# US 8,465,840 B2 · Polyurethane systems for producing polyurethane sandwich parts at low molding temperatures > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,465,840 B2 - Document ID: US8465840B2 - Status: Granted - Kind: B2 - Application number: 12/921,514 - Filed: 2009-03-18 - Published: 2011-01-20 - Granted: 2013-06-18 - Earliest claimed: 2008-03-20 - Assignees: BASF SE - Applicants: Michael Fader - Inventors: Michael Fader - Web page: https://patentgrep.com/patent/US8465840B2 ## CPC - C08G 18/1875: {containing ammonium salts or mixtures of secondary of tertiary amines and acids} - B29C 70/003: {characterised by the matrix material, e.g. material composition or physical properties} - B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)} - B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core - B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material - C08G 2101/00: Manufacture of cellular products - Y10T 428/31551: Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.] - 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) - 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 - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The present invention relates to the use of a polyurethane system, comprising (a) polyisocyanates, (b) at least one isocyanate-reactive compound, (c) at least one carboxylic salt of an amine catalyst, where, based on one equivalent of the amine of the amino catalyst, from 0.5 to 1.5 equivalents of acid groups of a carboxylic acid are comprised, (d) if appropriate, further catalysts, (e) if appropriate, a reactive chain extender having at least two groups reactive toward isocyanates, where at least one group reactive toward isocyanates is a free, primary, NH2 group, and (f) if appropriate, further additives, for the production of polyurethane sandwich components. The present invention further relates to a process for the production of polyurethane sandwich components, and also to the polyurethane sandwich components obtained by the process of the invention. ## Claims ### Claim 1 A polyurethane sandwich component obtained by a process of (i) applying a polyurethane system to at least one reinforcement fiber layer on a core layer, to yield a first component, (ii) placing the first component from (i) into a mold, and giving the first component from (i) a three-dimensional shape by compressing the core layer in the mold, and hardening the polyurethane system, to yield a molding, (iii) removing the molding from the mold, and (iv) optionally, subjecting the molding to further operations, wherein the polyurethane sandwich component comprises the core layer and the polyurethane system, the polyurethane system comprising: a) at least one polyisocyanate; b) at least one isocyanate-reactive compound; c) at least one carboxylic salt of an amine catalyst; d) optionally, at least one further catalyst; e) optionally, a reactive chain extender comprising at least two groups reactive toward isocyanates, wherein at least one group reactive toward isocyanates is a free, primary NH2 group; and f) optionally, at least one further additive, and, based on one equivalent of amine of the amine catalyst, from 0.5 to 1.5 equivalents of acid groups of a carboxylic acid are comprised. ### Claim 2 (depends on 1) The polyurethane sandwich component according to claim 1, wherein the carboxylic acid is a dicarboxylic acid of a formula HOOC—(CH2)n—COOH, where n is a whole number from 2 to 14. ### Claim 3 (depends on 2) The polyurethane sandwich component according to claim 2, wherein the amine catalyst c) has at least one isocyanate-reactive group. ### Claim 4 (depends on 2) The polyurethane sandwich component according to claim 2, wherein the reactive chain extender e) is comprised in the polyurethane system at from 0.1 to 10% by weight, based on the total weight of components b) to f). ### Claim 5 (depends on 2) The polyurethane sandwich component according to claim 2, wherein the carboxylic acid is adipic acid. ### Claim 6 (depends on 5) The polyurethane sandwich component according to claim 5, wherein the amine catalyst c) has at least one isocyanate-reactive group. ### Claim 7 (depends on 5) The polyurethane sandwich component according to claim 5, wherein the reactive chain extender e) is comprised in the polyurethane system at from 0.1 to 10% by weight, based on the total weight of components b) to f). ### Claim 8 (depends on 1) The polyurethane sandwich component according to claim 1, wherein the amine catalyst c) has at least one isocyanate-reactive group. ### Claim 9 (depends on 1) The polyurethane sandwich