Polyurethane-polyisocyanurate structural rim systems with enhanced processing

Abstract

Low and high density structural RIM compositions are disclosed which have low viscosities. These compositions contain a resin "B-side" component which comprises a hydroxyl-functional tertiary amine polyol.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The sub3ect invention pertains to the field of fiber-reinforced reaction-injection-moldings. More particularly, the subject invention pertains to reactive systems useful in preparing rigid, fiber-reinforced polyurethane-polyisocyanurate parts especially adapted to the transportation and other industries. Such fiber-reinforced reaction-injection-molded systems and the resulting parts are known as structural-RIM or SRIM.

2 Description of the Related Art

Reaction-injection-molding (RIM) systems by now are well known to those skilled in the art. Commercial systems produce elastomeric products containing polyurethane-polyurea linkages which have many uses, for example as automobile facias. However, such systems have relatively low heat distortion temperatures and lack the flex modulus and tensile strength necessary for many applications. The chemistry of these reactive systems involves the use of a polyisocyanate "A side" (A component) and a "B side" employing a mixture of compounds containing isocyanate-reactive hydrogens. These "B side" components generally include one or more hydroxyl-functional polyether or polyester polyols and one or more sterically hindered diamines. The polyol components react with the isocyanate to form urethane linkages while the amine components react to form urea linkages. Such systems are disclosed, for example, in Weber U.S. Pat. No. 4,218,543.

The flex modulus and tensile strength of traditional RIM systems may be improved through the addition of short fiber reinforcement (RRIM). However, the addition of chopped fibers raises the viscosity of the system components as well as seriously affecting the ease of processing. Moreover, this addition of reinforcement has little effect on matrix dominated physical properties such as heat distortion temperature (HDT).

The use of woven or non-woven (random) fiber reinforcement (Structural RIM or SRIM) can provide parts with yet greater tensile strength and flex modulus. Furthermore, the physical properties may be made directional through the use of unidirectional fibers or combinations of both unidirectional and random fiber orientations. Unfortunately, the use of such reinforcement has not proven practical with traditional polyurethane-polyurea RIM systems due to the high viscosities of such systems. Finally, the low heat distortion temperature of such systems continues to present a detriment to the use of such systems. SRIM systems may be divided into cellular (blown) systems whose resin matrix has a density less then 1.0 g/cm.sup.3 and whose fiber reinforced part has a flexural modulus of less than about 500,000 psi; and high density systems which are essentially noncellular, have resin matrix densities greater than 1.0 g/cm.sup.3, and whose flexural modulus is in excess of 500,000 psi.

In U.S. Pat. No. 4,035,331 are disclosed high density polyurethane RIM systems employing a polyisocyanate, an amine-initiated polyether polyol, and a liquid modifier having a boiling point above 150.degree. C. all in the absence of a catalyst. The liquid modifier is present in an amount of from 5 to 60 weight percent, preferably from 15 to 40 weight percent of the overall system components. Systems which contain less than about 5 weight percent of modifier are said to produce unacceptable products, subject to swelling, cracking, and distortion. No mention is made of the viscosity of such systems or their suitability as SRIM systems.

In U.S. Pat. No. 4,709,002, some of the defficiencies of the '331 patent are overcome through the use of a polyisocyanate and a propylene carbonate adduct of a tertiary amine. The products of these systems are polyisocyanurate polymers which are suitable for use in SRIM systems. However, the alkylene carbonate tertiary amine adduct must be aged for considerable length of time, for example 500 hours, in order for its catalytic activity to stabilize somewhat. As the catalytic activity continues to change with time, such systems are not storage stable.

It would be desirable to formulate an SRIM system capable of providing a storage stable, high heat distortion system yet having a low viscosity suitable for both low density (microcellular) and high density (non-cellular) applications without the use of large amounts of liquid modifiers.

SUMMARY OF THE INVENTION

It has now been discovered that storage stable SRIM polyurethane-polyisocyanurate systems having low viscosity which provide parts having high heat distortion temperature may be prepared in the substantial absence of liquid modifiers and yet do not crack or distort, when certain tertiary amine polyols are used as the isocyanate-reactive component. Such systems may be utilized in both low density, open pour SRIM and low density and high density injection molded SRIM systems. Finally, low density systems lend themselves to use in all water-blown systems, eliminating the use of chlorofluorocarbons, although all CFC blown systems and co-blown (CFC and water) are also feasible.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The reactive components of the subject invention SRIM systems comprise one or more polyisocyanates and an isocyanate-reactive component which is a hydroxyl-functional tertiary amine polyether polyol. The isocyanate-reactive component in high density SRIM systems may optionally include a minor amount, i.e. 4 weight percent or less based on the total system weight, of a hydroxyl functional polyether or polyester polyol. In low density (cellular) SRIM systems, the isocyanate-reactive component may contain up to about 50 weight percent based on the total polyol (Bside) component of a conventional or graft polyol and or low molecular weight chain extender. Traditional polyurethane-polyisocyanurate system components such as fillers, flame retardants, catalysts, blowing agents, UV stabilizers, surfactants, dyes and pigments may also be added when necessary or desirable.

