.49 22.96 31.52 2570
Polycarbonate diol 1 0.21 105 Des W 1.00 TMP 0.30 1,4-butanediol
0.51 23.67 32.49 2493 Polycarbonate diol 1 0.19
TABLE-US-00008 TABLE 7 Molecular Hard Urethane Cyclic Weight per
Segment Formulation Polyisocyanate Branched Polyol Diol Content
Content Crosslink Content No. Type Equivalents Type Equivalents
Type Equivalents (wt. %) (wt. %) (g/mole) (wt. %) 106 Des W 1.00
TMP 0.30 1,4-butanediol 0.52 24.04 33.00 2455 Polycarbonate diol 1
0.18 107 Des W 1.00 TMP 0.30 1,4-butanediol 0.53 24.42 33.52 2416
Polycarbonate diol 1 0.17 108 Des W 1.00 TMP 0.30 1,4-butanediol
0.54 24.81 34.07 2378 Polycarbonate diol 1 0.16 109 Des W 1.00 TMP
0.30 1,4-butanediol 0.55 25.22 34.63 2339 Polycarbonate diol 1 0.15
110 Des W 1.00 TMP 0.05 CHDM 0.95 29.22 40.11 2019 111 Des W 1.00
TMP 0.05 Isopropylidene bis 0.95 13.43 18.44 12900 96.00
[(2-(2,6-dibromo- phenoxy)ethanol 112 Des W 1.00 TMP 0.05 CHDM 0.5
29.42 40.38 2006 96.00 Xylene glycol 0.45 113 Des W 1.00 TMP 0.05
1,8-octanediol 0.95 29.08 39.92 2029 114 Des W 1.00 TMP 0.05
1,10-decanediol 0.95 27.29 37.47 2162 115 Des W 1.00 TMP 0.05 CHDM
0.95 26.69 36.64 10965 Polycarbonate diol 1 0.05 116 Des W 1.00 TMP
0.05 1,4-butanediol 0.95 33.48 78.00 10570 95.00 117 Des W 1.00 TMP
0.05 1,5-pentanediol 0.95 32.26 44.30 11000 96.00 118 Des W 1.00
TMP 0.30 Polycaprolactone diol 0.2 23.31 32.00 2531 1,5-pentanediol
0.5 119 Des W 1.00 TMP 0.30 Polycaprolactone diol 0.15 25.10 34.46
2351 1,5-pentanediol 0.55 120 Des W 1.00 TMP 0.30
Dibutyl-1,3-propanediol 0.7 28.03 38.48 2105 75.00 121 Des W 1.00
TMP 0.30 Neopentyl glycol 0.7 32.58 44.74 1811 71.00 122 Des W 1.00
TMP 0.30 Ethylene glycol 0.7 35.50 48.80 1661 70.00
TABLE-US-00009 TABLE 8 Formulation Light Yellowness Refractive
Density No. Transmittance(%) Index Index (g/cm.sup.3) 1 91.84 0.44
1.524 1.1417 2 91.91 0.34 1.531 1.1307 3 91.9 0.33 1.531 1.1388 4
91.88 0.4 1.531 1.1209 5 91.58 0.66 1.544 1.1346 6 91.84 0.37 1.533
1.1261 7 91.87 0.34 1.531 1.1144 8 91.8 1.65 1.524 1.1051 9 91.93
0.5 1.527 1.0912 10 91.72 1.7 1.527 1.0929 15 1.524 1.0969 16 1.52
1.0685 17 1.525 1.1002 18 1.517 1.0976 19 1.521 1.0886 20 1.517
1.0979 21 1.517 1.1327 23 1.523 1.1043 24 1.517 1.0971 25 1.521
1.1372 26 1.525 1.0876 29 1.512 1.0984 30 1.531 1.1049 31 1.508
1.072 32 1.527 1.1123 37 1.522 1.086 38 1.522 1.0831 39 1.524
1.0921 40 1.525 1.0846 41 1.522 1.0866 42 1.524 1.0928 43 1.525
1.076 44 1.526 1.0796 58 1.145
TABLE-US-00010 TABLE 9 Tensile Gardner Modulus at Elongation at
Impact Formulation Taber Abrasion Bayer Abrasion Yield Yield
Strength No. # Cycles % Haze % Haze K-Factor (lb/in.sup.2) (%)
(In-lbs) 1 100 28.5 29.45 1245.6 336000 41 427 2 60+ 30.8 31.48
1362.4 367000 19/38 628 3 100 20.5 22.55 781.83 350000 3.9/19 100 4
100 29 35.87 1313.6 311000 56 595 5 100 27.8 26.53 902.82 338000
4.7 168 6 100 24.7 28.75 1152.1 339000 32 214 7 100 28.6 33.05
1230.1 327000 34 236 8 100+ 31.1 39.92 1522.3 287000 55 584 9 100+
32.4 47.7 3564.8 251000 14 576 10 100+ 31 44.75 3104.1 258000 17
593 15 60+ 32.7 42.17 2073 259000 16 512 16 60 45.9 45.5 3621
238000 19 365 17 100 28.7 32.7 940 295000 8.4 158 18 26.4 34.68
1227 286000 14 220 19 33.9 45.9 4309 260000 14 595 20 25.1 42.88
1765 378000 4.3 553 21 28 40.77 3211 312000 14 536 23 38 43.08 4628
265000 12 461 24 39.1 43.17 4869 251000 15 497 25 24.5 37.83 4528
246000 14 627 26 38.1 38.78 1415 262000 19 179 28 42.6 834 327000 3
29 40.4 33.88 2351 369000 4.4 146 30 22.4 38.78 1150 274000 16 204
31 41.8 25.32 2252 216000 433 32 41.83 46.55 1852 278000 14 518
TABLE-US-00011 TABLE 10 Tensile Gardner Modulus at Elongation at
Impact Formulation Taber Abrasion Bayer Abrasion Yield Yield
Strength No. # Cycles % Haze % Haze K-Factor (lb/in.sup.2) (%)
(In-lbs) 38 45.82 41.72 1319 264000 15 614 39 46.58 38.47 1749
256000 18 632 40 45.78 44.52 1651 255000 22 531 41 45.02 41.7 1771
247000 16 356 42 36.23 41.12 1777 249000 18 581 43 43.12 40.85 4005
238000 15 598 44 41.88 35.67 997 279000 4.6 71 48 295000 5.4 192 49
295000 6.1 327 50 284000 8.6 104 51 290000 5.6 426 52 294000 8.3 71
53 299000 5.3 112 54 292000 5.3 111 55 292000 5.9 164 56 314000 5.7
40 57 299000 5.1 70 58 215000 20 365 59 4035 283000 10 299 60 1598
284000 18 379 61 260000 17 546 62 876 346000 3.2 24 63 737 334000
4.2 14 64 1119 349000 2.9 27 65 669 357000 2.8 66 638 368000 2.4 12
67 216
TABLE-US-00012 TABLE 11 Tensile Gardner Modulus at Elongation at
Impact Formulation Taber Abrasion Bayer Abrasion Yield Yield
Strength No. # Cycles % Haze % Haze K-Factor (lb/in.sup.2) (%)
(In-lbs) 68 203 69 133 70 80 71 56 72 106 73 136 74 40 75 38 76 63
77 64 78 125 79 333 80 376 81 376 82 346 83 2235 84 2185 86 317 87
328 88 451 89 227000 15 472 90 244000 11 445 91 255000 21 411 92
263000 19 426 93 266000 9 443 94 270000 12 403 95 259000 13 406 96
280000 19 255 97 299000 5 290 98 272000 13 405 99 346 100 333 101
363 102 364
TABLE-US-00013 TABLE 12 Tensile Gardner Modulus at Elongation at
Impact Formulation Taber Abrasion Bayer Abrasion Yield Yield
Strength No. # Cycles % Haze % Haze K-Factor (lb/in.sup.2) (%)
(In-lbs) 103 367 104 367 105 360 106 404 107 362 108 371 109 327
110 97 113 334 114 552 118 82
TABLE-US-00014 TABLE 13 Coefficient of Dynatup Glass Thermal
Formulation Impact Shore D Transition Expansion No. Strength
Hardness Temp. (in/in) 1 17.6 79 126 2 24.28 88 119 81.91 3 4.04 88
140 4 25.4 86 117.1 5 8.6 88 156 6 15.2 86 132 7 27.2 86 129.9 8
31.5 82 106 9 38.4 80 99.1 94.65 10 35.5 81 102 15 24.8 80 105 16
34.4 79 93 17 13.9 88 123.9 18 40.9 83 119 19 44.3 81 89.1 20 26.1
83 75.1 70.01 21 39.6 81 97 23 17.9 79 87 101.11 24 33.4 80 79.2
97.2 25 44.9 78 76.1 95.66 26 28.6 84 106 29 5.34 85 71.1 72.36 30
30.7 85 120.1 31 41 79 52.1 96.91 32 46.5 82 104 38 33.2 81 111.1
39 32.9 81 103.9 40 41.9 81 101.1 41 27.5 80 42 25.1 81 43 35.3 80
97 44 3.15 86 48 25.2 49 4.24 50 26.3 51 21.6 52 31.6 53 22.2 54
26.7 55 41.6 56 20..7
TABLE-US-00015 TABLE 14 Coefficient of Dynatup Glass Thermal
Formulation Impact Shore D Transition Expansion No. Strength
Hardness Temp. (in/in) 57 17.2 58 62.3 66 59 36.6 60 37.4 61 38.9
62 152 63 134 64 150 65 174 66 166 67 161 89 42.6 90 48.4 91 50.2
92 48 93 56.5 94 45.1 95 47.5 96 47.5 97 34.3 98 39.2
TABLE-US-00016 TABLE 15 Molecular Weight Hard Urethane Cyclic per
Segment Formulation Polyisocyanate Branched Polyol Diol Content
Content Crosslink Content Water No. Type Equivalents Type
Equivalents Type Equivalents (wt. %) (wt. %) (g/mole) (wt. %)
(Equivalents) 123 Des W 1.00 TMP 0.3 1,5-pentanediol 0.554 29.67
40.74 1988 0.19 Polycarbonate 0.57 diol 1 124 Des W 1.00 TMP 0.3
1,5-pentanediol 0.374 27.73 38.07 2128 0.22 Polycarbonate 0.11 diol
1 125 Des W 1.00 TMP 0.3 1,5-pentanediol 0.5 34.22 46.98 1724 0.20
126 Des W 1.00 TMP 0.3 1,5-pentanediol 0.45 30.85 42.35 1913 0.20
Polycarbonate 0.05 diol 1 127 Des W 1.00 TMP 0.3 1,5-pentanediol
0.4 28.08 38.55 2101 0.20 Polycarbonate 0.1 diol 1 128 Des W 1.00
TMP 0.30 CHDM 0.6 31.25 42.91 1888 0.1 129 Des W 1.00 TMP 0.90
34.24 47.00 1723 0.1 130 Des W 1.00 TMP 0.30 CHDM 0.55 31.79 43.64
1856 0.15 131 Des W 1.00 TMP 0.3 1,5-pentanediol 0.55 30.17 41.42
1956 0.10 Polycarbonate 0.05 diol 1 132 Des W 1.00 TMP 0.3
1,5-pentanediol 0.5 27.52 37.78 2144 0.10 Polycarbonate 0.1 diol 1
133 Des W 1.00 TMP 0.3 1,5-pentanediol 0.55 33.80 46.40 1746
0.15
TABLE-US-00017 TABLE 16 Light Formulation Transmittance Yellow
Refractive Density No. (%) Index Index (g/cm.sup.3) 125 1.119 126
1.125 127 1.133 128 1.113 129 1.128 130 1.113 131 1.127 132
1.129
TABLE-US-00018 TABLE 17 Tensile Gardner Modulus at Elongation at
Impact Formulation Taber Abrasion Bayer Abrasion Yield Yield
Strength No. # Cycles % Haze % Haze K-Factor (lb/in.sup.2) (%)
(In-lbs) 125 355000 13 51 126 1113 305000 4 24 127 1551 282000 12
244 128 853 369000 16 56 129 686 441000 7.5 8 130 766 389000 15 37
131 290000 7.7 126 132 289000 19 328 133 289000 11 224
TABLE-US-00019 TABLE 18 Coefficient of Dynatup Glass Thermal
Formulation Impact Shore D Transition Expansion No. Strength
Hardness Temp. (in/in) 125 137 126 14.6 115 127 30 67 128 3.31 161
129 3 130 8.67 153 131 32.5 132 133 9.29
[0922] The above samples exhibited low yellowness, high light
transmittance, high impact strength and good ballistic
resistance.
[0923] A 6''.times.6'' (15.2 cm.times.15.2 cm) laminate of 2'' (5.1
cm) of molded Formulation 2 below facing outward, laminated to a
1'' (2.5 cm) ply of molded Formulation 9 below, and 0.5'' (1.3 cm)
of molded Formulation 60 stopped or deflected four consecutive
AK-47, 7.62 mm.times.39 mm shots from 150 feet (45.7 m). Each layer
was molded as described above. No glass ply was used in the
laminate. The laminate was heated in an autoclave at about
300.degree. F. (149.degree. C.) for about 2 hours.
[0924] Samples of Polycast 84 aerospace stretched acrylic
(commercially available from Spartech of Clayton, Mo.) and samples
of polymer of Example A, Formulation 2 (synthesized at 110.degree.
C. and cured at 143.degree. C. as discussed above) were evaluated
for physical properties as set forth in Table 19 below. The Sample
of Example A, Formulation 2 had lower density, higher impact
strength and elongation, and was tougher than the tested sample of
stretched acrylic. LEXAN #8574K26 polycarbonate (commercially
available from McMaster Carr Supply Co. of Cleveland, Ohio) and
samples of polymer of Example A, Formulation 84 (synthesized at
110.degree. C. and cured at 143.degree. C. as discussed above) were
evaluated for physical properties as set forth in Table 20 below.
The Example A, Formulation 84 had better solvent resistance, UV
resistance and higher impact strength than the tested sample of
LEXAN.
TABLE-US-00020 TABLE 19 Sample of Formulation 2 of Property
Stretched Acrylic Example A Light Transmission 92 92 % Haze <1%
<0.1% Density 1.18 1.13 Solvent/75% aqueous sulfuric 1000-4000
psi stress acid resistance K factor 2400 1500 Gardner Impact Test
(in-lbs) 16 628 High Speed Multiaxial Impact 3.6 26.5 (unprocessed)
% Elongation (at break) <5 38% % Elongation <5 40% (1000 hrs
QUV-B) Tensile Strength 11,250 11,800 Tensile Modulus 450,000
367,000 Glass Transition Temperature 205 247.degree. F.
(119.degree. C.) Heat Distortion Temp. shrinks above 180.degree. F.
235.degree. F. (113.degree. C.) Abrasion Resistance: % Haze, 30 15
100 cycles Taber Abrader Refractive Index 1.49 1.519 Shore D
Durometer 94 90
TABLE-US-00021 TABLE 20 Sample of Formulation 84 of Property
Polycarbonate Example A Light Transmission 88 92 Density 1.2 1.08
Solvent Resistance Poor OH, H+, Acetone Good OH, H+, Acetone
Gardner Impact Mean Failure 588 in-lb >640 in-lbs Energy (>72
J) High Speed Multiaxial Impact 72 joules 105 Joules % Haze, 100
cycles Taber 60% 15% Abrader Refractive Index 1.586 1.519 Tensile
Modulus 320,000 300,000 Tensile Strength 8000 psi 8500 psi %
Elongation (at break) 100% 200% % Elongation severe degradation 97%
(1000 hrs QUV-B) brittle-yellow Heat Distortion Temp. 275.degree.
F. 220.degree. F. Glass Transition Temperature 305 F. 240 F. Shore
D Durometer 85 80
DMA Testing
[0925] A sample of Formulation 114 (prepared from 0.95 equivalents
of 1,10-decanediol, 0.05 equivalents of trimethylolpropane and 1.0
equivalents of 4,4'-methylene-bis-(cyclohexyl isocyanate) (DESMODUR
W)) using Dynamic Mechanical Analysis (DMA) for storage modulus,
loss modulus and tan Delta. The DMA analysis was conducted on a
solid, clamped sample (2''.times.2''.times.1/8'') (5.1 cm.times.5.1
cm.times.0.3 cm) vibrated at a frequency of 1 Hz over a wide
temperature range increased at a rate of 3.degree. C./min. As shown
in FIG. 16, the sample exhibited a low temperature transition in
the loss modulus at about -70.degree. C., which is unusual for
glass polymers and indicates molecular torsional motion at this low
temperature. A second transition is present at about 14.degree. C.
The glass transition temperature of this polymer is 71.degree. C.,
which is a maximum in the tan Delta graph. At this temperature, the
polymer is most efficient at converting mechanical vibrations into
heat, thus it is at this temperature that the polymer reaches a
maximum in damping properties. The storage modulus is the energy
conserved by the polymer and can be related to the Young's Modulus
or stiffness of the polymer.
Ballistics Testing
Example AA
[0926] A 6''.times.6''.times.1'' (15.2 cm.times.15.2 cm.times.2.5
cm) thick sample of Formulation 2 from Example A above was cured by
heating at 290.degree. F. (143.degree. C.) for 48 hours. Four .40
caliber bullets shot from 30 feet (9.1 m) at a velocity of 987
ft/sec (300 m/sec) ricocheted off the surface of the sample and the
plastic did not crack. A photograph of a perspective view of the
test sample is shown in FIG. 17.
Example AB
[0927] A 6''.times.6''.times.3/8'' (15.2 cm.times.15.2 cm.times.1
cm) formulation thick sample of Formulation 2 from Example A above
was cured by heating at 290.degree. F. (143.degree. C.) for 48
hours. A 12-gauge shotgun shot from 20 feet (6.1 m) at a velocity
of 1290 ft/sec (393 m/sec) using heavy game lead shot pellets
ricocheted off the surface of the sample and the plastic did not
crack. A photograph of a front elevational view of the test sample
is shown in FIG. 18.
Example AC
[0928] A 6''.times.6''.times.1'' (15.2 cm.times.15.2 cm.times.2.5
cm) thick sample of Formulation 93 from Example A above was cured
by heating at 290.degree. F. (143.degree. C.) for 48 hours. Three 9
mm bullets shot from 20 feet (6.1 m) at a velocity of 1350 ft/sec
(411 m/sec) stuck in the sample. A photograph of a front
elevational view of the test sample is shown in FIG. 19.
Example AD
[0929] A 6''.times.6''.times.1'' (15.2 cm.times.15.2 cm.times.2.5
cm) thick sample of Formulation 94 from Example A above was cured
by heating at 290.degree. F. (143.degree. C.) for 48 hours. A 9 mm
bullet shot from 20 feet (6.1 m) at am initial velocity of 1350
ft/sec (411 m/sec) stuck in the sample. Photographs of the test
sample is shown in FIGS. 20 and 21. FIG. 20 is a perspective view
of the sample showing the bullet embedded in the sample surface.
FIG. 21 is a side elevational view of the sample showing the bullet
entrance into the sample.
Example AE
[0930] A 6''.times.6''.times.1'' (15.2 cm.times.15.2 cm.times.2.5
cm) thick sample of Formulation 2 from Example A above was cured by
heating at 290.degree. F. (143.degree. C.) for 48 hours. A
6''.times.6''.times.1'' thick sample of Formulation 9 from Example
A above was cured by heating at 290.degree. F. (143.degree. C.) for
48 hours. A 6''.times.6''.times.0.5'' (15.2 cm.times.15.2
cm.times.1.75 cm) thick sample of Formulation 58 from Example A
above was cured by heating at 290.degree. F. (143.degree. C.) for
48 hours. A composite was prepared by assembling a 1'' (2.5 cm)
thick layer of the sample of Formulation 2, a 1'' (2.5 cm) thick
layer of the sample of Formulation 9, and a 0.5'' (1.25 cm) thick
layer of the sample of Formulation 58 such that the layer of
Formulation 2 faced the rifle.
[0931] Four 7.62.times.39 mm bullets having a steel core were shot
from an AK-47 rifle from a distance of 30 yards (27.4 m) at an
initial velocity of 2700 ft/sec (823 m/sec). The first bullet
stopped in the middle layer of Formulation 9, generally parallel to
the initial shot direction. The second through fourth bullets
stopped in the far layer of Formulation 58, generally parallel to
the initial shot direction. Photographs of the test sample is shown
in FIGS. 22 and 23. FIG. 22 is a front elevational view of a
portion of the sample showing bullet entry points and two bullets
embedded in the sample surface. FIG. 23 is a rear perspective view
of the sample showing the two exiting bullets lodged in the
Formulation 58 layer of the sample.
Example AF
[0932] Samples prepared from Formulations 58 and 89-97 of Example A
above performed similarly, i.e., all "caught" bullets. A sample
prepared from Formulation 94 showed the least amount of sample
penetration with about 1/8'' of the back of the bullet protruding
from the surface. No ductile bulge was observed in the back of the
sample prepared from Formulation 94. Penetration was greatly
reduced compared to samples prepared from Formulations 58 and
89-92
Example B
Comparative Non-Limiting Example of Processing Temperature of
80.degree. C. vs. 110.degree. C.
[0933] Short chain diols (aliphatic diols having 4 to 8 carbon
atoms as discussed above) are typically immiscible in isocyanates
due to the polarity difference and surface tension difference
between the two materials. It has been found that when the short
chain diol and isocyanate are mixed at 80.degree. C. or less, they
take longer to become a clear solution than at 110.degree. C. or
higher. Although the solutions may both appear clear, it has been
found that there is an inhomogeneity that manifests itself in cured
articles at much lower impact strengths than when the solutions are
made at or above 110.degree. C. In addition, when casting or
reaction injection molding into a glass mold, any cooling that
occurs from pouring and exposure to air, or the mold temperature
being below 100.degree. C., exacerbates the inhomogeneity problem
as further cooling increases the inhomegeneity. If temperatures
drop even further, the short chain diol and isocyanate will phase
separate and appear as haze. This haze generally will not clear in
an oven heated to 120.degree. C. to 140.degree. C. after pouring
into a mold and heating for 24 to 48 hours. Higher variations in
impact strength also have been observed as the processing
temperatures drop below 100.degree. C. Above 110.degree. C., the
initial Gardner Impact strengths for polymers of this invention are
higher initially, and show less variation in impact strengths from
batch to batch when processed above 110.degree. C. The examples
below illustrate the temperature effect.
Example B1
[0934] The following components 20.1 grams of 1,5 pentanediol, 7.5
grams of trimethylolpropane and 72.45 grams of DESMODUR W
containing 20% trans-trans isomer of 4,4'-methylene-bis-(cyclohexyl
isocyanate) were charged into a glass kettle fitted with a
thermometer and overhead stirrer. The charge was brought up to a
temperature of 110.degree. C. to 120.degree. C. while mixing and
applying vacuum (2 mm mercury (266 Pa)) to remove bubbles. The
batch was mixed for 10 to 20 minutes after reaching 110.degree. C.
to 120.degree. C.
[0935] The batch was cast into a heated glass mold that was
preheated in an oven at 140.degree. C. The polymer was cured for 48
hours at 140.degree. C. without catalyst. After curing, the mold
was removed from the oven and allowed to cool to room temperature.
The plastic sheet was then removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The initial Gardner Impact
strength averaged 260 in-lbs (30 J).
Example B2
[0936] The following components: 20.1 grams of 1,5 pentanediol, 7.5
grams of trimethylolpropane and 72.45 grams of DESMODUR W
containing 20% trans-trans isomer of 4,4'-methylene-bis-(cyclohexyl
isocyanate) were charged into a glass kettle fitted with a
thermometer and overhead stirrer. The charge was brought up to a
temperature of 80.degree. C. to 90.degree. C. while mixing and
applying vacuum (2 mm mercury (266 Pa)) to remove bubbles. The
batch was mixed for 1 to 2 hours after reaching 80.degree. C. to
90.degree. C. until the batch appeared clear.
[0937] The batch was cast into a heated glass mold that had been
preheated in an oven at 140.degree. C. The polymer was cured for 48
hours at 140.degree. C. without catalyst. After curing, the mold
was removed from the oven and allowed to cool to room temperature.
The plastic sheet was removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The initial Gardner Impact
strength averaged 62 in-lbs (7 J).
Example B3
[0938] The following components 17.9 grams of 1,4 butanediol, 7.4
grams of trimethylolpropane and 74.47 grams of DESMODUR W
containing 20% trans-trans isomer of 4,4'-methylene-bis-(cyclohexyl
isocyanate) were charged into a glass kettle fitted with a
thermometer and overhead stirrer. The charge was brought up to a
temperature of 110.degree. C. to 120.degree. C. while mixing and
applying vacuum (2 mm mercury (266 Pa)) to remove bubbles. The
batch was mixed for 10 to 20 minutes after reaching 110.degree. C.
to 120.degree. C.
[0939] The batch was cast into a heated glass mold that had been
preheated in an oven at 140.degree. C. The polymer was cured for 48
hours at 140.degree. C. without catalyst. After curing, the mold
was removed from the oven and allowed to cool to room temperature.
The plastic sheet was removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The initial Gardner Impact
strength averaged 180 in-lbs (21 J).
Example B4
[0940] The following components: 17.9 grams of 1,4 butanediol, 7.4
grams of trimethylolpropane and 74.47 grams of DESMODUR W
containing 20% trans-trans isomer of 4,4'-methylene-bis-(cyclohexyl
isocyanate) were charged into a glass kettle fitted with a
thermometer and overhead stirrer. The charge was brought up to a
temperature of 80.degree. C. to 90.degree. C. while mixing and
applying vacuum (2 mm mercury (266 Pa)) to remove bubbles. The
batch was mixed for 1 hour to 2 hours after reaching 80.degree. C.
to 90.degree. C. until clear.
[0941] The batch was cast into a heated glass mold that had been
preheated in an oven at 140.degree. C. The polymer was cured for 48
hours at 140.degree. C. without catalyst. After curing, the mold
was removed from the oven and allowed to cool to room temperature.
The plastic sheet was removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The initial Gardner Impact
strength averaged 10-15 in-lbs (1 J-1.5 J).
Example C
[0942] To estimate the overall percentage of aligned crystalline
domains in samples of polyurethanes according to the present
invention, samples of Formulation No. 2 (0.7 equivalents of
1,5-pentanediol (PDO), 0.3 equivalents of trimethylolpropane (TMP)
and 1 equivalent of 4,4'-methylene-bis-(cyclohexyl isocyanate)
(DESMODUR W)) and Formulation No. 136 (0.95 equivalents of PDO,
0.05 equivalents of TMP and 1 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate) (DESMODUR W)) were
tested using Differential Scanning Calorimetry (DSC) at 2.degree.
C./min and Thermogravimetric Analysis (TGA).
[0943] Each sample was prepared by mixing all components in the
respective formulation at about 110.degree. C. for about 30
minutes, degassed under vacuum for about 5 to about 10 minutes,
then casting in a glass mold heated to about 200.degree. F.
(93.degree. C.) for about 48 hours and cooled to room temperature
(25.degree. C.) and released from the mold. The sample of
Formulation No. 2 was aged at about 25.degree. C. for about seven
months.
[0944] The sample of Formulation No. 136 (aged at about 25.degree.
C. for about two weeks) was used as a control sample, and its
percentage of aligned crystalline domains was used as a reference
for 100% crystallinity. With respect to the 100% crystallinity of
the sample of Formulation No. 136, the percentage of aligned
crystalline domains in Formulation No. 2 was calculated to be 42%.
