# US 10,865,283 B2 · Method for producing composite fiber components

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- Number: US 10,865,283 B2
- Document ID: US10865283B2
- Status: Granted
- Kind: B2
- Application number: 16/076,915
- Filed: 2017-03-01
- Published: 2019-02-14
- Granted: 2020-12-15
- Earliest claimed: 2016-03-04
- Assignees: Covestro Deutschland AG
- Applicants: Covestro Deutschland AG
- Inventors: Marcel Schornstein
- Web page: https://patentgrep.com/patent/US10865283B2

## CPC

- C08G 18/4825: {Polyethers containing two hydroxy groups (C08G18/4833 - C08G18/5096 take precedence)}
- B29C 70/345: {using matched moulds}
- B29C 70/545: {Perforating, cutting or machining during or after moulding}
- C08G 18/4833: {Polyethers containing oxyethylene units}
- C08G 18/7664: {containing alkylene polyphenyl groups}
- C08J 5/04: Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J 5/10: characterised by the additives used in the polymer mixture
- C08J 5/244: {using glass fibres}
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- C08J 2375/04: Polyurethanes
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

The present disclosure relates to sheet moulding compounds (SMC) and to a method for producing composite fiber components from said SMC, based on a polyurethane reaction mixture consisting of (A) at least one aromatic isocyanate component, (B) 70 to 100 wt % of at least one polyol component having at least 70% secondary OH groups, a number average OH count of 15-500 mg KOH/g and functionality of 1.9-2.5, (C) 0-30 wt % of at least one polyol having a number average OH count of 15-500 mg KOH/g and a functionality of 1.9-2.5, (D) as applicable, short-chain polyol, (E) internal separating agent, (F) a thermolatent catalyst, and (G) as applicable, auxiliary and/or additional substances, wherein the PUR reaction mixture has an initial viscosity of 2,500-14,000 mPas at 23° C. and the ratio of NCO groups/OH groups is 1.35:1-10:1.

## Claims

### Claim 1

A process for producing a polyurethane-based fiber composite component part comprising the following process steps:
a) producing a polyurethane reaction mixture;
b) applying the reaction mixture atop at least one of two carrier films;
c) bestowing the reaction mixture on the at least one of the two carrier films with reinforcing fibers;
d) bringing together the two carrier films from c) so that the carrier films on both sides surround the reaction mixture comprising the reinforcing fibers and a sandwich is formed;
e) rolling the sandwich via at least one of rolls and rollers;
g) converting the product from step e) to a desired size and removing the two carrier films;
i) molding and completely curing the product from step g) in a mold to afford the fiber composite component part,
wherein the employed polyurethane reaction mixture consists of the following components:
A) one or more aromatic isocyanate components;
B1) 70% to 100% by weight of one or more polyol components selected from the group consisting of polyether polyols, polyester polyols and polycarbonate polyols having 70% to 100% secondary OH groups based on all of the OH groups in the respective molecule of the polyol components and having a number average OH number of 15 to 500 mg KOH/g and a number-average functionality of 1.9 to 2.5;
B2) 0% to 30% by weight of one or more polyols selected from the group consisting of polyether polyols, polyester polyols and polycarbonate polyols having a number average OH number of 15 to 500 mg KOH/g and a number-average functionality of 1.9 to 2.5 excluding the polyol component B1);
wherein B1) and B2) sum to 100% by weight and at least 70% of the entirety of the OH groups of components B1) and B2) are secondary OH groups;
C) optionally one or more short-chain polyols having a number average OH number of 550 to 2000 mg KOH/g and a number average functionality of 1.9 to 6;
D) one or more internal release agents;
E) one or more thermolatent catalysts catalytically active at temperatures of 50° C. to 120° C.;
F) inorganic fillers; and
G) optionally auxiliary and/or additive substances;
wherein at 23° C. the polyurethane reaction mixture has a starting viscosity of 2500 to 14000 mPas and the ratio of the number of NCO groups of component A) to the number of OH groups of
components B1), B2) and C) is from 1.35:1 to 10:1.

### Claim 2 (depends on 1)

The process of claim 1, wherein step e) further comprises at least one of:
subsequent rolling up of the sandwich to afford a sheet molding compound (SMC); and
subsequent cutting of the sandwich into SMC pieces and stacking of the SMC pieces.

### Claim 3 (depends on 2)

The process of claim 2, further comprising storing the rolled-up SMC or the SMC stack.

### Claim 4 (depends on 1)

The process of claim 1, further comprising stacking a plurality of products from step g).

### Claim 5 (depends on 1)

The process of claim 1, wherein the one or more thermolatent catalysts of component E) are catalytically active at temperatures of 60° C. to 100° C.