Polyisocyanates which may be used as the isocyanate component include the modified and unmodified polyisocyanates which are well known to those skilled in the art. Unmodified polyisocyanates include aromatic and aliphatic polyisocyanates such as 2,4- and 2,6-toluenediisocyanates, 2,4-, and 2,6-methylcyclohexyldiisocyanates, 1,6-hexamethylenediisocyanate, isophoronediisocyanate, 2,4'-4,4'-, and 2,2'-diphenylmethanediisocyanates, and polyphenylenepolymethylenepolyisocyanates. Mixtures of the above isocyanates as well as crude polyisocyanates, particularly less highly refined mixtures of the diphenylmethanediisocyanates and polyphenylenepolymethylenepolyisocyanates (crude MDI) may be useful.

Modified polyisocyanates may also be useful, particularly those isocyanates which have reduced viscosity. Examples of modified polyisocyanates include urethane, urea, biuret, and carbodiimide modified polyisocyanates. Such modified polyisocyanates are well known to those skilled in the art. Preferred isocyanates are the various diphenylmethanediisocyanates, their higher ring oligomers and their mixtures. Modified diphenylmethanediisocyanates and mixtures of such isocyanates with unmodified diphenlmethanediisocyanates and/or polyphenylenepolymethylene polyisocyanates are also preferred.

The isocyanate-reactive component comprises one or more hydroxyl-functional tertiary amine polyether polyols. Such polyols are prepared by oxyalkylating an aliphatic or aromatic amine, preferably an aliphatic amine, with an alkylene oxide. Examples of suitable aromatic amines which are useful as initiators include the various phenylenediamines, toluenediamines, and diphenylmethanediamines. Examples of suitable aliphatic amines include ethylenediamine, propylenediamine, 1,4-butanediamine, 1,6-hexanediamine, diethylenetriamine, triethylenetetraamine and the like. Hydroxyalkylamines may also be useful, for example 2hydroxyethylamine and 2- and 3-hydroxypropylamine, bis[2-hydroxyethyl]ethylamine, tris[2-hydroxyethyl]amine and the like. The preferred initiators are 2-hydroxypropylamine and bis[2-hydroxyethyl]-2-hydroxypropylamine.

The amine or hydroxyalkylamine initiators are oxyalkylated with sufficient alkylene oxide to convert at least one and preferably all amino groups to tertiary amino groups. As alkylene oxides may be mentioned ethylene oxide, propylene oxide, and butylene oxide. Mixtures of these alkylene oxides may be used, or they or their mixtures may be used sequentially to form homopolymeric, block, heteric, or block-heteric polyether polyols. The process of preparation of such polyether polyols is conventional and is well known to those skilled in the art.

Preferred hydroxyl-functional tertiary amine polyether polyols are polyoxypropylated 2-hydroxypropyl amines. Such polyols are trifunctional and may have molecular weights from about 194 to about 2000, and hydroxyl numbers from 50 to about 600, preferably from 250 to about 600, and most preferably about 500. Polyols with lower hydroxyl numbers tend to make the polyurethane-polyisocyanurate product more flexible, usually at the expense of the heat distortion temperature. Lower molecular weight, higher hydroxyl number polyols are used to prepare more rigid products.

The flexibility of the SRIM product matrix may also be adjusted by including lower or higher functionality hydroxyl-functional tertiary amine polyether polyols. For example, inclusion of polyols with a functionality of two lowers the crosslink density thus increasing flexibility, while inclusion of polyols with functionalities of from 4 to 6 or higher lead to an increase in crosslink density. In general, systems with higher crosslink densities have greater rigidity and higher heat distortion temperatures.

Useful in minor amounts are amine initiated polyether polyols which have free amino hydrogens and hydroxyl-functional polyoxyalkylene moieties. Such polyols are prepared as taught by U.S. Pat. No. 4,517,383, by oxyalkylating an aliphatic or aromatic amine with a stoichiometric excess of alkylene oxide, but utilizing an extraordinarily high amount of basic oxyalkylation catalyst which must be present at the onset of oxyalkylation. Such dual-functionality assymetric polyols create both urethane and urea linkages in the finished product, and further have the advantage of lower viscosities than their fully oxyalkylated, symmetrical analogues.

Also useful in minor amounts, are conventional polyether polyols and acrylonitrile/styrene graft polymer polyol dispersions. Both these types of polyols are well known items of commerce, and generally have functionalities from two to about eight, preferably from 2 to about 3, and hydroxyl numbers from 20 to about 600, preferably from 20 to about 500. The use of such polyols increases the urethane linkages in the finished product. Use of graft polyols may increase the flexural modulus and tensile strength. In low density SRIM systems, the minor amount of conventional or graft polyols may be up to about half the total polyol component weight. In high density SRIM systems, however, the minor amount should be less than about 4 weight percent based on the total system weight.