An endothermic peak at around .about.260.degree. C. was found for
both samples and attributed to the melting of their ordered
domains. The DSC data for each of the samples of Formulation Nos. 2
and 136 are presented in Table 21 below and in FIGS. 24 and 25,
respectively. Thermogravimetric Analysis data (TGA) for a sample of
Formulation 136 is presented in FIG. 26.
TABLE-US-00022 TABLE 21 Summary of DSC Test Results Sample No. 136
2 Equivalents and Components 0.95 PDO + 0.05 0.7 PDO + 0.3 TMP + of
Formulation TMP + 1 Des W 1 Des W Tg (.degree. C.) 99 Peak
Endotherm (.degree. C.) 260 260 Heat Capacity (J/g) 3.77 1.63
Estimated Crystalline 100 42 Domain (%) (Control)
Example D
Ballistic Testing
Example D1
[0945] A polyurethane polymer according to the present invention
was prepared from the components listed below in Table 22:
TABLE-US-00023 TABLE 22 Desired Polymer Batch Solids Wt. (g) Size
(g) Monomer Name 1,10- TMP Des W 205.30 300.00 decanediol OH # --
-- -- Acid # -- -- -- Equivalent Wt. 87 44.00 131.2 Equivalents
desired 0.7 0.3 1.0 Mass Monomer 60.90 13.20 131.20 Weight %
Monomer 29.66% 6.43% 63.91% Monomer masses 88.99 19.29 191.72 for
experiment Weight % Hard 74.40 Segment Weight % Urethane 28.74
Molecular Weight 2053.00 per Crosslink (g/mole) (M.sub.c)
[0946] The 1,10 decanediol, trimethylolpropane and DESMODUR W were
preheated to 80.degree. C. and added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.115.degree. C. and allowed to compatibilize. Once clear,
the mixture was degassed, and cast into a
12''.times.12''.times.0.125'' (30.5 cm.times.30.5 cm 0.3 cm)
casting cell preheated to 121.degree. C. The filled cell was cured
for 48 hours at 143.degree. C.
[0947] This formulation in a 6''.times.6''.times.1'' (15.2
cm.times.15.2 cm.times.2.5 cm) thickness passed a .40 caliber
pistol shot from 30 feet (9.1 m) and 987 ft/sec speed with no
cracking. From 20 feet (6.1 m) the bullet was also stopped and no
cracking was observed. The formulation also passed multiple 9 mm,
1350 ft/sec (411 m/sec) shots from 20 feet (6.1 m) without
cracking. In addition, the formulation also passed 3 consecutive
12-gauge shotgun shots (1290 ft/sec) from 30 feet (9.1 m) in a
3/8'' thickness (18''.times.12''.times.3/8'') (46 cm.times.30
cm.times.1 cm) using heavy game lead shot. In each test, the
bullets ricocheted off the target.
Example D2
[0948] A polyurethane polymer according to the present invention
was prepared from the components listed below in Table 23:
TABLE-US-00024 TABLE 23 Desired Polymer Batch Solids Wt. (g) Size
(g) Monomer Name PC-1733 1,5-pentanediol TMP Des W 239.04 300.00 OH
# -- -- -- -- Acid # -- -- -- -- Equivalent 440 52.08 44.00 131.2
Wt. Equivalents 0.15 0.55 0.3 1.0 desired Mass 66.00 28.64 13.20
131.20 Monomer Weight % 27.61% 11.98% 5.52% 54.89% Monomer Monomer
82.83 35.95 16.57 164.66 masses for experiment Weight % 35.84 Hard
Segment Weight % 24.68 Urethane Molecular 2390.4 Weight per
Crosslink (g/mole) (M.sub.c)
[0949] The 1,5 pentanediol, PC-1733, and trimethylolpropane and
DESMODUR W preheated to 80.degree. C. were added to a glass kettle.
Under nitrogen blanket and with constant stirring, the mixture was
heated to .about.105.degree. C. and allowed to compatibilize. Once
clear, the mixture was degassed, and cast into a
12''.times.12''.times.0.125'' (30.5 cm.times.30.5 cm 0.3 cm)
casting cell preheated to 121.degree. C. The filled cell was cured
for 48 hours at 143.degree. C.
[0950] This formulation passed multiple 9 mm, 115 grain, 1350
ft/sec shots by "catching" in bulk of the polymer in a
6''.times.6''.times.1'' (15.2 cm.times.15.2 cm.times.2.5 cm)
sample. The bullet penetration was approximately 0.25'' (0.6 cm)
with no ductile bulge in the back of the sample. The same
formulation 4''.times.4''.times.1'' (10.1 cm.times.10.1
cm.times.2.5 cm) sample also passed multiple .40 caliber shots in
which the bullet was not caught or ricocheted. The bullet was
sitting, slightly deformed, at the base of the sample. In a 3/8''
(1 cm) thickness, this formulation passed three 12-gauge shotgun
shots from 30 feet (9.1 m). Most of the shots were embedded in the
surface of the sample.
Example D3
[0951] A polyurethane polymer according to the present invention
was prepared from the components listed below in Table 24:
TABLE-US-00025 TABLE 24 Desired Polymer Batch Solids Wt. (g) Size
(g) Monomer Name 1,4- TMP Des W 175.94 300.00 butanediol OH # -- --
-- Acid # -- -- -- Equivalent Wt. 45.06 44.00 131.2 Equivalents
desired 0.7 0.3 1.0 Mass Monomer 31.54 13.20 131.20 Weight %
Monomer 17.93% 7.50% 74.57% Monomer masses 53.78 22.51 223.71 for
experiment Weight % Hard 70.13 Segment Weight % Urethane 33.53
Molecular Weight 1759.42 per Crosslink (g/mole) (M.sub.c)
[0952] The 1,4-butanediol, trimethylolpropane and DESMODUR W
preheated to 80.degree. C. were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. Once clear,
the mixture was degassed, and cast into a
12''.times.12''.times.0.125'' (30.5 cm.times.30.5 cm 0.3 cm)
casting cell preheated to 121.degree. C. The filled cell was cured
for 48 hours at 143.degree. C.
[0953] This formulation in a 6''.times.6''.times.1'' (15.2
cm.times.15.2 cm.times.2.5 cm) sample passed multiple .40 caliber
shots from 30 feet (9.1 m) with no cracking. The speed of the .40
caliber was 987 ft/sec (300 m). In 3/8'' thickness at 60 ft (18.2
m), it passed multiple 12-gauge shotgun impacts with heavy gauge
shot at 1290 ft/sec (393 m/sec) muzzle velocity. At 20 fit (6.1 m)
and 30 ft (9.1 m), this formulation in 1'' (2.5 cm) thickness broke
when shot with a 9 mm pistol, 115 grain bullet with a speed of 1350
ft/sec (411 m/sec).
Example D4
[0954] A polyurethane polymer according to the present invention
was prepared from the components listed below in Table 25:
TABLE-US-00026 TABLE 25 Desired Polymer Batch Solids Wt. (g) Size
(g) Monomer Name 1,5- TMP Des W 180.85 300.00 pentanediol OH # --
-- -- Acid # -- -- -- Equivalent Wt. 52.075 44.00 131.2 Equivalents
0.7 0.3 1.0 desired Mass Monomer 36.45 13.20 131.20 Weight % 20.16%
7.30% 72.55% Monomer Monomer masses 60.47 21.90 217.64 for
experiment Weight % Hard 70.94 Segment Weight % 32.62 Urethane
Molecular Weight 1808.53 per Crosslink (g/mole) (M.sub.c)
[0955] The 1,5-pentanediol, trimethylolpropane and DESMODUR W
preheated to 80.degree. C. were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to 115.degree. C. and allowed to compatibilize. Once clear, the
mixture was degassed, and cast into a 12''.times.12''.times.0.125''
(30.5 cm.times.30.5 cm 0.3 cm) casting cell preheated to
121.degree. C. The filled cell was cured for 48 hours at
143.degree. C.
[0956] This formulation in a 6''.times.6''.times.1'' (15.2
cm.times.15.2 cm.times.2.5 cm) sample passed a .40 caliber pistol
shot from 30 feet (9.1 m) and 987 ft/sec (300 m) speed with no
cracking. From 20 feet (6.1 m) the bullet was also stopped but some
small cracks were observed. The formulation also passed multiple 9
mm, 1350 ft/sec (411 m/sec) shots from 20 feet (6.1 m) without
cracking. In addition, the formulation also passed three
consecutive 12-gauge shotgun shots (1290 ft/sec) (393 m/sec) from
30 feet (9.1 m) in a 3/8'' (1 cm) thickness using heavy game lead
shot.
Example D5
[0957] A polyurethane polymer according to the present invention
was prepared from the components listed below in Table 26:
TABLE-US-00027 TABLE 26 Desired Polymer Batch Solids Wt. (g) Size
(g) Monomer Name KM10-1733 1,5-pentanediol TMP Des W 258.44 300.00
OH # -- -- -- -- Acid # -- -- -- -- Equivalent Wt. 440 52.075 44.00
131.2 Equivalents 0.2 0.5 0.3 1.0 desired Mass Monomer 88.00 26.04
13.20 131.20 Weight % 34.05% 10.07% 5.11% 50.77% Monomer Monomer
masses 102.15 30.22 15.32 152.30 for experiment Weight % Hard 44.20
Segment Weight % 22.83 Urethane Molecular Weight 2584.38 per
Crosslink (g/mole) (M.sub.c)
[0958] The 1,5 pentanediol, KM10-1733 polycarbonate diol, and
trimethylolpropane and DESMODUR W preheated to 80.degree. C. were
added to a glass kettle. Under nitrogen blanket and with constant
stirring, the mixture was heated to .about.105.degree. C. and
allowed to compatibilize. Once clear, the mixture was degassed, and
cast into a 12''.times.12''.times.0.125'' (30.5 cm.times.30.5 cm
0.3 cm) casting cell preheated to 143.degree. C. The filled cell
was cured for 48 hours at 121.degree. C.
[0959] This formulation passed multiple 9 mm, 115 grain, 1350
ft/sec (393 m/sec) shots by "catching" in bulk of the polymer in a
6''.times.6''.times.1'' (15.2 cm.times.15.2 cm.times.2.5 cm)
sample. The bullet penetration was approximately 0.5'' (1.2 cm)
with a slight ductile bulge in the back of the sample. The same
sample 4''.times.4''.times.1'' (10.1 cm.times.10.1 cm.times.2.5 cm)
also passed multiple .40 caliber shots in which the bullet was not
caught or ricocheted. It was sitting, slightly deformed at the base
of the sample. In a 3/8'' (1 cm) thickness this formulation passed
three 12-gauge shotgun shots from 30 feet (9.1 m). Most of the
shots were embedded in the surface of the sample.
[0960] All 9 mm shots were 115 grain, 1350 ft/sec (411 m/sec)
muzzle velocity shot from a Ruger 9 mm pistol. All .40 caliber
shots were shot at 987 ft/sec (300 m) muzzle velocity from a Smith
& Wesson .40 caliber pistol. All 12-gauge shotgun shots were
shot using a Remington 12-gauge shotgun using lead shot, heavy game
load, at 1290 ft/sec (393 m/sec) muzzle velocity. Samples were shot
attached to a 12'' thick wooden block using Velcro.RTM. with no
framing to hold the sample. Shooting was conducted outdoors at
temperatures ranging from about 60.degree. F. (15.degree. C.) to
about 80.degree. F. (27.degree. C.).
Example E
[0961] Samples prepared from Formulation 2 of Example A above were
prepared and tested for Gardner Impact Strength as in Example A
above. Sample E1 was prepared using a 35 weight percent trans,
trans isomer of 4,4'-methylene-bis-(cyclohexyl isocyanate). Sample
E2 was prepared using a 17 weight percent trans, trans isomer of
4,4'-methylene-bis-(cyclohexyl isocyanate). The Gardner Impact
Strength of Sample E1 was 150 in-lbs (17 J). The Gardner Impact
Strength of Sample E2 was 40 in-lbs (5 J). The Sample E1 prepared
using a higher weight percentage of trans, trans
4,4'-methylene-bis-(cyclohexyl isocyanate) had higher Gardner
Impact Strength than Sample E2, which was prepared using a lower
weight percentage of trans, trans 4,4'-methylene-bis-(cyclohexyl
isocyanate).
Example F
[0962] Samples were prepared from Formulation 1 of Example 1 above,
further including 3 weight percent of CIBA TINUVIN B75 liquid light
stabilizer system (commercially available from Ciba Specialty
Chemicals) (which is a mixture of 20 weight percent IRGANOX 1135,
40 weight percent of TINUVIN 571 and 40 weight percent of TINUVIN
765). The initial Gardner Impact Strength was 75 in-lbs (9 J).
After 1000 hours QUV-B, the Gardner Impact Strength was 75 in-lbs
(9 J). The initial tensile strength was 13,400 psi (92.4 MPa) and
after 1000 hours QUV-B was 13,100 psi (90.3 MPa). The initial
percent elongation was 40% and after 1000 hours QUV-B was 50%.
Example G
Elastoplastic Polyurethane Examples
Example G1
[0963] The following reactants: 131.2 grams of DESMODUR W, 13.41
grams of trimethylolpropane, 26.015 grams of 1,5 pentanediol, and
81.712 grams Stahl KM-1733 1000 molecular weight polycarbonate diol
based on hexanediol were mixed together, heated to 80.degree. C.
and degassed. Ten ppm of dibutyltindiacetate was added and mixed
until the solution was homogeneous. The mixture was poured into a
glass mold and cured for 48 hours at 290.degree. F. (143.degree.
C.). After curing, the cell was allowed to cool to room temperature
(25.degree. C.) and the polymer was released from the mold. The
polymer had a Young's Modulus of 215,000 psi (about 1482 MPa). The
weight % urethane content was 23.4%. The molecular weight per
crosslink was 2548 grams/mole. The weight % cyclic content was
32%.
[0964] An article of 6''.times.6''.times.1'' (15.2 cm.times.15.2
cm.times.2.5 cm) thickness prepared from this polymer stopped a 9
mm, 125 grain, bullet shot an initial velocity of 1350 ft/sec (411
m/sec) (from 20 feet (6.1 m) distance by trapping the bullet in the
polymer. The back of the bullet penetrated approximately 1/8'' (0.3
cm) into the sample with a very small raise on the backside.
Example G2
[0965] The following reactants: 131.2 grams of DESMODUR W, 13.41
grams of trimethylolpropane, 28.096 grams of 1,5 pentanediol, and
65.370 grams Stahl KM-1733 1000 molecular weight polycarbonate diol
based on hexanediol were mixed together, heated to 80.degree. C.
and degassed. Ten ppm of dibutyltindiacetate was added and mixed
until the solution was homogeneous. The mixture was poured into a
glass mold and cured for 48 hours at 290.degree. F. (143.degree.
C.). After curing, the cell was allowed to cool to room temperature
(25.degree. C.) and the polymer was released from the mold. The
polymer had a Young's Modulus of 215,000 psi (about 1482 MPa). The
weight % urethane content was 24.8%. The molecular weight per
crosslink was 2404 grams/mole. The weight % cyclic content was
34%.
[0966] An article of 6''.times.6''.times.1'' (15.2 cm.times.15.2
cm.times.2.5 cm) prepared from this polymer stopped a 9 mm, 125
grain, bullet shot an initial velocity of 1350 ft/sec (411 m/sec)
from 20 feet (6.1 m) distance by trapping the bullet in the
polymer. Four/fifths (4/5) of the length of the bullet penetrated
the sample with the back of the bullet protruding out of the
impacted surface approximately 1/8'' (0.3 cm).
Example G3
[0967] The following reactants: 131.2 grams of DESMODUR W, 13.41
grams of trimethylolpropane, 28.617 grams of 1,5 pentanediol, and
61.284 grams Stahl KM-1733 1000 molecular weight polycarbonate diol
based on hexanediol were mixed together, heated to 80.degree. C.
and degassed. Ten ppm of dibutyltindiacetate was added and mixed
until the solution was homogeneous. The mixture was poured into a
glass mold and cured for 48 hours at 290.degree. F. (143.degree.
C.). After curing, the cell was allowed to cool to room temperature
(25.degree. C.) and the polymer was released from the mold. The
polymer had a Young's Modulus of 215,000 psi (about 1482 MPa). The
weight % urethane content was 25.15%. The molecular weight per
crosslink was 2369 grams/mole. The weight % cyclic content was
34.53%.
[0968] An article of 6''.times.6''.times.1'' (15.2 cm.times.15.2
cm.times.2.5 cm) prepared from this polymer stopped a 9 mm, 125
grain, bullet shot an initial velocity of 1350 ft/sec (411 m/sec)
from 20 feet (6.1 m) distance by trapping the bullet. Four/fifths
(4/5) of the length of the bullet penetrated the sample with the
back of the bullet protruding out of the impacted surface
approximately 1/8'' (0.3 cm).
Poly(Ureaurethane) Examples
Example G4
[0969] The following reactants: 318.26 grams of DESMODUR W and 0.84
grams of trimethylolpropane containing 0.5% of dibutyltindiacetate
were charged into a glass kettle and heated and stirred at
75.degree. C. Deionized water (4.37 grams) was added, mixed, and
reacted to form polyurea hard segments within the polyurethane
prepolymer. Carbon dioxide foam was removed under vacuum. The
temperature was then increased to 80.degree. C. and reacted for 30
minutes. Outgassing was performed using 2 mm mercury vacuum and
63.42 grams of 1,5 pentanediol was added along with 32.76 grams of
trimethylolpropane. The mixture was stirred and vacuum increased
slowly. The exothermic temperature reached 95.degree. C. at which
time the mixture was poured into a 6''.times.6''.times.1/8'' (15.2
cm.times.15.2 cm.times.0.3 cm) glass mold. The material was cured
at 290.degree. F. (143.degree. C.) for 48 hours. The material was
released from the mold at room temperature (25.degree. C.) yielding
a clear, highly transparent plastic.
Example G5
[0970] The following reactants: 2.23 grams of trimethylolpropane
was reacted with 76.133 grams of DESMODUR W containing 10 ppm of
dibutyltindiacetate at 80.degree. C. to form a branched
polyurethane terminated with isocyanate groups. Water (0.9 grams)
was added to the batch after the temperature was lowered to
60.degree. C., and reacted for two hours to form the polyurea
portion of the polyurethane polyurea prepolymer. The carbon dioxide
was then removed with vacuum and 38 grams of trimethylolpropane was
added, mixed, degassed under vacuum and poured into a glass mold as
described above at 75.degree. C. After curing for 48 hours at
290.degree. F. (143.degree. C.), the plastic was removed from the
mold at room temperature (25.degree. C.) yielding a high modulus,
highly transparent plastic. The Young's Modulus was 441,000 psi
measured on an Instron testing machine at a 6''/minute crosshead
speed.
Example G6
[0971] The following reactants: 2.23 grams of trimethylolpropane
was reacted with 131.2 grams of DESMODUR W using 10 ppm of
dibutyltindiacetate by weight of total batch to make a branched,
isocyanate-terminated polyurethane prepolymer. Deionized water
(1.34 grams) was added and reacted at 60.degree. C. The carbon
dioxide was removed via vacuum degassing. The temperature was
increased to 75.degree. C. and 39.66 grams of cyclohexanedimethanol
was added as a chain extender. After mixing and degassing, the
liquid was poured into a glass mold as described above and cured at
290.degree. F. (143.degree. C.) for 48 hours. Demolding was done at
room temperature (25.degree. C.) and yielded a high optical quality
plastic sheet.
Example H
Example H1
[0972] A polyurethane was prepared from the following
components:
TABLE-US-00028 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 1,4- TMP Des W 175.94 300.00 butanediol OH # -- -- --
Acid # -- -- -- Equivalent Wt. 45.06 44.00 131.2 Equivalents
desired 0.7000 0.300 1.000 Mass Monomer 31.54 13.20 131.20 Weight %
Monomer 17.93% 7.50% 74.57% Monomer masses 53.78 22.51 223.71 for
experiment
[0973] The 1,4-butanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. Once clear,
the mixture was degassed and cast into a
12''.times.12''.times.0.125'' (30 cm.times.30 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. and 6 hours at 150.degree. C. The mean
Gardner Impact Strength was 102 in-lbs (12 J).
Example H2
[0974] A polyurethane was prepared from the following
components:
TABLE-US-00029 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer 1,4-butanediol TMP Des W 175.94 300.00 Name OH # -- -- --
Acid # -- -- -- Equivalent 45.06 44.00 131.2 Wt. Equivalents 0.7000
0.300 1.000 desired Mass 31.54 13.20 131.20 Monomer Weight % 17.93%
7.50% 74.57% Monomer Monomer 53.78 22.51 223.71 masses for
experiment Weight % 70.13 Hard Segment Weight % 33.53 Urethane
M.sub.c 1759.42
[0975] The 1,4-butanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 110 in-lbs (13 J).
Example H3
[0976] A polyurethane was prepared from the following
components:
TABLE-US-00030 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 1,4- TMP Des W 175.94 300.00 butanediol OH # -- -- --
Acid # -- -- -- Equivalent Wt. 45.06 44.00 131.2 Equivalents
desired 0.7000 0.300 1.000 Mass Monomer 31.54 13.20 131.20 Weight %
Monomer 17.93% 7.50% 74.57% Monomer masses 53.78 22.51 223.71 for
experiment Weight % Hard 70.13 Segment Weight % Urethane 33.53
M.sub.c 1759.42
[0977] The 1,4-butanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 131 in-lbs (15 J).
Example H4
[0978] A polyurethane was prepared from the following
components:
TABLE-US-00031 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 1,5- TMP Des W 180.85 300.00 pentanediol OH # -- -- --
Acid # -- -- -- Equivalent Wt. 52.075 44.00 131.2 Equivalents
0.7000 0.300 1.000 desired Mass Monomer 36.45 13.20 131.20 Weight %
20.16% 7.30% 72.55% Monomer Monomer masses 60.47 21.90 217.64 for
experiment Weight % Hard 70.94 Segment Weight % 32.62 Urethane
M.sub.c 1808.53
[0979] The 1,5-pentanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to 115.degree. C. and allowed to compatibilize. The mixture was
degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 135 in-lbs (15 J).
Example H5
[0980] A polyurethane was prepared from the following
components:
TABLE-US-00032 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 1,5- TMP Des W 178.43 300.00 pentanediol OH # -- -- --
Acid # -- -- -- Equivalent Wt. 52.075 44.00 131.2 Equivalents
0.4000 0.600 1.000 desired Mass Monomer 20.83 26.40 131.20 Weight %
11.67% 14.80% 73.53% Monomer Monomer masses 35.02 44.39 220.59 for
experiment Weight % Hard 41.09 Segment Weight % 33.07 Urethane
M.sub.c 892.15
[0981] The 1,5-pentanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.115.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 71 in-lbs (8 J).
Example H6
[0982] A polyurethane was prepared from the following
components:
TABLE-US-00033 Polymer Desired Solids Wt. (g) Batch Size (g)
Monomer Name CHDM 1,5-pentanediol TMP Des W 187.86 300.00 OH # --
-- -- -- Acid # -- -- -- -- Equivalent Wt. 72.11 52.075 44.00 131.2
Equivalents 0.3500 0.3500 0.300 1.000 desired Mass Monomer 25.24
18.23 13.20 131.20 Weight % 13.43% 9.70% 7.03% 69.84% Monomer
Monomer masses 40.30 29.11 21.08 209.51 for experiment Weight %
Hard 37.88 Segment Weight % 31.41 Urethane M.sub.c 1878.65
[0983] The 1,5-pentanediol, CHDM, trimethylolpropane, and DESMODUR
W (preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 143 in-lbs (16 J).
Example H7
[0984] A polyurethane was prepared from the following
components:
TABLE-US-00034 Polymer Desired Wt. Batch Solids (g) Size (g)
Monomer Name CHDM TMP Des W 194.88 352.00 OH # -- -- -- Acid # --
-- -- Equivalent Wt. 72.11 44.00 131.2 Equivalents desired 0.7000
0.300 1.000 Mass Monomer 50.48 13.20 131.20 Weight % Monomer 25.90%
6.77% 67.32% Monomer masses for 91.17 23.84 236.98 experiment
Weight % Hard 73.03 Segment Weight % Urethane 30.28 M.sub.c
1948.77
[0985] The CHDM, trimethylolpropane, and DESMODUR W (preheated to
80.degree. C.) were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to
.about.105.degree. C. and allowed to compatibilize. The mixture was
degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 63 in-lbs (7 J).
Example H8
[0986] A polyurethane was prepared from the following
components:
TABLE-US-00035 Polymer Solids Wt. (g) Monomer Name CHDM 1,4- TMP
Des W 185.41 butanediol OH # -- -- -- -- Acid # -- -- -- --
Equivalent Wt. 72.11 45.06 44.00 131.2 Equivalents desired 0.3500
0.3500 0.300 1.000 Mass Monomer 25.24 15.77 13.20 131.20 Weight %
Monomer 13.61% 8.51% 7.12% 70.76% Monomer masses 40.84 25.52 21.36
212.29 for experiment Weight % Hard 38.38 Segment Weight % Urethane
31.82 M.sub.c 1854.10
[0987] The 1,4-butanediol, CHDM, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 47 in-lbs (5 J).
Example H9
[0988] A polyurethane was prepared from the following
components:
TABLE-US-00036 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 1,6- TMP Des W 185.76 300.00 hexanediol OH # -- -- --
Acid # -- -- -- Equivalent Wt. 59.09 44.00 131.2 Equivalents
desired 0.7000 0.300 1.000 Mass Monomer 41.36 13.20 131.20 Weight %
Monomer 22.27% 7.11% 70.63% Monomer masses for 66.80 21.32 211.88
experiment Weight % Hard 71.71 Segment Weight % Urethane 31.76
M.sub.c 1857.63
[0989] The 1,6-hexanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 130 in-lbs (15 J).
Example H10
[0990] A polyurethane was prepared from the following
components:
TABLE-US-00037 Polymer Desired Solids Wt. (g) Batch Size (g)
Monomer Name 1,6- 1,4- TMP Des W 180.85 300.00 hexanediol
butanediol OH # -- -- -- -- Acid # -- -- -- -- Equivalent Wt. 59.09
45.06 44.00 131.2 Equivalents 0.3500 0.3500 0.300 1.000 desired
Mass Monomer 20.68 15.77 13.20 131.20 Weight % 11.44% 8.72% 7.30%
72.55% Monomer Monomer 34.31 26.16 21.90 217.64 masses for
experiment Weight % Hard 91.09 Segment Weight % 32.62 Urethane
M.sub.c 1808.53
[0991] The 1,6-hexanediol, 1,4-butanediol, trimethylolpropane, and
DESMODUR W (preheated to 80.degree. C.) were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.115.degree. C. and allowed to
compatibilize. The mixture was degassed, and cast into a
12''.times.12''.times.0.125'' (30 cm.times.30 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The mean Gardner Impact Strength was 53
in-lbs (6 J).
Example H11
[0992] A polyurethane was prepared from the following
components:
TABLE-US-00038 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name CHDM 1,6-hexanediol TMP Des W 190.32 300.00 OH # -- --
-- -- Acid # -- -- -- -- Equivalent Wt. 72.11 59.09 44.00 131.2
Equivalents 0.3500 0.3500 0.300 1.000 desired Mass Monomer 25.24
20.68 13.20 131.20 Weight % 13.26% 10.87% 6.94% 68.94% Monomer
Monomer masses 39.78 32.60 20.81 206.81 for experiment Weight %
Hard 96.51 Segment Weight % 31.00 Urethane M.sub.c 1903.20
[0993] The 1,6-hexanediol, CHDM, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.115.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 124 in-lbs (14 J).