component according to claim 1, wherein the reactive chain extender e) is comprised in the polyurethane system at from 0.1 to 10% by weight, based on the total weight of components b) to f). ### Claim 10 (depends on 1) The polyurethane sandwich component according to claim 1, wherein from 0.7 to 1.3 equivalents of acid groups are present based on one equivalent of the amine of the amine catalyst. ### Claim 11 (depends on 1) The polyurethane sandwich component according to claim 1, wherein from 0.9 to 1.10 equivalents of acid groups of the carboxylic acid are present based on one equivalent of the amine of the amine catalyst. ### Claim 12 (depends on 1) The polyurethane sandwich component according to claim 1, wherein, based on one equivalent of amine of the amine catalyst, from 0.5 to 0.95 equivalents of acid groups of a carboxylic acid are comprised. ### Claim 13 (depends on 12) The process according to claim 12, wherein, based on one equivalent of amine of the amine catalyst, from 0.5 to 0.95 equivalents of acid groups of a carboxylic acid are comprised. ### Claim 14 (depends on 12) The process according to claim 12, wherein, based on one equivalent of amine of the amine catalyst, from 0.5 to 0.9 equivalents of acid groups of a carboxylic acid are comprised. ### Claim 15 (depends on 1) The polyurethane sandwich component according to claim 1, wherein, based on one equivalent of amine of the amine catalyst, from 0.5 to 0.9 equivalents of acid groups of a carboxylic acid are comprised. ### Claim 16 A process for the production of a polyurethane sandwich component, comprising: i) applying a polyurethane reaction mixture to at least one reinforcement fiber layer on a core layer, to yield a first component; ii) placing the first component from i) into a mold, and giving the first component from i) a three-dimensional shape by compressing the core layer in the mold, and hardening the polyurethane reaction mixture, to yield a molding; iii) removing the molding from the mold; and iv) optionally, subjecting the molding to further operations, wherein the polyurethane reaction mixture is obtained via mixing of the components of the polyurethane system comprising: a) at least one polyisocyanate; b) at least one isocyanate-reactive compound; c) at least one carboxylic salt of an amine catalyst; d) optionally, at least one further catalyst; e) optionally, a reactive chain extender comprising at least two groups reactive toward isocyanates, wherein at least one group reactive toward isocyanates is a free, primary NH2 group; and f) optionally, at least one further additive, and wherein, based on one equivalent of amine of the amine catalyst, from 0.5 to 1.5 equivalents of acid groups of a carboxylic acid are comprised. ### Claim 17 (depends on 16) The process according to claim 16, wherein mold temperature is below 110° C. ### Claim 18 (depends on 17) The process according to claim 17, wherein the carboxylic acid is a dicarboxylic acid of a formula HOOC—(CH2)n—COOH, where n is an integer from 2 to 14. ### Claim 19 (depends on 17) The process according to claim 17, wherein the carboxylic acid is adipic acid. ### Claim 20 (depends on 17) The process according to claim 17, wherein the mold in ii) comprises a decorative element. ### Claim 21 (depends on 16) The process according to claim 16, wherein the mold in ii) comprises a decorative element. ### Claim 22 (depends on 21) The process according to claim 21, wherein the carboxylic acid is a dicarboxylic acid of a formula HOOC—(CH2)n—COOH, where n is an integer from 2 to 14. ### Claim 23 (depends on 16) The process according to claim 16, wherein the carboxylic acid is a dicarboxylic acid of a formula HOOC—(CH2)n—COOH, where n is an integer from 2 to 14. ### Claim 24 (depends on 16) The process according to claim 16, wherein the carboxylic acid is adipic acid. ### Claim 25 (depends on 16) The process according to claim 16, wherein the amine catalyst c) has at least one isocyanate-reactive group. ### Claim 26 (depends on 16) The process according to claim 16, wherein the reactive chain extender e) is comprised in the polyurethane system at from 0.1 to 10% by weight, based on the total weight of components b) to f). ### Claim 27 (depends on 16) The process according to claim 16, wherein from 0.7 to 1.3 equivalents of acid groups are present based on one equivalent of the amine of the amine catalyst. ### Claim 28 (depends on 16) The process according to claim 16, wherein from 0.9 to 1.10 equivalents of acid groups of the carboxylic acid are present based on one equivalent of the amine of the amine catalyst.