Elastomeric urethane composition

Abstract

An elastomeric urethane composition that is substantially free of particulates includes the reaction product of a resin composition, including a polyetherol, and an isocyanate. The resin composition and the isocyanate are reacted, in the presence of a catalyst, to form a polyurethane elastomer. The catalyst includes a metal selected from the group of titanium, zirconium and hafnium. The elastomeric urethane composition is used in a method of making an article in a mold. The method includes reacting the resin composition and the isocyanate to form the elastomeric urethane composition, applying the elastomeric urethane composition to the mold cavity, and allowing the elastomeric urethane composition to cure to form a first layer. The method also includes applying a urethane composition, different from the elastomeric urethane composition, to the mold to form a second layer. The method further includes curing the article in the mold and de-molding the article from the mold.

Description

FIELD OF THE INVENTION[0001]The present invention generally relates to an elastomeric urethane composition used to form a polyurethane elastomer. The invention also relates to a method of forming an article that is formed from the elastomeric urethane composition. More specifically, the present invention relates to an elastomeric urethane composition that includes the reaction product of a resin composition and an isocyanate, in the presence of a catalyst.DESCRIPTION OF THE RELATED ART[0002]Various elastomeric urethane compositions have been investigated for use in industrial processes to form polyurethane elastomers. Polyurethane elastomers are non-foamed and can be used in a wide variety of applications including in both automotive and non-automotive supplies. Polyurethane elastomers include the reaction product of a polyol and an isocyanate reactive with the polyol. In the past, unsuccessful efforts have been made to reduce production costs associated with formation of the polyur...

AI Technical Summary

Benefits of technology

[0012]Particulates, which are not as widely produced as polyetherols and isocyanates, are known to be more expensive than polyetherols and isocyanates. The present invention does not require spending money on the particulates which decreases overall production costs of producing the polyurethane elastomer. The resin composition and the elastomeric urethane composition is homogeneous. The homogeneity of the resin composition and the elastomeric urethane composition allows the polyurethane elastomer to have an excellent roller fatigue resistance (i.e., an increased resiliency) when subjected to roller fatigue testing. The roller fatigue resistance of the polyurethane elastomer increases marketability of the polyurethane elastomer. The homogeneity of the resin composition and the elastomeric urethane composition also allows the resin composition and the elastomeric urethane composition to be used by a customer with great ease and with a reduced chance that settling will occur within the resin composition that would require mixing. Ease of use of the elastomeric urethane composition increases marketability.

[0013]The catalyst, including the metal selected from the group of titanium, zirconium and hafnium, has a high catalytic efficiency for the reaction of the polyetherol and the isocyanate. The high catalytic efficiency increases the rate of the reaction. As a result, the elastomeric urethane composition can be sprayed while minimizing dripping that accompanies spraying the polyetherol and isocyanate, when these components are not reacted or when these components are reacting slowly. When dripping is minimized, the elastomeric urethane composition is used more efficiently, thereby further reducing production costs. An increased rate of reaction also allows the polyurethane elastomer formed from the elastomeric urethane composition to be de-molded in a short period of time further reducing production costs associated with time spent waiting for de-molding.

[0014]The catalyst also has decreased sensitivity to water and humidity present in the reaction vessel and is, therefore, not deactivated when exposed to water and humidity. The water in the reaction vessel does not have to be removed. Also, less catalyst is required for use in the reaction and costs, therefore, are reduced.

[0015]The catalyst also does not effectively catalyze the undesired side reaction of water and humidity with the isocyanate that forms gaseous carbon dioxide. As such, the polyurethane elastomer has structural integrity and sufficient density. The catalyst also does not include highly toxic metals such as tin and mercury. As a result, the catalyst does not require costly disposal, still further decreasing potential production costs.

Problems solved by technology

In the past, unsuccessful efforts have been made to reduce production costs associated with formation of the polyurethane elastomers.

The production costs include money spent on raw materials, costs for controlling an amount of water in the raw materials and humidity of the production area to ensure an efficient cure of the polyurethane elastomer, and time expended on inefficient reactions of the polyol and the isocyanate.

As is well known in the art, the reaction of the polyol and the isocyanate typically proceeds slowly, thereby decreasing a cost effectiveness of the reaction.

Although effective, these catalysts are highly toxic and require expensive disposal, further contributing to production costs.

Many of these catalysts not only increase the rate of the reaction of polyol and the isocyanate, but also catalyze a reaction of the isocyanate and any water and humidity present in the reaction vessels, which is undesirable.

The formation of gaseous carbon dioxide leads to formation of voids and blisters in the polyurethane elastomer which decrease structural integrity and density of the polyurethane elastomer.

As such, production costs associated with forming the polyurethane elastomers are also high due to the need for removing water from the raw materials and humidity from the production area.

Many of these catalysts also deactivate when exposed to water and humidity.

Consequently, use of more catalyst increases production costs.

However, addition of particulates to the polyol and / or the isocyanate, although useful for absorbing water and humidity and for decreasing formation of the gaseous carbon dioxide, is expensive and increases production costs.

Addition of particulates may also weaken structural stability and decreases roller fatigue resistance of the polyurethane elastomer.

Particulates may also disrupt a uniformity of the volume, mass, and density of the elastomeric urethane compositions, resulting in inconsistencies in homogeneity, texture, and durability of the polyurethane elastomers.

Inconsistencies in the durability may cause the elastomeric urethane composition to break down when subjected to environmental stresses such as changes in temperature and pressure, thereby decreasing marketability and usability.

Although the '686 patent discloses useful advances in catalyst technology, the '686 patent does not disclose a reduction of particulates present in the polyol and / or isocyanate as a way to reduce production costs or to improve durability, roller fatigue resistance, usefulness and marketability of the polyurethane elastomer.

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