Example H12
[0994] A polyurethane was prepared from the following
components:
TABLE-US-00039 Polymer Desired Solids Wt. (g) Batch Size (g)
Monomer Name 1,4-cyclohexanediol TMP Des W 185.06 352.00 OH # -- --
-- Acid # -- -- -- Equivalent Wt. 58.08 44.00 131.2 Equivalents
desired 0.7000 0.300 1.000 Mass Monomer 40.66 13.20 131.20 Weight %
21.97% 7.13% 70.90% Monomer Monomer masses 77.33 25.11 249.56 for
experiment Weight % Hard 71.60 Segment Weight % Urethane 31.88
M.sub.c 1850.56
[0995] The 1,4-cyclohexanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.95.degree. C. and allowed to compatibilize. Once clear,
the mixture was degassed, and cast into a
6''.times.6''.times.0.25'' (15 cm.times.15 cm.times.0.3 cm) casting
cell preheated to 121.degree. C. The casting was cured for 48 hours
at 121.degree. C. The Gardner Impact Strength was 7 in-lbs (1
J).
Example H13
[0996] A polyurethane was prepared from the following
components:
TABLE-US-00040 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name Ethylene TMP Des W 166.12 300.00 glycol OH # -- -- --
Acid # -- -- -- Equivalent Wt. 31.035 44.00 131.2 Equivalents
desired 0.7000 0.300 1.000 Mass Monomer 21.72 13.20 131.20 Weight %
Monomer 13.08% 7.95% 78.98% Monomer masses for 39.23 23.84 236.93
experiment Weight % Hard 68.36 Segment Weight % Urethane 35.52
M.sub.c 1661.25
[0997] The ethylene glycol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 4 in-lbs (4 J).
Example H14
[0998] A polyurethane was prepared from the following
components:
TABLE-US-00041 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name 1,4- penta- Des W 172.95 300.00 butanediol erythritol
OH # -- -- -- Acid # -- -- -- Equivalent Wt. 45.06 34.04 131.2
Equivalents 0.7000 0.300 1.000 desired Mass Monomer 31.54 10.21
131.20 Weight % 18.24% 5.90% 75.86% Monomer Monomer masses 54.71
17.71 227.58 for experiment Weight % Hard 71.34 Segment Weight %
34.11 Urethane M.sub.c 2306.04
[0999] The 1,4-butanediol, pentaerythritol, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.150.degree. C. The pentaerythritol never dissolved.
Example H15
[1000] A polyurethane was prepared from the following
components:
TABLE-US-00042 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name 1,4- TMP Des W 192.76 300.00 benzene- dimethanol OH #
-- -- -- Acid # -- -- -- Equivalent Wt. 69.085 44.00 131.2
Equivalents 0.7000 0.300 1.000 desired Mass Monomer 48.36 13.20
131.20 Weight % 25.09% 6.85% 68.06% Monomer Monomer masses 75.26
20.54 204.19 for experiment 95.81 Weight % Hard 72.73 Segment
Weight % 30.61 Urethane M.sub.c 1927.60
[1001] The 1,4-benzenedimethanol, trimethylolpropane, and DESMODUR
W (preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. The mixture
was degassed, and cast into a 12''.times.12''.times.0.125'' (30
cm.times.30 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 63 in-lbs (7 J).
Example H16
[1002] A polyurethane was prepared from the following
components:
TABLE-US-00043 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer CHDM 1,4- TMP Des W 193.82 300.00 Name benzenedimethanol OH
# -- -- -- -- Acid # -- -- -- -- Equivalent 72.11 69.085 44.00
131.2 Wt. Equivalents 0.3500 0.3500 0.300 1.000 desired Mass 25.24
24.18 13.20 131.20 Monomer Weight % 13.02% 12.48% 6.81% 67.69%
Monomer Monomer 39.07 37.43 20.43 203.08 masses for experiment
Weight % 98.38 Hard Segment Weight % 30.44 Urethane M.sub.c
1938.18
[1003] The 1,4-benzenedimethanol, CHDM, trimethylolpropane, and
DESMODUR W (preheated to 80.degree. C.) were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.115.degree. C. and allowed to
compatibilize. The mixture was degassed, and cast into a
12''.times.12''.times.0.125'' (30 cm.times.30 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The mean Gardner Impact Strength was 75
in-lbs (9 J).
Example H17
[1004] A polyurethane was prepared from the following
components:
TABLE-US-00044 Polymer Desired Batch Solids Wt. (g) Size (g)
Monomer 1,4- 1,4- TMP Des W 184.35 300.00 Name benzenedimethanol
butanediol OH # -- -- -- -- Acid # -- -- -- -- Equivalent 69.085
45.06 44.00 131.2 Wt. Equivalents 0.3500 0.3500 0.300 1.000 desired
Mass 24.18 15.77 13.20 131.20 Monomer Weight % 13.12% 8.55% 7.16%
71.17% Monomer Monomer 39.35 25.66 21.48 213.51 masses for
experiment Weight % 93.16 Hard Segment Weight % 32.00 Urethane
M.sub.c 1843.51
[1005] The 1,4-benzenedimethanol, 1,4-butanediol,
trimethylolpropane, and DESMODUR W (preheated to 80.degree. C.)
were added to a glass kettle. Under nitrogen blanket and with
constant stirring, the mixture was heated to .about.115.degree. C.
and allowed to compatibilize. Once clear, the mixture was degassed,
and cast into a 12''.times.12''.times.0.125'' (30 cm.times.30
cm.times.0.3 cm) casting cell preheated to 121.degree. C. The
casting was cured for 48 hours at 121.degree. C. The Gardner Impact
Strength was 62 in-lbs (7 J).
Example H18
[1006] A polyurethane was prepared from the following
components:
TABLE-US-00045 Polymer Solids Wt. (g) Monomer Name 1,4- 1,6- TMP
Des W 189.26 benzene- hexanediol dimethanol OH # -- -- -- -- Acid #
-- -- -- -- Equivalent Wt. 69.085 59.09 44.00 131.2 Equivalents
0.3500 0.3500 0.300 1.000 desired Mass Monomer 24.18 20.68 13.20
131.20 Weight % 12.78% 10.93% 6.97% 69.32% Monomer Monomer masses
38.33 32.78 20.92 207.97 for experiment Weight % Hard 95.93 Segment
Weight % 31.17 Urethane M.sub.c 1892.61
[1007] The 1,4-benzenedimethanol, 1,6-hexanediol,
trimethylolpropane, and DESMODUR W (preheated to 80.degree. C.)
were added to a glass kettle. Under nitrogen blanket and with
constant stirring, the mixture was heated to .about.115.degree. C.
and allowed to compatibilize. Once clear, the mixture was degassed,
and cast into a 12''.times.12''.times.0.125'' (30 cm.times.30
cm.times.0.3 cm) casting cell preheated to 121.degree. C. The
casting was cured for 48 hours at 121.degree. C. The Gardner Impact
Strength was 64 in-lbs (7 J).
Example H19
[1008] A polyurethane was prepared from the following
components:
TABLE-US-00046 Polymer Desired Batch Solids Wt. (g) Size (g)
Monomer Name 4,4'-trimethylene TMP Des W 213.80 300.00 dipiperidine
OH # -- -- -- Acid # -- -- -- Equivalent Wt. 99.14 44.00 131.2
Equivalents desired 0.7000 0.300 1.000 Mass Monomer 69.40 13.20
131.20 Weight % 32.46% 6.17% 61.37% Monomer Monomer masses 97.38
18.52 184.10 for experiment Weight % Hard 75.42 Segment Weight %
27.60 Urethane M.sub.c 2137.98
[1009] The 4,4'-trimethylene dipiperidine, TMP and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. The
initial temperature was about 50.degree. C., and when stirred
jumped to about 60.degree. C. and gelled into a white mass.
Example H20
[1010] A polyurethane was prepared from the following
components:
TABLE-US-00047 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 1,4-bis- TMP Des W 205.38 300.00 (hydroxyethyl)
piperazine OH # -- -- -- Acid # -- -- -- Equivalent Wt. 87.12 44.00
131.2 Equivalents 0.7000 0.300 1.000 desired Mass Monomer 60.98
13.20 131.20 Weight % 29.69% 6.43% 63.88% Monomer Monomer masses
89.08 19.28 191.64 for experiment Weight % Hard 74.41 Segment
Weight % 28.73 Urethane M.sub.c 2053.84
[1011] The 1,4-bis(hydroxyethyl)piperazine, trimethylolpropane, and
DESMODUR W (preheated to 80.degree. C.) were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.105.degree. C., when the viscosity
raised to a point where it could no longer be stirred. The mixture
was not clear and non-melted 1,4-bis(hydroxyethyl)piperazine was
present in the mixture.
Example H21
[1012] A polyurethane was prepared from the following
components:
TABLE-US-00048 Solids Monomer Name N,N'-bis 1,4- TMP Des W
(2-hydroxyethyl) butanediol oxamide OH # -- -- -- -- Acid # -- --
-- -- Equivalent Wt. 88.08 45.06 44.00 131.2 Equivalents desired
0.3500 0.3500 0.300 1.000 Mass Monomer 30.83 15.77 13.20 131.20
Weight % Monomer 16.14% 8.26% 6.91% 68.69% Monomer masses for 22.60
11.56 9.68 96.17 experiment -- 11.61 4.83 47.94 Weight % Hard 40.18
Segment Weight % Urethane 30.89 M.sub.c 1909.99
[1013] The N,N'-bis(2-hydroxyethyl) oxamide, 1,4-butanediol,
trimethylolpropane, and DESMODUR W (preheated to 80.degree. C.)
were added to a glass kettle. Under nitrogen blanket and with
constant stirring, the mixture was heated to .about.105.degree. C.,
when the viscosity raised to a point where it could no longer be
stirred. The mixture was not clear and non-melted
N,N'-bis(2-hydroxyethyl) oxamide was present in the mixture.
Example H22
[1014] A polyurethane was prepared from the following
components:
TABLE-US-00049 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 3,6-dithia- TMP Des W 208.52 300.00 1,2- octanediol OH
# -- -- -- Acid # -- -- -- Equivalent Wt. 91.6 44.00 131.2
Equivalents desired 0.7000 0.300 1.000 Mass Monomer 64.12 13.20
131.20 Weight % Monomer 30.75% 6.33% 62.92% Monomer masses 92.25
18.99 188.76 for experiment -- Weight % Hard 74.79 Segment Weight %
Urethane 28.29 M.sub.c 2085.20
[1015] The 3,6-dithia-1,2-octanediol, trimethylolpropane, and
DESMODUR W (preheated to 80.degree. C.) were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.105.degree. C., when the viscosity
raised to the point that it could no longer be stirred. The mixture
was degassed, and cast into a 6''.times.6''.times.0.25'' (15
cm.times.15 cm.times.0.3 cm) casting cell preheated to 121.degree.
C. The casting was cured for 48 hours at 121.degree. C. The mean
Gardner Impact Strength was 81 in-lbs (9 J).
Example H23
[1016] A polyurethane was prepared from the following
components:
TABLE-US-00050 Polymer Solids Wt. (g) Monomer 3,6-dithia- bis(4-(2-
CHDM TMP Des W 258.90 Name 1,2- hydroxyethoxy)- octanediol
3,5-dibromophenyl)sulfone OH # -- -- -- -- -- Acid # -- -- -- -- --
Equivalent 91.6 326.985 72.11 44.00 131.2 Wt. Equivalents 0.2333
0.2333 0.2333 0.300 1.000 desired Mass 21.37 76.30 16.83 13.20
131.20 Monomer Weight % 8.26% 29.47% 6.50% 5.10% 50.68% Monomer
Monomer 24.77 88.41 19.50 15.30 152.03 300.00 masses for experiment
Weight % 99.10 Hard Segment Weight % 22.79 Urethane M.sub.c
2588.96
[1017] The 3,6-dithia-1,2-octanediol,
bis(4-(2-hydroxyethoxy)-3,5-dibromophenyl) sulfone, CHDM,
trimethylolpropane, and DESMODUR W (preheated to 80.degree. C.)
were added to a glass kettle. Under nitrogen blanket and with
constant stirring, the mixture was heated to .about.115.degree. C.
and allowed to compatibilize. The mixture was degassed, and cast
into a 12''.times.12''.times.0.125'' (30 cm.times.30 cm.times.0.3
cm) casting cell preheated to 121.degree. C. The casting was cured
for 48 hours at 121.degree. C.
Example H24
[1018] A polyurethane polymer according to the present invention
was prepared from the components listed below:
TABLE-US-00051 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 2,2- TMP Des W 187.17 200.00 thiodiethanol OH # -- --
-- Acid # -- -- -- Equivalent Wt. 61.10 44.00 131.2 Equivalents
0.7000 0.300 1.000 desired Mass Monomer 42.77 13.20 131.20 Weight %
22.85% 7.05% 70.10% Monomer Monomer masses 45.70 14.11 140.20 for
experiment Weight % Hard 71.92 Segment Weight % 31.52 Urethane
M.sub.c 1871.67
[1019] The 2,2-thiodiethanol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.95.degree. C. and allowed to compatibilize. Once clear,
the mixture was degassed, and cast into a
6''.times.6''.times.0.25'' (15 cm.times.15 cm.times.0.3 cm) casting
cell preheated to 121.degree. C. The casting was cured for 48 hours
at 121.degree. C. The Gardner Impact Strength was 5 in-lbs. (1 J)
and the sample was brittle.
Example H25
[1020] A polyurethane was prepared from the following
components:
TABLE-US-00052 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name thiodiethanol 1,4-butanediol TMP Des W 181.56 300.00
OH # -- -- -- -- Acid # -- -- -- -- Equivalent Wt. 61.1 45.06 44.00
131.2 Equivalents 0.3500 0.3500 0.300 1.000 desired Mass Monomer
21.39 15.77 13.20 131.20 Weight % 11.78% 8.69% 7.27% 72.26% Monomer
Monomer 35.34 26.06 21.81 216.79 masses for experiment Weight %
Hard 37.07 Segment Weight % 32.50 Urethane M.sub.c 1815.56
[1021] The thiodiethanol, 1,4-butanediol, trimethylolpropane, and
DESMODUR W (preheated to 80.degree. C.) were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.105.degree. C. and allowed to
compatibilize. The mixture was degassed, and cast into a
12''.times.12''.times.0.125'' (30 cm.times.30 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The mean Gardner Impact Strength was 39
in-lbs (4 J).
Example H26
[1022] A polyurethane was prepared from the following
components:
TABLE-US-00053 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer thiodiethanol 1,6-hexanediol TMP Des W 186.47 300.00 Name
OH # -- -- -- -- Acid # -- -- -- -- Equivalent Wt. 61.1 59.09 44.00
131.2 Equivalents 0.3500 0.3500 0.300 1.000 desired Mass Monomer
21.39 20.68 13.20 131.20 Weight % 11.47% 11.09% 7.08% 70.36%
Monomer Monomer 34.41 33.27 21.24 211.08 masses for experiment
Weight % Hard 36.09 Segment Weight % 31.64 Urethane M.sub.c
1864.67
[1023] The thiodiethanol, 1,6-hexanediol, trimethylolpropane, and
DESMODUR W (preheated to 80.degree. C.) were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.105.degree. C. and allowed to
compatibilize. The mixture was degassed, and cast into a
12''.times.12''.times.0.125'' (30 cm.times.30 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The mean Gardner Impact Strength was 55
in-lbs (6 J).
Example H27
[1024] A polyurethane was prepared from the following
components:
TABLE-US-00054 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name 1,4- Des N Des W 182.80 300.00 butanediol 3400 OH # --
-- -- Acid # -- -- -- Equivalent Wt. 45.06 153.00 131.2 Equivalents
1.0000 0.300 0.700 desired Mass Monomer 45.06 45.90 91.84 Weight %
24.65% 25.11% 50.24% Monomer Monomer 73.95 75.33 150.72 masses for
experiment Weight % Hard 96.42 Segment Weight % 32.28 Urethane
M.sub.c 1828.00
[1025] The 1,4-butanediol, Des N 3400 and DESMODUR W (preheated to
80.degree. C.) were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to
.about.105.degree. C. The mixture was degassed, and cast into a
6''.times.6''.times.0.25'' (15 cm.times.15 cm.times.0.3 cm) casting
cell preheated to 121.degree. C. The casting was cured for 48 hours
at 121.degree. C. The mean Gardner Impact Strength was 35 in-lbs (4
J).
Example H28
[1026] A polyurethane was prepared from the following
components:
TABLE-US-00055 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name H.sub.2O 1,4-butanediol TMP Des W 163.32 300.00 OH #
-- -- -- -- Acid # -- -- -- -- Equivalent Wt. 9.01 45.06 44.00
131.2 Equivalents 0.3500 0.3500 0.300 1.000 desired Mass Monomer
3.15 15.77 13.20 131.20 Weight % 1.93% 9.66% 8.08% 80.33% Monomer
Monomer masses 5.79 28.97 24.25 240.99 for experiment Weight % Hard
79.41 Segment Weight % 36.12 Urethane M.sub.c 1633.25
[1027] The 1,4-butanediol, TMP, DESMODUR W (preheated to 80.degree.
C.), and deionized water were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.105.degree. C. and allowed to compatibilize. After
compatibilization, condensation (water) was observed on the sides
of the kettle.
Example H29
[1028] A polyurethane was prepared from the following
components:
TABLE-US-00056 Equivalent Component Weight Equivalents Weight (g)
Weight (%) TMP 44.7 0.05 2.2 1.3 1,4-butanediol 45 0.95 42.8 24.3
Des W 131 1.0 131 74.4
[1029] The 1,4-butanediol, TMP and DESMODUR W (preheated to
80.degree. C.) were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to
.about.110.degree. C. The mixture was degassed, and cast into a
15''.times.15''.times.0.125'' (38 cm.times.38 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The mean Gardner Impact Strength was 300
in-lbs (35 J). The W.sub.u was 33.5%, the W.sub.c was 46% and the
M.sub.c was 10,569 g/mol.
Example H30
[1030] A polyurethane was prepared from the following
components:
TABLE-US-00057 Equivalent Component Weight Equivalents Weight (g)
Weight (%) TMP 44.7 0.05 2.2 1.2 1,5-pentanediol 52 0.95 49.5 27.1
Des W 131 1.0 131 71.7
[1031] The 1,5-pentanediol, TMP and DESMODUR W (preheated to
80.degree. C.) were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to
.about.110.degree. C. The mixture was degassed, and cast into a
15''.times.15''.times.0.125'' (38 cm.times.38 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The mean Gardner Impact Strength was 400
in-lbs (46 J). The W.sub.u was 32.3%, the W.sub.c was 44.3% and the
M.sub.c was 10,973 g/mol.
Example H31
[1032] A polyurethane was prepared from the following
components:
TABLE-US-00058 Equivalent Component Weight Equivalents Weight (g)
Weight (%) TMP 44.7 0.05 2.2 1.0 1,10-decanediol 87 0.95 82.8 38.3
Des W 131 1.0 131 60.6
[1033] The 1,10-decanediol, TMP and DESMODUR W (preheated to
80.degree. C.) were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to
.about.110.degree. C. The mixture was degassed, and cast into a
15''.times.15''.times.0.125'' (38 cm.times.38 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The mean Gardner Impact Strength was
>640 in-lbs (>74 J). The W.sub.u was 27.3%, the W.sub.c was
37.5% and the M.sub.c was 12,974 g/mol. The Dynatup Impact Strength
was 77 Joules.
Example H32
[1034] A polyurethane was prepared from the following
components:
TABLE-US-00059 Equivalent Component Weight Equivalents Weight (g)
Weight (%) TONE 210 406.4 0.2 81.3 32.3 1,5-pentanediol 52 0.5 26.0
10.3 TMP 44.7 0.3 13.4 5.3 Des W 131 1.0 131 52.0
[1035] The TONE 210, 1,5-pentanediol, TMP and DESMODUR W (preheated
to 80.degree. C.) were added to a glass kettle. Under nitrogen
blanket and with constant stirring, the mixture was heated to
.about.110.degree. C. The mixture was degassed, and cast into a
15''.times.15''.times.0.125'' (38 cm.times.38 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The W.sub.u was 23.4%, the W.sub.c was
32% and the M.sub.c was 2542 g/mol.
Example H33
[1036] A polyurethane was prepared from the following
components:
TABLE-US-00060 Equivalent Component Weight Equivalents Weight (g)
Weight (%) TONE 210 406.4 0.15 61.0 26.1 1,5-pentanediol 52 0.55
28.6 12.2 TMP 44.7 0.3 13.4 5.7 Des W 131 1.0 131 56.0
[1037] The TONE 210, 1,5-pentanediol, TMP and DESMODUR W (preheated
to 80.degree. C.) were added to a glass kettle. Under nitrogen
blanket and with constant stirring, the mixture was heated to
.about.110.degree. C. The mixture was degassed, and cast into a
15''.times.15''.times.0.125'' (38 cm.times.38 cm.times.0.3 cm)
casting cell preheated to 121.degree. C. The casting was cured for
48 hours at 121.degree. C. The W.sub.u was 25.2%, the W.sub.c was
34.6% and the M.sub.c was 2342 g/mol.
Example I
[1038] Samples of Formulations 1-10 of Example A, Plexiglas from
McMasterCarr, Poly 84 stretched acrylic and commercial grade LEXAN
were tested for K-factor according to the following conditions:
[1039] Load cell: 2000 lb.sub.f
[1040] Humidity(%): 50
[1041] Temperature: 73.degree. F. (23.degree. C.)
[1042] Test Speed: 320 lb.sup.f/min
[1043] Thickness: 0.120''
TABLE-US-00061 Thickness Crack Test# Sample ID Width (in.) (in.)
(in.) Load (lbs) Time (sec) K Factor 34 1A 2.138 0.123 0.575
345.800 345.800 1296.220 36 1B 2.144 0.122 0.600 318.400 318.400
1241.140 35 1C 2.135 0.128 0.700 294.200 294.200 1199.424 31 2A
1.995 0.123 0.750 304.400 304.400 1477.415 33 2B 1.990 0.131 0.650
322.100 322.100 1330.586 32 2C 1.965 0.132 0.750 278.700 278.700
1279.169 29 3A 1.986 0.125 0.475 216.400 216.400 777.079 30 3B
1.972 0.130 0.425 228.200 228.200 746.028 1 3C 1.988 0.127 0.750
175.600 117.067 822.370 26 4A 2.017 0.125 0.600 327.500 327.500
1321.788 27 4B 2.009 0.120 0.750 276.500 276.500 1359.195 28 4C
2.023 0.123 0.675 283.500 283.500 1259.891 24 5A 2.023 0.122 0.600
20.9.4 157.050 866.505 23 5B 2.020 0.120 0.750 179.900 107.940
874.598 25 5C 2.056 0.166 0.700 205.100 205.100 967.357 14 6A 2.053
0.124 0.650 291.000 218.250 1225.187 16 6B 2.039 0.122 0.670
245.900 245.900 1086.512 15 6C 2.068 0.127 0.690 271.100 232.371
1144.531 12 7A 2.024 0.127 0.620 277.600 185.067 1125.576 13 7B
2.034 0.130 0.750 288.300 192.200 1288.378 11 7C 2.019 0.128 0.750
278.700 101.345 1276.297 10 8A 2.006 0.124 0.960 238.400 158.933
1388.038 9 8B 2.021 0.124 0.800 284.600 87.569 1402.845 2 8C 2.009
0.118 0.750 355.400 266.550 1776.120 6 9A 2.003 0.118 0.520
1179.000 428.727 4681.823 8 9B 2.020 0.123 0.670 345.800 106.400
1525.675 7 9C 1.992 0.118 0.450 1220.000 395.676 4486.874 3 10A
2.010 0.116 0.750 782.300 586.725 3956.318 4 10B 2.021 0.119 0.450
742.600 270.036 2655.849 5 10C 2.023 0.119 0.450 756.000 274.909
2700.237 21 11A 2.011 0.132 0.650 272.200 98.982 1106.454 22 11B
2.006 0.130 0.650 220.700 115.148 910.576 20 11C 2.011 0.130 0.650
255.000 78.462 1048.797 19 12A 2.019 0.134 0.650 873.600 268.800
3470.984 17 12B 2.021 0.132 0.680 798.900 290.509 3313.758 18 12C
2.023 0.133 0.710 863.400 313.964 3655.555 37 13A 2.036 0.125 1.500
1435.000 521.818 15960.663 38 13B 2.024 0.126 1.500 1401.000
262.688 15670.107 39 13C 2.024 0.133 1.500 1456.000 273.000
15489.381
Example J
[1044] A polyurethane was prepared from the following
components:
TABLE-US-00062 Desired Polymer Wt. Batch Size Solids (g) (g)
Monomer Name 1,5- TMP Des W 2100.00 pentanediol OH # -- -- -- Acid
# -- -- -- Equivalent Wt. 52.075 44.00 131.2 Equivalents 0.4000
0.600 1.000 desired Mass Monomer 20.83 26.40 131.20 178.43 (sum)
Weight % 11.67% 14.80% 073.53% Monomer Monomer 245.15 310.71
1544.13 masses for experiment Weight % Hard 41.09 0.4(131 + 52)/
Segment 178.43 Weight % 33.07 59 g/eq./ Urethane 178.43 g/eq.
M.sub.c 892.15 178.43/ 0.2 moles TMP
[1045] The 1,5-pentanediol, trimethylolpropane, and DESMODUR W
(preheated to 80.degree. C.) were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.115.degree. C. and allowed to compatibilize. Once clear,
the mixture was degassed, and cast into a
14''.times.14''.times.0.375'' casting cell preheated to 121.degree.
C. A first set of samples was cured for 48 hours at 121.degree. C.
A second set of samples was cured for 48 hours at 121.degree. C.
and for 12 hours at 145.degree. C. Each set of samples was
evaluated for stress craze resistance by immersion for 30 minutes
in 75% aqueous solution of sulfuric acid. The second set of samples
passed 30 minutes at 4000 psi.
Example K
[1046] Trimethylolpropane (0.05 equivalents), 1,10-decanediol (0.95
equivalents) and DESMODUR W (1.0 equivalents, preheated to
80.degree. C.) were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to 110.degree.
C. and allowed to compatibilize. Once clear, the mixture was
degassed, and cast into a 12''.times.12''.times.0.125'' casting
cell preheated to 143.degree. C. The filled cell was cured for 48
hours at 121.degree. C. The Dynatup Multiaxial Impact Strength was
77 Joules, measured in accordance with ASTM-D 3763-02. The Dynatup
Multiaxial Impact Strength of a sample of Lexan was 72 Joules.
Example L
Example L1
[1047] An isocyanate functional urethane prepolymer was prepared by
reacting 0.3 equivalents of 1,5-pentanediol, 1.0 equivalent of
DESMODUR W and 10 ppm dibutyltin diacetate as reactants in a glass
kettle under vacuum. The reaction temperature was maintained at
143.degree. C. for 10 hours and 0.4 equivalents of 1,5-pentanediol
and 0.3 equivalents of trimethylolpropane were added. After about
30 minutes at 110.degree. C., the mixture was cast between release
coated glass molds and cured for 72 hours at 290.degree. F.
