WO2021222192A1

WO2021222192A1 - Polyurethane compositions

Info

Publication number: WO2021222192A1
Application number: PCT/US2021/029320
Authority: WO
Inventors: Andrew John Tennant; Michael Jeffrey KRAUSE; Mark Paul KUJAWSKI; Brett Tyler SHERREN
Original assignee: Presidium Usa, Inc.
Priority date: 2020-04-29
Filing date: 2021-04-27
Publication date: 2021-11-04

Abstract

Disclosed is a polyurethane composition comprising (a) residues of a polyol composition containing (i) at least one polyol having three or more hydroxyl groups; (ii) residues of at least one cyclic carbonate comprising one or more hydroxyl groups; and (b) residues of at least one isocyanate functional component. At least a portion of the residues of the polyol and cyclic carbonate are bound by one or more urethane linkages to the residues of the isocyanate functional component which may be residues of a polyisocyanate, a latent polyisocyanate, or a mixture thereof. Also disclosed are curable compositions, polyurethanes and articles prepared from such curable compositions and methods of using the curable compositions.

Description

POLYURETHANE COMPOSITIONS

FIELD

[0001] This disclosure relates polymeric compositions. In particular, this disclosure relates to polyurethane compositions, articles comprising the same and methods for the manufacture of such polyurethane compositions and articles.

BACKGROUND

[0002] Polyurethanes are important industrial polymers used in a wide variety of applications including rigid and flexible foams, thermoplastic and thermosetting elastomers, sealants, coatings and adhesives, elastomeric fibers, and synthetic leather-like materials and are typically prepared by reacting a polyisocyanate with a polyol or mixture of polyols to form a product. Most polyurethanes used commercially are elastomers with Young’s moduli less than about 50,000 psi, but some polyurethanes in unfilled form have moduli ranging from 250,000 psi to 500,000 psi or more. Examples include TPU engineering plastics (Isoplast ®) and a number of commercial cast systems. Polyurethanes have several shortcomings including the need for mold release agents, long demold times (poor green strength) and intense in-mold exotherms that can cause visual imperfections in a molded part. Such imperfections include color change and surface splay from outgassing. Most polyurethane elastomers are generally not used for structural applications due to their typical low modulus and strength. The flexural moduli of most polyurethane compositions are well below 300,000 psi and flexural strength values are typically below 10,000 psi. Known polyurethanes may be deficient in terms of their resistance to heat and are frequently characterized by heat distortion temperatures which are less than 100°C. In addition, upon exposure to conditions of high humidity at moderate temperature known polyurethanes may exhibit significant loss of material properties.

[0003] There has long been interest in the preparation of polyurethanes incorporating cyclic carbonate structures as a means of eliminating or reducing reliance on isocyanates in the manufacture of polyurethanes.

[0004] United States patent US3072613 (Whelan) discloses polyurethanes prepared from the reaction product of glycerol carbonate with an isocyanate-functional monomer, such as hexamethylene diisocyanate. The reaction product is then converted to linear and branched polyurethanes by reaction with a diamine or triamine. [0005] United States patent US5688891 (Hovestadt) discloses an oligourethane prepared by reaction of a hydroxyl group-containing cyclic carbonate with an isocyanate-functional monomer and conversion of the oligourethane to a polyurethane by further reaction with a polyamine.

[0006] United States patent US6562463 (Melchiors) discloses an oligourethane prepared by reaction of a hydroxyl group-containing cyclic carbonate with an isocyanate-functional monomer and converting the resultant cyclic carbonate capped oligourethane into a polymeric product by combining the oligourethane with a compound having at least 2 hydroxyl groups causing the mixture to cure.

[0007] United States patent US8118968 (Moeller) discloses prepolymers containing isocyanate groups prepared from polymeric polyols and polyisocyanates. The prepolymers so prepared are then reacted with glycerol carbonate in an amount sufficient to reduce the isocyanate group concentration to less than 0.1 percent by weight to produce a glycerol carbonate functionalized prepolymer. The glycerol carbonate prepolymers are then reacted with a polyamine to give a polyurethane.

