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US 9,517,607 B2Granted
Skinned substrates with highly crosslinked polyurethane layer
AssigneeDow Global Technologies LLC
InventorsSara Cavalca, Sabrina Fregni
Life of this patent
Estimating the term…
Abstract
PVC-skinned composites include a substrate, a skin and an intermediate polyurethane layer. The polyurethane layer is characterized in having a low molecular weight between crosslinks, i.e., is somewhat highly crosslinked. The high level of crosslinking in the polyurethane leads to improved performance of the skin layer. The skin layer retains its original color upon aging, is less prone to shrinking and other loss of physical properties, and adheres better to the polyurethane layer.
Claims12
A skinned composite comprising
- a) a substrate,
- b) an exterior plasticized polymeric skin having a thickness of 0.5 to 2 mm covering at least a portion of the substrate, the exterior plasticized polymer skin comprising a thermoplastic polymer and 25 to 45% by weight of a plasticizer based on the combined weight of the plasticizer and the thermoplastic polymer and further having one or more score lines on an exposed and/or an inner surface;
- and
- c) a polyurethane layer interposed between the substrate and the plasticized polymeric skin, wherein the polyurethane layer is the reaction product of a reaction mixture that contains one or more polyisocyanates and one or more isocyanate-reactive compounds that contain two or more isocyanate-reactive groups, wherein the polyurethane has a calculated molecular weight per crosslink of no greater than 1250 as calculated by the formula
- MW
- xl
- =
- A
- +
- B
- A
-
- (
- C
- -
- 2
- )
- CD
- +
- B
-
- (
- F
- -
- 2
- )
- EFG
- +
- B
-
- (
- F
- -
- 1
- )
-
- (
- 1
- -
- 1
- E
- )
- (
- E
- +
- 1
- )
-
- G
- wherein
- A is the combined weight, in grams, of all isocyanate-reactive materials that contain at least 2 isocyanate-reactive groups/molecule, including any water, provided to the reaction mixture;
- B is the combined weight, in grams, of all isocyanate compounds provided to the reaction mixture;
- C is average functionality of all isocyanate-reactive compounds provided to the reaction mixture that contain at least 2 isocyanate-reactive groups/molecule, including any water;
- D is the average equivalent weight in grams per hydroxyl group of all isocyanate-reactive compounds provided to the reaction mixture that contain at least 2 isocyanate-reactive groups/molecule, including any water;
- E is the isocyanate index, calculated as the number of equivalents of isocyanate groups provided to the reaction mixture divided by the number of equivalents of isocyanate-reactive groups provided to the reaction mixture;
- F is the average functionality of all isocyanate compounds provided to the reaction mixture;
- and
- G is the average equivalent weight in grams per isocyanate group of all isocyanate compounds provided to the reaction mixture.
55 more elements
A skinned composite comprising
- a) a substrate,
- b) an exterior plasticized polymeric skin having a thickness of 0.5 to 2 mm covering at least a portion of the substrate, the exterior plasticized polymer skin comprising a thermoplastic polymer and 25 to 45% by weight of a plasticizer based on the combined weight of the plasticizer and the thermoplastic polymer, and further having one or more score lines on an exposed and/or an inner surface;
- and
- c) a polyurethane layer interposed between the substrate and the plasticized polymeric skin, wherein the polyurethane layer is the reaction product of a reaction mixture that contains one or more polyisocyanates and one or more isocyanate-reactive compounds that contain two or more isocyanate-reactive groups, wherein the reaction mixture has an isocyanate index of from 0.9 to 1.25 and the isocyanate-reactive compounds that contain two or more isocyanate-reactive groups are selected from the group consisting of:
- 1) a blend of a high functionality polyol having a hydroxyl functionality of at least 4, and a hydroxyl equivalent weight of 80 to 250 with at least one low equivalent weight polyol, aminoalcohol or polyamine that has an equivalent weight per isocyanate group of up to about 125, and a functionality of 3 to 4;
- 2) a blend of a high functionality polyol having a hydroxyl functionality of at least 4, and a hydroxyl equivalent weight of 80 to 250 with one or more high equivalent weight polyether polyols or polyether amines, the high equivalent weight polyol or polyether amine having a functionality of 2 to 3 and an equivalent weight of at least 350 to 2200;
- 3) a blend of a high functionality polyol having a hydroxyl functionality of at least 4, and a hydroxyl equivalent weight of 80 to 250 with at least one low equivalent weight polyol, aminoalcohol or polyamine that has an equivalent weight per isocyanate group of up to about 125and a functionality of 3 to 4 and one or more high equivalent weight polyols or polyether amines having a functionality of 2 to 3 and an equivalent weight of at least 350 to 2200;
- 4) a blend as in any of 1)-3), further including water;
- and
- 5) a blend as in any of 1)-4), further including one or more aliphatic polyesters having a hydroxyl functionality of at least 2 and a hydroxyl equivalent weight of about 350 to 1500 and which are a reaction product of an aliphatic dicarboxylic acid (or corresponding acid chloride or diester) with at least one polyol having at least 2 hydroxyl groups and a hydroxyl equivalent weight of 150 or less, or a mixture of such a polyol with one or more diols having a hydroxyl equivalent weight of 150 or less.
7 more elements
Dependencies are inferred from the claim text.