Methods for making compositions for making thermoplastic aliphatic urethane/urea elastomers, which are in turn used to make molding compositions used in forming molded articles, particularly, shells for automotive applications. The molding compositions comprise an aliphatic thermoplastic urethane/urea elastomer and a polyolefin-based modifier. These compositions may be used to form a powder, pellets, microspheres or minibeads which may then be cast to form air bag door and instrument panel cover skins which may meet automotive deployment and weathering requirements.

New stretchable electrically conductive composite materials comprising at least one polymer and a plurality of nanoparticles are provided, which exhibit high conductivity even at high strain levels. The composite may comprise polyurethane as the polymer and spherical gold nanoparticles. Such materials have conductivity levels as high as 11,000 Scm.sup.1 at 0% strain and 2,400 Scm.sup.1 at 110% strain. Furthermore, certain embodiments of the composite have a maximum tensile strain of 480% while still exhibiting conductivity of 35 Scm.sup.1. The inventive materials are highly flexible, highly conductive and suitable for a variety of applications, especially for advanced medical devices, implants, and flexible electronics. The disclosure also provides methods of making such stretchable electrically conductive nanocomposites, including formation by layer-by-layer and vacuum assisted flocculation. In certain embodiments, stretchable chiral plasmonic composite materials for use as optic devices and methods for making them are provided.

Co-cured urethane and vinyl ester, epoxy, or unsaturated polyester gel coats having improved toughness and flexibility compared with conventional polyester gel coats are disclosed. The gel coats, which have 10-50 wt. % urethane content, adhere well to structural layers and can be used in a traditional in-mold process. Co-cured elastomeric coatings comprising from 50 to 95 wt. % of a urethane component and an unsaturated polyester, epoxy, or vinyl ester are also disclosed. Unlike conventional urethane coatings, the elastomeric coatings adhere well to structural layers and can be used in a traditional in-mold process. Castings or structural layers comprising a reinforced thermoset of co-cured urethane and vinyl ester, epoxy, or unsaturated polyester components, including 10-95 wt. % of the urethane component, are also described. The invention includes in-mold processes for making laminates that utilize the gel coats, elastomeric coatings, and/or structural layers. The in-mold process gives flexible, durable, urethane-containing laminates having good interlayer adhesion.

An erosion resistant article such as rotor blades for helicopters and wind turbines having the leading edge surface protected from damage from high speed impingement of rain or sand with a protective coating formed from specific polyurethane or polyurea coating having a defined set of minimum physical properties where the protective coating can be applied as a liquid coating and cured in place or as a preformed complementary shaped covering to protect the leading edge against erosion damage in service.

Co-cured urethane and vinyl ester, epoxy, or unsaturated polyester gel coats having improved toughness and flexibility compared with conventional polyester gel coats are disclosed. The gel coats, which have 10-50 wt. % urethane content, adhere well to structural layers and can be used in a traditional in-mold process. Co-cured elastomeric coatings comprising from 50 to 95 wt. % of a urethane component and an unsaturated polyester, epoxy, or vinyl ester are also disclosed. Unlike conventional urethane coatings, the elastomeric coatings adhere well to structural layers and can be used in a traditional in-mold process. Castings or structural layers comprising a reinforced thermoset of co-cured urethane and vinyl ester, epoxy, or unsaturated polyester components, including 10-95 wt. % of the urethane component, are also described. The invention includes in-mold processes for making laminates that utilize the gel coats, elastomeric coatings, and/or structural layers. The in-mold process gives flexible, durable, urethane-containing laminates having good interlayer adhesion.

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

The laminate according to the invention is a multiple layer structure and contains predominantly urethane-based polymeric materials in the cap and base layers thereof, with no significant amount of PVC. As such, under combustion conditions, the laminate releases substantially no harmful halogen-based bases, such as HCl or other toxic gases, and exhibits toxicity and smoke generation parameters well below acceptable industry standards.

Photochromic polyurethane laminates and methods for the formation of same wherein a photochromic polyurethane layer of the laminate is interposed between two primer coated transparent resin sheets.

The laminate according to the invention is a multiple layer structure and contains predominantly urethane-based polymeric materials in the cap and base layers thereof, with no significant amount of PVC. As such, under combustion conditions, the laminate releases substantially no harmful halogen-based bases, such as HCl or other toxic gases, and exhibits toxicity and smoke generation parameters well below acceptable industry standards.

Photochromic polyurethane laminates and methods for the formation of same wherein a photochromic polyurethane layer of the laminate is interposed between two primer coated transparent resin sheets.