[0008] United States patent US8981032 (Bernard) discloses the reaction of glycerol carbonate with an isocyanate-functional oligomer in amounts such that the molar ratio of isocyanate groups to hydroxyl groups is about 1.1 to 1 . The oligomeric product contains both cyclic carbonate groups and isocyanate groups in about a 10:1 ratio of cyclic carbonate groups to isocyanate groups. A polyester containing polyol is then added in an amount sufficient to consume the remaining isocyanate groups. The resultant product is then reacted with a polyamine to provide a polyurethane.

[0009] United States patent US9556304 (Laas) discloses the reaction of glycerol carbonate with a large molar excess of isocyanate-functional monomer to provide a mixture comprising the starting isocyanate-functional monomer and a product monomeric urethane comprising both an isocyanate group and a cyclic carbonate group. Excess isocyanate-functional monomer is removed in a film evaporator. The purified product is then reacted with a polyol to afford a urethane product which is further reacted with a polyamine to afford a polyurethane.

[0010] Each of the cited references discloses polyurethanes produced in multistep processes in which the hydroxyl group-containing cyclic carbonate is reacted with an isocyanate-functional moiety in a step apart from the step in which the polyurethane is formed. There is a need for new polyurethane compositions which can be made more efficiently and which exhibit superior processability, improved strength, hardness, and molding characteristics relative to known polyurethane materials. BRIEF DESCRIPTION

[0011] This disclosure addresses many of the shortcomings of known polyurethanes by providing a new class of polyurethanes having superior processing characteristics, heat resistance and durability. The curable compositions disclosed herein are of sufficiently low viscosity to permit the use of currently available pumping and mixing equipment. The curable compositions disclosed herein are adapted to provide structurally robust, temperature resistant polyurethanes. The polyurethane compositions disclosed herein may exhibit heat distortion temperatures in excess of 110°C. The new polyurethanes exhibit lower peak exotherms, typically less than 280°F during in-mold curing/polymerization, a beneficial attribute in making molded parts using FRP tooling. In addition, articles comprising the polyurethanes of this disclosure exhibit flexural strengths in excess of 24,000 psi and flexural modulus in excess of 520,000 psi, exhibit outstanding green strength, and superior UV stability. The curable compositions disclosed herein may be used to provide structurally robust, temperature resistant polyurethane foams using methods known in the art and those disclosed in the applicants’ copending application PCT/US2020/061747 (PRES- 114-C-PCT) filed November 23, 2020 and which is incorporated by reference in its entirety for all purposes.

[0012] There is disclosed a polyurethane composition comprising: (a) residues of a polyol composition comprising: (i) at least one polyol having 3 or more hydroxyl groups; (ii) residues of at least one cyclic carbonate comprising one or more hydroxyl groups; and (b) residues of at least one isocyanate functional component; wherein at least a portion of the residues of the at least one polyol and at least a portion of the residues of the at least one cyclic carbonate are bound by one or more urethane linkages to the residues of the least one isocyanate functional component. The residues of the polyol composition; residues of the at least one polyol and the at least one cyclic carbonate, and the residues of at least one isocyanate functional component may be present in any amounts which provide the desired physical properties of the polyurethane composition. The residues of the at least one cyclic carbonate may present in an amount from about five weight percent to about forty weight percent based on the total weight of the residues of the polyol composition. The polyol composition may have any viscosity which provides the desired physical properties of a mixture of the polyol composition and the isocyanate functional component. The polyol composition may have any viscosity which provides the desired physical properties of the polyurethane composition. The polyol composition may have viscosity of less than 1000 cps at 150°C. There is disclosed a polyurethane composition comprising residues of the components of a curable composition as disclosed herein, wherein urethane linkages of the polyurethane composition are formed by reaction of at least a portion of the hydroxyl groups of the at least one polyol and the at least one cyclic carbonate with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form urethane linkages of the product polyurethane composition.

[0013] There is disclosed a polyurethane composition comprising a filler prepared by reacting, in the presence of the filler, a curable composition as disclosed herein, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and the at least one cyclic carbonate to react with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form urethane linkages of the product polyurethane composition.