(143.degree. C.). The mold was removed from the oven and the
plastic released. The Gardner Impact strength was 256 in-lbs (29
J).
[1048] An isocyanate functional urethane prepolymer was prepared by
reacting 0.5 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W and 10 ppm dibutyltin diacetate as reactants in a glass
kettle under vacuum. The reaction temperature was maintained at
143.degree. C. for 10 hours and 0.2 equivalents of 1,5-pentanediol
and 0.3 equivalents of trimethylolpropane were added. After about
30 minutes at 110.degree. C., the mixture was cast between release
coated glass molds and cured for 72 hours at 290.degree. F.
(143.degree. C.). The mold was removed from the oven and the
plastic released. The Gardner Impact strength was 256 in-lbs (29
J).
[1049] The sample prepared from an isocyanate functional urethane
prepolymer having a higher amount (0.5 equivalents) of
1,5-pentanediol had a higher Gardner Impact strength. While not
intending to be bound by any theory, it is believed that the
miscibility between the components is improved by pre-reacting a
portion of the short chain diol with the polyisocyanate.
Example L2
Samples Prepared Using Isocyanate Functional Prepolymer
[1050] Sample A
[1051] An isocyanate functional urethane prepolymer was prepared by
reacting 0.3 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W 4,4'-methylene-bis-(cyclohexyl isocyanate) in a glass
reaction kettle under vacuum and nitrogen blanket. The prepolymer
components were preheated to a temperature of 110.degree. C.,
liquefied and degassed in a vacuum oven before mixing. The glass
reaction kettle was preheated to a temperature of between
60.degree. C.-80.degree. C. before the addition of the prepolymer
components. The reaction temperature was maintained at 120.degree.
C. for 15 minutes. Next, 0.4 equivalents of 1,5-pentanediol and 0.3
equivalents of trimethylolpropane were added. The 0.4 equivalents
of 1,5-pentanediol and 0.3 equivalents of trimethylolpropane were
preheated to a temperature of 80.degree. C., liquefied and degassed
in a vacuum oven before their addition to the mixture. The kettle
was placed into a preheated heating mantle for about 15 minutes up
to a temperature of approximately 120.degree. C. while the
formulation was stirred and outgassed under a vacuum pressure of
-28 mmHg. Next, the mixture was cast between release coated
1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1 cm)
casting cell glass molds with a resin volume of 3600 grams which
had been preheated to a temperature of approximately 120.degree. C.
The mixture was cured for two hours at approximately 120.degree.
C., followed by 22 hours at 160.degree. C. The mold was removed
from the oven and the plastic released. The plastic sheet was then
removed from the glass mold and cut into 2''.times.2''.times.1/8''
(5.1 cm.times.5.1 cm.times.0.3 cm) samples for Gardner Impact
testing. The Gardner Impact strength was 256 in-lbs (29 J).
[1052] Sample B
[1053] An isocyanate functional urethane prepolymer was prepared by
reacting 0.3 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W in a glass reaction kettle under vacuum and nitrogen
blanket. The prepolymer components were preheated to a temperature
of 110.degree. C., liquefied and degassed in a vacuum oven before
mixing. The glass reaction kettle was preheated to a temperature of
between 60.degree. C.-80.degree. C. before the addition of the
prepolymer components. The reaction temperature was maintained at
120.degree. C. for 15 minutes. Next, 0.1 equivalents of
1,5-pentanediol and 0.6 equivalents of trimethylolpropane were
added. The 0.1 equivalents of 1,5-pentanediol and 0.6 equivalents
of trimethylolpropane were preheated to a temperature of 80.degree.
C., liquefied and degassed in a vacuum oven before their addition
to the mixture. The kettle was placed into a preheated heating
mantle for about 15 minutes up to a temperature of approximately
120.degree. C. while the formulation was stirred and outgassed
under a vacuum pressure of -29 mmHg. Next, the mixture was cast
between release coated 1''.times.15''.times.15'' (2.5 cm.times.38.1
cm.times.38.1 cm) casting cell glass molds with a resin volume of
3600 grams which had been preheated to a temperature of
approximately 120.degree. C. The mixture was cured for two hours at
approximately 120.degree. C., followed by 22 hours at 160.degree.
C. The mold was removed from the oven and the plastic released. The
plastic sheet was then removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The Gardner Impact strength was
100 in-lbs (11.3 J).
[1054] Sample C
[1055] An isocyanate functional urethane prepolymer was prepared by
reacting 0.3 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W in a glass reaction kettle under vacuum and nitrogen
blanket. The prepolymer components were preheated to a temperature
of 110.degree. C., liquefied and degassed in a vacuum oven before
mixing. The glass reaction kettle was preheated to a temperature of
between 60.degree. C.-80.degree. C. before the addition of the
prepolymer components. The reaction temperature was maintained at
120.degree. C. for 15 minutes. Next, 0.2 equivalents of
1,5-pentanediol and 0.5 equivalents of trimethylolpropane were
added. The 0.2 equivalents of 1,5-pentanediol and 0.5 equivalents
of trimethylolpropane were preheated to a temperature of 80.degree.
C., liquefied and degassed in a vacuum oven before their addition
to the mixture. The kettle was placed into a preheated heating
mantle for about 15 minutes up to a temperature of approximately
120.degree. C. while the formulation was stirred and outgassed
under a vacuum pressure of -28 mmHg. Next, the mixture was cast
between release coated 1''.times.15''.times.15'' (2.5 cm.times.38.1
cm.times.38.1 cm) casting cell glass molds with a resin volume of
3600 grams which had been preheated to a temperature of
approximately 120.degree. C. The mixture was cured for two hours at
approximately 120.degree. C., followed by 22 hours at 160.degree.
C. The mold was removed from the oven and the plastic released. The
plastic sheet was then removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The Gardner Impact strength was
56 in-lbs (6.3 J).
[1056] Samples A-C were evaluated for glass transition temperature
(Tg), Gardner Impact Strength, Yellowness Index (YI), Light
Transmittance (% T), Tensile Strength at Yield, Tensile Elongation
at Break, and Young's Modulus. Glass transition temperature (Tg)
was measured using DMA. Rectangular bars with nominal dimensions:
.about.60 mm length.times.13 mm width.times..about.3 mm thickness
were mounted onto a TAI DMA 2980 in the three-point bending mode
(50 mm span) and scanned at 3.degree. C./min. from -90 to
180.degree. C. at a frequency of 1 Hz, 20 .mu.m amplitude, 120%
auto strain, 10 mN static force and a data point collected per 4
sec. Tensile strength at yield, Tensile elongation at break and
Young's Modulus were measured at about 25.degree. C. in accordance
with ASTM-D-638-03 for five samples of each of Samples A-C. Prior
to testing, the samples were conditioned for about 40 hours at
about 23.degree. C. and 50% RH. The average sample dimensions were
7''.times.0.506''.times.0.136'' (17.78 cm.times.1.285
cm.times.0.345 cm). The crosshead speed was 6.0 inches/min (15.24
cm/min). The results are set forth below:
TABLE-US-00063 Gardner Tensile Tensile Tensile Impact Strength
Elongation Modulus DMA T.sub.g Strength at at Break (Youngs) Sample
# (.degree. C.) (In-lbs) Optical YI % T Yield(PSI) (%) (PSI) A 116
126 0.71 89.63 12700 20 301000 A 140 A 77 B 134 28 1.2 91.48 14200
15 328000 C 130 61 1.21 90.58 13900 14 321000
[1057] Sample D
[1058] An isocyanate functional urethane prepolymer was prepared by
reacting 0.1 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W in a glass reaction kettle under vacuum and nitrogen
blanket. The glass reaction kettle was preheated to a temperature
of between 60.degree. C.-80.degree. C. before the addition of the
prepolymer components. The initial reaction temperature of the
components was 67.degree. C. and heated to 90.degree. C. The
prepolymer components were preheated to a temperature of
110.degree. C., liquefied and degassed in a vacuum oven before
mixing. The temperature was increased to 125.degree. C. over
approximately 135 minutes until the temperature of the prepolymer
components was approximately 121.degree. C. Next, 0.9 equivalents
of trimethylolpropane were added to the mixture. The 0.9
equivalents of trimethylolpropane were preheated to a temperature
of 130.degree. C., liquefied and degassed in a vacuum oven before
their addition to the mixture. Next, the mixture was cast between
release coated 1''.times.15''.times.15'' (2.5 cm.times.38.1
cm.times.38.1 cm) casting cell glass molds with a resin volume of
3600 grams which had been preheated to a temperature of
approximately 120.degree. C. The mixture was cured for two hours at
approximately 120.degree. C., followed by 22 hours at 160.degree.
C. The mold was removed from the oven and the plastic released. The
plastic sheet was then removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The Gardner Impact strength was
27 in-lbs (3 J).
[1059] Sample E
[1060] An isocyanate functional urethane prepolymer was prepared by
reacting 0.2 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W in a glass kettle under vacuum and nitrogen blanket. The
reaction temperature was maintained at 120.degree. C. for two hours
and 0.8 equivalents of trimethylolpropane were added. After about
30 minutes at 110.degree. C., the mixture was cast between release
coated 1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1
cm) casting cell glass molds with a resin volume of 3600 grams
which had been preheated to a temperature of approximately
120.degree. C., and then cured for 72 hours at 290.degree. F.
(143.degree. C.). The mold was removed from the oven and the
plastic released. The plastic sheet was then removed from the glass
mold and cut into 2''.times.2''.times.1/8'' (5.1 cm.times.5.1
cm.times.0.3 cm) samples for Gardner Impact testing. The Gardner
Impact strength was 20 in-lbs (2.2 J). The K Factor crack
propagation resistance was 800 lb/in.sup.3/2. A sample was
evaluated for stress craze resistance by immersion in 75% aqueous
solution of sulfuric acid. No degradation of the sample was
observed after two months at 4000 psi (27.6 MPa) stress.
[1061] Samples D and E were evaluated for tensile modulus, glass
transition temperature and Gardner Impact Strength in the manner
discussed above for Samples A-C, as well as density, K-factor,
Percent Haze (Taber Abrasion), Solvent resistance using methylene
chloride according to MIL-PRF-25690B (Jan. 29, 1993) and Amendment
I (Jun. 25, 1995), stress craze resistance using 75% sulfuric acid,
and coefficient of thermal expansion. Density (grams/cm.sup.3) of
solids was measured in accordance with ASTM-D 792-00. Taber
Abrasion (% haze) was measured for 100 cycles using a Taber Abrader
having a CS-10F abrasion wheel with 500 grams of weight, for a
sample size 3'' by 3'' by 1/8'' (7.62 cm by 7.62 cm by 0.32 cm)
according to ASTM D 1044-99. K-Factor crack propagation resistance
was measured according to U.S. Dept. of Defense MIL-PRF-25690B
(Jan. 29, 1993). Stress craze resistance was measured by immersion
in 75% aqueous solution of sulfuric acid at 3500 psi according to
ML-PRF-25690B (Jan. 29, 1993) and Amendment I (Jun. 25, 1995).
Linear Coefficient of Thermal Expansion was measured using a duPont
Thermomechanical analyzer (TMA) according to ASTM E 228-95. Results
are set forth below:
TABLE-US-00064 Sample D Sample E 0.1PDO/ 0.21PDO/ 0.9 TMP/DesW 0.9
TMP/Des W Tensile Modulus (PSI) 421,000 395,000 density
(g/cm.sup.3) 1.131 1.125 Tg (.degree. C.) 174 163 K-factor 752 868
% Haze 15.8 15.8 (Abrasion-100 cycles) Impact (in-lb) 22 22 Solvent
Resistance 24 hours 25 hours methylene Chloride Stress-Craze
Resistance 11 days + (75% H.sub.2SO.sub.4 @ 3500 psi) Coefficient
of Thermal Expansion 68.06 63.14 (PPM/.degree. C.)
[1062] Sample F
[1063] An isocyanate functional urethane prepolymer was prepared by
reacting 0.2 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W in a glass kettle under vacuum and nitrogen blanket. The
reaction temperature was maintained at 120.degree. C. for two
hours, then the sample was cooled to room temperature (about
25.degree. C.). The sample was reheated to 110.degree. C. and 0.2
equivalents of 1,5-pentanediol was added. The reaction temperature
was maintained at 120.degree. C. for 12 hours and 0.6 equivalents
of trimethylolpropane were added. After about 30 minutes at
110.degree. C., the mixture was cast between release coated
1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1 cm)
casting cell glass molds with a resin volume of 3600 grams which
had been preheated to a temperature of approximately 120.degree.
C., and then cured for 72 hours at 290.degree. F. (143.degree. C.).
The mold was removed from the oven and the plastic released. The
plastic sheet was then removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The Gardner Impact strength was
100 in-lbs (11.3 J). A one inch thick sample was held in front of a
white-surfaced board and no striations were observed when light was
directed onto the sample ("Visual Striation Test").
[1064] Sample G
[1065] An isocyanate functional urethane prepolymer was prepared by
reacting 0.2 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W in a glass kettle under vacuum and nitrogen blanket. The
reaction temperature was maintained at 120.degree. C. for two
hours, then the sample was cooled to room temperature (about
25.degree. C.). The sample was reheated to 110.degree. C. and 0.15
equivalents of 1,5-pentanediol was added. The reaction temperature
was maintained at 120.degree. C. for 12 hours and 0.6 equivalents
of trimethylolpropane and 0.05 equivalents of 1,5-pentanediol were
added. After about 30 minutes at 110.degree. C., the mixture was
cast between release coated 1''.times.15''.times.15'' (2.5
cm.times.38.1 cm.times.38.1 cm) casting cell glass molds with a
resin volume of 3600 grams which had been preheated to a
temperature of approximately 120.degree. C., and then cured for 72
hours at 290.degree. F. (143.degree. C.). The mold was removed from
the oven and the plastic released. The plastic sheet was then
removed from the glass mold and cut into 2''.times.2''.times.1/8''
(5.1 cm.times.5.1 cm.times.0.3 cm) samples for Gardner Impact
testing. The Gardner Impact strength was 110 in-lbs (12.4 J). A one
inch thick sample was held in front of a white-surfaced board and
no striations were observed when light was directed onto the
sample.
[1066] Ballistics Testing
[1067] A 6''.times.6''.times.1'' (15.2 cm.times.15.2 cm.times.2.5
cm) thick sample of each of Formulations A-G from Example L2 above
was cured by heating at 290.degree. F. (143.degree. C.) for 48
hours. A .40 caliber bullet shot from 30 feet (9.1 m) at a velocity
of 987 ft/sec (300 m/sec) ricocheted off the surface of each sample
and the plastic did not crack. A 9 mm bullet shot from 20 feet (6.1
m) at a velocity of 1350 ft/sec (411 m/sec) ricocheted off the
surface of each sample and the plastic did not crack.
[1068] Samples Prepared without Prepolymer
[1069] Sample H A polyurethane was prepared from the following
components:
TABLE-US-00065 Equivalent Component Weight Equivalents Weight (g)
Weight (%) TMP 44.7 0.90 40.2 22.8 1,5-pentanediol 52 0.10 5.20
2.95 Des W 131 1.0 131 74.2
[1070] The 1,5-pentanediol, TMP and DESMODUR W (each preheated to
80.degree. C.) were added to a glass reaction kettle (under
nitrogen blanket) that had been preheated to a temperature of
between 60.degree. C.-80.degree. C. before the addition of the
components. The kettle was placed into a preheated heating mantle
for about 30 minutes and heated up to a temperature of
approximately 118.degree. C. while the formulation was stirred and
outgassed under a vacuum pressure of -29 mmHg. Next, the mixture
was cast between release coated 1''.times.15''.times.15'' (2.5
cm.times.38.1 cm.times.38.1 cm) casting cell glass molds with a
resin volume of 3600 grams which had been preheated to a
temperature of about 120.degree. C. The mixture was cured for two
hours at approximately 120.degree. C., followed by 22 hours at
160.degree. C. The mold was removed from the oven and the plastic
released. The plastic sheet was then removed from the glass mold
and cut into 2''.times.2''.times.1/8'' (5.1 cm.times.5.1
cm.times.0.3 cm) samples for Gardner Impact testing. The Gardner
Impact strength was 27 in-lbs (3 J).
[1071] Sample I
[1072] A polyurethane was prepared from the following
components:
TABLE-US-00066 Equivalent Component Weight Equivalents Weight (g)
Weight (%) TMP 44.7 0.79 35.3 19.9 1,5-pentanediol 52 0.21 10.9 6.2
Des W 131 1.0 131 73.9
[1073] The 1,5-pentanediol, TMP and DESMODUR W (preheated to
80.degree. C.) were added to a glass reaction kettle (under
nitrogen blanket) preheated to a temperature of between 60.degree.
C.-80.degree. C. before the addition of the components. The kettle
was placed into a preheated heating mantle for about 30 minutes and
heated to a temperature of approximately 118.degree. C. while the
formulation was stirred and outgassed under a vacuum pressure of
-29 mmHg. Next, the mixture was cast between release coated
1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1 cm)
casting cell glass molds with a resin volume of 3600 grams which
had been preheated to a temperature of about 120.degree. C. The
mixture was cured for two hours at approximately 120.degree. C.,
followed by 22 hours at 160.degree. C. The mold was removed from
the oven and the plastic released. The plastic sheet was then
removed from the glass mold and cut into 2''.times.2''.times.1/8''
(5.1 cm.times.5.1 cm.times.0.3 cm) samples for Gardner Impact
testing. The Gardner Impact strength was 100 in-lbs (11 J). The
Weight % Hard Segment was 21.69, the Weight % Urethane was 33.25,
and the M.sub.c was 673.8 g/mol.
[1074] Sample J
[1075] A polyurethane was prepared from the following
components:
TABLE-US-00067 Equivalent Component Weight Equivalents Weight (g)
Weight (%) 1,4-butanediol 45.1 0.63 28.4 14.1 PC-1733 407.6 0.07
28.5 14.2 TMP 44.7 0.30 13.4 6.7 Des W 131.2 1.0 131.2 65.1
[1076] The 1,4-butanediol, PC-1733 polycarbonate diol, TMP and
DESMODUR W (preheated to 80.degree. C.) were added to a glass
reaction kettle (under nitrogen blanket) preheated to a temperature
of between 60.degree. C.-80.degree. C. before the addition of the
components. The kettle was placed into a preheated heating mantle
for about 20 minutes and heated to a temperature of approximately
121.degree. C. while the formulation was stirred and outgassed
under a vacuum pressure of -28 mmHg. Next, the mixture was cast
between release coated 1''.times.15''.times.15'' (2.5 cm.times.38.1
cm.times.38.1 cm) casting cell glass molds with a resin volume of
3600 grams which had been preheated to a temperature of about
120.degree. C. The mixture was cured for 2 hours at approximately
120.degree. C., followed by 22 hours at 160.degree. C. The mold was
removed from the oven and the plastic released. The plastic sheet
was then removed from the glass mold and cut into
2''.times.2''.times.1/8'' (5.1 cm.times.5.1 cm.times.0.3 cm)
samples for Gardner Impact testing. The Gardner Impact strength was
520 in-lbs (29 J). The Weight % Hard Segment was 55%, the Weight %
Urethane was 29.276, and the M.sub.c was 2015.3 g/mol.
[1077] Sample K
[1078] A polyurethane was prepared from the following
components:
TABLE-US-00068 Equivalent Component Weight Equivalents Weight (g)
Weight (%) CHDM 72.1 0.80 57.7 24.6 PC-1733 407.6 0.10 40.8 17.4
TMP 44.7 0.10 4.5 1.9 Des W 131.2 1.0 131.2 56.0
[1079] The CHDM, PC-1733, TMP and DESMODUR W (preheated to
80.degree. C.) were added to a glass reaction kettle (under
nitrogen blanket) preheated to a temperature of between 60.degree.
C.-80.degree. C. before the addition of the components. The kettle
was placed into a preheated heating mantle for about 20-25 minutes
and heated to a temperature of approximately 121.degree. C. while
the formulation was stirred and outgassed under a vacuum pressure
of -28 mmHg. Next, the mixture was cast between release coated
1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1 cm)
casting cell glass molds with a resin volume of 3600 grams which
had been preheated to a temperature of about 120.degree. C. The
mixture was cured for two hours at approximately 120.degree. C.,
followed by 22 hours at 160.degree. C. The mold was removed from
the oven and the plastic released. The W.sub.c was 27.5%, the
Weight % Urethane was 25.33, and the M.sub.c was 7094.5.
[1080] Sample L
[1081] A polyurethane was prepared from the following
components:
TABLE-US-00069 Equivalent Component Weight Equivalents Weight (g)
Weight (%) CHDM 72.1 0.70 50.5 20.2 PC-1733 407.6 0.15 61.1 24.5
TMP 44.7 0.15 6.7 2.7 Des W 131.2 1.0 131.2 52.6
[1082] The CHDM, PC-1733, TMP and DESMODUR W (preheated to
80.degree. C.) were added to a glass reaction kettle (under
nitrogen blanket) preheated to a temperature of between 60.degree.
C.-80.degree. C. before the addition of the components. The kettle
was placed into a preheated heating mantle for about 20-25 minutes
up to a temperature of approximately 122.degree. C. while the
formulation was stirred and outgassed under a vacuum pressure of
-28 mmHg. Next, the mixture was cast between release coated
1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1 cm)
casting cell glass molds with a resin volume of 3600 grams which
had been preheated to a temperature of about 120.degree. C. The
mixture was cured for two hours at approximately 120.degree. C.,
followed by 22 hours at 160.degree. C. The mold was removed from
the oven and the plastic released. The Weight % Hard Segment was
23.85, the Weight % Urethane was 25.2, and the M.sub.c was
4680.
[1083] Sample M
[1084] A polyurethane was prepared from the following
components:
TABLE-US-00070 Equivalent Component Weight Equivalents Weight (g)
Weight (%) CHDM 72.1 0.70 50.5 21.8 PC-1733 407.6 0.10 40.8 17.6
TMP 44.7 0.20 8.9 3.9 Des W 131.2 1.0 131.2 56.7
[1085] The CHDM, PC-1733, TMP and DESMODUR W (preheated to
80.degree. C.) were added to a glass reaction kettle (under
nitrogen blanket) preheated to a temperature of between 60.degree.
C.-80.degree. C. before the addition of the components. The kettle
was placed into a preheated heating mantle for about 20-25 minutes
up to a temperature of approximately 121.degree. C. while the
formulation was stirred and outgassed under a vacuum pressure of
-28 mmHg. Next, the mixture was cast between release coated
1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1 cm)
casting cell glass molds with a resin volume of 3600 grams which
had been preheated to a temperature of approximately 120.degree. C.
The mixture was cured for two hours at approximately 120.degree.
C., followed by 22 hours at 160.degree. C. The mold was removed
from the oven and the plastic released. The Weight % Hard Segment
was 61.5%, the Weight % Urethane was 25.5, and the M.sub.c was
3505.7.
Example L3
[1086] An isocyanate functional urethane prepolymer was prepared by
reacting 0.3 equivalents of 1,5-pentanediol, 1.0 equivalent of
DESMODUR W 4,4'-methylene-bis-(cyclohexyl isocyanate) and 5 ppm
dibutyltin diacetate as reactants. The DESMODUR W and
1,5-pentanediol were each pre-heated to a temperature of about
80.degree. C. under a nitrogen atmosphere for at least about four
hours prior to mixing. The components were mixed using a Max
Urethane Processing System Model No. 601-000-282 available from Max
Machinery, Inc. of Healdsburg, Calif. for Trials 1-3 and Max
Urethane Processing System Model No. 601-000-333 for Trials
4-6.
[1087] The Max Urethane Processing System was used to heat the raw
materials to the specified temperatures desired, maintain the
temperature of the raw materials delivered to the mix head, degass
each component, and deliver the specified quantities of each raw
material to a dynamic pin mixer for blending and dispensing. See
"Max Urethane Processing System", a publication of Max Machinery,
Inc. (2005), incorporated by reference herein.
[1088] Subsequently, the isocyanate functional urethane prepolymer
was reacted with 0.4 equivalents of 1,5-pentanediol and 0.3
equivalents of trimethylolpropane (Formulation 2), 0.1 equivalents
of 1,5-pentanediol and 0.6 equivalents of trimethylolpropane
(Formulation 3), or 0.2 equivalents of 1,5-pentanediol and 0.5
equivalents of trimethylolpropane (Formulation 81), as indicated
below. Each of the reactants was heated to the temperature
indicated below prior to mixing. The flow rate of each reactant and
temperature at the mix head for each Trial is specified in Table 27
below. The mixing speed was 13,000 rpm.
Trial 1
TABLE-US-00071 [1089] TABLE 27 Tank temperature (.degree. C.) Temp.
Sample # Formulation Prepolymer PDO TMP mix head 1 2 110 89 89 110
2 2 110 89 89 110 3 2 110 89 89 110 4 2 110 89 89 110 5 2 120 100
100 120 6 2 120 100 100 120 7 2 126 100 100 126 8 2 127 100 100 127
9 2 126 100 100 126 10 2 110 100 100 110 11 2 110 100 100 110 12 2
110 100 100 110 13 3 110 100 100 110 14 3 110 100 100 110 15 3 121
110 110 121 16 3 121 110 110 121 17 81 121 110 110 121 18 81 121
110 110 121 19 2 121 110 110 110 20 2 121 110 110 110 21 2 121 110
110 110 22 2 121 110 110 110 23 2 121 110 110 110 24 2 121 110 110
110 25 2 121 110 110 110 26 2 121 110 110 110 27 2 121 110 110 110
28 2 121 110 110 110 29 2 121 110 110 110 30 81 121 110 110 110 31
81 121 110 110 110 32 81 121 110 110 110 33 81 121 110 110 110 34
81 121 110 110 110 35 81 121 110 110 110 36 81 121 110 110 110 37
81 121 110 110 110 38 81 121 110 110 110 39 81 121 110 110 110 40 3
121 110 110 110 41 3 121 110 110 110 42 3 121 110 110 110 43 3 121
110 110 110 44 3 121 110 110 110 45 3 121 110 110 110 46 3 121 110
110 110 47 3 121 110 110 110 48 3 121 110 110 110 49 3 121 110 110
110 50 3 121 110 110 110 51 3 121 110 110 110 52 3 121 110 110 110
53 3 121 110 110 110 54 2 121 110 110 110 55 2 121 110 110 110 56 2
121 110 110 110 57 2 121 110 110 110 58 2 121 110 110 110 59 2 121
110 110 110 60 3 121 110 110 110 61 3 121 110 110 110 62 81 121 110
110 110 63 3 121 110 110 110 64 81 121 110 110 110 65 2 121 110 110
110 66 2 121 110 110 110 67 2 121 110 110 110 68 2 121 110 110 110
69 3 121 110 110 110 70 3 121 110 110 110 71 3 121 110 110 110 72 3
121 110 110 110 73 81 121 110 110 110 74 81 121 110 110 110 75 81
121 110 110 110 81 121 110 110 110
[1090] The flow rate in grams per minute of the prepolymer,
trimethylolpropane and 1,5-pentanediol into the mix head is set
forth in the table below. The mixtures were cast between release
coated 1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1
cm) casting cell glass molds with a resin volume of 3600 grams
which had been preheated to a temperature of about 140.degree. C.
and cured for the respective times and temperatures set forth in
Table 28 below. After curing, each mold was removed from the oven
and allowed to cool to room temperature.
TABLE-US-00072 TABLE 28 Cure Flow Rate (g/min) Time Sample # Form.