The flexural modulus, heat distortion temperature, and rigidity of the matrix may also ad3usted by varying the urethane/isocyanurate content of the product. The isocyanurate content is increased by increasing the ratio of isocyanate (A side) to polyol (B side). In general, isocyanate indices of from 100 to about 700 are useful, preferably from 120 to about 300, and most preferably from 150 to 250.

Hydroxyl-functional and amine-functional chain extenders may be used in both low density and high density SRIM systems. Preferred hydroxyl-functional chain extenders are ethylene glycol, glycerine, trimethylolpropane, 1,4-butanediol, propylene glycol, dipropylene glycol, 1,6-hexanediol, and the like. Suitable amine-functional chain extenders include the sterically hindered amines such as diethyltoluene diamine and the other hindered amines disclosed in Weber U.S. Pat. No. 4,218,543. In both high and low density SRIM systems, the amount of chain extender is generally less than 15 weight percent based on the total weight of the polyol component, preferably less than 10 weight percent. In high density SRIM systems, the amount of chain extender useful is generally very low, i.e. less than about 4 weight percent, and lower when a conventional or graft polyol is used. Prepolymers, particularly those prepared by reacting di- or polyisocyanates with polyester polyols may be used. Such prepolymers may desirably lower the system reactivity.

Plasticizers may also be used in the subject invention SRIM systems. In low density SRIM, the amount of plasticizer is generally less than 25 weight percent of the total polyol (B-side) component. In high density SRIM systems, generally no plasticizer is used, although very minor amounts, i.e. less than about 4 weight percent may be useful in some applications.

Mold releases, both external and internal, may be utilized. Internal mold releases are generally mixtures of long chain carboxylate salts, particularly ammonium and substituted ammonium stearates, and calcium and zinc stearates. External mold releases are well known commercial products and include waxes and silicones, for example.

In low density SRIM systems, a blowing agent is necessary. Water is the preferred blowing agent, and may be used in amounts of up to about 4 weight percent of the polyol (B-side) component. The density of the foam decreases with increasing water content. When water is used in the blowing agent, the polyisocyanate component is increased proportionately. Calculating the amount of water required and isocyanate required are routinely performed by those skilled in the arts of polyurethane and polyisocyanurate foams.

Chlorofluorocarbons (CFC's) and other volatile organic compounds may also be used as blowing agents, either alone, or in conjunction with water. When used alone, CFC blowing agents and other halogenated organics such as methylene chloride are generally used in amounts up to about 30 weight percent of the polyol component, preferably from 15 to about 25 weight percent. Other volatile organic compounds such as pentane, isopentane, acetone, and the like, are used in correspondingly lesser amounts due to their lower molecular weights. When co-blown, the CFC type blowing agents are utilized in lesser amounts, for example up to about 20 weight percent of the polyol component.

Flame retardants may also be used when required by the formulation. Suitable flame retardants are well known to those skilled in the art, but the low molecular weight halogenated phosphate esters, polyhalogenated biphenyls and biphenyloxides and the like may be used when flame retardants are necessary. As the presence of such flame retardants generally causes a decrease in physical properties, use of flame retardants is not preferred.

In high density SRIM systems, a water scavenger may be useful to prevent any blowing by trace amounts of water. Suitable water scavengers may be silica gels, anhydrous silica, and molecular sieves. A suitable molecular sieve which is available commercially is Baylith.RTM. paste, available from the Mobay Chemical Company.

Ultraviolet stabilizers and absorbers may also be useful. Such stabilizers generally act by absorbing ultraviolet radiation. Many such ultraviolet absorbers are commercially vailable, such as the Uvinul.RTM. absorbers manufactured by BASF Corporation, Parsippany, N.J.

Catalysts may also be useful, and are preferred in high density systems. Suitable catalysts include both urethane and isocyanurate reaction promoting catalysts, and are well known to those skilled in the art of polyurethanes. The presence of at least an effective amount of isocyanurate promoting catalyst is necessary. This catalyst may be purposely added, or may be present in the polyol by neutralization of the alkali metal polyoxyalkylation catalyst with a carboxylic acid. Preferred urethane catalysts are amine catalysts such as those available commercially from Air Products Chemical Company as DABCO.RTM. X-8154 and DABCO.RTM. 33LV. Preferred trimerization (isocyanurate) catalysts are metal carboxylates such as potassium 2-ethylhexanoate and potassium acetate. The latter is advantageously utilized as a 40 weight percent solution in ethylene glycol, referred to herein as KX25. The catalysts such as dibutyltindilaurate and dibutyltindiacetate are also useful urethane catalysts. mixtures of amine and tin or other catalysts may be used.