[0014] There is disclosed a polyurethane composition comprising a filler and the residue of a curable composition as disclosed herein, wherein urethane linkages of the polyurethane composition are formed by reaction of at least a portion of the hydroxyl groups of the at least one polyol and the at least one cyclic carbonate with isocyanate groups, latent isocyanate groups, or a mixture there of the isocyanate functional component.

[0015] There is disclosed a curable composition comprising: (a) a polyol composition comprising: (i) at least one polyol comprising 3 or more hydroxyl groups; (ii) at least one cyclic carbonate comprising one or more hydroxyl groups; (b) at least one isocyanate functional component; and optionally (c) a catalyst; wherein the composition when subjected to conditions sufficient to cause the polyol composition and the isocyanate functional component to react, the composition cures by reaction of at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form urethane linkages of a polyurethane composition. The isocyanate functional component may comprise a latent polyisocyanate. The composition may comprise a latent catalyst. The composition may comprise a filler. The filler may be present in either or both of the polyol composition and the isocyanate functional component.

[0016] There is disclosed a curable composition comprising (a) a first part comprising: (i) at least one polyol comprising 3 or more hydroxyl groups; and (ii) at least one cyclic carbonate comprising one or more hydroxyl groups; and (b) a second part comprising at least one isocyanate functional component; and optionally (c) a catalyst; wherein when the first part and the second part are contacted, optionally in the presence of the catalyst, the composition cures by reaction of at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate with the isocyanate groups or latent isocyanate groups of the at least one isocyanate functional component. The composition may be part of a polyurethane forming kit. The composition may comprise a filler. The filler may be present in either or both of the first and second parts.

[0017] There is disclosed a method comprising: contacting a curable composition as disclosed herein, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate to react with isocyanate groups or latent isocyanate groups of the at least one isocyanate functional component to form a polyurethane product. The contacting may be conducted in the presence of a filler to form a filled polyurethane product. The contacting may be carried out in a mold which may comprise one or more fiber reinforced plastics (FRP), metals such as aluminum metal, or a mixture thereof. An internal mold temperature may be greater than 250°F during the contacting. An internal mold temperature may be less than 290°F during the contacting.

[0018] There is disclosed a method comprising: (a) transferring a curable composition as disclosed herein into a mold; and (b) curing the composition within the mold to afford a molded polyurethane product wherein during step (b) at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate react with one or more isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form a molded polyurethane product. The mold may contain a reinforcing filler. The method may provide a molded polyurethane part. The method may provide a molded polyurethane part comprising a filler.

[0019] There is disclosed an article comprising a polyurethane composition as disclosed herein. The article may comprise a reinforcing filler. The article may be essentially free of any reinforcing filler. The article may exhibit a heat distortion temperature greater than 110°C. The article may exhibit a heat distortion temperature greater than 130°C. The article may exhibit a flexural strength greater than 24,000 psi. The article may exhibit a flexural strength greater than 30,000 psi. The article may exhibit a Young’s modulus greater than 1 ,000,000 psi. The article may exhibit a flexural modulus greater than 520,000 psi.

[0020] The polyurethane materials provided by this disclosure are well suited for use in the manufacture of structural and semi-structural parts. Such parts include automotive and heavy truck body panels, floor panels, brackets, bumper covers, footsteps and housings, and interior parts such as door panels, arm rests, center console bodies and covers, cup holders and similar parts, and may be filled or unfilled materials. Other applications include the use of the polyurethanes in the manufacture of structural and semi-structural agricultural equipment components such as tractor body parts, brackets, grilles, fan shrouds and the like, and building and construction and industrial infrastructural pieces such as decks and railings, building trim, window lineals, manhole covers and electrical boxes. Further applications include manufacture of aquatic sports equipment such as kayaks, canoes, personal watercraft such as jet skis, paddle boards, surf boards, and light weight fishing craft. Further applications include manufacture of window frames, phone poles, assembly profiles, car bumpers, battery boxes for electric vehicles, speakers, urban mobility platforms, computer server room ventilation units and platforms, and water filtration frames.