Prepolymer TMP PDO Total Temp. (.degree. C.) (hours) 1 2 2500
353.93 228.04 3081.97 132 -- 2 2 3500 495.50 319.25 4314.75 132 --
3 2 3900 552.13 355.74 4807.87 132 -- 4 2 3500 495.50 319.25
4314.75 99/127 5/14 5 2 3500 495.50 319.25 4314.75 132 -- 6 2 3500
495.50 319.25 4314.75 25/99/160 .5/2/14 7 2 3500 495.50 319.25
4314.75 99/127 1.25/14 8 2 3500 495.50 319.25 4314.75 99/127 0.5/14
9 2 3000 424.71 273.64 3698.36 121/160 2.75/15.5 10 2 3000 424.71
273.64 3698.36 110/160 2/15.5 11 2 3000 424.71 273.64 3698.36
100/160 4.5/15.5 12 2 3500 495.50 319.25 4314.75 100/160 4.5/15.5
13 3 3500 638.55 123.90 4262.45 100/160 1/15.5 14 3 3500 638.55
123.90 4262.45 100/160 1/15.5 15 3 3000 106.20 547.33 3653.53
100/160 1.5/15.5 16 3 3000 106.20 547.33 3653.53 100/160 1.5/15.5
17 81 3000 212.38 456.11 3668.49 100/160 1.25/15.5 18 81 3000
212.38 456.11 3668.49 100/160 1.25/15.5 19 2 500 70.79 45.61 616.39
121/160 3/15.5 20 2 500 70.79 45.61 616.39 121/160 3/15.5 21 2 500
70.79 45.61 616.39 121/160 3/15.5 22 2 500 70.79 45.61 616.39
121/160 3/15.5 23 2 500 70.79 45.61 616.39 121/160 3/15.5 24 2 500
70.79 45.61 616.39 121/160 3/15.5 25 2 800 113.26 72.97 986.23
121/160 3/15.5 26 2 800 113.26 72.97 986.23 121/160 3/15.5 27 2 800
113.26 72.97 986.23 121/160 3/15.5 28 2 800 113.26 72.97 986.23
121/160 3/15.5 29 2 800 113.26 72.97 986.23 121/160 3/15.5 30 81
500 35.40 76.02 611.41 121/160 2/15.5 31 81 500 35.40 76.02 611.41
121/160 2/15.5 32 81 500 35.40 76.02 611.41 121/160 2/15.5 33 81
500 35.40 76.02 611.41 121/160 2/15.5 34 81 500 35.40 76.02 611.41
121/160 2/15.5 35 81 800 56.63 121.63 978.26 121/160 2/15.5 36 81
800 56.63 121.63 978.26 121/160 2/15.5 37 81 800 56.63 121.63
978.26 121/160 2/15.5 38 81 800 56.63 121.63 978.26 121/160 2/15.5
39 81 800 56.63 121.63 978.26 121/160 2/15.5 40 3 800 28.32 145.95
974.27 121/160 2/15.5 41 3 800 28.32 145.95 974.27 121/160 2/15.5
42 3 800 28.32 145.95 974.27 121/160 2/15.5 43 3 800 28.32 145.95
974.27 121/160 2/15.5 44 3 800 28.32 145.95 974.27 121/160 2/15.5
45 3 1000 35.40 182.44 1217.84 121/160 2/15.5 46 3 1000 35.40
182.44 1217.84 121/160 2/15.5 47 3 1000 35.40 182.44 1217.84
121/160 2/15.5 48 3 1000 35.40 182.44 1217.84 121/160 2/15.5 49 3
1000 35.40 182.44 1217.84 121/160 0.5/15.5 50 3 1000 35.40 182.44
1217.84 121/160 0.5/15.5 51 3 1000 35.40 182.44 1217.84 121/160
0.5/15.5 52 3 1000 35.40 182.44 1217.84 121/160 0.5/15.5 53 3 1000
35.40 182.44 1217.84 121/160 0.5/15.5 54 2 3500 495.50 319.25
4314.75 121/160 0.5/15.5 55 2 2500 353.93 228.04 3081.97 121/160
0.5/15.5 56 2 2000 283.14 182.43 2465.57 121/160 0.5/15.5 57 2 1500
212.36 136.82 1849.18 121/160 0.5/15.5 58 2 3000 424.71 273.64
3698.36 121/160 2/15.5 59 2 2500 353.93 228.04 3081.97 121/160
2/15.5 60 3 3000 106.20 547.33 3653.53 121/160 2/15.5 61 3 2500
88.50 456.11 3044.61 121/160 2/15.5 62 81 2500 176.98 380.09
3057.07 121/160 2/15.5 63 3 2000 70.80 364.89 2435.69 121/160
2/15.5 64 81 2000 141.59 304.07 2445.66 121/160 2/15.5 65 2 800
72.97 113.26 986.23 121/160 2/15.5 66 2 800 72.97 113.26 986.23
121/160 2/15.5 67 2 800 72.97 113.26 986.23 121/160 2/15.5 68 2 800
72.97 113.26 986.23 121/160 2/15.5 69 3 800 145.95 28.32 974.27
121/160 2/15.5 70 3 800 145.95 28.32 974.27 121/160 2/15.5 71 3 800
145.95 28.32 974.27 121/160 2/15.5 72 3 800 145.95 28.32 974.27
121/160 2/15.5 73 81 800 121.63 56.63 978.26 121/160 2/15.5 74 81
800 121.63 56.63 978.26 121/160 2/15.5 75 81 800 121.63 56.63
978.26 121/160 2/15.5 81 800 121.63 56.63 978.26 121/160 2/15.5
[1091] Selected samples were evaluated for various physical
properties. Yellowness Index (YI) and Light Transmittance (% T)
after 333 hours (equivalent to about one year) exposure to QUV-B
was determined according to ASTM G-53. The results are set forth in
Table 29 below.
TABLE-US-00073 TABLE 29 After 333 hrs Initial QUV B Final - Initial
SAMPLE ID YI % T YI % T YI % T 66 1.53 91.66 70 1.63 91.96 74 1.54
90.84 67 6.34 89.68 67 6.06 89.36 Average 6.2 89.52 4.67 -2.14 71
9.62 89.89 71 8.43 88.76 Average 9.025 89.325 7.395 -2.635 75 9.15
88.64 75 7.24 89.41 Average 8.195 89.025 6.655 -1.815
Trial 2
[1092] For Trial 2, mixtures were prepared using the components as
in Trial 1 above, except the respective mixing and casting
conditions are set forth in Tables 30-31 below.
TABLE-US-00074 TABLE 30 Tank temperatures (.degree. C.) temp Sample
# Formulation. Prepolymer PDO TMP mix head (.degree. C.) 1 2 100
110 110 121 2 2 121 110 110 121 3 2 121 110 110 121 4 2 121 110 110
121 5 3 121 110 110 121 6 2 121 110 110 121 7 2 123 111 110 121 8 2
123 111 110 121 9 2 121 110 110 121 10 2 121 110 110 121 11 2 121
110 110 121 12 2 121 110 110 121 13 3 121 110 110 121 14 3 121 110
110 121 15 81 121 110 110 121 16 2 121 110 110 121 17 3 121 110 110
121 18 81 121 110 110 121 19 2 121 110 110 121 20 2 121 110 110 121
21 3 121 110 110 121 22 3 121 110 110 121 23 81 121 110 110 121 24
2 121 110 110 121 25 3 121 110 110 121 26 3 121 110 110 121 27 81
121 110 110 121 28 81 121 110 110 121 29 2 121 110 110 121 30 3 121
110 110 121 31 81 121 110 110 121 32 2 121 110 110 121 33 2 121 110
110 121 34 3 121 110 110 121 35 3 121 110 110 121 36 81 121 110 110
121 37 2 121 110 110 121 38 3 121 110 110 121 39 81 121 110 110 121
40 2 121 110 110 121 41 3 121 110 110 121 42 2 121 110 110 121 43 2
121 110 110 121 44 3 121 110 110 121 45 2 121 110 110 121 46 2 121
110 110 121 47 2 121 110 110 121 48 2 121 110 110 121 49 3 121 110
110 121 50 2 121 110 110 121 51 2 121 110 110 121 52 2 121 110 110
121 53 2 121 110 110 121 54 2 121 110 110 121 55 2 121 110 110 121
56 2 121 110 110 121 57 2 121 110 110 121 58 3 121 110 110 121 59
81 121 110 110 121
TABLE-US-00075 TABLE 31 Flow Rates (g/min) mix head Residence Cure
Sample # Prepolymer TMP PDO Total volume (cc) Time (sec) Temp
(.degree. C.) time 1 800 113.26 72.97 986.23 70 4.26 250/320
5.5/14.25 2 800 113.26 72.97 986.23 140 8.52 250/320 5.25/14.25 3
800 113.26 72.97 986.23 140 8.52 250/320 /14.25 4 820 116.09 74.80
1010.88 22 1.31 250/320 /14.25 5 820 29.03 149.60 998.63 22 1.32
250/320 /14.25 6 1500 212.36 136.82 1849.18 140 4.54 250/320 /14.25
7 2500 353.93 228.04 3081.97 140 2.73 250/320 /14.25 8 3500 495.50
319.25 4314.75 140 1.95 250/320 /14.25 9 800 113.26 72.97 986.23
140 8.52 320 /14.25 10 800 113.26 72.97 986.23 140 8.52 320 /14.25
11 3500 319.25 495.50 4314.75 140 1.95 230/320 12 3500 319.25
495.50 4314.75 140 1.95 230/320 13 2500 456.11 88.50 3044.61 140
2.76 230/320 14 2500 456.11 88.50 3044.61 140 2.76 230/320 15 3000
456.11 212.38 3668.49 140 2.29 230/320 16 3500 319.25 495.50
4314.75 140 1.95 230/320 17 2500 456.11 88.50 3044.61 140 2.76
230/320 18 3000 456.11 212.38 3668.49 140 2.29 230/320 19 800 72.97
113.26 986.23 140 8.52 230/320 20 800 72.97 113.26 986.23 140 8.52
230/320 21 800 145.95 28.32 974.27 140 8.62 230/320 22 800 145.95
28.32 974.27 140 8.62 230/320 23 800 121.63 56.63 978.26 140 8.59
230/320 24 3500 319.25 495.50 4314.75 140 1.95 230/320 25 2500
456.11 88.50 3044.61 140 2.76 230/320 26 2500 456.11 88.50 3044.61
140 2.76 230/320 27 3000 456.11 212.38 3668.49 140 2.29 230/320 28
3000 456.11 212.38 3668.49 140 2.29 230/320 29 800 72.97 113.26
986.23 140 8.52 230/320 30 800 145.95 28.32 974.27 140 8.62 230/320
31 800 121.63 56.63 978.26 140 8.59 230/320 32 2500 228.04 353.93
3081.97 140 2.73 230/320 33 2500 228.04 353.93 3081.97 140 2.73
230/320 34 2000 364.89 70.80 2435.69 140 3.45 230/320 35 2000
364.89 70.80 2435.69 140 3.45 230/320 36 2500 380.09 176.98 3057.07
140 2.75 230/320 37 1250 114.02 176.96 1540.98 70 2.73 230/320 38
1000 182.44 35.40 1217.84 70 3.45 230/320 39 1250 190.04 88.49
1528.54 70 2.75 230/320 40 820 74.80 116.09 1010.88 140 8.31
230/320 41 820 149.60 29.03 998.63 140 8.41 230/320 42 1200 109.46
169.89 1479.34 140 5.68 230/320 43 410 37.40 58.04 505.44 70 8.31
230/320 44 410 74.80 14.51 499.32 70 8.41 230/320 45 600 54.73
84.94 739.67 70 5.68 230/320 46 600 54.73 84.94 739.67 70 5.68
230/320 47 1750 159.63 247.75 2157.38 70 1.95 230/320 48 1500
136.82 212.36 1849.18 70 2.27 230/320 49 1250 228.05 44.25 1522.30
70 2.76 230/320 50 1500 136.82 212.36 1849.18 70 2.27 230/320 51
800 72.97 113.26 986.23 70 4.26 230/320 52 800 72.97 113.26 986.23
70 4.26 230/320 53 800 72.97 113.26 986.23 70 4.26 230/320 54 800
72.97 113.26 986.23 70 4.26 230/320 55 800 72.97 113.26 986.23 70
4.26 230/320 56 800 72.97 113.26 986.23 70 4.26 230/320 57 1250
114.02 176.96 1540.98 70 2.73 230/320 58 1500 273.67 53.10 1826.76
70 2.30 230/320 59 1250 190.04 88.49 1528.54 70 2.75 230/320
[1093] Selected samples were evaluated for various physical
properties. The results of Gardner Impact strength testing
according to ASTM D-5420-04 of selected samples are set forth in
Table 32 below and in FIG. 27. For the Samples below having
stabilizers added to the formulation (Y), 0.5% by weight of IRGANOX
1076 antioxidant was added during preparation of the prepolymer,
based upon total weight of the prepolymer, and 1% by weight of
SANDUVOR VSU and 0.5% by weight of SANDUVOR 3058 were added during
mixing of the prepolymer with the other monomers. As shown in FIG.
27, increased residence time of the reactants in the mix head can
provide improved Gardner Impact strength in molded articles
prepared from samples according to the present invention.
TABLE-US-00076 TABLE 32 Impact Residence Strength Sample
Formulation Trial Time (sec) Stabilizers (in-lbs/J) 20 2 20 8.52 N
288/33 22 3 22 8.62 N 48/5 23 81 23 8.59 N 74/8 37 2 37 2.73 Y
115/13 38 3 38 3.45 Y 43/5 45 2 45 5.68 Y 195/22 47 2 47 1.95 Y
104/12 50 2 50 2.27 Y 40/5 53 2 53 4.26 Y 195/22 54 2 54 4.26 Y
161/18 55 2 55 4.26 Y 193/22 56 2 56 4.26 Y 164/19 44 3 44 8.41 Y
60/7
[1094] Yellowness Index (YI) and Light Transmittance (% T) for
selected samples were determined according to ASTM G-53. Also,
results for testing of selected samples tested initially and after
exposure to QUV-B for 333 hours in a manner discussed above were
determined. The results are set forth in Tables 33 and 34
below.
TABLE-US-00077 TABLE 33 INITIAL DATA SAMPLE YI % T 20 1.38 92.04 22
0.97 91.36 23 0.95 91.13 37 1.88 91.38 38 2.04 91.26 45 2.64 90.43
47 2.52 91.9 50 2.46 90.6 53 2.5 92.15 54 2.37 92.02 55 2.1 91.01
56 2.41 92.1
TABLE-US-00078 TABLE 34 INITIAL 33 h QUV DATA 3 DATA SAMPLE YI % T
YI % T 29 2.28 91.47 2.86 91.10 30 1.68 90.87 2.48 90.48 39 1.95
90.84 2.31 90.83 51 2.15 90.68 2.48 90.63
[1095] Glass transition temperature (Tg) of selected samples was
measured using DMA. Rectangular bars with nominal dimensions: 60 mm
length.times.13 mm width.times..about.3 mm thickness were mounted
onto a TAI DMA 2980 in the three-point bending mode (50 mm span)
and scanned at 3.degree. C./min. from -90 to 180.degree. C. at a
frequency of 1 Hz, 20 .mu.m amplitude, 120% auto strain, 10 mN
static force and a data point collected per 4 sec. The results are
set forth in Table 35 below and in FIGS. 28-34.
TABLE-US-00079 TABLE 35 Tan gamma (low temperature), Tan delta max.
temperature, Tan beta Sample (.degree. C.) 19 -66, 19, 114 21 -67,
24, 131 31 -74, 20, 127 46 -70, 14, 109 48 -68, 18, 109 49 -67, 20,
129 52 -67, 15, 108
[1096] FIG. 28 is a graph of storage modulus, loss modulus and tan
Delta as a function of temperature measured using DMA for a casting
of a polyurethane prepared according to Trial 2, Sample 19. FIG. 29
is a graph of storage modulus, loss modulus and tan Delta as a
function of temperature measured using DMA for a casting of a
polyurethane prepared according to Trial 2, Sample 21. FIG. 30 is a
graph of storage modulus, loss modulus and tan delta as a function
of temperature measured using DMA for a casting of a polyurethane
prepared according to Trial 2, Sample 31. FIG. 31 is a graph of
storage modulus, loss modulus and tan Delta as a function of
temperature measured using DMA for a casting of a polyurethane
prepared according to Trial 2, Sample 46. FIG. 32 is a graph of
storage modulus, loss modulus and tan Delta as a function of
temperature measured using DMA for a casting of a polyurethane
prepared according to Trial 2, Sample 48. FIG. 33 is a graph of
storage modulus, loss modulus and tan Delta as a function of
temperature measured using DMA for a casting of a polyurethane
prepared according to Trial 2, Sample 49. FIG. 34 is a graph of
storage modulus, loss modulus and tan Delta as a function of
temperature measured using DMA for a casting of a polyurethane
prepared according to Trial 2, Sample 52.
[1097] Table 36 and FIG. 35 show the results of testing of selected
samples for Young's Modulus (psi) as a function of residence time
in the mix head (sec).
TABLE-US-00080 TABLE 36 Young's Formulation Sample Modulus
Residence time in No. No. (psi) mix head (sec) 2 19 313000 8.52 3
21 337000 8.62 81 31 341000 8.59 2 46 320000 5.68 2 48 317000 2.27
3 49 337000 2.76 2 52 317000 4.26
[1098] The results of Gardner Impact strength testing according to
ASTM D-5420-04 of selected samples are set forth in Table 37 below.
Stabilizers were included as discussed above.
TABLE-US-00081 TABLE 37 Impact Residence Strength Sample
Formulation Trial Time (sec) Stabilizers (in-lbs/J) 20 2 20 8.52 N
288/33 22 3 22 8.62 N 48/5 23 81 23 8.59 N 74/8 37 2 37 2.73 Y
115/13 38 3 38 3.45 Y 43/5 44 3 44 8.41 Y 60/7 45 2 45 5.68 Y
195/22 47 2 47 1.95 Y 104/12 50 2 50 2.27 Y 40/5 53 2 53 4.26 Y
195/22 54 2 54 4.26 Y 161/18 55 2 55 4.26 Y 193/22 56 2 56 4.26 Y
164/19
[1099] Gardner Impact strength was measured in accordance with ASTM
D-5420-04 for sample runs as indicated in Table 38 below. Samples
were tested after cure and after two or 78 hours of QUV-B exposure
according to ASTM G-53.
TABLE-US-00082 TABLE 38 Summary Results for Gardner Impact Testing
according to ASTM D5420-04 FORMULATION # 2 2 78 78 Sample # 2 1 2 3
4 2 APT w/ 2 control stab control stab APT stab APT Mean Failure
360 243 19 24 50 10 18 Height
Trial 3
[1100] For Trial 3, mixtures were prepared using the components as
in Trial 1 above, except the respective mixing and casting
conditions are set forth in Tables 39-40 below. The samples were
cured for two hours at 250.degree. F. (121.degree. C.), then for 16
hours at 320.degree. F. (160.degree. C.). The mixtures were cast
between release coated 1''.times.15''.times.15'' (2.5 cm.times.38.1
cm.times.38.1 cm) casting cell glass molds with a resin volume of
3600 grams which had been preheated to a temperature of about
140.degree. C. and cured for the respective times and temperatures
set forth in the table below. After curing, each mold was removed
from the oven and allowed to cool to room temperature.
TABLE-US-00083 TABLE 39 Sample Tank temperatures .degree. C. temp #
Prepolymer PDO TMP mix head (.degree. C.) Formulation 1 125 110 110
120 3 2 125 110 110 120 3 3 125 110 110 120 2 4 125 110 110 120 2 5
125 110 110 120 2 6 125 110 110 120 2 7 125 110 110 120 2 8 125 110
110 120 2 9 125 110 110 120 2 10 125 110 110 120 2 11 125 110 110
120 2 12 125 110 110 120 2 13 125 110 110 120 2 14 125 110 110 120
2 15 125 110 110 120 2 16 125 110 110 120 2 17 125 110 110 120 2 18
125 110 110 120 2 19 125 110 110 120 2 20 125 110 110 120 2 21 125
110 110 120 2 22 125 110 110 120 2 23 125 110 110 120 2 24 125 110
110 120 2 25 125 110 110 120 2 26 125 110 110 120 2 27 125 110 110
120 2 28 125 110 110 120 2 29 125 110 110 120 2 30 125 110 110 120
2 31 125 110 110 120 2 32 125 110 110 120 2 33 125 110 110 120 2 34
125 110 110 120 2 35 125 110 110 120 2 36 125 110 110 120 2 37 125
115 120 125 2 38 125 110 110 120 3 39 125 110 110 120 3 40 125 110
110 120 3 41 125 110 110 120 81 42 125 110 110 120 81 43 125 110
110 120 81 44 125 110 110 120 81 45 125 110 110 120 81 46 125 110
110 120 81 47 125 110 110 120 81 48 125 110 110 120 81 49 125 110
110 120 81 50 125 110 110 120 81 51 125 110 110 120 3 52 125 110
110 120 3 53 125 110 110 120 3 54 125 110 110 120 3 55 125 110 110
120 3 56 125 110 110 120 3 57 125 110 110 120 3 58 125 110 110 120
3 59 125 110 110 120 3 60 125 110 110 120 3 61 125 110 110 120 3 62
125 110 110 120 81 63 125 110 110 120 2 64 125 110 110 120 2 65 125
110 110 120 2 66 125 110 110 120 2 67 125 110 110 120 262 68 125
110 110 120 262 69 125 110 110 120 263 70 125 110 110 120 263 71
125 110 110 120 264 72 125 110 110 120 264 73 125 110 110 120 265
74 125 110 110 120 265 75 125 110 110 120 2 76 125 110 110 120 2 77
125 110 110 120 2 78 125 110 110 120 2 79 125 110 110 120 2 80 125
110 110 120 2 81 125 110 110 120 2 82 125 110 110 120 2 83 125 110
110 120 2 84 125 110 110 120 2 85 125 110 110 120 2 86 125 110 110
120 2 87 125 110 110 120 2 88 125 110 110 120 2 89 125 110 110 120
2 90 125 110 110 120 2 91 125 110 110 120 2 92 125 110 110 120 3 93
125 110 110 120 2 94 125 110 110 120 2 95 125 110 110 120 2 96 125
110 110 120 2 97 125 110 110 120 2
TABLE-US-00084 TABLE 40 Sample Flow Rates (g/min) Total mix head
residence # Formulation Prepolymer Stabilizer PDO TMP g/min volume
(cc) time (s) 1 3 1000 35.43 182.63 1218.06 205 10.10 2 3 1000
35.43 182.63 1218.06 205 10.10 3 2 800 28 113.38 73.05 986.43 205
12.47 4 2 1000 141.72 91.32 1233.04 205 9.98 5 2 1200 170.06 109.58
1479.64 205 8.31 6 2 1500 212.58 136.97 1849.55 205 6.65 7 2 2000
283.44 182.63 2466.07 205 4.99 8 2 2500 354.30 228.29 3082.59 205
3.99 9 2 2100 297.61 191.76 2589.37 205 4.75 10 2 800 113.38 73.05
986.43 205 12.47 11 2 1500 212.58 136.97 1849.55 205 6.65 12 2 2100
297.61 191.76 2589.37 205 4.75 13 2 900 127.55 82.18 1109.73 205
11.08 14 2 1100 155.89 100.45 1356.34 205 9.07 15 2 1300 184.24
118.71 1602.95 205 7.67 16 2 1400 198.41 127.84 1726.25 205 7.13
Sample Flow Rates (g/min) Total mix head residence # Formulation
Prepolymer PDO TMP g/min volume (cc) time (s) 17 2 1600 226.75
146.11 1972.86 205 6.23 18 2 1700 240.92 155.24 2096.16 205 5.87 19
2 1800 255.10 164.37 2219.46 205 5.54 20 2 1900 269.27 173.50
2342.77 205 5.25 21 2 800 113.38 73.05 986.43 250 15.21 22 2 900
127.55 82.18 1109.73 250 13.52 23 2 1000 141.72 91.32 1233.04 250
12.17 24 2 1100 155.89 100.45 1356.34 250 11.06 25 2 1200 170.06
109.58 1479.64 250 10.14 26 2 1300 184.24 118.71 1602.95 250 9.36
27 2 1400 198.41 127.84 1726.25 250 8.69 28 2 1500 212.58 136.97
1849.55 250 8.11 29 2 1600 226.75 146.11 1972.86 250 7.60 30 2 1700
240.92 155.24 2096.16 250 7.16 31 2 1800 255.10 164.37 2219.46 250
6.76 32 2 1900 269.27 173.50 2342.77 250 6.40 mix Flow Rates
(g/min) head Sample Stabilizer and Total volume residence #
Formulation Prepolymer Prepolymer PDO TMP g/min (cc) time (s) 33 2
2000 283.44 182.63 2466.07 250 6.08 33 34 2 2100 297.61 191.76
2589.37 250 5.79 35 2 800 113.38 73.05 986.43 250 15.21 36 2 1500
212.58 136.97 1849.55 250 8.11 37 2 800 824.24 113.38 73.05 986.43
250 15.21 38 3 800 824.24 22.41 151.20 973.61 250 15.41 39 3 800
824.24 22.41 151.20 973.61 250 15.41 40 3 800 824.24 22.41 151.20
973.61 250 15.41 41 81 800 824.24 51.74 126.00 977.75 250 15.34 42
81 800 824.24 51.74 126.00 977.75 250 15.34 43 81 800 824.24 51.74
126.00 977.75 250 15.34 44 81 800 824.24 51.74 126.00 977.75 250
15.34 45 81 800 824.24 51.74 126.00 977.75 250 15.34 46 81 800
824.24 51.74 126.00 977.75 250 15.34 47 81 800 824.24 51.74 126.00
977.75 250 15.34 48 81 800 824.24 51.74 126.00 977.75 250 15.34 49
81 1500 1545.45 97.02 236.25 1833.27 250 8.18 50 81 2100 2163.63
135.83 330.76 2566.58 250 5.84 51 3 2100 2163.63 297.61 191.76
2589.37 250 5.79 52 3 1500 1545.45 212.58 136.97 1849.55 250 8.11
53 3 800 824.24 113.38 73.05 986.43 250 15.21 54 3 800 824.24
113.38 73.05 986.43 250 15.21 55 3 800 824.24 113.38 73.05 986.43
250 15.21 56 3 800 824.24 113.38 73.05 986.43 250 15.21 57 3 800
824.24 113.38 73.05 986.43 250 15.21 58 3 800 824.24 113.38 73.05
986.43 250 15.21 59 3 800 824.24 113.38 73.05 986.43 250 15.21 60 3
800 824.24 113.38 73.05 986.43 250 15.21 61 3 800 824.24 113.38
73.05 986.43 250 15.21 62 81 800 824.24 51.74 126.00 977.75 250
15.34 63 2 800 824.24 110.44 75.58 986.01 250 15.21 64 2 800 824.24
110.44 75.58 986.01 250 15.21 65 2 800 824.24 110.44 75.58 986.01
250 15.21 66 2 800 824.24 110.44 75.58 986.01 250 15.21 67 262 800
824.24 127.55 60.88 1012.66 250 14.81 68 262 800 824.24 127.55
60.88 1012.66 250 14.81 69 263 800 824.24 141.72 48.70 1014.66 250
14.78 70 263 800 824.24 141.72 48.70 1014.66 250 14.78 71 264 800
824.24 155.89 36.53 1016.66 250 14.75 72 264 800 824.24 155.89
36.53 1016.66 250 14.75 73 265 800 824.24 170.06 24.35 1018.65 250
14.73 74 265 800 824.24 170.06 24.35 1018.65 250 14.73 75 2 800
824.24 113.38 73.05 986.43 250 15.21 76 2 900 927.27 127.55 82.18
1109.73 250 13.52 77 2 1000 1030.3 141.72 91.32 1233.04 250 12.17
78 2 1100 1133.33 155.89 100.45 1356.34 250 11.06 79 2 1200 1236.36
170.06 109.58 1479.64 250 10.14 80 2 1500 1545.45 212.58 136.97
1849.55 250 8.11 81 2 1700 1751.51 240.92 155.24 2096.16 250 7.16
82 2 2000 2060.6 283.44 182.63 2466.07 250 6.08 83 2 2100 2163.63
297.61 191.76 2589.37 250 5.79 84 2 800 824.24 113.38 73.05 986.43
205 12.47 85 2 1000 1030.3 141.72 91.32 1233.04 205 9.98 86 2 1200
1236.36 170.06 109.58 1479.64 205 8.31 87 2 1500 1545.45 212.58
136.97 1849.55 205 6.65 88 2 1700 1751.51 240.92 155.24 2096.16 205
5.87 89 2 2000 2060.6 283.44 182.63 2466.07 205 4.99 90 2 2100
2163.63 297.61 191.76 2589.37 205 4.75 91 2 800 824.24 113.38 73.05
986.43 205 12.47 92 3 800 824.24 28.34 146.11 974.45 205 12.62 93 2
800 824.24 113.38 73.05 986.43 62 3.77 94 2 1000 1030.3 141.72
91.32 1233.04 62 3.02 95 2 1200 1236.36 170.06 109.58 1479.64 62
2.51 96 2 1500 1545.45 212.58 136.97 1849.55 62 2.01 97 2 2000
2060.6 283.44 182.63 2466.07 62 1.51
[1101] Fischer microhardness values for selected samples were
determined according to ISO 14577-1:2002. The test results are set
forth in Table 41 below.
