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CN-121975084-A - Spray polyurethane elastomer and production method thereof

CN121975084ACN 121975084 ACN121975084 ACN 121975084ACN-121975084-A

Abstract

The present disclosure relates to spray-coated polyether and polyester polyurethane elastomeric articles and related methods of producing such elastomeric articles. More specifically, the present invention provides spray coated polyester polyurethane elastomer articles that exhibit excellent tensile and tear strength, excellent elongation properties and improved abrasion resistance, with adjustable tensile modulus.

Inventors

  • WANG LIYING
  • B.J. MARTIN

Assignees

  • 巴斯夫欧洲公司

Dates

Publication Date
20260505
Application Date
20200930
Priority Date
20190930

Claims (20)

  1. 1. A spray-on polyurethane elastomer comprising: (a) Isocyanate functional urethane prepolymers derived from monomeric diphenylmethane diisocyanate (MMDI) and polyester polyols, and (B) An isocyanate-reactive component comprising: (i) A first polyol in an amount of 60 to 98 parts by weight of the isocyanate-reactive component, wherein the first polyol is a polyol having a hydroxyl number of 30 to 200 mg KOH/g, the first polyol is a polyester polyol, Wherein the density of the spray polyurethane elastomer is 0.60-0.95 g/cm 3 , The viscosity of the spray polyurethane elastomer is about 2500 to 6800 cps at 25 ℃ and the viscosity of the isocyanate functional urethane prepolymer is 1000 to 1100 cps at 25 ℃.
  2. 2. The spray polyurethane elastomer of claim 1, wherein the amount of the first polyol is 70 to 95 parts by weight of the isocyanate-reactive component.
  3. 3. The spray polyurethane elastomer of claim 1, wherein the amount of the first polyol is 80 to 95 parts by weight of the isocyanate-reactive component.
  4. 4. The spray polyurethane elastomer of claim 1, wherein the first polyol has a weight average molecular weight of 500 to 5000 g/mol.
  5. 5. The spray polyurethane elastomer of claim 1, wherein the first polyol is an adipic acid-ethylene glycol-1, 4-butanediol initiated polyester polyol.
  6. 6. The spray polyurethane elastomer of claim 1, further comprising a catalyst in an amount of 0.05 to 4.00 parts by weight of the isocyanate-reactive component.
  7. 7. The spray polyurethane elastomer of claim 1, further comprising a chain extender having a molecular weight of 60 to 400.
  8. 8. The spray polyurethane elastomer of claim 1, wherein the isocyanate-reactive component further comprises a second polyol.
  9. 9. The spray polyurethane elastomer of claim 8, wherein the second polyol is a polyester polyol.
  10. 10. The spray polyurethane elastomer of claim 1, wherein the elastomer has a lower density than a non-spray elastomer.
  11. 11. The spray polyurethane elastomer of claim 1, wherein the elastomer is applicable to a mold having a high thermal conductivity or a low thermal conductivity.
  12. 12. The spray coated polyurethane elastomer of claim 1, wherein the elastomer can be applied to a non-synthetic textile, glass fiber mat, or carbon fiber mat to produce a reinforced composite.
  13. 13. The spray coated polyurethane elastomer of claim 1, wherein the elastomer can be applied to a non-synthetic fabric or a synthetic fabric to produce a reinforced composite.
  14. 14. The spray polyurethane elastomer of claim 12 or 13, wherein the reinforced composite can be used to form an industrial or consumer article.
  15. 15. The spray polyurethane elastomer of claim 14, wherein the industrial or consumer article comprises clothing, footwear, automotive components, tools, appliances, outdoor items, landscaping materials.
  16. 16. The spray polyurethane elastomer of claim 14, wherein the article is flexible or rigid.
  17. 17. A process for preparing the spray polyurethane elastomer of claim 1, comprising the steps of: Reacting MMDI with a polyester polyol to form an isocyanate functional urethane prepolymer, Blending polyols to form an isocyanate-reactive component; and mixing the isocyanate prepolymer and isocyanate-reactive component at an isocyanate index of 100 to 110 to form a polyurethane elastomer, wherein the amount of polyester polyol having a hydroxyl number of 30 to 200 mg KOH/g is 60 to 98 parts by weight of the isocyanate-reactive component.
  18. 18. The method of claim 17, further comprising the step of reducing the density of the elastomer.
  19. 19. The method of claim 18, wherein the step of reducing the density of the elastomer comprises air injection, addition of a physical blowing agent, addition of a chemical blowing agent, addition of a nucleating agent, or addition of a filler.
  20. 20. The method of claim 19, wherein the nucleating agent comprises dry air or nitrogen, and/or wherein the filler comprises hollow glass bubbles or microspheres.