BRIEF DESCRIPTION OF THE FIGURES

[0021] FIG. 1 shows a photograph of a molded article comprising the polyurethane composition of Example 1 ; and

[0022] FIG. 2 shows an infrared spectrum of the molded polyurethane article comprising the polyol composition of Example 7; and

[0023] FIG. 3 shows a photograph of a molded article comprising the polyurethane composition of Comparative Example 7.

DETAILED DESCRIPTION

[0024] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the disclosure, its principles, and its practical application. The specific embodiments of the present disclosure as set forth are not intended as being exhaustive or limiting of the disclosure. The scope of the disclosure should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all references cited, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the claims, which are also hereby incorporated by reference into this written description.

Definitions

[0025] One or more as used herein means that at least one, or more than one, of the recited components may be used as disclosed. Nominal as used with respect to functionality means the theoretical functionality. This can be calculated from the stoichiometry of the ingredients used. The actual functionality may be different due to imperfections in raw materials, incomplete conversion of the reactants and formation of by-products. Nominal with respect to molecular weight refers to the molecular weight of a particular structure. Nominal with respect to the molecular weight of a component of a chemical substance disclosed herein may differ from the actual molecular weight of the substance, for example as when the substance consists of a mixture of structurally related compounds as is the case with many commercially available polyether polyols. Durability in this context means that the composition once cured remains sufficiently strong to perform its designed function. Residual content of a component refers to the amount of the component present in free form or reacted with another material such as a cured product. The residual content of a component can be calculated from the ingredients utilized to prepare the component or composition. It may be determined utilizing known analytical techniques. Heteroatom means any of nitrogen, oxygen, sulfur, silicon, selenium and phosphorus. Heteroatoms may include nitrogen and oxygen. Hydrocarbyl as used herein refers to a group containing one or more carbon atom backbones and hydrogen atoms, which may optionally contain one or more heteroatoms. As used herein, the term “hydrocarbyl” refers an organic radical which may be any of an aromatic radical, a cycloaliphatic radical, or an aliphatic radical as those terms are defined herein. Where the hydrocarbyl group contains heteroatoms, the heteroatoms may form one or more functional groups well known to one skilled in the art. Hydrocarbyl groups may contain cycloaliphatic segments, aliphatic segments, aromatic segments or any combination of such segments. The aliphatic segments can be straight or branched. The aliphatic and cycloaliphatic segments may include one or more double and/or triple bonds. Included in hydrocarbyl groups are alkyl, alkenyl, alkynyl, aryl, cycloalkyl, cycloalkenyl, alkaryl and aralkyl groups. Cycloaliphatic groups may contain both cyclic portions and noncyclic portions.. As used herein percent by weight or parts by weight refer to, or are based on, the weight of the disclosed composition unless otherwise specified.

[0026] The term isocyanate-reactive compound as used herein includes any organic compound having nominally greater than one, or at least 2, isocyanate-reactive moieties. For the purposes of this invention, an active hydrogen containing moiety refers to a moiety containing a hydrogen atom which, because of its position in the molecule, displays significant activity according to the Zerewitinoff test described by Wohler in the Journal of the American Chemical Society, Vol. 49, p. 3181 (1927). Illustrative of such isocyanate reactive moieties, such as active hydrogen moieties, are — COOH, —OH, — NH₂, — NH— , — CONH₂, — SH, and — CONH— . Active hydrogen containing compounds include polyols, polyamines, polymercaptans and polyacids. The isocyanate reactive compound may be a polyol, and may be a polyether polyol. [0027] As used herein, the term “aromatic radical” refers to an array of atoms having a valence of at least one comprising at least one aromatic group. The array of atoms having a valence of at least one comprising at least one aromatic group may include heteroatoms, or may be composed exclusively of carbon and hydrogen. As used herein the term “cycloaliphatic radical” refers to a radical having a valence of at least one, and comprising an array of atoms which is cyclic but which is not aromatic. As defined herein a “cycloaliphatic radical” does not contain an aromatic group. As used herein the term “aliphatic radical” refers to an organic radical having a valence of at least one consisting of a linear or branched array of atoms which is not cyclic. Aliphatic radicals are defined to comprise at least one carbon atom.