TABLE-US-00085 TABLE 41 Fischer Sample Microhardness No.
(N/mm.sup.2) 14 106 15 113 16 113 17 113 18 113 19 114 20 114 21
113 22 113 23 114 24 113 25 112 26 112 27 115 28 114 29 113 30 113
32 113 33 113 34 113 35 112 36 113
[1102] Gardner Impact strength (in-lbs) was measured in accordance
with ASTM D-5420-04 for sample runs as indicated in Table 42
below.
TABLE-US-00086 TABLE 42 Summary Results for Gardner Impact Testing
according to ASTM D5420-04 FORMULATION # 2 2 2 2 2 2 2 2 2 2 2 2 2
2 Sample # 75 76 77 78 79 80 81 82 83 84 85 86 87 88 Mean Failure
Height 50 111 145 171 107 72 50 66 208 219 168 294 165 175 (in-lbs)
FORMULATION # 2 2 2 2 2 2 2 2 Sample # 89 90 91 93 94 95 96 97 Mean
Failure Height 161 109 184 225 61 134 116 243 FORMULATION # 2 2 2 2
2 2 2 2 2 2 2 81 81 81 Sample # 3 4 7 10 12 21 23 33 35 36 37 44 47
49 Mean Failure Height 62 45 101 180 98 131 115 60 78 37 148 28 26
38 FORMULATION # 81 3 3 3 3 Sample # 50 51 52 54 57 Mean Failure
Height 64 69 104 98 54
[1103] Light transmittance and Yellowness testing were conducted
according to ASTM D1003 Test Method for Haze and Luminous
Transmittance of Transparent Plastics and D1925 Test Method for
Yellowness Index of Plastics. The test results are presented in
Table 43 below.
TABLE-US-00087 TABLE 43 Illuminant: C Observer: 2.degree. Sample ID
14 15 16 17 18 19 20 21 22 23 24 CIE X (%) 87.86 88.46 87.98 88.61
87.40 87.43 88.38 87.51 88.00 88.01 88.37 CIEYX (%) 89.59 90.16
89.67 90.31 89.10 89.14 90.10 89.22 89.71 89.73 90.07 CIE Z (%)
105.44 105.96 105.64 106.21 104.78 104.89 106.24 104.97 105.66
105.16 105.85 CIE Y 89.59 90.16 89.67 90.31 89.10 89.14 90.10 89.22
89.71 899.73 90.07 CIE x 0.3106 0.3108 0.3106 0.3108 0.3107 0.3106
0.3104 0.3107 0.3106 0.3111 0.3108 CIE y 0.3167 0.3168 0.3165
0.3167 0.3168 0.3167 0.3165 0.3167 0.3166 0.3172 0.3168 CIE L*
95.83 96.06 95.86 96.12 95.62 95.64 96.04 95.67 95.88 95.88 96.03
CIE a* 0.00 0.06 0.08 0.07 0.03 0.01 0.02 0.02 0.04 0.03 0.06 CIE
b* 0.29 0.39 0.23 0.34 0.35 0.31 0.17 0.32 0.25 0.56 0.39 DW (nm)
580.63 582.40 588.54 583.79 581.47 581.28 587.36 581.63 584.68
579.81 582.32 CIE Cab* 0.29 0.39 0.24 0.35 0.35 0.31 0.18 0.32 0.25
0.56 0.39 Purity (%) 0.23 0.34 0.18 0.29 0.30 0.26 0.12 0.26 0.20
0.50 0.34 CIE Huge 90.68 81.29 70.71 78.19 85.69 87.82 81.83 86.44
80.50 87.01 81.61 Yi 0.78 1.01 0.71 0.92 0.91 0.82 0.57 0.84 0.72
1.32 1.01 Sample ID 25 26 27 28 29 30 32 33 34 35 36 CIE X 88.52
87.87 88.61 88.03 88.07 87.82 88.04 88.63 88.39 88.17 88.41 (%)
CIEYX (%) 90.23 89.59 90.34 89.75 89.78 89.53 89.75 90.35 90.10
89.87 90.14 CIE Z 106.11 105.54 106.23 105.66 105.78 105.37 105.72
106.1 105.78 105.63 106.31 (%) CIE Y 90.23 89.59 90.34 89.75 89.78
89.53 89.75 90.35 90.10 89.87 90.14 CIE x 0.3107 0.3105 0.3107
0.3106 0.3016 0.3106 0.3105 0.3109 0.3109 0.3108 0.3104 CIE y
0.3168 0.3166 0.3168 0.3166 0.3166 0.3167 0.3166 0.3169 0.3170
0.3168 0.3164 CIE L* 96.09 95.83 96.14 95.89 95.91 95.80 95.89
96.14 96.04 95.94 96.05 CIE a* 0.04 0.00 0.03 0.02 0.03 0.04 0.04
0.04 0.05 0.05 0.02 CIE b* 0.35 0.24 0.35 0.28 0.27 0.29 0.24 0.44
0.45 0.38 0.16 DW (nm) 582.36 582.38 581.75 582.18 583.46 582.96
584.60 580.98 581.25 582.18 588.09 CIE Cab* 0.35 0.24 0.35 0.28
0.27 0.29 0.24 0.44 0.46 0.38 0.16 Purity (%) 0.30 0.18 0.30 0.22
0.22 0.24 0.19 0.38 0.40 0.33 0.11 CIE Huge 82.76 88.82 84.75 86.58
82.90 83.15 81.32 84.94 83.73 82.32 83.25 Yi 0.92 0.67 0.91 0.76
0.76 0.81 0.70 1.09 1.13 0.99 0.53
Trial 4
[1104] For Trial 4, mixtures were prepared using the components as
in Trial 1 above, except the respective mixing conditions are set
forth in Tables 44-45 below. The samples were cured for two hours
at 250.degree. F. (121.degree. C.), then for 16 hours at
320.degree. F. (160.degree. C.). The mixtures were cast between
release coated 1''.times.15''.times.15'' (2.5 cm.times.38.1
cm.times.38.1 cm) casting cell glass molds with a resin volume of
3600 grams which had been preheated to a temperature of about
140.degree. C. and cured for the respective times and temperatures
set forth in the table below. After curing, each mold was removed
from the oven and allowed to cool to room temperature.
Prepolymer (PP) was prepared as follows:
[1105] An isocyanate functional urethane prepolymer was prepared by
reacting 0.21 equivalents of 1,5-pentanediol, 0.09 equivalents of
trimethylolpropane, 1.0 equivalents of DESMODUR W
4,4'-methylene-bis-(cyclohexyl isocyanate) and 5 ppm dibutyltin
diacetate as reactants. The DESMODUR W, 1,5-pentanediol and
trimethylolpropane were each pre-heated to a temperature of about
80.degree. C. under a nitrogen atmosphere for at least about four
hours prior to mixing. The components were mixed using a Max
Urethane Processing System Model No. 601-000-333. The mix head
volume was 205 cc.
[1106] Subsequently, the isocyanate functional urethane prepolymer
was reacted with 0.21 equivalents of trimethylolpropane and 0.49
equivalents of 1,5-pentanediol. Each of the reactants was heated to
the temperature indicated below prior to mixing. The flow rate of
each reactant and temperature at the mix head is specified below.
The mixing speed was 13,000 rpm.
TABLE-US-00088 TABLE 44 temp mix Sample Line temperatures .degree.
C. head # Prepolymer PDO TMP (.degree. C.) Formulation. 1 120 120
120 120 2 2 120 120 120 120 2 3 120 120 120 120 2 4 120 120 120 120
X 5 120 120 120 120 2 6 125 120 125 125 2 7 125 120 125 125 2 8 125
120 125 125 X 9 125 120 125 125 3 10 125 120 125 125 3 11 125 120
125 125 3 12 125 120 125 125 3 13 125 120 125 125 2 14 125 120 125
125 2 15 125 120 125 125 2 16 125 120 125 125 2 17 125 120 125 125
2 18 125 120 125 125 2 19 125 120 125 125 3 20 125 120 125 125 3 21
125 120 125 125 3 22 125 120 125 125 2 23 125 120 125 125 2 24 125
120 125 125 2 25 125 120 125 125 2 26 125 120 125 125 2 27 125 120
125 125 2 28 125 120 125 125 2 29 125 120 125 125 3 30 125 120 125
125 2 31 125 120 125 125 2 32 125 120 125 125 2 33 125 120 125 125
3 34 125 120 125 125 3 35 125 120 125 125 3 36 125 120 125 125 2 37
125 120 125 125 2 38 125 120 125 125 2 39 125 120 125 125 3 40 125
120 125 125 3 41 125 120 125 125 3 42 125 120 125 125 352 43 125
120 125 125 352 44 125 120 125 125 352 45 125 120 125 125 352 46
125 120 125 125 2 47 125 120 125 125 2 48 125 120 125 125 2 49 125
120 125 125 3 50 125 120 125 125 3 51 125 120 125 125 3 52 125 120
125 125 2 53 125 120 125 125 2 54 125 120 125 125 2 55 125 120 125
125 3 56 125 120 125 125 3 57 125 120 125 125 3
TABLE-US-00089 TABLE 45 Flow Rates Sample DesW/NCO Residence #
Prepolymer PDO TMP Total Time (s) 1 665.43 112.66 41.48 819.57
15.01 2 807.32 140.83 51.85 1000.00 12.30 3 831.78 140.83 51.85
1024.46 12.01 4 670.10 44.22 101.98 816.30 15.07 5 837.62 140.83
51.85 1030.30 11.94 6 670.10 112.66 41.48 824.24 14.92 7 837.62
140.83 51.85 1030.30 11.94 8 670.10 44.22 101.98 816.30 15.07 9
847.54 55.28 127.48 1030.30 11.94 10 847.54 55.28 127.48 1030.30
11.94 11 847.54 55.28 127.48 1030.30 11.94 12 847.54 55.28 127.48
1030.30 11.94 13 837.62 140.83 51.85 1030.30 11.94 14 837.62 140.83
51.85 1030.30 11.94 15 837.62 140.83 51.85 1030.30 11.94 16 670.10
112.66 41.48 824.24 14.92 17 1005.14 169.00 62.22 1236.36 9.95 18
1005.14 169.00 62.22 1236.36 9.95 19 678.03 44.22 101.98 824.24
14.92 20 678.03 44.22 101.98 824.24 14.92 21 678.03 44.22 101.98
824.24 14.92 22 586.33 98.58 36.30 721.21 17.05 23 670.10 112.66
41.48 824.24 14.92 24 753.86 126.75 46.67 927.27 13.26 25 837.62
140.83 51.85 1030.30 11.94 26 1005.14 169.00 62.22 1236.36 9.95 27
1256.43 211.25 77.78 1545.45 7.96 28 670.10 113.23 41.69 825.01
14.91 29 678.03 44.45 102.49 824.97 14.91 30 670.10 113.23 41.69
825.01 14.91 31 670.10 113.23 41.69 825.01 14.91 32 670.10 113.23
41.69 825.01 14.91 33 678.03 44.45 102.49 824.97 14.91 34 678.03
44.45 102.49 824.97 14.91 35 678.03 44.45 102.49 824.97 14.91 36
837.62 141.53 52.11 1031.26 11.93 37 837.62 141.53 52.11 1031.26
11.93 38 837.62 141.53 52.11 1031.26 11.93 39 847.54 55.56 128.12
1031.21 11.93 40 847.54 55.56 128.12 1031.21 11.93 41 847.54 55.56
128.12 1031.21 11.93 42 658.88 141.12 800.00 15.38 43 658.88 141.12
800.00 15.38 44 658.88 141.12 800.00 15.38 45 658.88 141.12 800.00
15.38 46 645.86 113.23 41.69 800.77 15.36 47 645.86 113.23 41.69
800.77 15.36 48 645.86 113.23 41.69 800.77 15.36 49 653.79 44.45
102.49 800.73 15.36 50 653.79 44.45 102.49 800.73 15.36 51 653.79
44.45 102.49 800.73 15.36 52 807.32 141.53 52.11 1000.96 12.29 53
807.32 141.53 52.11 1000.96 12.29 54 807.32 141.53 52.11 1000.96
12.29 55 817.24 55.56 128.12 1000.91 12.29 56 817.24 55.56 128.12
1000.91 12.29 57 817.24 55.56 128.12 1000.91 12.29
[1107] Yellowness Index (YI) and Light Transmittance (% T) for
selected samples were determined according to ASTM G-53. Also,
results for testing of selected samples tested initially and after
exposure to QUV-B for 333 hours in a manner discussed above were
determined. The results are set forth in Table 46 below.
[1108] Fischer microhardness values for selected samples were
determined according to ISO 14577-1:2002. Young's Modulus values
were derived from the Fischer microhardness values by conversion
formulae well-known to those skilled in the art. The test results
are set forth in Table 47 below.
[1109] Gardner Impact strength was measured in accordance with ASTM
D-5420-04 for sample runs as indicated in Table 48 below and FIGS.
36 and 37 below.
Cabin Window Forming Example
[1110] A (27''.times.34''.times.0.42'') billet of Sample 11 of
Trial #4, (Formulation 3) was prepared for forming to a simple
curvature by bonding a urethane foam material around the periphery
of the billet. The billet and peripheral urethane foam were then
clamped to a female vacuum mold and heated to a temperature of
about 135.degree. C. (275.degree. F.) until the plastic softened
and sagged. Vacuum was applied until the billet part conformed to
the shape of the mold. The vacuum was maintained and the part was
cooled to a temperature of about 65.degree. C. (150.degree. F.), at
which time the vacuum was discontinued and the molded billet was
removed from the mold. The forming temperature range for each
composition was determined by a plot of storage modulus vs.
temperature derived from Dynamic Mechanical Analysis (DMA) testing.
For example, see FIG. 38 for the DMA analysis of a sample of Sample
11 of Trial #4. Appropriate forming temperatures are generally near
the onset of the glass transition temperature, but not at the glass
transition temperature, to prevent mold markoff on the plastic
molded part. The molded part can be polished, if desired.
TABLE-US-00090 TABLE 46 SAMPLE initial YI QUV YI .DELTA. YI INITIAL
% T QUV % T .DELTA. % T STAB 1 1.37 1.30 -0.07 90.23 90.33 0.10 Y
18 1.24 1.47 0.23 90.06 90.50 0.44 Y 21 1.19 1.67 0.48 90.33 90.54
0.21 Y 22 1.35 1.31 -0.04 90.87 89.64 -1.23 Y 23 1.69 1.63 -0.06
90.81 90.09 -0.72 Y 24 1.27 1.50 0.23 90.23 90.39 0.16 Y 25 1.29
1.38 0.09 90.22 90.92 0.70 Y 27 0.91 1.37 0.46 90.24 90.61 0.37 Y
35 1.12 1.48 0.36 91.45 91.13 -0.32 Y 37 1.05 1.51 0.46 91.40 91.76
0.36 Y 41 0.86 1.72 0.86 91.46 91.54 0.08 Y 45 1.02 1.72 0.70 91.16
91.55 0.39 Y 48 0.87 1.67 0.80 91.58 91.68 0.10 Y 51 1.06 1.50 0.44
91.45 90.81 -0.64 Y 52 0.93 1.48 0.55 91.60 91.47 -0.13 Y 53 1.09
1.40 0.31 91.44 91.38 -0.06 Y 57 0.99 1.46 0.47 91.30 91.44 0.14
Y
TABLE-US-00091 TABLE 47 Fischer Young's Microhardness Modulus
Sample (N/mm2) (Kpsi) 1 113 348 18 114 350 21 124 373 22 116 355 23
115 352 24 113 348 25 112 345 27 113 348 41 123 372 45 130 387 48
124 374 51 113 348 52 115 352 57 113 348
TABLE-US-00092 TABLE 48 Gardner Impact Strength Residence Mean
Failure Formulation # Sample # Time Height 2 27 7.96 97 2 18 9.95
99 2 25 11.94 47 2 52 12.29 63 2 24 13.26 70 2 23 14.92 72 2 1
15.01 182 2 48 15.36 33 2 22 17.05 63 3 41 11.93 34 3 57 12.29 62 3
35 14.91 40 3 21 14.92 36 3 51 15.36 122 352 45 15.38 19 Summary
Results for Gardner Impact Testing according to ASTM D5420-04
FORMULATION # 2 2 3 2 2 2 2 2 3 Sample # 1 18 21 22 23 24 25 27 35
Mean Failure Height 182 99 36 63 72 70 47 97 40 FORMULATION # 3 NEW
2 3 2 3 Sample # 41 45 48 51 52 57 Mean Failure Height 34 19 33 122
63 62
Trial 5
[1111] For Trial 5, mixtures were prepared using the components as
in Trial 1 above, except the respective mixing and casting
conditions are set forth in Tables 49 and 50 below.
[1112] A 12''.times.12''.times.0.42'' billet of each sample was
held vertically and exposed to the flame of a propane torch for 15
seconds. Each of the samples self-extinguished after the flame was
removed. The Gardner Impact strength was 100 in-lbs for a 0.125
inch thick sample and 610 in-lbs for a 0.42 inch thick sample.
Cabin Window Forming
[1113] A 27''.times.34''.times.0.42'' billet of each of Samples 1-6
from Trial 5 were prepared for forming to a simple curvature by
bonding a urethane foam material around the periphery of the
billet. The billet and peripheral urethane foam were then clamped
to a female vacuum mold and heated to a temperature of about
135.degree. C. (275.degree. F.) until the plastic softened and
sagged. Vacuum was applied until the billet part conformed to the
shape of the mold. The vacuum was maintained and the part was
cooled to a temperature of about 65.degree. C. (150.degree. F.), at
which time the vacuum was discontinued and the molded billet was
removed from the mold. The forming temperature range for each
composition was determined by a plot of storage modulus vs.
temperature derived from Dynamic Mechanical Analysis (DMA) testing
of corresponding samples. The molded part can be polished, if
desired.
TABLE-US-00093 TABLE 49 Sample Tank temperatures .degree. C. temp #
Prepolymer PDO TMP mix head (.degree. C.) Formulation 1 121 110 110
121 2 2 180 110 111 118 2 3 121 110 110 121 3 4 121 110 110 121 3 5
121 110 110 121 81 6 124 108 114 116 81
TABLE-US-00094 TABLE 50 Flow Rates (g/min) mix head Sample
Prepolymer + Total volume residence Cure Temp. Cure Time #
Formulation Prepolymer Stabilizer PDO TMP g/min (cc) time (s)
(.degree. C.) (hrs) 1 2 1000 1030.3 141.72 91.32 1233.04 140 6.81
110/160 4.38/15.17 2 2 1000 1030.3 141.72 91.32 1233.04 140 6.81
110/160 3.80/17.0 3 3 1000 1030.3 26.87 181.26 1208.13 140 6.95
110/160 1.90/18.37 4 3 1000 1030.3 35.43 182.63 1218.06 140 6.90
110/160 2.53/17.0 5 81 1000 1030.3 62.03 151.05 1213.06 140 6.92
110/160 1.65/18.37 6 81 1000 1030.3 70.86 152.19 1223.05 140 6.87
110/160 2.02/16.17
Trial 6
[1114] An isocyanate functional urethane prepolymer was prepared by
reacting 0.35 equivalents of 1,5-pentanediol, 1.0 equivalent of
DESMODUR W 4,4'-methylene-bis-(cyclohexyl isocyanate) and 5 ppm
dibutyltin diacetate as reactants as per Trial 1 above.
Subsequently, the isocyanate functional urethane prepolymer was
reacted with 0.05 equivalents of 1,5-pentanediol and 0.6
equivalents of trimethylolpropane (Formulation 3), and the
indicated weight percentage of IRGANOX.RTM. 1076
octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate
available from Ciba, HOSTAVIN.RTM. VSU
N-(2-ethoxyphenyl)-N'-(4-ethylphenyl)-ethylene diamide UV absorber
available from Clariant Corp., and LOWILITE.RTM. 92 mixture of
bis(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate and
methyl(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate available from
Chemtura was added, as shown in Tables 51 and 52 below. Each of the
reactants was heated to the temperature of about 125-130.degree. C.
prior to mixing. The flow rate of each reactant and temperature at
the mix head is specified below. The mixing speed was 13,000
rpm.
[1115] A cabin window can be prepared from this polymer composition
according to the method set forth in detail below.
TABLE-US-00095 TABLE 51 Weight percent of additive Thickness
HOSTAVIN LOWILITEL IRGANOX Formulation # Run # of sample dye VSU 92
1076 3 1 0.125 3 ppm 2.44 0.75 0.50 3 2 0.125 3 ppm 2.44 0.75 0.50
3 3 0.125 3 ppm 2.44 0.75 0.50 3 4 0.42 3 ppm 2.44 0.75 0.50 3 5
0.42 3 ppm 2.44 0.75 0.50 3 6 0.42 3 ppm 2.44 0.75 0.50 3 7 0.42 3
ppm 2.44 0.75 0.50 3 8 0.42 3 ppm 2.44 0.75 0.50 3 9 0.42 3 ppm
2.44 0.75 0.50 3 10 0.42 3 ppm 2.44 0.75 0.50 3 11 0.42 3 ppm 2.44
0.75 0.50 3 12 1 3 ppm 2.44 0.75 0.50 3 13 1 3 ppm 2.44 0.75
0.50
TABLE-US-00096 TABLE 52 Mix Second Head Cure Flow Rates (grams)
Volume Residence 1st Cure Time Temp Time Prepolymer TMP Total (cc)
Time (s) Temp (.degree. C.) (hrs) (.degree. C.) (hrs) Point Source
light/white background--Straie 1252.91 233.80 1486.71 250 0.099 250
2 320 22 1252.91 233.80 1486.71 250 0.099 250 2 320 22 1252.91
233.80 1486.71 250 0.099 250 2 320 22 1252.91 233.80 1486.71 250
0.099 250 2 320 22 straie top fill side and bottom 1252.91 233.80
1486.71 250 0.099 250 2 320 22 pre-release lines, straie an fill
side 1/3 and bottom 1252.91 233.80 1486.71 250 0.099 250 2 320 22
straie around edges, large swirls 1252.91 233.80 1486.71 250 0.099
250 2 320 22 very little straie on fill an bottom 1252.91 233.80
1486.71 250 0.099 250 2 320 22 very little straie around edges
1252.91 233.80 1486.71 250 0.099 250 2 320 22 light straie around
edges and top middle 1252.91 233.80 1486.71 250 0.099 250 2 320 22
little bit of straie around sides and bottom, scratch in view area
1252.91 233.80 1486.71 250 0.099 250 2 320 22 light straie fill
side and bottom 1252.91 233.80 1486.71 250 0.099 250 2 320 22
straie heavy all through 1252.91 233.80 1486.71 250 0.099 250 2 320
22 straie heavy all through
Deflection and K-Factor Testing
[1116] Selected samples were evaluated for K-Factor crack
propagation resistance and creep or deflection. K-Factor crack
propagation resistance was measured according to U.S. Dept. of
Defense MIL-PRF-25690B (Jan. 29, 1993). The K-Factor crack
propagation resistance for stretched acrylic cabin windows is
generally about 2400 lbs/in.sup.3/2. In some non-limiting
embodiments, the K-Factor crack propagation resistance of cabin
windows prepared according to the present invention is at least
2000 lbs/in.sup.3/2.
[1117] A flexural test was developed to simulate the creep
phenomenon under 3,294 psig (300 times the service pressure at
3,500 feet altitude) for 3 hrs. Each test specimen was 6'' by 1/2''
by 1/8'' (15.2 cm.times.1.3 cm.times.0.3 cm). The deflection tests
were done using a Zwick ProLine testing machine. A flexural
pressure of 3,294 psig (22.7 MPa) was applied on the specimen for
three hours. The maximum deflection of each specimen was measured.
The results are shown in FIG. 39.
[1118] FIG. 39 is a graph of nominal strain in mm as a function of
test time for samples of conventional stretched acrylic and a
sample according to the present invention.
[1119] FIG. 39 shows the deflection of Sample #1 (Formulation 3),
Trial A (preparation described below) compared to stretched
acrylic. This had a tensile modulus around 60% of that of a control
sample of stretched acrylic. As shown in FIG. 39, even though the
sample of Formulation 3 deflected more at the beginning, its
deflection rate with time was much slower so it deflected less than
stretched acrylic after around 2 hrs.
