Abstract: A fiber-reinforced layer comprises A) a urethane polyacrylate and B) a fiber component. The urethane polyacrylate comprises the polymerization product of an acrylate component and a urethane acrylate. The urethane acrylate is the reaction product of an isocyanate component and a stoichiometric excess of the acrylate component. The isocyanate component has at least two isocyanate groups. The acrylate component has at least one functional group that is reactive with at least one of the isocyanate groups. The fiber component includes fibers having a length of less than or equal to about 0.25 inches present in an amount of at least 10 parts by weight based on 100 parts by weight of the fiber component. Rolling of the fiber-reinforced layer is unnecessary during making of the fiber-reinforced layer due to the presence of the fiber component and urethane polyacrylate in the fiber-reinforced layer and excellent physical properties are obtained even without rolling.

Abstract: An elastomeric urethane composition includes the reaction product of a resin composition, including a polyol, and an isocyanate. The resin composition and the isocyanate are reacted, in the presence of a first and a second catalyst, to form a polyurethane elastomer. The first catalyst includes a metal selected from the group of iron, titanium, zirconium and hafnium. The second catalyst includes an amine. The elastomeric urethane composition may be used in a method of making an article. The method includes reacting the resin composition and the isocyanate to form the elastomeric urethane composition, applying the elastomeric urethane composition to a 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, curing the article in the mold, and de-molding the article from the mold.

Abstract: A urethane acrylate composition includes a resin system and a catalyst system. The resin system includes a urethane acrylate adduct including a reaction product of an isocyanate component and a functionalized acrylate reactive with the isocyanate component. The resin system also includes a first metal salt and a peroxide. The catalyst system includes a second metal salt and an accelerator selected from the group of anilines, amines, amides, pyridines, and combinations thereof. The catalyst system catalyzes a free-radical reaction of the urethane acrylate composition. The resin and catalyst systems may be used in a method of making a composite structure in a mold. The method includes applying a first layer and the urethane acrylate composition to the mold. The method further includes curing the structure in the mold and demolding the structure from the mold.

Abstract: A urethane acrylate composition includes a resin system and a catalyst system. The resin system includes a urethane acrylate adduct including a reaction product of an isocyanate component and a functionalized acrylate reactive with the isocyanate component. The resin system also includes a first metal salt and a second metal salt. The catalyst system includes a peroxide. The catalyst system catalyzes a free-radical reaction of the urethane acrylate composition. The resin and catalyst systems may be used in a method of making a composite structure in a mold. The method includes applying a first layer and the urethane acrylate composition to the mold. The method further includes curing the structure in the mold and demolding the structure from the mold.

Abstract: A urethane acrylate composite structure includes a first layer that is a show surface of the urethane acrylate composite structure and a support layer. The support layer includes a urethane acrylate composition that includes a urethane acrylate adduct. The urethane acrylate adduct is the reaction product of an isocyanate component and a stoichiometric excess of a functionalized acrylate component. The isocyanate component includes toluene diisocyanate and polymeric polyphenylmethane polyisocyanate. The functionalized acrylate component is reactive with the isocyanate component. The urethane acrylate composition exhibits improved viscosity due to the isocyanate component. The combination of the toluene diisocyanate and the polymeric polyphenylmethane polyisocyanate results in the improved viscosity of the urethane acrylate composition while maintaining excellent resin curing and finished composite structure properties.

Abstract: A composite article includes an acrylic layer, a UV-cured layer formed from a UV-curable composition, and a polyurethane backing layer. A method of forming the composite article includes applying the UV-curable composition to the acrylic layer such that the composition is between the acrylic layer and the polyurethane backing layer to enhance bonding between these layers. The UV-curable composition includes at least one monomer which is an ethylenically unsaturated methacrylate monomer, an ethylenically unsaturated acrylate monomer, or both. The at least one monomer has a hydroxy functional group. The monomer is compatible with the acrylic layer and the hydroxy functional group of the monomer is reactive with a polyisocyanate from the polyurethane backing layer. The UV-curable composition also includes a curing initiator that is reactive with the monomer. Upon exposure of the UV-curable composition to UV electromagnetic radiation, the curing initiator enables the composition to cure to the acrylic layer.

Abstract: A composite structure including a first layer, comprising a styrenated polyester, and a polyurethane layer is disclosed. The first layer is a show surface of the composite structure. The polyurethane layer is the reaction product of a resin component and a stochiometric excess of polyisocyanate relative to the polyol. The resin component includes a polyol having a propylene oxide cap of at least 80 percent by weight.

Abstract: The subject invention discloses a composite structure and a resin component for use in the composite structure. The composite structure includes a first layer, comprising a styrenated unsaturated polyester, and a second layer. The first layer is a show surface of the composite structure. The second layer includes the reaction product of the resin component and an isocyanate component. The resin component includes an isocyanate-reactive component, an amine-based catalyst, and a temperature-activated catalyst that is different from the amine-based catalyst. The amine-based catalyst is active at ambient temperature for initiating an exothermic reaction between the isocyanate component and the resin component thereby establishing a reaction temperature greater than the ambient temperature. The temperature-activated catalyst is active at the reaction temperature for completing a cure of the isocyanate component with the resin component.

Abstract: A composite structure includes a first layer and a support layer. The first layer is a show surface of the composite structure and is preformed from a polymer. The support layer includes a urethane acrylate composition that includes a urethane acrylate adduct. The urethane acrylate adduct is the reaction product of an isocyanate component and a stoichiometric excess of a functionalized acrylate component. The isocyanate component has at least two isocyanate groups. The functionalized acrylate component has at least one isocyanate-reactive functional group that is reactive with at least one of the isocyanate groups for forming the urethane acrylate adduct. The urethane acrylate composition also includes a catalyst system including a peroxide and a first metal salt. The resulting urethane acrylate composition is sufficiently low in viscosity for many processing applications, and the support layer including the urethane acrylate composition exhibits sufficient adhesion to the first layer.