[0028] As used herein the term polyol may include any polyol known in the art and those disclosed herein. Polyols falling within generic structure I may be referred to as monomeric polyols. Monomeric polyols are defined as polyols comprising a single residue of a constituent base polyol, for example a single residue of pentaerythritol or an alkoxylated pentaerythritol. Polyols falling within generic structure II or III may be referred to as higher polyols. Polyols having structures II and III incorporate residues of 2 or more constituent polyols having structure I and incorporate 2 or more residues of a constituent base polyol, for example two or more residues of diglycerol or an alkoxylated diglycerol. Polyols such as diglycerol, dipentaerythritol ditrimethylolpropane and alkoxylated derivatives thereof are defined herein as higher polyols since each contains 2 residues of constituent base polyols glycerol, pentaerythritol and trimethylolpropane respectively. Polyols having structures II and III are linear higher polyols. Linear polyols are defined as having 2 and only 2 terminal residues of 2 constituent polyols having structure I which terminal residues may be the same or different. A branched polyol is defined herein as having more than 2 terminal residues of at least three constituent polyols having structure I which may be the same or different. A terminal polyol residue is defined as a polyol residue which is bound to only one other constituent polyol residue. An internal polyol residue is defined as a polyol residue which is bound to more than one other constituent polyol residue. Polyols II and III may be formed as a reaction product obtained by reacting a carbonate source with one or more polyols having structure I as disclosed herein and in PCT/US2020/061747 incorporated by reference above. The reaction product may be obtained as a statistical mixture of starting polyol I and product polyols II and polyols III. Such polyols may exhibit lower viscosity and enhanced utility when the reaction product contains a significant amount of starting polyol I. Polyol compositions containing a statistical mixture of starting polyol I and product polyols II and III may contain, based on the entire weight of the composition, about 25 % by weight or greater polyol I, about 20 % by weight or greater of a first product polyol comprising 2 residues of the starting polyol I linked by a single carbonate group, about 10 % by weight or greater of a second polyol comprising 3 residues of the polyol I linked by 2 carbonate groups, about 5 % by weight or greater of a third polyol comprising 4 residues of the polyol I linked by 3 carbonate groups and about 1 % by weight or greater of a fourth polyol comprising 5 residues of the polyol I linked by 4 carbonate groups. Such polyol compositions may contain, based on the entire weight of the composition, about 35 % by weight or less polyol I, about 30 % by weight or less of a first polyol comprising 2 residues of the polyol I linked by a single carbonate group, about 20 % by weight or less of a second polyol comprising 3 residues of the polyol I linked by 2 carbonate groups, about 10 % by weight or less of a third polyol comprising 4 residues of the monomeric polyol linked by 3 carbonate groups and about 5 % or less of a fourth polyol comprising 5 residues of the polyol I linked by 4 carbonate groups. As used herein, the term aliphatic polyol refers to a polyol comprising at least one aliphatic radical and not comprising a cycloaliphatic radical or an aromatic radical. As used herein the term FRP tooling refers to fiber reinforced plastic tooling. As used herein residue means the remainder of a compound or functional group utilized to form a reaction product remaining in the reaction product wherein the residue is covalently bonded into the formed reaction product. Residues of functional groups such as hydroxyl groups, isocyanate groups and latent isocyanate groups may be covalently bound to the formed reaction product or may be present as unreacted hydroxy groups, unreacted isocyanate groups, or unreacted latent isocyanate groups within a structure of the formed reaction product.