[1120] Sample #1, Trial A (Formulation 3) was prepared from the
same components in the same manner as in Trial #1 of Example L3
discussed above, as follows:
TABLE-US-00097 Formulation 3 Tank temperature (.degree. C.) -
prepolymer 180 Tank temperature (.degree. C.) - PDO 110 Tank
temperature (.degree. C.) - TMP 111 Temp. mix head 118 Flow rate
(g/min) - Prepolymer 1000 Flow rate (g/min) - Prepolymer +
Stabilizer 1030.3 Flow rate (g/min) - TMP 182.63 Flow rate (g/min)
- PDO 35.43 Flow rate (g/min) - Total 1218.06 Residence Time (sec)
6.90 Cure - Temp. (.degree. C.) 110/160 Cure - Time (hrs) 3/17
[1121] Sample #2, Trial A of (Formulation 81) (discussed below) was
prepared from the same components in the same manner as in Trial #1
of Example L3 discussed above, as follows:
TABLE-US-00098 Formulation 81 Tank temperature (.degree. C.) -
prepolymer 180 Tank temperature (.degree. C.) - PDO 110 Tank
temperature (.degree. C.) - TMP 111 Temp. mix head 118 Flow rate
(g/min) - Prepolymer 1000 Flow rate (g/min) - Prepolymer +
Stabilizer 1030.3 Flow rate (g/min) - TMP 152.19 Flow rate (g/min)
- PDO 70.86 Flow rate (g/min) - Total 1223.05 Residence Time (sec)
6.87 Cure - Temp. (.degree. C.) 110/160 Cure - Time (hrs) 3/17
[1122] Sample #1, Trial B of (Formulation 2) (discussed below) was
prepared as follows:
An isocyanate functional urethane prepolymer was prepared by
reacting 0.3 equivalents of 1,5-pentanediol and 1.0 equivalent of
DESMODUR W 4,4'-methylene-bis-(cyclohexyl isocyanate) in a glass
reaction kettle under vacuum and nitrogen blanket. The prepolymer
components were preheated to a temperature of 110.degree. C.,
liquefied and degassed in a vacuum oven before mixing. The glass
reaction kettle was preheated to a temperature of between
60.degree. C.-80.degree. C. before the addition of the prepolymer
components. The reaction temperature was maintained at 120.degree.
C. for 15 minutes. Next, 0.4 equivalents of 1,5-pentanediol and 0.3
equivalents of trimethylolpropane were added. The 0.4 equivalents
of 1,5-pentanediol and 0.3 equivalents of trimethylolpropane were
preheated to a temperature of 80.degree. C., liquefied and degassed
in a vacuum oven before their addition to the mixture. The kettle
was placed into a preheated heating mantle for about 15 minutes up
to a temperature of approximately 120.degree. C. while the
formulation was stirred and outgassed under a vacuum pressure of
-28 mmHg. Next, the mixture was cast between release coated
1''.times.15''.times.15'' (2.5 cm.times.38.1 cm.times.38.1 cm)
casting cell glass molds with a resin volume of 3600 grams which
had been preheated to a temperature of approximately 120.degree. C.
The mixture was cured for 2 hours at approximately 120.degree. C.,
followed by 22 hours at 160.degree. C. The mold was removed from
the oven and the plastic released.
[1123] Four formulations (240, 244, 245 and 246 from Example L2
above) were designed for cabin windows to meet deflection under
pressure and K-factor crack propagation resistance, as well as good
solvent/abrasion resistance, good flame retardation and low creep.
K-Factor and deflection properties for these formulations together
with Sample #1 of Trial A (Formulation 3), Sample #2 of Trial A
(Formulation 81) and Sample #1 of Trial B (Formulation 2)
(discussed below) were evaluated. The deflection tests were
conducted as discussed above, and then the final deflection values
were compared. The final deflection values of all four new
formulations were less than that of Sample #1 of Trial B
(Formulation 2), which had met the specification of deflection
under pressure. Particularly, Sample L of Example L2 reached an
average k-factor of 2,350 lb.sub.f/in.sup.3/2. FIG. 40 is a bar
chart of average K-factor in lb.sub.f/in.sup.3/2 and deflection in
mm for selected samples of Samples A, B, C, J, K L and M,
respectively, of Example L2 above.
Examples M
Example M1
[1124] An isocyanate functional prepolymer (NCO/OH ratio of 3.8)
having an equivalent weight of 327 grams/mole was prepared by
reacting the following components:
TABLE-US-00099 Equivalent. Number of Component Weight % Wt.
equivalents DESMODUR W 54.42 131.2 0.42 4,4'-methylene-bis-
(cyclohexyl isocyanate) DBT FASTCAT 4202 0.005 (dibutyl tin
dilaurate) PLURACOL E400NF 5.095 200 0.03 (polyethylene glycol)
PLURONIC L62D 33.97 1180 0.03 (ethylene oxide/propylene oxide block
copolymer) TRIMETHYLOLPROPANE 2.32 45 0.05 CAPA 2077A 1.23 375
0.003 polycaprolactone polyol IRGANOX 1010 0.49 CYASORB UV 5411
0.97 TINUVIN 328 1.46 IRGANOX MD 1024 0.05 Total 100.000000
at a temperature of about 104.degree. C. for about 5 hours. All of
the components were mixed together, except the stabilizers which
were dissolved after the prepolymer was reacted.
[1125] About 9 grams of acrylamide was dissolved in about 45 grams
of 1,4-butanediol at a temperature of about 25.degree. C. and mixed
with about 365 grams of the above prepolymer and about 0.1 weight
percent of azobisisobutyronitrile (AIBN) based on total solids. The
mixture was cast into a glass mold and heated in an oven at a
temperature of about 80.degree. C. for about 48 hours with constant
stirring. A clear polymerizate was formed. A sample of the cured
polymer was evaluated for light transmittance and Gardner Impact
Strength. The light transmittance of the sample was 91% and the
Gardner Impact Strength was 150 in-lbs (17 J).
Example M2
[1126] A polyurethane polymer according to the present invention
was prepared from the above isocyanate functional prepolymer,
cyclohexanedimethanol (CHDM) and 1,4-butanediol as listed
below:
TABLE-US-00100 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Prepolymer CHDM 1,4- 417.53 200.00 Name butanediol OH # --
-- -- Acid # -- -- -- Equivalent 365.71 72.11 45.06 Wt. Equivalents
1.00 0.25 0.75 desired Mass 365.71 18.03 33.80 Monomer Weight %
87.59% 4.32% 8.09% Monomer Monomer 175.18 8.64 16.19 masses for
experiment
[1127] The prepolymer, CHDM (preheated to 80.degree. C.) and
1,4-butanediol were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to
.about.40.degree. C. and allowed to compatibilize. Once clear, the
mixture was degassed, and cast into a 6''.times.6''.times.0.25''
(15 cm.times.15 cm.times.0.6 cm) casting cell and aluminum cups
preheated to 80.degree. C. The filled cell was cured for 24 hours
at 121.degree. C.
[1128] An article of 6''.times.6''.times.1'' thickness (15
cm.times.15 cm.times.2.5 cm) prepared from this polymer stopped a 9
mm, 125 grain, bullet shot at an initial velocity of 1350 ft/sec
(411 m/sec) from 20 feet (6.1 m) distance with little surface
damage. The same sample also withstood a .40 caliber shot with
little surface damage. The bullets did not ricochet or embed in the
polymer. The bullets were laying partly deformed at the bottom of
the sample.
Example M3
[1129] A polyurethane polymer according to the present invention
was prepared from the above isocyanate functional prepolymer,
cyclohexanedimethanol (CHDM) and 1,4-butanediol as listed
below:
TABLE-US-00101 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name Prepolymer CHDM 1,4- 424.30 200.00 butanediol OH # --
-- -- Acid # -- -- -- Equivalent Wt. 365.71 72.11 45.06 Equivalents
1.00 0.50 0.50 desired Mass Monomer 365.71 36.06 22.53 Weight %
86.19% 8.50% 5.31% Monomer Monomer masses 172.38 17.00 10.62 for
experiment
[1130] The prepolymer, CHDM (preheated to 80.degree. C.) and
1,4-butanediol were added to a glass kettle. Under nitrogen blanket
and with constant stirring, the mixture was heated to
.about.40.degree. C. and allowed to compatibilize. Once clear, the
mixture was degassed, and cast into a 6''.times.6''.times.0.25''
(15 cm.times.15 cm.times.0.6 cm) casting cell and aluminum cups
preheated to 80.degree. C. The filled cell was cured for 24 hours
at 121.degree. C.
Example M4
[1131] A polyurethane polymer according to the present invention
was prepared from the above isocyanate functional prepolymer and
hydroquinone bis(hydroxyethyl)ether as listed below:
TABLE-US-00102 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name Prepolymer Hydroquinone 483.40 250.00
bis(hydroxyethyl) ether OH # -- -- Acid # -- -- Equivalent Wt.
384.29 99.11 Equivalents 1.00 1.00 desired Mass Monomer 384.29
99.11 Weight % 79.50% 20.50% Monomer Monomer masses 198.74 51.26
for experiment
[1132] The prepolymer and hydroquinone bis(hydroxyethyl)ether were
added to a glass kettle and placed in a heating mantle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to 85.degree. C. and allowed to compatibilize. Once clear, the
mixture was placed under vacuum and degassed, and cast into a
6''.times.6''.times.0.25'' (15 cm.times.15 cm.times.0.6 cm) casting
cell preheated to 80.degree. C. The filled cell was cured for 24
hours at 121.degree. C. The cast sample was clear, but showed some
haze. The Gardner Impact Strength was 320 in-lbs (37 J).
Example N
[1133] An isocyanate functional prepolymer was prepared by reacting
the following components:
TABLE-US-00103 Equivalent. Number of Component Weight % Wt.
equivalents DESMODUR W 54.42 131.2 0.42 4,4'-methylene-bis-
(cyclohexyl isocyanate) DBT FASTCAT 4202 0.005 (dibutyl tin
dilaurate) PLURACOL E400NF 5.095 200 0.03 (polyethylene glycol)
PLURONIC L62D 33.97 1180 0.03 (ethylene oxide/propylene oxide block
copolymer) TRIMETHYLOLPROPANE 2.32 45 0.05 CAPA 2077A 1.23 375
0.003 polycaprolactone polyol Total 100.000000
at a temperature of about 104.degree. C. for about 5 hours. All of
the components were mixed together, except the stabilizers which
were dissolved after the prepolymer was reacted.
[1134] A polyurethane polymer according to the present invention
was prepared from the above prepolymer and 1,4-butanediol as listed
below:
TABLE-US-00104 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Name Prepolymer 1,4-butanediol 375.38 100.00 OH # -- --
Acid # -- -- Equivalent Wt. 330.32 45.06 Equivalents desired 1.00
1.00 Mass Monomer 330.32 45.06 Weight % Monomer 88.00% 12.00%
Monomer masses for 88.00 12.00 experiment
[1135] The prepolymer and 1,4-butanediol were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.45.degree. C. and allowed to
compatibilize. Once clear, the mixture was degassed, and cast into
a 4''.times.4''.times.60 mil casting cell preheated to 80.degree.
C. The filled cell was cured for 24 hours at 121.degree. C.
[1136] An article of 6''.times.6''.times.1'' (15 cm.times.15
cm.times.2.5 cm) prepared from this polymer stopped a 9 mm, 125
grain, bullet shot at an initial velocity of 1350 ft/sec (411
m/sec) from 20 feet (6.1 m) distance with little surface damage.
The same sample also withstood a .40 caliber shot with little
surface damage.
Examples O
Example O1
[1137] An isocyanate functional prepolymer was prepared by reacting
the following components:
TABLE-US-00105 Prepolymer Formulation Equivalent Normalized
Equivalents Component weight Equivalents Wt. (g) Weight % to Des W
Normalized Wt. (g) CAPA 2047 200.0 0.14 27.8 27.8% 0.28 56.68 CAPA
2077 375.0 0.018 6.65 6.7% 0.036 13.56 TMP 44.6 0.027 1.2 1.2%
0.055 2.45 OH Totals = -- 0.18 35.65 -- 0.37 72.69 Des W 131.2 0.49
64.35 64.4% 1.0000 131.20 Total = 78.5% Prepolymer M.sub.w = 203.89
Prepolymer W.sub.urethane = 28.94% Prepolymer M.sub.c = 11150
Prepolymer W.sub.b = 7433
at a temperature of about 104.degree. C. for about 5 hours. All of
the components were mixed together, except the stabilizers which
were dissolved after the prepolymer was reacted.
[1138] A polyurethane polymer according to the present invention
was prepared from the above prepolymer and CHDM as listed
below:
TABLE-US-00106 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name Prepolymer CHDM 402.98 800.00 OH # -- -- Acid # -- --
Equivalent Wt. 330.87 72.11 Equivalents desired 1.00 1.0000 Mass
Monomer 330.87 72.11 Weight % Monomer 82.11% 9.01% Monomer masses
656.85 143.15 for experiment
[1139] The prepolymer and CHDM were added to a glass kettle. Under
nitrogen blanket and with constant stirring, the mixture was heated
to .about.55.degree. C. and allowed to compatibilize. Once clear,
the mixture was degassed, and cast into a
13''.times.13''.times.0.25'' casting cell preheated to 80.degree.
C. The filled cell was cured for 24 hours at 121.degree. C.
Example O2
[1140] A polyurethane polymer according to the present invention
was prepared from the above prepolymer and CHDM as listed
below:
TABLE-US-00107 Desired Polymer Batch Size Solids Wt. (g) (g)
Monomer Name Prepolymer 2,2- 391.97 700.00 thiodiethanol OH # -- --
Acid # -- -- Equivalent Wt. 330.87 61.10 Equivalents desired 1.00
1.0000 Mass Monomer 330.87 61.10 Weight % Monomer 84.41% 15.59%
Monomer masses 590.89 109.11 for experiment
[1141] The prepolymer and 2,2-thiodiethanol were added to a glass
kettle. Under nitrogen blanket and with constant stirring, the
mixture was heated to .about.55.degree. C. and allowed to
compatibilize. Once clear, the mixture was degassed, and cast into
a 13''.times.13''.times.0.25'' casting cell preheated to 80.degree.
C. The filled cell was cured for 24 hours at 121.degree. C.
Example P
[1142] As a comparative example, a thermoplastic polymer was
prepared using 1.0 equivalent of 1,10-decanediol and 1.0 equivalent
of DESMODUR W as reactants and 10 ppm dibutyltindiacetate as
catalyst. The polymer was mixed at 110.degree. C. in a glass kettle
under vacuum. After about 30 minutes at 110.degree. C., the mixture
was cast between release coated glass molds and cured for 72 hours
at 290.degree. F. (143.degree. C.). The mold was removed from the
oven and the plastic released. The Gardner Impact strength was less
than 40 in-lbs (5 J) and averaged about 16 in-lbs (2 J).
[1143] A polymer according to the present invention was prepared in
a similar manner using a small amount of a branched polyol, namely
0.05 equivalents of trimethylolpropane, as well as 0.95 equivalents
of 1,10-decanediol, and 1.0 equivalents of DESMODUR W. The Gardner
Impact strength averaged 640-in-lbs for this branched thermoplastic
with a molecular weight per crosslink of about 12,900
grams/mole.
Example Q
Comparative Example
[1144] For comparison, a prepolymer was prepared by reacting about
0.1 equivalents of trimethylol propane with about 1.0 equivalent of
4,4'-methylene-bis-(cyclohexyl isocyanate) (DESMODUR W) to form a
polyurethane polyisocyanate dissolved in an excess (0.9 eqs.) of
DESMODUR W. About 10 ppm of dibutyltindiacetate was used as a
catalyst. While mixing rapidly at room temperature, about 0.1
equivalents of 4,4'-methylene-bis-cyclohexylamine, a diamine analog
of DESMODUR W, was added. Immediately, a white, flaky precipitate
formed. The precipitate increased in concentration sitting
overnight and would not dissolve upon heating up to about
290.degree. F. (143.degree. C.). The above example was repeated in
the same order as above, but the polyisocyanate was heated to about
40.degree. C. While mixing rapidly, the diamine was added and a
similar white precipitate formed which could not be dissolved upon
heating up to about 290.degree. F. (143.degree. C.).
[1145] According to the present invention, the same polyisocyanate
above was heated to about 40.degree. C. About 0.1 equivalents of
water was added while mixing rapidly. Vacuum was applied (4 mm Hg)
to remove the carbon dioxide and a polyurea formed within the
polyurethane to form a polyurethane polyurea polyisocyanate that
was slightly hazy. The diamine analog of DESMODUR W was formed in
situ when the water was reacted. This mixture was then reacted with
0.8 equivalents of trimethylolpropane to form a high modulus
plastic with high optical clarity. The light transmittance of a
1/8'' thick (0.3 cm) sample was 91.8% with less than 0.1% haze. The
glass transition temperature was 175.degree. C.
[1146] According to the present invention, the same polyisocyanate
was reacted with 0.2 equivalents of water at about 40.degree. C.
and the carbon dioxide removed via vacuum. The diamine analog of
DESMODUR W was formed in situ when the water was reacted. About 0.5
equivalents of pentanediol and about 0.2 equivalents of
trimethylolpropane were reacted with the polyurethane polyurea
polyisocyanate to form a high clarity optical plastic with a light
transmittance of 91.74% for a 1/8'' thick (0.3 cm) sample and a
glass transition temperature of about 137.degree. C.
Examples R
Example R1
[1147] In a glass kettle under nitrogen blanket with stirring, were
charged 8.26 weight % 3,6-dithia-1,2-octanediol (91.6 equivalent
wt.); 29.47 weight % bis(4-(-hydroxyethoxy)-3,5-dibromophenyl)
sulfone (326.985 equivalent wt.); 6.50 weight %
1,4-cyclohexanedimethanol (CHDM) (72.1 equivalent wt.); 5.10 weight
% trimethylolpropane (TMP) (44 equivalent wt.); and 50.68 weight %
4,4'-methylenebis (cyclohexyl isocyanate) (DESMODUR W) (131.2
equivalent wt.) preheated to a temperature of 80.degree. C. The
mixture was then heated to a temperature of 115.degree. C.
[1148] The mixture was then degassed and cast into a
12''.times.13''.times.0.125'' (30 cm.times.33 cm.times.0.3 cm)
casting cell which had been preheated to a temperature of
121.degree. C. The filled cell was then cured in an oven for a
period of 48 hours at 121.degree. C.
[1149] The refractive index of the resulting lens was measured as
n.sub.D=1.5519.
Example R2
[1150] In a glass kettle under nitrogen blanket with stirring, were
charged 30.75 weight % 3,6-dithia-1,2-octanediol (91.6 equivalent
wt.); 6.23 weight % TMP (44.0 equivalent wt.) and 62.92 weight %
DESMODUR W (131.2 equivalent wt.) which was preheated to a
temperature of 80.degree. C. The mixture was heated to a
temperature of 105.degree. C.
[1151] The mixture was then degassed and cast into a
12''.times.13''.times.0.125'' (30 cm.times.33 cm.times.0.3 cm)
casting cell which had been preheated to a temperature of
121.degree. C. The filled cell was then cured in an oven for a
period of 48 hours at 121.degree. C.
[1152] The refractive index of the resulting lens was measured as
n.sub.D=1.5448 and the impact as 82.0 in-lbs (9 J).
Example R3
[1153] In a glass kettle under nitrogen blanket with stirring, were
charged 9.70 weight % 1,5-pentanediol (52.1 equivalent wt.); 7.03
weight % TMP (44.0 equivalent wt.); 13.43 weight % CHDM (72.1
equivalent wt.) and 69.84% DESMODUR W (131.2 equivalent wt.) which
was preheated to a temperature of 80.degree. C. The mixture was
heated to a temperature of 105.degree. C.
[1154] The mixture was then degassed and cast into a
12''.times.13''.times.0.125'' (30 cm.times.33 cm.times.0.3 cm)
casting cell which had been preheated to a temperature of
121.degree. C. The filled cell was then cured in an oven for a
period of 48 hours at 121.degree. C.
[1155] The impact was measured as 160.0 in-lbs (18 J).
Example R4
[1156] This example was conducted in accordance with the procedure
in Example 3 with the exception that 1,4-butanediol (45.1
equivalent wt.) was used instead of 1,5 pentanediol and CHDM was
not present in the mixture. 17.28% 1,4 butanediol, 7.23%
trimethylolpropane, and 75.48% DESMODUR W.
[1157] The impact was measured as 120.0 in-lbs (14 J).
Example R5
[1158] This example was conducted in accordance with the procedure
in Example 4 with the exception that 1,4-benzenedimethanol (69.1
equivalent wt.) was used instead of 1,4-butanediol. 25.09 weight %
1,4 benzenedimethanol, 6.85 weight % trimethylolpropane, and 74.57
weight % DESMODUR W.
[1159] The impact was measured as 72.0 in-lbs (8 J). It was
observed that after fifteen minutes into the cure cycle, the
material turned hazy. Thus, the oven temperature had been increased
to 143.degree. C. for the remainder of the cure cycle, but the
material remained hazy.
Example R6
[1160] This example was conducted in accordance with the procedure
in Example 5 with the exceptions that 1,4-butanediol (45.1
equivalent weight) was also added to the mixture and the mixture
was heated to a temperature of 115.degree. C. instead of
105.degree. C. 13.12 weight % 1,4 benzenedimethanol, 8.55 weight %
1,4 butanediol, and 71.17 weight % DESMODUR W.
[1161] The impact was measured as 72.0 in-lbs (8 J).
Example R7
[1162] This example was conducted in accordance with the procedure
in Example 6 with the exception that 1,6-hexanediol (59.1
equivalent wt.) was used instead of 1,4-butanediol. 12.76 weight %
1,4 benzenedimethanol, 10.93 weight % 1,6 hexanediol, and 69.32
weight % DESMODUR W.
[1163] The impact was measured as 64.0 in-lbs (7 J).
Example R8
[1164] This example was conducted in accordance with the procedure
in Example 7 with the exceptions that thiodiethanol (61.1
equivalent wt.) was used instead of 1,4-benzenedimethanol and the
mixture was heated to a temperature of 105.degree. C. instead of
115.degree. C. 11.78 weight % 2,2-thiodiethanol, 8.69 weight % 1,4
butanediol, 7.27 weight % trimethylolpropane, and 70.10 weight %
DESMODUR W.
[1165] The impact was measured as 72.0 in-lbs (8 J).
Example R9
[1166] This example was conducted in accordance with the procedure
in Example 3 with the exceptions that CHDM was not present in the
mixture and the mixture was heated to a temperature of 115.degree.
C. instead of 105.degree. C. 20.16 weight % 1,5 pentanediol, 7.3
weight % trimethylolpropane, and 72.55 weight % DESMODUR W.
[1167] The impact was measured as 200.0 in-lbs (23 J).
Example R10
[1168] This example was conducted in accordance with the procedure
in Example 9 with the exception that 1,8-octanediol (73.1
equivalent wt.) was used instead of 1,5-pentanediol. 26.14 weight %
1,8 octanediol, 6.75 weight % trimethylol propane, and 67.11 weight
% DESMODUR W.
[1169] The impact was measured as 624.0 in-lbs (72 J).
Example R11
[1170] This example was conducted in accordance with the procedure
in Example 10 with the exception that 1,10-decanediol (87.1
equivalent wt.) was used instead of 1,8-octanediol. 29.66 weight %
1,10 decanediol, 6.43 weight % trimethylolpropane, and 63.9 weight
% DESMODUR W.
[1171] The impact was measured as 624.0 in-lbs (72 J).
Example R12
[1172] This example was conducted in accordance with the procedure
in Example 11 with the exceptions that ethyleneglycol (31.0
equivalent wt.) was used instead of 1,10-decanediol and the mixture
was heated to a temperature of 105.degree. C. instead of
115.degree. C. 13.06 weight % ethylene glycol, 7.95 weight %
trimethylolpropane, and 78.99 weight % DESMODUR W
[1173] The impact was measured as 8.0 in-lbs (1 J).
Example R13
[1174] This example was conducted in accordance with the procedure
in Example 11 with the exception that 1,12-dodecanediol was used
instead of 1,10-decanediol. 32.87 weight % 1,12 dodecanediol, 6.14
weight % trimethylolpropane, and 60.99 weight % DESMODUR W.
[1175] The impact was measured as 624.0 in-lbs (72 J).
Example R14
[1176] This example was conducted in accordance with the procedure
in Example 13 with the exceptions that 1,6-hexanediol (59.1
equivalent wt.) was used instead of 1,12-dodecanediol and the
mixture was heated to a temperature of 105.degree. C. instead of
115.degree. C. 22.24 weight % 1,6 hexanediol, 7.11 weight %
trimethylolpropane, and 70.65 weight % DESMODUR W.
[1177] The impact was measured as 144 in-lbs (17 J).
Example R15
[1178] This example was conducted in accordance with the procedure
in Example 9. The impact was measured as 80.0 in-lbs (9 J).
Example R16
[1179] This example was conducted in accordance with the procedure
in Example 11 with the exceptions that 101.2 equivalent wt of
1,10-decanediol was used; and KM-1733 (a 1000 MW carbonate diol
made from hexanediol and diethylcarbonate, and commercially
available from ICI) (428 equivalent wt.) was added to the mixture.
28.29% 1,10 decanediol, 9.48 weight % PC-1733, 5.69 weight %
trimethylolpropane, and 56.54 weight % DESMODUR W.
[1180] The impact was measured as 640.0 in-lbs (74 J).
Example R17
[1181] Formulations 1 through 11 were prepared in accordance with
the procedure of Example 3 with the exception that the components
listed in Table 21 were used to prepare the reaction mixture. The
resultant properties (including tensile strength at yield, %
elongation at yield, tensile strength at break, % elongation at
break, and Young's Modulus were measured in accordance with ASTM-D
638-03; Gardner Impact was measured in accordance with ASTM-D
5420-04; Tg was measured using Dynamic Mechanical Analysis; and
Density was measured in accordance with ASTM-D 792) of formulations
1 through 11 as are shown in Tables 27-29.
TABLE-US-00108 TABLE 27 Equivalent Wt. Formulation # Component
(g/Eq.) Equivalents Weight Weight % Wu (%) Wc (%) Mc (g/mole) 1 TMP
44.7 0.3 13.40 6.5 28.7 39.4 2055 1,10 dodecanediol 87.1 0.7 60.97
29.7 DESMODUR W 131.0 1.0 131.0 63.8 2 TMP 44.7 0.3 13.40 6.7 29.4
40.4 2006 1,10 dodecanediol 87.1 0.35 30.48 15.2 1,8 octanediol
73.1 0.35 25.58 12.7 DESMODUR W 131.0 1.0 131.0 65.4 3 TMP 44.7 0.3
13.40 7.61 33.5 46.04 1759 1,4 butanediol 45.0 0.7 31.5 17.9
DESMODUR W 131.0 1.0 131.0 74.49 4 TMP 44.7 0.3 13.40 7.40 32.6
44.8 1808 1,5 pentanediol 52.0 0.7 36.4 20.13 DESMODUR W 131.0 1.0
131.0 72.47 5 TMP 44.7 0.6 26.82 11.64 33.0 45.81 1786 1,5
pentanediol 52.0 0.4 20.8 15.06 DESMODUR W 131.0 1.0 131.0 73.3 6
TMP 44.7 0.3 13.40 7.20 31.77 43.62 1857 1,6 hexanediol 59.0 0.7
41.3 22.26 DESMODUR W 131.0 1.0 131.0 70.54 7 TMP 44.7 0.3 13.40
6.81 30.44 1938 1,4 CHDM 72.11 0.35 25.24 13.02 1,6 BDM 69.08 0.35
24.18 12.48 DESMODUR W 131.0 1.0 131.0 131.0
TABLE-US-00109 TABLE 28 Equivalent Wt. Wu Wc Mc Formulation #
Component (g/Eq.) Equivalents Weight Weight % (%) (%) (g/mole) 8
TMP 44.7 0.3 13.40 7.03 31.41 43.1 1879 1,4 CHDM 72.11 0.35 25.24
13.43 1,5 52.0 0.35 18.23 9.70 pentanediol 9 TMP 44.7 0.3 13.40
6.94 31.0 42.55 1903 1,4 CHDM 72.11 0.35 25.24 13.26 1,6 59.09 0.35
20.68 10.87 hexanediol DESMODUR W 131.0 1.0 131.0 68.94 10 TMP 44.7
0.3 13.20 6.7 30.2 41.4 1956 1,8 73.1 0.7 51.17 26.2 octanediol
DESMODUR W 131.0 1.0 1.0 67.1 11 TMP 44.7 0.3 13.40 6.33 28.29
38.84 2085 3,6-dithia-1,2 91.6 0.7 64.12 30.75 octanediol DESMODUR
W 131.0 1.0 131.0 62.92 Note: Formula 11 has a refractive index of
1.55 and a Gardner Impact strength of 65 in-lbs.