When volatile organics are used as blowing agents, traditional polyurethane system surfactants are generally necessary. Such surfactants are well known to those skilled in the art. Preferred surfactants are DC190 and DC193, silicon-containing surfactants available from Dow-Corning, Midland, Mich.

Fibrous reinforcement suitable for use with SRIM is widely varied. Both woven and non-woven (random) reinforcement, or combinations thereof, may be used. Suitable fibers are synthetic fibers of nylon, polyester, aramid, polyetheretherketones, polyethersulfones, polyimides, and the like; natural fibers such as cotton, hemp, flax, jute; and mineral or ceramic fibers including Wollastonite alumina, glass fibers, and carbon fibers. Preferred fibrous reinforcement due to its low cost and physical properties is glass fiber, either woven or nonwoven. A unique non-glass material is Colback.RTM. spunbonded nonwoven comprised of a bicomponent fiber having a polyester core and polyamide skin, available from BASF Corporation, Fibers Division, Parsippany, N.J.

One or more layers of fiber reinforcement may be used depending on the desired fiber weight. Up to 70 weight percent of the SRIM part may comprise glass fiber reinforcement. When less dense reinforcement is utilized, the weight percent of reinforcement is generally less, for example up to about 50 weight percent of the part.

In addition to layers of fibrous reinforcement, chopped fibers and other fillers may be added to the isocyanate resin side of the system, the polyol side, or both in amounts up to about 70 weight percent of the SRIM part. Both man made reinforcement such as glass fiber, carbon fiber, silicon carbide fiber, ceramics and the like may be used, or natural reinforcement such as flaked mica, jute, cellulose fiber, among others.

When smooth surface finishes are required a surfacing skin or veil may be placed in the mold prior to injection of the reactive components. An alternative method is to spray or coat the mold with a surfacing paint or coating. Smooth finishes are facilitated when tightly woven glass fabrics or highly needed random reinforcements are utilized.

In low density SRIM, the fiber reinforcement and surfacing film or fabric, if any, are laid into the mold. The mold may be shot with the intimately mixed A and B sides while open and then closed, or may be closed and shot. The heat of reaction causes volatile blowing agents to vaporize, while water blown foams result from the reaction of water with the isocyanate. Following a reaction time of from several seconds to several minutes, the part may be demolded. Generally, a mold release coating is necessary. Either external mold releases or internal mold releases may In high density SRIM, the in jection is under relatively high pressure, i.e. 170 bar. As no blowing agent is present, the resultant part is essentially noncellular. Mold temperature for both how density and high density SRIM is from 100.degree.-180.degree. F., preferably from 115.degree.-150.degree. F., and most preferably about 140.degree. F. Preferred low density SRIM systems comprise

(A) an "A side" component comprising one or more polyisocyanates;

(B) a "B side" isocyanate reactive component, comprising

(1) 60 weight percent or more of isocyanate-reactive compounds relative to the weight of component (B) which, based on the weight of component (1), comprises, (a) about 50 weight percent or more of a hydroxyl-functional tertiary amine polyol; (b) less than about 50 weight percent of an isocyanate-reactive component selected from the group consisting of (i) conventional polyoxyalkylene polyether polyols having hydroxyl numbers from 20 to about 600; (ii) polyoxyalkylated amines having free amino hydrogens; (iii) acrylonitrile/styrene graft polymer polyol dispersions; (iv) hydroxyl-functional polyester polyols having hydroxyl numbers from 20 to about 600; and (v) mixtures thereof; and (c) up to about 15 weight percent of a low molecular weight isocyanate-reactive component selected from the group consisting of (i) hydroxyl-functional chain extenders having an average functionality of about 2 and a molecular weight of less than about 150; (ii) hydroxyl-functional crosslinkers having an average functionality greater than 2 and a molecular weight of less than about 150; (iii) sterically hindered aromatic amines having a molecular weight of less than about 400; and (iv) mixtures thereof; and (2) a blowing agent selected from the group consisting of (a) volatile organic compounds; (b) water; and (c) mixtures thereof; (3) up to about 25 weight percent based on the weight of component (B) of a plasticizer; (4) an effective amount of an isocyanurate-promoting catalyst; wherein the isocyanate index of the system is from 100 to about 700, and wherein the viscosity of component (B) is less than about 1000 cp, preferably less than about 500 cp, nd most preferably less than about 300 cp.

