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US-12617890-B2 - Polyurethane multi-part kit system

US12617890B2US 12617890 B2US12617890 B2US 12617890B2US-12617890-B2

Abstract

A multi-part kit system may be used to repair damaged products used in industrial applications, comprising a part A which includes (A1) MDI prepolymer, (A2) fumed silica, and (A3) plasticizer; a part B which includes (B1) hydroquinone di-(2-hydroxyethyl)ether and (B2) plasticizer; and a part C which includes (C1) polyol, (C2) optionally, catalyst, and (C3) optionally, plasticizer.

Inventors

  • Loc Tran
  • Brett Budd

Assignees

  • LANXESS SOLUTIONS AUSTRALIA PTY. LTD.

Dates

Publication Date
20260505
Application Date
20210205

Claims (20)

  1. 1 . A multi-part kit system, comprising: a part A comprising (A1) MDI prepolymer, (A2) fumed silica, and (A3) a first plasticizer; and a part B comprising (B1) hydroquinone di-(2-hydroxyethyl) ether, and (B2) a second plasticizer; and a part C comprising (C1) polyol, (C2) a catalyst, and (C3) optionally, a third plasticizer, wherein the catalyst is a composition comprising a tin catalyst in a range of from 1 to 20 wt. % and plasticizer in a range of from 80 to 99 wt. %.
  2. 2 . The system of claim 1 , wherein the part A comprises (A1) the MDI prepolymer in a range of from 70 to 85 wt. %, (A2) the fumed silica in a range of from 2 to 10 wt. %, and (A3) the first plasticizer in a range of from 10 to 25 wt. %, based on a total weight of the part A, wherein the part B comprises (B1) the hydroquinone di-(2-hydroxyethyl)ether, in particulate form, in a range of from 25 to 50 wt. %, and (B2) the second plasticizer in a range of from 50 to 75 wt. %, based on a total weight of the part B, and wherein the part C comprises (C1) the polyol in a range of from 10 to 35 wt. %, (C2) the catalyst in a range of from 2 to 15 wt. %, and (C3) optionally, the third plasticizer in a range of from 10 to 75 wt. %, based on a total weight of the part C.
  3. 3 . The system of claim 1 , wherein the part A comprises (A1) the MDI prepolymer in a range of from 75 to 80 wt % (A2) the fumed silica in a range of from 3 to 7 wt. %, and (A3) the first plasticizer in a range of from 13 to 17 wt. %, based on a total weight of the part A; and wherein the part B comprises (B1) the hydroquinone di-(2-hydroxyethyl) ether, in particulate form, in a range of from 28 to 38 wt. %, and (B2) the second plasticizer in a range of from 62 to 72 wt. %, based on a total weight of the part B; and wherein the part C comprises (C1) the polyol in a range of from 20 to 26 wt. %, (C2) the catalyst in a range of from 20 to 28 wt. %, and (C3) optionally, the third plasticizer in a range of from 30 to 50 wt. %, based on a total weight of the part A.
  4. 4 . The system of claim 1 , wherein the part A comprises free 4,4′-methylene diphenyl diisocyanate monomer in less than 1 wt. %, based on a total weight of the MDI prepolymer.
  5. 5 . The system of claim 1 , consisting of: the part A, the part B, and the part C.
  6. 6 . The system of claim 1 , wherein a weight ratio of the part A to the part B to the part C is in a range of from 100:15:1 to 100:50:15.
  7. 7 . The system of claim 1 , wherein the MDI prepolymer comprises, in reacted form, 4,4′methylene diphenyl diisocyanate and polytetramethylene ether glycol.
  8. 8 . The system of claim 1 , wherein the hydroquinone di-(2-hydroxyethyl) ether (B1) is solid and present in ground form.
  9. 9 . The system of claim 1 , wherein the hydroquinone di-(2-hydroxyethyl) ether (B1) has a particle diameter D90 of less than 90 micrometer, measured according to ASTM E2651.
  10. 10 . The system of claim 1 , wherein the first plasticizer (A3), the second plasticizer (B2), and/or the third plasticizer (C3) is alkylsulfonic phenyl ester.
  11. 11 . The system of claim 1 , wherein the first plasticizer (A3), the second plasticizer (B2), and the third plasticizer (C3) are the same.
  12. 12 . The system of claim 1 , wherein the polyol (C1) is a polyethylene glycol having a molecular weight in a range of 180 to 220 g/mol.
  13. 13 . The system of claim 1 , wherein the composition of the catalyst (C2) comprises the third plasticizer, in a range of from 90 to 99 wt. %, and the tin catalyst, in a range of from 1 to 10 wt. %.
  14. 14 . A process for preparing a curable composition, the process comprising: mixing all parts of the multi-part kit system of claim 1 .
  15. 15 . A curable composition, comprising: the parts A, B, and C of the multi-part kit system of claim 1 .
  16. 16 . A polyurethane, in cured form: the curable composition of claim 15 , cured at a temperature of 15° C. or more, as a cured polyurethane.
  17. 17 . The polyurethane of claim 16 , wherein the cured polyurethane has a hardness of 50 to 95 Shore A, 60 to 85 Shore A, measured according to ASTM D2240.
  18. 18 . A process to repair a damaged surface, the process comprising: (a) abrading an area of a substrate to be repaired, to provide an abraded substrate; (b) cleaning a surface of the area of the abraded substrate, using a solvent, to provide an abraded, cleaned substrate; (c) optionally, applying a primer to the surface of the abraded, cleaned substrate; (d) mixing the part A and the part B, of claim 1 , to form a curable composition; (e) optionally, mixing the part C, with the curable composition from the mixing (d); (f) applying the curable composition of the mixing (d) or (e) onto the surface of the abraded, cleaned substrate, to obtain an applied curable composition; and (h) curing the applied curable composition at a temperature of 15° C. or more.
