PROCESS FOR PRODUCING FIBER COMPOSITE MATERIAL USING HYBRID POLYOL

Abstract

Provided herein is a process for producing fiber composite materials which includes mixing an isocyanate component A and a polyol component B to afford a reaction mixture, impregnating fibers with the reaction mixture and the curing the impregnated fibers, wherein the polyol component B includes the alkoxylation product of a mixture of fat-based alcohol (i) and at least one OH-functional compound having aliphatically bonded OH groups and an OH functionality of 2 to 4 which is not a fat-based alcohol (ii). The present compound further relates to a fiber composite material obtainable by such a process and using the fiber composite material as a mast.

Claims

1. A process for producing fiber composite materials which comprises: mixing an isocyanate component A and a polyol component B to afford a reaction mixture, impregnating fibers with the reaction mixture, and curing the impregnated fibers, wherein the polyol component B comprises the alkoxylation product of a mixture comprising (i) at least one fat-based alcohol and (ii) at least one OH-functional compound having aliphatically bonded OH groups and an OH functionality of 2 to 4 that is not a fat-based alcohol.

2. The process according to claim 1, wherein alkoxylation to produce the alkoxylation product of the mixture comprising (i) at least one fat-based alcohol and (ii) at least one OH-functional compound having aliphatically bonded OH groups and an OH functionality of 2 to 4 that is not a fat-based alcohol is carried out using at least one of a nucleophilic and a basic catalyst and at least one alkylene oxide.

3. The process according to claim 1, wherein the fat-based alcohol comprises castor oil.

4. The process according to claim 1, wherein the alkylene oxide comprises propylene oxide.

5. The process according to claim 1, wherein the OH-functional compound comprises 3 OH groups.

6. The process according to claim 1, wherein the OH-functional compound is at least one of glycerol and trimethylolpropane.

7. The process according to claim 1, wherein an OH number of the alkoxylation product of the mixture of (i) at least one fat-based alcohol and (ii) at least one OH-functional compound having aliphatically bonded OH groups and an OH functionality of 2 to 4 is 300 to 600 mg KOH/g.

8. The process according to any of claim 1, wherein a viscosity of the alkoxylation product of the mixture of (i) at least one fat-based alcohol and (ii) at least one OH-functional compound having aliphatically bonded OH groups and an OH functionality of 2 to 4 is less than 1500, measured according to DIN 53019.

9. The process according to claim 1, wherein a proportion of (i) the at least one fat-based alcohol is 10% to 90% by weight and a proportion of (ii) the at least one OH-functional compound having aliphatically bonded OH groups and an OH functionality of 2 to 4 is 90% to 10% by weight in each case based on the total weight of the components (i) and (ii).

10. The process according to claim 1, wherein the fibers employed are endless fibers of glass or carbon fiber.

11. The process according to claim 1, wherein the proportion of fiber material is 30% to 90% by weight based on the total weight of the fiber composite material.

12. The process according to claim 1, wherein the isocyanate component A comprises a mixture of monomeric diphenylmethane diisocyanate and higher-nuclear diphenylmethane diisocyanate.

13. The process according to claim 1, wherein the impregnated fibers are wound up before curing.

14. A fiber composite material obtainable by a process according to claim 1.

15. A method of using the fiber composite material according to claim 14, wherein the method comprises: utilizing the fiber composite material as one of a mast and a pipe.

Description

POLYOL SYNTHESIS EXAMPLES 1

Polyol Synthesis Example 1 (Synthesis 1)

[0049] 94 kg of glycerol, 0.040 kg of aqueous imidazole solution (50% by weight) and 118.0 kg of castor oil (FSG quality) were initially charged into a 600 L reactor at 25 C. This was then inertized with nitrogen. The vessel was heated to 150 C. and 188.0 kg of propylene oxide were added. After a reaction time of 10 h the reactor was evacuated for 40 minutes under complete vacuum at 100 C. and then cooled down to 25 C. 392.0 kg of product were obtained.

[0050] The obtained polyether ester had the following characteristics: [0051] OH number: 483 mg KOH/g [0052] Viscosity (25 C.): 775 mPas [0053] Acid number: 0.03 mg KOH/g [0054] Water content: 0.03% by weight

[0055] Polyols having identical hydroxyl numbers were produced by mixing the recited polyols with water scavengers and defoamers according to table 1. These were mixed with Iso 1 at an isocyanate index of 120 to afford a reaction mixture from which polyurethane test sheets having dimensions of 2003002 mm were cast. It was found that for identical OH numbers the hardness, flexural strength, flexural elastic modulus, tensile strength and tensile elastic modulus of the test sheet were markedly improved using the hybrid polyol. The open time of the reaction mixture was also approximately doubled from 21.5 minutes to 40 minutes when using the hybrid polyol.

TABLE-US-00001 TABLE 1 Polyol Hybrid mixture polyol Polyol 1 49.8 Water scavenger 5 5 Defoamer 0.2 0.2 Polyol 3 94.8 Polyol 2 45 100 100 OHN of polyol component 462.09 464.52 Iso 1 X X Hardness [Shore D] 79 81 Flexural strength [MPa] 86 115 Flexural elastic modulus [MPa] 1937 2521 Elongation [MPa] 66 81 Elongation at break [%] 9.1 8.5 Elongation elastic modulus 2210 3005 Tg (DSC) Open time (Geltimer) [min] 21.5 40