The preferred high density SRIM systems comprise

(A) an "A Side" component comprising one or more polyisocyanates;

(B) an isocyanate reactive component, comprising

(1) 85 weight percent or more of a hydroxyl-functional tertiary amine polyol; (2) up to about 8 weight percent, based on the weight of (B), of an isocyanate-reactive component selected from the group consisting of (a) hydroxyl-functional polyoxyalkylene polyether polyols having hydroxyl numbers of from 20 to about 600; (b) hydroxyl-functional polyester polyols having hydroxyl numbers of from 20 to about 600; (c) acrylonitrile/styrene graft polymer polyol dispersions; (d) a low molecular weight isocyanate-reactive component selected from the group consisting of (i) hydroxyl-functional chain extenders having an average functionality of about 2 and a molecular weight less than about 150. (ii) hydroxyl-functional crosslinkers having an average functionality greater than 2 and a molecular weight less than 150; and (iii) mixtures thereof; (3) up to about 14 weight percent based on the weight of (B) of a sterically hindered aromatic diamine chain extender; and wherein the isocyanate index is from 100 to about 700, and wherein the viscosity of component B is less than about 500 cps. Preferably, the high density SRIM forming composition contains no plasticizer and no reactive or nonreactive liquid diluents or modifiers.

The subject invention will now be illustrated by several examples. In the examples, all parts are parts by weight.

EXAMPLES 1-7 LOW AND HIGH DENSITY SRIM FORMULATIONS

Low density SRIM formulations were prepared according to Table I. In Table I, the tertiary amine polyol is an oxypropylated ethanolamine having a hydroxyl number of about 500 and a water content of 0.05 weight percent maximum and a functionality of 2.98. Residual oxyalkylation catalyst (potassium hydroxide) was neutralized with 2-ethylhexanoic acid. Catalyst A is a 40 weight percent solution of potassium acetate in ethylene glycol, catalyst B is 50 weight percent solution of potassium acetate in ethylene glycol, catalyst C is dimethylcyclohexylamine, Catalyst D is DABCO.RTM. 33LV, while Catalyst E is DABCO x-8154. Plasticizer A is Plastolein.RTM. 9214, a plasticizer supplied by Quantum Chemical Corporation and believed to be an epoxidized fatty ester. Surfactant A is DC190, while surfactant B is DC193, both surfactants useful in formulating polyurethane foams, and which are supplied by the Dow Corning Company. Polyol A is a tertiary amine based polyol polyether polyol having a functionality of 3 and a hydroxyl number of 500. Polyol B is Dianol 2210, a polyoxypropylene glycol supplied by Akzo, having a functionality of 2 and a hydroxyl number of 280. Polyol C is SD490, a polyether polyol having a functionality of 4.4 and a hydroxyl number of 490 supplied by Alkaril Chemicals, Ltd.

Isocyanate M10 is a polymeric isocyanate having an NCO content of 32 weight percent, and a viscosity of 60 cps when measured at 25C; isocyanate M2OS is a polymeric isocyanate having an NCO content of 31.8 weight percent and a viscosity of 195 cps at 25C. Isocyanate MM103, a carbodiimide modified methylenediphenylene diisocyanate having an NCO content of 29.5 weight percent and a viscosity of 50 cps at 25C, has also been found to work well in these systems.

Material selection exclusive of fibrous reinforcement is shown in Table 1 and the parameters of use are shown in Table 2.

TABLE 1______________________________________ ExampleComponent.sup.1 1.sup.2 2.sup.3 3.sup.3 4.sup.3 5.sup.4______________________________________Polyol A 64.4 67 37.5 36 98Polyol B 4.0Polyol C 28.1 27Plasticizer A 19 18.8 22.5Glycerine 6.4 7.7 7.1 6.8Surfactant A 1.6 1.9Surfactant B 1.9 1.8Catalyst A 1.2 1.5 0.45Catalyst B 0.7Catalyst C 1.6 0.8 0.45Catalyst D 0.3Catalyst E 0.1Water 0.8 2.4 2.4 2.9CFC R11 B 20.0Carbon Black 1.5 1.9 1.9 2.0Baylith .RTM. Paste 1.0 100 100 100 100 100 wt % wt % wt % wt % wt %______________________________________ .sup.1 These components are for the resin side of the twocomponent chemical system, resin and isocyanate .sup.2 Low density SRIM coblown chemical system .sup.3 Low density SRIM water blown chemical system .sup.4 High density SRIM unblown chemical system

The results of physical testing of various systems at various resin/iso ratios and with various reinforcements types and content are give below.

TABLE 2__________________________________________________________________________ ExampleProperty 1.sup.1 2 3 4 5__________________________________________________________________________Viscosity of Resin at 25.degree. C., cp <100 150 1250 800 290Isocyanate Used with Resin M20S M20S M20S M20S M10Viscosity of Isocyanate 195 195 195 195 60at 25.degree. C., cpFoam Free Rise Density, PCF 6.25 2.75 3.20 2.75 68.6Resin/Isocyanate Ratios Used A A A A A 100/120 100/120 100/150 100/160 100/160 B B 100/150 100/170 C C 100/180 100/180__________________________________________________________________________ .sup.1 Trials A, B, C

Test plaques were produced by use of an open pour method for low density SRIM (though a closed injection method could have been used also); and test plaques were produced by use of a closed injection method for high density SRIM. Test plaques measured 21.times.21 inches (53.3.times.53.3 cm). Both fiberglass and Colback.RTM. reinforcement were utilized.