  19. 19 . Equipment, comprising, coated thereon: the polyurethane of claim 16 .
  20. 20 . A method of repairing a damaged surface of a substrate, the method comprising: contacting the multi-part kit system of claim 1 with the damaged surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present application is the national stage of international application PCT/AU2021/050093, filed on Feb. 5, 2021, and claims the benefit of the filing date of U.S. Prov. Appl. No. 62/971,275, filed on Feb. 7, 2020, the content of each of which is incorporated by reference. FIELD OF THE INVENTION This invention relates to a multi-part kit system to repair damaged products used in industrial applications, comprising a part A which comprises A1) MDI prepolymer, A2) fumed silica and A3) plasticizer; a part B which comprises B1) hydroquinone di-(2-hydroxyethyl)ether and B2) plasticizer; and a part C which comprises C1) polyol, C2) optionally catalyst and C3) optionally plasticizer. BACKGROUND OF THE INVENTION Elastomeric and rigid polymeric repair kits are used throughout many industries especially mining, quarries and marine. Products made from metal, plastic, elastomers and other engineering materials, might be damaged by abrasion, erosion or impact when used in their intended operational environments. Product damage results in reduced operating efficiencies, lost production, increased worker risk and cost increases. Removal and transporting the damaged products for repair, further compounds costs and inconvenience. Repair systems, which allow the repair of damaged product surfaces on site and/or in situ are therefore often used to get equipment back into service in short periods of time, preferably within 24 hours. The repaired equipment shall function until the repaired part can be easily replaced, e.g. during a non-production phase or during scheduled maintenance periods. There are several of repair systems disclosed in the prior art. US-A-2016312090 discloses a kit for repairing a defect in an elastomer comprising: a two part adhesive formulation of a Part A comprising: polyol, an adhesion promoter, a chain extender, a catalyst, a water scavenger; and a Part B comprising: polyurethane prepolymer, adhesion promoter and a plasticizer. US-A-2016040050 discloses a polyurethane-based composition which includes a polyurethane prepolymer, a solvent, a plasticizer and a curing agent, wherein the curing agent contains a mononuclear aromatic polyamine, and is present in an amount such that the molar ratio of all amine functions in the polyamine to all isocyanate functions in the composition is at least 0.7 to 1. U.S. Pat. No. 4,345,058 discloses a urethane prepolymer repair system provided by an isocyanate-terminated polytetramethylene ether glycol prepolymer of about 3,500-10,500 molecular weight that cures to an elastomer upon exposure to atmospheric moisture. U.S. Pat. No. 4,327,138 discloses a composition for applying and bonding a curable prepolymer, for example, an amine curable prepolymer, at ambient temperatures to the surface of a cured elastomer substrate. The elastomer article or substrate is treated with an organic oxidant. AU-B-2011297666 discloses a chemical composition to be used in reconstruction and recovery of worn rubber surfaces comprising a crosslinkable polyurethane prepolymer based on a toluene diisocyanate (TDI) in a ratio between 74 to 87% in weight of the final composition, a solvent, a dye and a diethylmethylbenzenodiamine (DETDA) catalyst. U.S. Pat. No. 7,387,819 discloses a method of repairing a vehicle bed-liner including depositing a two-component patching material. The polyurea patching composition comprises two parts comprising IPDI, amines and filler. WO-A-2017/194034 discloses a three-component plasticized conventional polyester polyurethane elastomer derived from a polyester MDI-prepolymer, a polyester polyol and hydroquinone di-(2-hydroxyethyl)ether (HQEE). US-A-2007/0231156 discloses an airfoil repair kit comprising an elastomeric repair material such as polyurethanes. Repair kits are available in the prior art that require typically approximately 30 to 45 minutes working time and enable the repaired equipment to be returned to service after 24 hours. However, the materials which are applied are typically hazardous. It was thus an object of the invention to provide a repair kit for on-site repair which is easy and safe to use, which is fast curing at room temperature, which can be troweled immediately once put in place, allows the device being returned to service after a minimum of 3 hours, which has improved hydrolytic stability in environments in the range of 50 to 85° C. and which is weather resistant (e.g. UV and improved color stability). It was also an object that the properties of the repair material need to suit the target application. One further object is that the repair kit can be applied easily over a longitudinal damage, such as a groove in a conveyor belt without flowing or changing shape. One further object is, that the repair kit is low-hazardous and thus can be applied with reduced environmental health and safety concerns compared to other repair kits. SUMMARY OF THE INVENTION The problem was solved by providing a multi