Description

Spray polyurethane elastomer and production method thereof The present application is a divisional application of patent application number 202080068752.5 entitled "spray polyurethane elastomer and method for producing same". The original application corresponds to International application PCT/US2020/053385, the application date is 9 months 30 days in 2020, and the priority date is 9 months 30 days in 2019. Technical Field The present application relates generally to spray polyurethane elastomers, methods for producing articles utilizing such spray polyurethane elastomers, and the resulting articles. Background Spray polyurethane elastomers are used in a number of applications, including high end products for automotive and other related applications, for purposes such as interior materials, instrument panel skins, and seat skins. Typically, spray polyurethane elastomers are based on two-component polyurethane systems formulated from polyol resins and isocyanate or isocyanate prepolymers. Conventional spray elastomers can be divided into three main categories, namely spray polyurethanes, spray polyureas and mixed systems derived from the use of polyether polyols, polyamines or combined polyurethane/polyurea. The resin composition generally contains a low viscosity polyol and additives such as catalysts, surfactants, chain extenders, crosslinking agents, fillers, and the like. Most polyurethane elastomers typically contain one or more polyols with high OH functionality that can be crosslinked to achieve better mechanical properties. When combined with complex finishing tools and techniques, spray coating techniques enable unique processes to be used to design products with attractive effects, including mixed colors, logos, textures. In addition, spray techniques also provide an attractive luxurious appearance and a beautiful feel over other materials. With the increasing demand for high tensile and tear strength as well as excellent elongation properties and scratch resistance, the development of improved spray polyurethane elastomers having such properties is continually desired for a variety of applications. For example, such elastomers may be used as abrasion or scratch resistant layers on certain articles or as protective coatings for shoe components, i.e., outsoles or midsoles, cell soles, or uppers. Because of their excellent physical properties, particularly tear and tensile strength, polyester polyurethane elastomers have been used in a variety of applications, including industrial and consumer products. However, polyester-based polyurethane elastomers are mainly produced by casting because of their viscosity, reactivity profile and processability characteristics. Polyester polyurethane systems have not been widely studied and processed via spray technology which may further) enable air injection to reduce the density to the range of 0.60-0.90 g/cm 3 as required. Spray polyester elastomers can also open the door for many new applications in which spray polyether polyurethanes and spray polyureas have shown limitations, for example, products with excellent elongation properties and high resistance to organic solvents, chemicals, greases, oils and fuels are desired. There is also an increasing desire to replace coated fabrics (e.g., synthetic leather) with improved materials. The coating is woven as a textile/scrim with a thin coating on one surface. Such textiles are used to provide performance attributes including tensile strength, tensile modulus, and tear resistance. Textiles are generally flexible and generally remain flexible after coating. The coating acts as a protective layer for the textile, providing a degree of abrasion resistance, while also providing aesthetic features such as color and texture. The coating contributes little to tensile strength, tensile modulus and tear resistance. Coated fabrics are known to have a high tensile modulus and thus have resistance to creep and permanent deformation in use. In many applications (e.g., footwear), creep resistance is desired. On the other hand, polyurethanes can be susceptible to creep and permanent deformation. Thus, a new polyurethane process is needed to obtain a suitable alternative to coated fabrics. With respect to tensile modulus, some applications may require a low tensile modulus, while other applications require a high tensile modulus. In either case, excellent strength and elongation are required. There is a need to develop spray polyester elastomers with adjustable tensile modulus, especially at lower densities of less than about 0.95 g/cm 3. In summary, there is a need for improved spray polyester elastomers having suitable densities (preferably lower densities), good permanent set resistance and adjustable modulus. Disclosure of Invention Novel compositions are disclosed herein that relate to spray-coated polyurethane elastomeric articles and related methods of producing such elastomeric articles. More specifically, provided her