Process conditions are shown in Table 3. For low-density SRIM chemical systems, the process can be considered to be one of a foam dispersed into a reinforcement mat within an open or closed mold cavity. Initial dispersal of the system is in a period of time less than the cream time of the material and in such a fashion that the mold is only partially filled. After the inception of cream, the foam flows through the reinforcement within the closed and heated mold cavity to create or composite part that has no voids and has cured sufficiently to be handled after removal. For the high density SRIM system, the process can be considered to be one of closed injection of a non-foam dispersed into a reinforcement mat under pressure and in a period of time less than the gel time of the material. In-mold paint, in-mold coatings, in-mold fabrics, and miscellaneous hardware can be placed in the mold at the time of molding with these chemical systems. In Table 4a and 4b, the trial designations, for example 2A-1 and 2B-4 indicate by their first digit the composition of the resin/isocyanate from Table 1; by A, B, or C the isocyanate index as in Table 2; and by the last digit, the numerical trial. Thus 2B-4 is trial number 4, using the chemistry of Example 2 from Table 1 at an isocyanate index of 150.

TABLE 3______________________________________Typical Process Conditions______________________________________Dispensing Machine: Elastogran Puromat 80 typComponent Temperatures:A-Comp., Polyol Resin 73.degree. F. (23.degree. C.)B-Comp., Isocyanate 73.degree. F. (23.degree. C.)Component ImpingementMixing Pressures:A-Comp. 2200-2500 psi (150-170 bar)B-Comp. 2200-2500 psi (150-170 bar)Molded Temperature: 140.degree. F. (60.degree. C.)Demold time: 2 minutes typ. for low- density SRIM, 1 minute typ. for high-density SRIMCream time: 20 seconds typ. for low-density SRIMGel time: 10 sec. typ. for high density SRIMFree rise density: 2.8 lb/cu ft. typ. (0.04 g/cc typ.) for low-density SRIMShot rate: 0.5 lb/sec. typ. (227 g/sec typ.)Shot size: 0.8 lb typ. (363 g typ.) for low-density SRIM 1.6 lb. typ. (726 g. typ.) for high-density SRIMMold pressure: 80-100 psi typ. for low-density SRIM 200 psi typ. for high-density SRIM______________________________________ TABLE 4a__________________________________________________________________________(Plaque* Data, Blown Chemical Systems)__________________________________________________________________________ Example: 2A-1 2A-2 2A-3 2B-4 2B-5 2B-6 REINFORCEMENT OCF 8610 OCF 8610 OCF 8610 OCF 8610 OCF 8610 PUB- GLASS MAT GLASS MAT GLASS MAT GLASS MAT GLASS MAT LISHED 29.5 wt % 28.8 wt % 0 wt % 28.3 wt % 28.2 wt % 29.2 wt %PROPERTY GLASS GLASS GLASS GLASS GLASS GLASS__________________________________________________________________________Thickness (in.) FBTM 57-4 0.163 0.169 0.178 0.200 0.193 0.178Specific Gravity ASTM D104 0.344 0.344 0.187 0.306 0.300 0.312Warpage % FBTM 58-28 0 0 4 0 1 0Tensile Strength (PSI) ASTM D103 2100 2100 400 1500 1900 1500Flex Strength (PSI) ASTM D790 2800 2400 400 2300 2500 2300Flex Modulus (PSI) ASTM D790 126,000 100,000 15,000 94,000 119,000 86,000Flammability (in/min) MVSS 302 0.2 0.4 1.0 0.2 0.2 0.2Heat Distortion SAE J315 190 160 140 180 170 170(.degree.F.) (264 PSI Load)24 Hr. Water 3 3 8 2 2 2Absorption (%)Water Swell (%) SAE J315 1.9 1.2 3.5 1.7 0 1.9Dimensional Stability SAE J315Expansion, 70.degree. F., 0.1 0.1 0.1 0.2 0.3 0.224 hrs.Contraction, 190.degree. F., 0.2 0.1 0.2 0.1 0.2 0.024 hrs.Coefficient of Linear ASTM D696 4.5 .times. 10.sup.-6 4.5 .times. 10.sup.-6 1 .times. 10.sup.-5 1.5 .times. 10.sup.-6 4.5 .times. 10.sup.-6 9 .times. 10.sup.-6Thermal Expansion(in./in. .degree.F.)__________________________________________________________________________ Example: 2B-7 2B-8 2B-9 2B-10 2B-11 2B-12 REINFORCEMENT OCF 8610 COLBACK COLBACK COLBACK COLBACK COLBACK PUB- GLASS MAT N80 N100 N120 2 .times. N80 4 .times. N80 LISHED 30.4 wt % 7.9 wt % 9.7 wt % 11.4 wt % 14.8 wt 23.3 wt %PROPERTY METHOD GLASS COLBACK COLBACK COLBACK COLBACK COLBACK__________________________________________________________________________Thickness (in.) FBTM 57-4 0.142 0.182 0.159 0.173 0.184 0.165Specific Gravity ASTM D104 0.317 0.223 0.213 0.239 0.242 0.300Warpage % FBTM 58-28 0 0 0 0 0 0Tensile Strength (PSI) ASTM D103 2200 600 500 600 1600 1200Flex Strength (PSI) ASTM D790 2300 600 600 600 600 1300Flex Modulus (PSI) ASTM D790 96,000 22,000 22,000 23,000 20,000 41,000Flammability (in/min) MVSS 302 0.2 0.8 0.6 0.8 0.2 0.2Heat Distortion SAE J315 180 140 140 160 160 150(.degree.F.) (264 PSI Load)24 Hr. Water 2 3 4 4 3 2Absorption (%)Water Swell (%) SAE J315 2.2 1.0 0.5 0.5 1.5 0.5Dimensional Stability SAE J315Expansion, 70.degree. F., 0.3 0.1 0.6 0.9 0.8 0.524 hrs.Contraction, 190.degree. F., 0.0 0.3 0.3 0.1 0.2 0.124 hrs.Coefficient of Linear ASTM D696 1.5 .times. 