Polyurethane Compositions and Articles Prepared Therefrom, and Methods for Making the Same

Abstract

The invention provides a composition comprising the following: at least one olefin multi-block interpolymer, at least one thermoplastic polyurethane, and at least one polydiene-based and / or polydiol-based polyurethane. These compositions are well-suited for promoting the adhesion between polar (for example, polyester, polycarbonate and polylactic acid) and non-polar materials and for the manufacture of, among other things, films, fibers, sheets and tie layers, tubes, adhesives, dispersions, protective apparel, footwear, coatings, laminates and foams.

Description

REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Application No. 60 / 863,887, filed on Nov. 1, 2006, and U.S. Provisional Application No. 60 / 894,353, filed on Mar. 12, 2007, and U.S. Provisional Application No. 60 / 952,254, filed on Jul. 27, 2007, and U.S. Provisional Application No. 60 / 952,266, filed on Jul. 27, 2007; each application is fully incorporated herein by reference.FIELD OF INVENTION[0002]The invention provides polyurethane compositions comprising the following: a) at least olefin multi-block interpolymer; b) at least one thermoplastic polyurethane; and c) at least one polydiene- or polydiol-based polyurethane.[0003]Polyolefins, as a class of materials, have relatively poor adhesion and compatibility with more polar polymeric materials. In most cases, a separate adhesive is required in order to adhere polyolefins to polar substrates like polyesters, polyamides, polyurethanes, and the like. Similarly, a third component compatibi...

AI Technical Summary

Problems solved by technology

Polyolefins, as a class of materials, have relatively poor adhesion and compatibility with more polar polymeric materials.

However significant amounts of compatibilizers are usually required to maintain the intimate blend of the polyolefin and polyurethane.

Moreover, the gloss of the material must remain low over the vehicle life-time.

The glass transition temperature (Tg) of plasticized polyvinyl chloride is typically −20° C. to −30° C., and thus, this polymer has impaired cold temperature impact properties at temperatures lower than its Tg.

Thermoplastic polyolefins also have better long-term durability compared to flexible polyvinyl chloride, as shown by little change in Theological and / or mechanical properties upon heat aging at 120° C. At 120° C., polyvinyl chloride typically loses plasticizer, and therefore loses elongation (elasticity), and becomes brittle and prone to cracking.

Thermoplastic polyolefins, due to their nonpolar nature, generally lack adhesion to polar materials, such as polyurethanes.

A discontinuous application of a primer solution may lead to the formation of voids between the thermoplastic olefin skin and polyurethane foam in areas that lack the primer.

Surface voids are a costly problem for automotive parts manufacturers, since parts that have surface voids cannot be used in an automotive assembly, and are instead scraped.

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