Abstract: A composite structure includes a first layer, a support layer, and a urethane acrylate layer disposed between the first layer and the support layer. The first layer is a show surface of the composite structure. The urethane acrylate layer includes a urethane acrylate composition that includes a urethane acrylate adduct. The urethane acrylate adduct is the reaction product of an isocyanate component and a stoichiometric excess of a functionalized acrylate component. The isocyanate component has at least two isocyanate groups. The functionalized acrylate component has at least one isocyanate-reactive functional group that is reactive with at least one of the isocyanate groups for forming the urethane acrylate adduct. The resulting urethane acrylate composition is sufficiently low in viscosity for many processing applications, and the urethane acrylate layer including the urethane acrylate composition exhibits sufficient adhesion to the first layer and support layer.

Abstract: A method of producing a urethane acrylate that is the reaction product of an isocyanate component and a functionalized acrylate component includes charging a reactor with the functionalized acrylate component. An inhibitor is combined with the functionalized acrylate component. The isocyanate component and the functionalized acrylate component are reacted together in the presence of the inhibitor to produce the urethane acrylate. A reaction temperature is maintained at less than 60° C. in the reactor throughout the step of reacting the isocyanate component with the functionalized acrylate component. The urethane acrylate exhibits excellent stability over time.

Abstract: The subject invention discloses a composite structure comprising a first layer and a support layer. The first layer is a show surface of the composite structure. The support layer includes a urethane acrylate that is the reaction product of an isocyanate component and a stoichiometric excess of an acrylate component. The isocyanate component has at least two isocyanate groups, which provide polymeric functionality to the urethane acrylate. The acrylate component has at least one functional group that is reactive with at least one of the isocyanate groups for forming the urethane acrylate.

Abstract: A urethane acrylate composition includes a urethane acrylate adduct. The urethane acrylate adduct is the reaction product of an isocyanate component and a stoichiometric excess of a functionalized acrylate component. The functionalized acrylate component is reactive with the isocyanate component. The urethane acrylate composition also includes an inhibitor and a first metal salt. The inhibitor has a functional group that is sterically hindered. The urethane acrylate composition exhibits excellent stability over time. The presence of the inhibitor in combination with the metal salt improves the storage stability of the urethane acrylate composition.

Abstract: A method of making a polyurea—polyurethane composite structure that is substantially free from emission of volatile organic compounds is disclosed. The composite structure produced according to the method of the subject invention has a flexural modulus of at least 200,000 lb/in2. The composite structure includes first and second layers. A mold substrate is provided and a first-layer polyisocyanate component and a first-layer resin component are reacted and sprayed onto the mold substrate to form the first-layer. The first-layer polyisocyanate component includes an aliphatic polyisocyanate, and the first-layer resin component includes a polyamine thereby forming a polyurea show surface having a Shore D hardness of at least 65. After application of the first-layer, a second-layer polyisocyanate component and a second-layer resin component are reacted and sprayed behind the first-layer to form the second-layer of the composite structure.

Abstract: A composite structure including a polyurea show surface, or top layer, and a polyurethane backing layer is disclosed. Preferably, the show surface of the composite structure is substantially free of volatile organic compounds and is aliphatic such that it is ultraviolet light stable. Specifically, the show surface is the reaction product of an aliphatic polyisocyanate or aliphatic polyisocyanate blend, and of a resin component which is a polyamine. The resin component reacts with the aliphatic polyisocyanate to form a polyurea. The show surface has a Shore D hardness of 70. Like the show surface, the polyurethane backing layer of the composite structure is substantially free of volatile organic compounds. This backing layer is the reaction product of a second polyisocyanate component, such as polymeric diphenylmethane diisocyanate, and of a second-layer resin component, which comprises a polyol having a functionality of at least three.

Abstract: A method of making a polyurea-polyurethane composite structure that is substantially free from emission of volatile organic compounds is disclosed. The composite structure produced according to the method of the subject invention has a flexural modulus of at least 200,000 lb/in2. The composite structure includes first and second layers. A mold substrate is provided and a first-layer polyisocyanate component and a first-layer resin component are reacted and sprayed onto the mold substrate to form the first-layer. The first-layer polyisocyanate component includes an aliphatic polyisocyanate, and the first-layer resin component includes a polyamine thereby forming a polyurea show surface having a Shore D hardness of at least 65. After application of the first-layer, a second-layer polyisocyanate component and a second-layer resin component are reacted and sprayed behind the first-layer to form the second-layer of the composite structure.

Abstract: A composite structure including a polyurea show surface, or top layer, and a polyurethane backing layer is disclosed. Preferably, the show surface of the composite structure is substantially free of volatile organic compounds and is aliphatic such that it is ultraviolet light stable. Specifically, the show surface is the reaction product of an aliphatic polyisocyanate or aliphatic polyisocyanate blend, and of a resin component which is a polyamine. The resin component reacts with the aliphatic polyisocyanate to form a polyurea. The show surface has a Shore D hardness of 70. Like the show surface, the polyurethane backing layer of the composite structure is substantially free of volatile organic compounds. This backing layer is the reaction product of a second polyisocyanate component, such as polymeric diphenylmethane diisocyanate, and of a second-layer resin component, which comprises a polyol having a functionality of at least three.