10.sup.-6 7.3 .times. 10.sup.-6 3.0 .times. 10.sup.-6 1.5 .times. 10.sup.-6 1.5 .times. 10.sup.-6 6.0 .times. 10.sup.-6Thermal Expansion(in./in. .degree.F.)__________________________________________________________________________ Example: 2B-13 2B-14 2B-15 2B-16 2C-17* 3A** REINFORCEMENT COLBACK 5 .times. N120 COLBACK OCF 8610 OCF 8610 PUB- 1 .times. N80 10 .times. N100 GLASS MAT GLASS MAT LISHED 33.3 wt % 42.6 wt % 0 wt % 29.0 wt % 0 wt % 31 wt %PROPERTY METHOD COLBACK COLBACK COLBACK GLASS GLASS GLASS__________________________________________________________________________Thickness (in.) FBTM 57-4 0.183 0.184 0.151 0.242 0.178 0.170Specific Gravity ASTM D104 0.503 0.524 0.203 0.267 0.160 0.55Warpage % FBTM 58-28 0 0 0 0 2 --Tensile Strength (PSI) ASTM D103 2400 3200 600 1000 380 3100Flex Strength (PSI) ASTM D790 2500 3200 500 1100 520 4900Flex Modulus (PSI) ASTM D790 91,000 112,000 20,000 66,000 17,000 482,000Flammability (in/min) MVSS 302 0.2 0.2 0.4 0.4 0.5 Self ExtinguishHeat Distortion SAE J315 160 170 150 200 148 --(.degree.F.) (264 PSI Load)24 Hr. Water 1 2 3 2 1.8 --Absorption (%)Water Swell (%) SAE J315 1.4 2.0 2.8 2.1 6.9 --Dimensional Stability SAE J315Expansion, 70.degree. F., 0.6 0.3 1.0 0.1 1.2 --24 hrs.Contraction, 190.degree. F., 0.1 0.2 0.2 0.4 0.2 --24 hrs.Coefficient of Linear ASTM D696 1.5 .times. 10.sup.-6 4.5 .times. 10.sup.-6 1.5 .times. 10.sup.-6 9.0 .times. 10.sup.-6 9.1 .times. 10.sup.-6 --Thermal Expansion(in./in. .degree.F.)__________________________________________________________________________ Example: 3B** 3C** 4A-1** 4A-2* 4A-3* REINFORCEMENT OCF 8610 OCF 8610 OCF 8610 OCF 8610 OCF 8610 PUB- GLASS MAT GLASS MAT GLASS MAT GLASS MAT GLASS MAT LISHED 31 wt % 31 wt % 24.4 wt % 27.0 wt % 31.0 wt %PROPERTY METHOD GLASS GLASS GLASS GLASS__________________________________________________________________________Thickness (in.) FBTM 57-4 0.150 0.160 0.103 0.106 0.105Specific Gravity ASTM D104 0.55 0.55 0.716 0.841 0.553Warpage % FBTM 58-28 -- -- 0.4 0.4 0.01Tensile Strength (PSI) ASTM D103 3000 3200 8700 10,400 5400Flex Strength (PSI) ASTM D790 4100 2800 12,000 11,000 8800Flex Modulus (PSI) ASTM D790 163,000 100,000 453,000 413,000 387,000Flammability (in/min) MVSS 302 Self Self Self Self Self Extinguish Extinguish Extinguish Extinguish ExtinguishHeat Distortion SAE J315 -- -- -- -- --(.degree.F.) (264 PSI Load)24 Hr. Water -- -- -- -- --Absorption (%)Water Swell (%) SAE J315 -- -- -- -- --Dimensional Stability SAE J315Expansion, 70.degree. F., -- -- 0.04 0.04 0.0324 hrs.Contraction, 190.degree. F., -- -- 0.04 0.04 0.0124 hrs.Coefficient of Linear ASTM D696 -- -- -- -- --Thermal Expansion(in./in. .degree.F.)__________________________________________________________________________ *21" .times. 21 **Notched Izod Impacts 5.26-5.52 ftlb/in TABLE 4b__________________________________________________________________________(Plaque* Data, Unblown Chemical Systems**)__________________________________________________________________________ Example: 5A-1 5A-2 5A-3 5A-4 5A-5 5A-6 REINFORCEMENT NICO 751 NICO 751 NICO 751 OCF 8610 OCF 8610 PUB- GLASS MAT GLASS MAT GLASS MAT GLASS MAT GLASS MAT LISHED 15.6 wt % 25.9 wt % 34.0 wt % 0 wt % 11.3 wt % 20.1 wt %PROPERTY METHOD GLASS GLASS GLASS GLASS GLASS GLASS__________________________________________________________________________Thickness (in.) 0.125 0.125 0.125 0.125 0.125 0.125Flex Modulus (PSI) ASTM D790 240,000 800,000 770,000 330,00 630,000 830,000Flex Strength (PSI) ASTM D790 7100 21,900 20,100 9200 13,800 20,700Tensile Strength (PSI) ASTM D103 7600 12,300 15,900 7000 7100 10,800Izod Impact 5.5 -- 10.0 0.28 4.4 5.6(Notched) (ft-lb/in.)Heat Distortion 246 312 327 190 206 315(.degree.F.) (264 PSI Load)__________________________________________________________________________ Example: 5A-7 5A-8 5A-9 5A-10 5A-11 REINFORCEMENT OCF 8610 GLASS MAT w/ COLBACK N120 BOTH OCF 8610 SIDES OF THE GLASS COLBACK COLBACK COLBACK GLASS MAT MAT N120 MAT N120 MAT N120 MAT PUBLISHED 28.0 wt % 28.0 wt % GLASS 3.7 wt % 14.9 wt 26.8 wt %PROPERTY METHOD GLASS 8.7 wt % COLBACK COLBACK COLBACK COLBACK__________________________________________________________________________Thickness (in.) 0.125 0.125 0.125 0.125 0.125Flex Modulus (PSI) ASTM D790 933,000 320,000 320,000 360,000 418,000Flex Strength (PSI) ASTM D790 24,200 9400 8500 10,000 11,200Tensile Strength (PSI) ASTM D103 18,600 21,300 5500 6600 7500Izod Impact (Notched) 8.7 8.8 0.37 2.18 3.20(ft-lb/in.)Heat Distortion (.degree.F.) 325 321 178 196 193(264 PSI Load)__________________________________________________________________________ Unblown Density = 70 lb/ft.sup.3 *21" .times. 21 **However, the entrainment of air may occur during the molding process