TABLE-US-00110 TABLE 29 Tensile Tensile Strength % Strength % At
Elongation At Elongation YounG's Gardner Yield At Yield Break At
Break Modulus Impact Density Formula (psi) (psi) (psi) (psi) (psi)
In-lbs Tg g/cc 1 9190 7.4 6710 57 268,000 600 99.1 1.091 2 9530 7.5
7030 65 282,000 592 102 1.093 3 12,100 9.2 9040 41 336,000 120 126
1.14 4 11,200 8.7 8230 38 321,000 190 119 1.13 5 13,100 9.6 11,000
19 351,000 71 140 1.13 6 11,000 8.7 8300 56 311,000 130 117 1.12 7
13,600 10 12,100 18 360,000 75 156 1.13 8 12,100 9.8 9380 32
339,000 143 132 1.12 9 11,900 9.4 8880 34 327,000 124 130 1.14 10
9880 7.9 7480 55 287,000 600 106 1.10 11 -- -- -- -- -- 65 --
--
Example R18
[1182] This example was conducted in accordance with the procedure
in Example 12 with the exceptions that 53.0 equivalent wt. of
diethylene glycol was used instead of ethylene glycol and the
mixture was heated to a temperature of 115.degree. C. instead of
105.degree. C.
[1183] The impact was measured as 6.0 in-lbs.
Example R19
[1184] This example was conducted in accordance with the procedure
in Example 18 with the exception that 67.0 equivalent wt.
dipropylene glycol was used instead of diethylene glycol.
[1185] The impact was measured as 8.0 in-lbs.
[1186] After curing, a set of the sheets coated with each of the
polymers A-D were abrasion tested using a standard Taber abrasion
test with CS10F wheels (one pair for all samples), 500 grams each
wheel. The wheels were re-surfaced before each cycle (25 cycles).
Test conditions were conducted at a temperature of ranging from
about 70.degree. F. to about 75.degree. F. and about 50% to about
60% relative humidity. Average scattered light haze for a given
number of Taber cycles was determined, with the results shown
below.
[1187] Standard QUV-B exposure test procedure over a period of 1000
hours, representing the equivalent of about three years of outdoor
exposure. The results are shown below.
Exposed Samples--1000 Hours QUV-B Exposure--3 yr. Equivalent
Outdoor
TABLE-US-00111 Coated with % Haze at number of Cycles Sample 0 100
300 500 1000 Polymer A Polymer B Polymer C Polymer D
Example S
Fire Retardance Testing
Example S1
[1188] A polyurethane polymer according to the present invention
was prepared from the components listed below:
TABLE-US-00112 Desired Polymer Batch Solids Wt. (g) Size (g)
Monomer Tetrabromobisphenol 1,6- TMP Des W 291.54 100.00 Name A
bis(2- hexanediol hydroxyethyl) ether OH # -- -- -- -- Acid # -- --
-- -- Equivalent 315.99 59.09 44.00 131.2 Wt. Equivalents 0.4000
0.5000 0.100 1.000 desired Mass 126.40 29.55 4.40 131.20 Monomer
Weight % 43.35% 10.13% 1.51% 45.00% Monomer Monomer 43.35 10.13
1.51 45.00 masses for experiment -- Weight % 20.24 Urethane
Molecular 8746.23 Weight per Crosslink (g/mole) (M.sub.c
[1189] The 1,6-hexanediol, trimethylolpropane and DESMODUR W
preheated to 80.degree. C. were added to a glass beaker along with
solid tetrabromobisphenol A bis(2-hydroxyethyl)ether. While
stirring on a hotplate, the mixture was heated until the mixture
had cleared and all solid tetrabromobisphenol A
bis(2-hydroxyethyl)ether had dissolved/melted.
[1190] Initial Gardner impact data showed better impact strength
than stretched acrylic (>6 in/lbs), and much higher than
PLEXIGLAS (2 in-lb). Burn testing with a Bunsen burner showed that
the flame was immediately self-extinguishing.
Example S2
[1191] A polyurethane polymer according to the present invention
was prepared from the components listed below:
TABLE-US-00113 Desired Batch Solids Size (g) Monomer Name
Tetrabromobisphenol A 1,6- TMP Des W 475.00 bis(2-hydroxyethyl)
hexanediol ether OH # -- -- -- -- Acid # -- -- -- -- Equivalent Wt.
315.99 59.09 44.00 131.2 Equivalents desired 0.4500 0.4500 0.100
1.000 Mass Monomer 142.20 26.59 4.40 131.20 Weight % 46.72% 8.74%
1.45% 43.10% Monomer Monomer masses 221.90 41.49 6.87 204.74 for
experiment -- Weight % 19.38 Urethane Molecular Weight 9131.58 per
Crosslink (g/mole) (M.sub.c
[1192] The polymer weight was 304.39 grams. The 1,6-hexanediol,
trimethylolpropane and DESMODUR W preheated to 80.degree. C. were
added to a glass kettle along with solid tetrabromobisphenol A
bis(2-hydroxyethyl)ether. Under nitrogen blanket and with constant
stirring, the mixture was heated to .about.105.degree. C., until
the mixture had cleared and all solid tetrabromobisphenol A
bis(2-hydroxyethyl)ether had dissolved/melted. Once clear, the
mixture was degassed, and cast into a 12''.times.12''.times.0.125''
casting cell preheated to 121.degree. C. The filled cell was cured
for 48 hours at 121.degree. C. Initial impact data showed very poor
performance (<16 in/lbs). Burn testing with a Bunsen burner
showed that the flame was immediately self-extinguishing.
Example S3
[1193] A polyurethane polymer according to the present invention
was prepared from the components listed below:
TABLE-US-00114 Desired Batch Solids Size (g) Monomer Name
Tetrabromobisphenol 1,6- TMP Des W 300.00 A hexanediol
bis(2-hydroxyethyl) ether OH # -- -- -- -- Acid # -- -- -- --
Equivalent Wt. 315.99 59.09 44.00 131.2 Equivalents 0.1000 0.8000
0.100 1.000 desired Mass Monomer 31.60 47.27 4.40 131.20 Weight %
14.73% 22.04% 2.05% 61.17% Monomer Monomer 44.20 66.12 6.15 183.52
masses for experiment -- Weight % 27.51 Urethane Molecular 6434.13
Weight per Crosslink (g/mole) (M.sub.c
[1194] The polymer weight was 214.47 grams. The 1,6-hexanediol,
trimethylolpropane and DESMODUR W preheated to 80.degree. C. were
added to a glass kettle along with solid tetrabromobisphenol A
bis(2-hydroxyethyl)ether. Under nitrogen blanket and with constant
stirring, the mixture was heated to .about.105.degree. C., until
the mixture had cleared and all solid tetrabromobisphenol A
bis(2-hydroxyethyl)ether had dissolved/melted. Once clear, the
mixture was degassed, and cast into a 12''.times.12''.times.0.125''
casting cell preheated to 121.degree. C. The filled cell was cured
for 48 hours at 121.degree. C. Burn testing with a Bunsen burner
showed that the polymer charred and burned for about 7 seconds
after the flame was removed.
Example T
Fiberglass Reinforced Polyurethane
[1195] The following reactants: 208 grams of 1,10-decanediol (2.39
equivalents) and 45.7 grams of trimethylolpropane (1.02
equivalents) were charged into a flask and heated to 125.degree. C.
under a nitrogen blanket with stirring. When a clear, homogenous
melt was formed the mixture was cooled to 105.degree. C. and 446
grams (3.41 equivalents) of DESMODUR W were added. After mixing for
15 minutes and reheating to about 90.degree. C. the mixture
clarified. After controlling the temperature at 90.degree. C. for
about 10 minutes, approximately 50% of the liquid was vacuum
transferred into a 20'' by 20'' by 1/8'' (50.8 cm.times.50.8
cm.times.0.3 cm) thick mold containing 4 layers of bidirectional
E-glass fiber mat covered by release fabric and flow mesh inside a
vacuum bag. The mold and glass were preheated to 105.degree. C.
before beginning the transfer.
[1196] After approximately 15 minutes, sufficient material was
transferred to completely fill the bag and wet the fiberglass. The
bag and mold were then heated to 143.degree. C. for 48 hours. The
temperature of the resulting fiberglass-urethane composite was then
reduced to 120.degree. C. and held for 1 hour, followed by a
further reduction in temperature to 38.degree. C. After a one hour
hold at 38.degree. C., the system was cooled to room temperature
and disassembled. The resulting part was rigid, colorless and
void-free.
Example U
Multilayer Composite of Cast Film According to the Present
Invention on Stretched Acrylic
[1197] A casting cell was constructed using 0.5'' Polycast 84.RTM.
stretched acrylic and 0.25'' of glass that was release coated with
dimethyldichlorosilane. A primer was applied to the stretched
acrylic for good urethane adhesion. The cell was 6''.times.6'' with
a 0.060'' gap between the glass and the stretched acrylic held
constant with a silicone rubber gasket. The edges were clamped. A
composition using 0.3 equivalents of trimethylolpropane, 0.7
equivalents of 1,5 pentanediol, and 1.0 equivalents of DESMODUR W
were mixed and degassed at 210.degree. F. and poured into the
described casting cell. The composition was cured at 180.degree. F.
for 3 days, allowed to cool to room temperature, and then the
film-cast plastic was separated from the glass release plate. A
high optical quality composite was produced that had excellent
substrate adhesion and high resistance to solvent stress-craze
resistance. The composite was stressed to 4,000 psi with the
polyurethane plastic in tensile stress and ethyl acetate was
applied, covered with a glass cover slip and allowed to sit for 30
minutes. No crazing was observed even under microscopic
examination. The same test was done on bare stretched acrylic in
which crazes are immediately visible without microscopic
examination. The same test was run on bare stretched acrylic
stressed to 1000 psi. Crazing was again immediately visible without
microscopic examination.
Examples V
Reinforced Composites
[1198] With reference to Table 30 below, a thermoset polyurethane
was prepared as follows:
[1199] A reaction vessel was equipped with a stirrer, thermocouple,
nitrogen inlet, distillation container and vacuum pump. Charge A
was then added and stirred with heating to 80.degree.
C.-100.degree. C. under vacuum and held for 1 hour. The reaction
mixture was then cooled to 80.degree. C., vacuum turned off and
Charge B was added to the vessel. The reaction mixture was then
heated to 80.degree. C. under vacuum and allowed to exotherm from
110.degree. C.-120.degree. C. The reaction mixture was then cast in
place between two 5'' by 5''.times. 3/16'' float glass plates which
were fitted with gaskets on three sides and held together using
clamps. Both glass plates had a silane release coating on their
faces that contacted the polyurethane. The spacing between the
plates was approximately three sixteenths of an inch. The casting
cell was preheated to a temperature of about 120.degree. C. before
casting. After casting, the assembly was given a 24 hour cure at
120.degree. C. and then a 16 hour cure at 143.degree. C. After
curing was complete, the cell was given a two hour gradual cool
down cycle from the 143.degree. C. temperature to 45.degree. C.
while remaining in the oven. The cell was removed from the oven and
the glass plates were separated from the polyurethane.
TABLE-US-00115 TABLE 30 Parts by Weight Charge A 1,10-Decanediol
61.00 Trimethylolpropane 13.41 Charge B DESMODUR W.sup.1 131.00
.sup.1Bis(4-isocyanatocyclohexyl)methane from Bayer Material
Science.
Example V
[1200] The following Examples show the infusion of various
inorganic particulate phases into a thermoset polymeric phase. The
thermoset polymers were contacted with various swelling solvents
and various precursors that formed the inorganic particulate phase
in situ.
Example VI
Infusion of Tetramethyl Orthosilicate in Methanol
[1201] The thermoset polyurethane of Example A was immersed into a
solution comprising 20.3% by weight (25% by volume) of anhydrous
methanol and 79.7% by weight (75% by volume) of tetramethyl
orthosilicate (TMOS) for 24 hours. The poly(urethane) was removed
from the methanol/TMOS solution and placed into deionized water for
three days. The poly(urethane) was subsequently placed in a vacuum
oven at 100.degree. C. for 2 hours. Transmission electron
microscopy (TEM) indicated that silica particles had infused into
the polyurethane phase. The silica particles had generated 250
.mu.m into the poly(urethane) substrate. Silica nanoparticle
morphology was generally spherical and the particle size ranged
from 10 to 20 nm. Discrete particles and clusters of particles were
seen in this specimen.
Example V2
Infusion of Tetraethyl Orthosilicate in Ethanol
[1202] The thermoset polyurethane of Example A was immersed into a
solution comprising 21.9% by weight (25% by volume) of anhydrous
ethanol and 78.1% by weight (75% by volume) of tetraethyl
orthosilicate (TEOS) for 24 hours. The poly(urethane) was removed
from the ethanol/TEOS solution and placed into a 14% aqueous
solution of ammonium hydroxide for four hours. The poly(urethane)
was rinsed with water and placed into an oven at 143.degree. C. for
four hours. TEM indicated silica nanoparticles had infused into the
polyurethane phase. The nanoparticles ranged in size from 10 to 70
nm, with most being in the 10 nm range.
Example V3
Infusion of Tetramethyl Orthosilicate in Xylene
[1203] The thermoset polyurethane of Example A was immersed into a
solution comprising 21.7% by weight (25% by volume) of anhydrous
xylene and 78.3% by weight (75% by volume) of tetramethyl
orthosilicate (TMOS) for 24 hours. The poly(urethane) was removed
from the xylene/TMOS solution and placed into a 14% aqueous
solution of ammonium hydroxide for four hours. The poly(urethane)
was rinsed with water and placed into an oven at 143.degree. C. for
four hours. TEM indicated silica nanoparticles had infused into the
polyurethane phase. The nanoparticles ranged in size from 7 to 40
nanometers.
Example V4
Infusion of Tetramethyl Orthosilicate in Ethyl Acetate
[1204] The thermoset polyurethane of Example A was immersed into a
solution comprising 22.4% by weight (25% by volume) of anhydrous
ethyl acetate and 77.6% by weight (75% by volume) of tetramethyl
orthosilicate (TMOS) for 24 hours. The poly(urethane) was removed
from the ethyl acetate/TMOS solution and placed into a 14% aqueous
solution of ammonium hydroxide for four hours. The poly(urethane)
was rinsed with water and placed into an oven at 143.degree. C. for
four hours. TEM indicated silica nanoparticles had infused into the
polyurethane phase.
Example V5
Infusion of Tetramethyl Orthosilicate in Dimethyl Sulfoxide
[1205] The polyurethane of Example A was immersed into a solution
comprising 25% by weight (25% by volume) of anhydrous dimethyl
sulfoxide (DMSO) and 75% by weight (75% by volume) of tetramethyl
orthosilicate (TMOS) for 24 hours. The poly(urethane) was removed
from the DMSO/TMOS solution and placed into a 14% aqueous solution
of ammonium hydroxide for four hours. The poly(urethane) was rinsed
with water and placed into an oven at 143.degree. C. for four
hours. TEM indicated silica nanoparticles had infused into the
polyurethane phase. The nanoparticles ranged in size from 7 to 30
nanometers.
Example V6
Infusion of Tetramethyl Orthosilicate into a Crosslinked Polyester
Film
[1206] A piece of crosslinked polyester film was immersed into a
solution comprising 20.3% by weight (25% by volume) of anhydrous
methanol and 79.7% by weight (75% by volume) of tetramethyl
orthosilicate (TMOS) for two hours. The film was removed from the
methanol/TMOS solution and placed into a 14% aqueous solution of
ammonium hydroxide for two hours. The film was rinsed with water
for 15 minutes and allowed to dry at room temperature for 17 hours.
A silica particulate phase infused into the polymeric phase. TEM
indicated the nanoparticles ranged in size from 7 to 300 nm.
Example V7
Infusion of Titanium Bis(Ethyl Acetoacetato) Diisopropoxide in
Ethyl Acetate
[1207] The thermoset polyurethane of Example A was immersed into a
solution comprising 80.1% by weight of anhydrous ethyl acetate and
19.9% by weight of titanium bis(ethyl acetoacetato) diisopropoxide
for 24 hours. The poly(urethane) was removed from the ethyl
acetate/titanium bis(ethyl acetoacetato) diisopropoxide solution
and placed into a 14% aqueous solution of ammonium hydroxide for
four hours. The poly(urethane) was rinsed with water and placed
into an oven at 143.degree. C. for four hours. A titania
particulate phase infused into the polyurethane phase. Tem
indicated the nanoparticles ranged in size from 5 to 200 nm.
Example V8
Infusion of Zirconium(IV) Acetylacetonate in Ethyl Acetate
[1208] The thermoset polyurethane of Example A was immersed into a
solution comprising 91.2% by weight of anhydrous ethyl acetate and
8.8% by weight of zirconium(IV) acetylacetonate for 24 hours. The
poly(urethane) was removed from the ethyl acetate/zirconium(IV)
acetylacetonate solution and placed into a 14% aqueous solution of
ammonium hydroxide for four hours. The poly(urethane) was rinsed
with water and placed into an oven at 143.degree. C. for four
hours. A zirconia particulate phase infused into the polyurethane
phase.
Examples W
Synthesis of Acrylic Silane Polymers
[1209] For each of Examples A to C in Table 23, a reaction flask
was equipped with a stirrer, thermocouple, nitrogen inlet and a
condenser. Charge A was then added and stirred with heat to reflux
temperature (75.degree. C.-80.degree. C.) under nitrogen
atmosphere. To the refluxing ethanol, charge B and charge C were
simultaneously added over three hours. The reaction mixture was
held at reflux condition for two hours. Charge D was then added
over a period of 30 minutes. The reaction mixture was held at
reflux condition for two hours and subsequently cooled to
30.degree. C.
TABLE-US-00116 TABLE 31 Example A Example B Example C Charge A
(weight in grams) Ethanol SDA 40B.sup.1 360.1 752.8 1440.2 Charge B
(weight in grams) Methyl Methacrylate 12.8 41.8 137.9 Acrylic acid
8.7 18.1 34.6 Silquest A-174.sup.2 101.4 211.9 405.4
2-hydroxylethylmethacrylate 14.5 0.3 0.64 n-Butyl acrylate 0.2 0.3
0.64 Acrylamide 7.2 -- -- Sartomer SR 355.sup.3 -- 30.3 -- Ethanol
SDA 40B 155.7 325.5 622.6 Charge C (weight in grams) Vazo 67.sup.4
6.1 12.8 24.5 Ethanol SDA 40B 76.7 160.4 306.8 Charge D (weight in
grams) Vazo 67 1.5 2.1 6.1 Ethanol SDA 40B 9.1 18.9 36.2 % Solids
17.9 19.5 19.1 Acid value (100% resin 51.96 45.64 45.03 solids) Mn
-- 3021.sup.5 5810 .sup.1Denatured ethyl alcohol, 200 proof,
available from Archer Daniel Midland Co.
.sup.2gamma-methacryloxypropyltrimethoxysilane, available from GE
silicones. .sup.3Di-trimethylolpropane tetraacrylate, available
from Sartomer Company Inc. .sup.42,2'-azo bis(2-methyl
butyronitrile), available from E. I. duPont de Nemours & Co.,
Inc. .sup.5Mn of soluble portion; the polymer is not completely
soluble in tetrahydrofuran.
Example W1
[1210] The acrylic-silane resin from Example A (8.5 grams) was
blended with polyvinylpyrrolidone (0.1 grams) and water (1.5
grams). The formulation was stored at room temperature for 225
minutes. A portion of the resulting solution was loaded into a 10
ml syringe and delivered via a syringe pump at a rate of 1.6
milliliters per hour to the spinneret as described in Example 1.
The conditions for electrospinning were as described in Example 1.
Ribbon shaped nanofibers having a thickness of 100-200 nanometers
and a width of 1200-5000 nanometers were collected on grounded
aluminum foil and were characterized by optical microscopy and
scanning electron microscopy. A sample of the nanofiber was dried
in an oven at 110.degree. C. for two hours. No measurable weight
loss was observed. This indicates the nanofibers were completely
crosslinked.
Examples W2 and W3
[1211] Transparent composite articles comprising a polyurethane
matrix and electrospun fibers of Example 1 were prepared as
follows:
[1212] For each of Examples 2 and 3, see Table 32 below, a reaction
vessel was equipped with a stirrer, thermocouple, nitrogen inlet,
distillation container and vacuum pump. Charge A was then added and
stirred with heating to 80.degree. C.-100.degree. C. under vacuum
and held for 1 hour. The reaction mixture was then cooled to
80.degree. C., vacuum turned off and Charge B was added to the
vessel. The reaction mixture was then heated to 80.degree. C. under
vacuum and allowed to exotherm from 110.degree. C.-120.degree. C.
The reaction mixture was then cast in place between two
5''.times.5''.times. 3/16'' float glass plates which were fitted
with gaskets on three sides and held together using clamps. Both
glass plates had a silane release coating on their faces that
contacted the electrospun fibers and the polyurethane. The fibers
were spun over the treated plates before assembling them into a
casting cell. The casting cell was assembled with the electrospun
nanofiber covered plate on the inside of the casting cell. The
spacing between the plates was approximately three sixteenths of an
inch. The casting cell was preheated to a temperature of about
120.degree. C. before casting. After casting, the assemblies were
given a 24 hour cure at 120.degree. C. and then a 16 hour cure at
143.degree. C. After curing was complete, the cells were given a
two hour gradual cool down cycle from the 143.degree. C.
temperature to 45.degree. C. while remaining in the oven. The cells
were removed from the oven and the glass plates were separated from
the composite article.
Polyurethane Examples 2 and 3
TABLE-US-00117 [1213] TABLE 32 Example 2 Example 3 Charge A (weight
in grams) 1,4 Butanediol 31.54 -- 1,10 Decanediol -- 61.00
Trimethylolpropane 13.41 13.41 Charge B (weight in grams) DESMODUR
W.sup.1 131.00 131.00 .sup.1Bis(4-isocyanatocyclohexyl)methane from
Bayer Material Science.
[1214] Each composite article was tested for scratch resistance by
subjecting the composite to scratch testing by linearly scratching
the surface with a weighted abrasive paper for ten double rubs
using an Atlas ATCC Scratch Tester, Model CM-5, available from
Atlas Electrical Devices Company of Chicago, Ill. The abrasive
paper used was 3M 281Q WETORDRY.TM. PRODUCTION.TM. 9 micron
polishing paper sheets, which are commercially available from 3M
Company of St. Paul, Minn.
[1215] After completing the scratch-test with a Crockmeter using a
9-.mu.m abrasive, the increase in the average roughness in the
surface of the scratched area was measured using an optical
profilometer. The surface of the scratched area was scanned
perpendicular to the direction on the Crockmeter scratching; that
is, across the scratches. An identical scan was taken in an
unscratched area to measure average roughness of the surface of the
original article. Change in average surface roughness for each
article was calculated by subtracting the average roughness of the
unscratched surface from the average roughness of the scratched
surface. Transparent articles with no nanofibers were compared with
transparent composite articles containing electrospun fibers from
Example 3.
[1216] Also, for the purpose of comparison, composite articles were
prepared as generally described above for Example 3, but in which
polyvinylidene fluoride (KYNAR) and nylon-6 fibers were electrospun
and used in place of the fibers of Example 3. The composite
articles were evaluated for scratch resistance as described above.
The results of the testing are reported in Table 33 below.
TABLE-US-00118 TABLE 33 Change in average Electrospun surface
roughness Example Fibers (nm) Control None 74.54 Example 4 Example
3 6.93 Example 4 (repeat) Example 3 -7.28 Control (repeat) None
81.48 Example 5 Example 3 -4.91 Comparative KYNAR 90.2 Comparative
Nylon-6 66.96
[1217] The results reported in Table 33 show the improvement in
scratch resistance provided by the acrylic-silane electrospun
fibers.
Example X
Powder Example
[1218] 1,4-Butanediol (5.47 grams, 0.122 equivalents) and
4,4'-methylene bis-cyclohexylisocyanate (DESMODUR W from Bayer
Corporation; NCO equivalent weight 131; 14.52 grams, 0.111
equivalents) were stirred together in a dry glass container. One
drop of dibutyltin dilaurate was added. The cloudy mixture warmed
spontaneously and became transparent. The mixture was then placed
in an oven at 120.degree. C. for 6 hours.
[1219] A 1.88 gram portion of the resulting glassy, solid
polyurethane was dissolved in 5.23 grams of M-Pyrol by boiling on a
hot plate. Similarly, isophorone diisocyanate trimer (0.23 grams)
was dissolved in 3.68 grams of M-Pyrol. The two solutions were
combined in an aluminum dish and baked at 145.degree. C. for 35
minutes. The resulting film was transparent, tough and hard.
Rubbing with methyl ethyl ketone did not soften the film or cause
it to become tacky, indicating it was thoroughly crosslinked.
Example Y
Liquid Infusion of Inorganic Precursors into Urethane Resulting in
In-Situ Generated Nanoparticles
[1220] A piece of urethane plastic was prepared by the following
method. Dimethyl dichlorosilane was vapor deposited onto the
surface of two pieces of tempered glass and the excess was wiped
off with isopropanol. A rubber gasket ( 3/16'' in diameter) was
placed between the two pieces of glass and the pieces of glass were
fastened together so that one end of the mold was open. The
prepolymer was prepared by heating 504 g 1,10-decanediol (3.55 mol,
0.7 equivalents) and 111 g trimethylolpropane (0.83 mol, 0.3
equivalents) in a three-neck round bottom flask to 120.degree. C.
under vacuum, where it was held for 30 minutes. The contents of the
flask were cooled to 80.degree. C. and 1084 g dicyclohexylmethane
diisocyanate (4.14 mol, 1 equivalent) was added. The reaction
exothermed to 105.degree. C. and the solution was poured into the
open end of the glass mold. The mold was placed into an oven at
120.degree. C. for 24 hours and 143.degree. C. for 16 hours. The
temperature was decreased to 43.degree. C. for one hour and the
mold was removed from the oven. The mold was disassembled to remove
the cast urethane plastic part.
[1221] A solution comprising 75% by volume of
tetramethylorthosilicate (TMOS) and 25% by volume of methanol was
prepared in a sealed container. A piece of urethane plastic was
placed into the sealed container and the container was flushed with
dry nitrogen gas. The urethane plastic soaked in the TMOS/methanol
solution for 4 or 24 hours. The urethane plastic was removed and
immersed in: 1) water for 72 hours, 2) 2 M HCl for one hour and
water for one hour or 3) 15% v/v solution of NH.sub.4OH in water
for one hour. The specimens were subsequently annealed at
143.degree. C. for 4 hours. The immersion soaks hydrolyzed and
condensed the liquid inorganic precursor (TMOS) that was infused in
the plastic. Each soak resulted in different sized nanoparticles
which were located at different depths in the plastic.
[1222] It will be appreciated by those skilled in the art that
changes could be made to the embodiments described above without
departing from the broad inventive concept thereof. It is
understood, therefore, that this invention is not limited to the
particular embodiments disclosed, but it is intended to cover
modifications which are within the spirit and scope of the
invention, as defined by the appended claims.
* * * * *