High viscosity, solvent resistant, thermoset polyetherpolyurethane and A process for making the same

Abstract

A high viscosity, solvent-resistant, thermoset polyetherpolyurethane molded article that includes a methylene-bridged polyarylpolyisocyanate component and a polyether polyol solution combined in catalytic urethane-forming reaction where the polyether polyol solution of the urethane-forming reaction includes a diol first component, a polyether polyol second component, a polyether polyol third component, and a polymer polyol fourth component having a nonaqueous dispersant stabilizer.

What is claimed is: 
     
       1. A high viscosity, solvent-resistant, thermoset polyetherpolyurethane comprising: a methylene-bridged polyarylpolyisocyanate component and a polyether polyol solution combined in catalytic urethane-forming reaction where the polyether polyol solution of the urethane-forming reaction includes a diol first component from about 2% to about 20% by weight of the polyether polyol solution having a molecular weight from about 75 to about 200; a polyether polyol second component from about 0% to about 75% by weight of the polyether polyol solution having no oxyethylene groups, a functionality greater than 2 and a hydroxyl number from about 30 to about 60; a polyether polyol third component from about 0% to about 75% by weight of the polyether polyol solution having no oxyethylene groups, a functionality greater than 2 and a hydroxyl number from about 170 to about 110; and a polymer polyol fourth component, from about 80% to about 10% by weight of the polyether polyol solution having a hydroxyl number from about 20 to about 100 and having a nonaqueous dispersant stabilizer.   
     
     
       2. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 1, wherein the functionality of the polyether polyol second component is 3 and the functionality of the polyether polyol third component is 3. 
     
     
       3. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 1, wherein the polyether polyol second component is a polyether triol ranging from about 10% to about 40% by weight of the polyether polyol solution and having a hydroxyl number ranging from about 50 to about 60 and the polyether polyol third component is a polyether triol ranging from about 10% to about 40% by weight of a polyether polyol solution and having a hydroxyl number of about 110 and to about 120 and the polymer polyol fourth component ranging from about 70% to about 30% of the polymer polyol wherein the polymer polyol includes styrene, acrylonitrile, and polyether polyol. 
     
     
       4. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 3, wherein the diol first component is 1,4 butanediol. 
     
     
       5. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 3, wherein the diol first component comprises from about 2% to about 20% butanediol. 
     
     
       6. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 1, wherein the polyether polyol solution includes a pigment. 
     
     
       7. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 1, wherein the catalyst includes dibutyltin dilaurate. 
     
     
       8. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 1, wherein the catalyst includes triethylenediamine. 
     
     
       9. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 1, wherein the catalyst includes a mixture of dibutyltin dilaurate and triethylenediamine. 
     
     
       10. The high viscosity, solvent-resistant, thermoset polyetherpolyurethane of claim 1, wherein styrene is from about 15% to about 35% by weight of the polymer polyol fourth component and acrylonitrile is from about 10% to about 20% by weight of the polymer polyol fourth component and polyether polyol is from about 75% to about 45% by weight of the polymer polyol fourth component with the acrylonitrile and styrene polymerized together. 
     
     
       11. A method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane comprising the steps of: mixing a diol first component from about 2% to about 20% by weight of a polyether polyol solution having a molecular weight from about 75 to about 200 with a polyether polyol second component from about 0% to about 75% by weight of the polyether polyol solution having no oxyethylene groups, a functionality greater than 2 and a hydroxyl number from about 30 to about 60 with a polyether polyol third component from about 0% to about 75% by weight of the polyether polyol solution having no oxyethylene groups, a functionality greater than 2 and a hydroxyl number from about 170 to about 110 with a polymer polyol fourth component, from about 80% to about 10% by weight of the polyether polyol solution having a hydroxyl number from about 20 to about 100 and having a nonaqueous dispersant stabilizer, to form a polyether polyol solution;   mixing a methylene-bridged polyarylpolyisocyanate component and the polyether polyol solution with a catalyst forming a polyetherpolyurethane; and   discharging the polyetherpolyurethane into a heated mold.   
     
     
       12. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the functionality of the polyether polyol second component is 3 and the polyether polyol third component is 3. 
     
     
       13. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the polyether polyol second component is a polyether triol ranging from about 10% to about 40% by weight of the polyether polyol solution and having a hydroxyl number ranging from about 50 to about 60 and the polyether polyol third component is a polyether triol ranging from about 10% to about 40% by weight of a polyether polyol solution and having a hydroxyl number of about 110 and to about 120 and the polymer polyol fourth component ranging from about 70% to about 30% of the polymer polyol wherein the polymer polyol includes styrene, acrylonitrile, and polyether polyol. 
     
     
       14. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the diol first component is 1,4 butanediol. 
     
     
       15. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the diol first component of the urethane forming reaction comprises from about 2% to about 20% butanediol. 
     
     
       16. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the polyether polyol solution includes a pigment. 
     
     
       17. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the catalyst includes dibutyltin dilaurate. 
     
     
       18. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the catalyst includes triethylenediamine. 
     
     
       19. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein the catalyst is a mixture of dibutyltin dilaurate and triethylenediamine. 
     
     
       20. The method for molding a high viscosity, solvent-resistant, thermoset polyetherpolyurethane as defined in claim 11, wherein styrene is from about 15% to about 35% by weight of the polymer polyol fourth component and acrylonitrile is from about 10% to about 20% by weight of the polymer polyol fourth component and polyether polyol is from about 75% to about 45% by weight of the polymer polyol fourth component with the acrylonitrile and styrene polymerized together.