Claims

1. A rigid polyurethane-polyisocyanurate low density structural RIM composite with a density of less than 1.0 g/cm.sup.3, having a matrix comprising:

(A) an "A side" component comprising one or more polyisocyanate;

(B) a "B side" isocyanate reactive component comprising 60 weight percent or more relative to the weight of the (B) component of isocyanate reactive compounds comprising a minimum of about 50 weight percent of hydroxyl-functional tertiary amine polyols; and

containing a reinforcement of a spunbonded nonwoven material comprised of a bicomponent fiber having a polyester core and polyamide skin.

2. The composite of claim 1, further containing fiberglass reinforcement.

3. The composite of claim 2, wherein spunbonded nonwoven material is located adjacent to both sides of said fiberglass reinforcement.

4. The composite of claim 1, wherein more than one layer of said spunbonded nonwoven material is contained in said matrix.

5. The composite of claim 1, wherien said spunbonded nonwoven material comprises up to 50 weight percent of the composite.

6. A rigid high density polyurethane-polyisocyanurate structural RIM composite with a density greater than 1.0 g/cm.sup.3, having a matrix comprising:

(A) an "A side" component comprising one or more polyisocyanates;

(B) a "B side" isocyanate reaction component comprising at least 85 weight percent or more of a hydroxyl-functional tertiary amine polyol; and

containing a reinforcement of a spunbonded nonwoven material comprised of a bicomponent fiber having a polyester core and a polyamide skin.

7. The composite of claim 6, further containing fiberglass reinforcement.

8. The composite of claim 7, wherein spunbonded nonwoven material is located adjacent to both sides of said fiberglass reinforcement.

9. The composite of claim 6, wherein more than one layer of said spunbonded nonwoven material is contained in said matrix.

10. The composite of claim 6, wherein said spunbonded nonwoven material comprises up to 42.6 weight percent of the composite.