[0029] The disclosed polyurethanes comprise residues of an isocyanate functional component and residues of a polyol composition comprising at least one polyol and at least one cyclic carbonate. The polyurethanes contain urethane units formed by reaction of the hydroxyl groups of the polyol and the hydroxyl groups of the cyclic carbonate with the isocyanate functional component. The residues of the polyol composition include residues of at least one polyol having three hydroxyl groups and residues of a cyclic carbonate having at least one hydroxyl group. Residues of the at least one polyol may be present in any amount which provides the desired physical properties of the polyurethane composition. Residues of the at least one polyol may be present in greater than about 20, 40, 60, or 80 percent by weight based on the total weight of the polyurethane composition. Residues of the at least one polyol may be present in an amount less than about 90, 75, 55, or 35 percent by weight based on the total weight of the polyurethane composition. Residues of the at least one cyclic carbonate may be present in any amount which provides the desired physical properties of the polyurethane composition. Residues of the at least one cyclic carbonate may be present in an amount greater than about 2, 5, 15, 25 or 35 percent by weight based on the total weight of resides of the polyol composition. Residues of the at least one cyclic carbonate may be present in an amount less than about 40, 35, 20, 10 or 5 percent by weight based on the total weight of the residues of the polyol composition. The residues of the at least one cyclic carbonate may be present in an amount from about 5 to about 40 weight percent based on the total weight of the residues of the polyol composition present in the polyurethane composition. The residues of the at least one cyclic carbonate may be present in an amount from about 10 percent to about 30 percent by weight based on the total weight of residues of the polyol composition present in the polyurethane composition. The polyurethane composition may have any ratio of residues of isocyanate groups, latent isocyanate groups, or a mixture thereof to residues of hydroxyl groups which provides the desired physical properties of the polyurethane composition. The polyurethane composition may have a ratio of residues of isocyanate groups, latent isocyanate groups, or a mixture thereof to residues of hydroxyl groups of the polyol composition greater than about 0.8, 1 .0 or 1 .05. The polyurethane composition may have a ratio of residues of isocyanate groups, latent isocyanate groups, or a mixture thereof to residues of hydroxyl groups of the polyol composition less than about 1 .2, 1 .1 or 1 .0. This ratio is essentially the same as the ratio of isocyanate groups, latent isocyanate groups, or mixture thereof to hydroxyl groups in the reactants used to form the polyurethane. The polyurethane composition may have a ratio of residues of isocyanate groups, latent isocyanate groups, or a mixture thereof to residues of hydroxyl groups in a range from about 1.2 to about 0.8. The polyurethane composition may have a glass transition temperature greater than 95, 100, 110 or 120°C. The polyurethane composition may have a glass transition temperature less than 150, 130, 120 or 110°C. While unfilled polyurethane compositions disclosed herein may have exceptional strength and heat resistance, their physical properties may be further enhanced by addition of one or more fillers. Fillers may be added to reinforce the composition. The polyurethane may comprise any filler in any amount which provides the desired physical properties of the polyurethanes and articles comprising such polyurethanes. For example, the presence of a filler may be used to enhance the heat distortion temperature and strength of a polyurethane composition. The polyurethane composition may comprise a filler which may comprise one or more clay fillers, glass flake fillers, glass fiber fillers, carbon black fillers, carbon fiber fillers, basalt fiber fillers, or a mixture thereof. The filler may be a fiber-based material which may be present in woven and non-woven structures, individual fibers, rovings comprising a plurality of fiber strands, chopped fibers and the like. The fillers may be glass, carbon, polymeric, metallic, ceramic and the like. The filler may be one or more of a continuous filament mat, a chopped or continuous strand mat, and an engineered stitched mat which may be used in single or multiple layers within a composite material prepared using the curable compositions disclosed herein. Exemplary fillers include Continuous filament mat (CFM) fiberglass reinforcing materials available from Owens Corning, such as M8643, UNIFLO U500 series reinforcing materials, and UNIFLO U700 series reinforcing materials. Exemplary fillers include chopped strand mat fiberglass reinforcing materials which include M6X1 CSM, M705 CSM and M723A CSM available from Owens Corning. Exemplary fillers include engineered knitted mat fiberglass reinforcing materials such as MULTIMAT reinforcing materials available from Owens Corning, ROVICORE reinforcing materials available from Chomarart, and FLOWMAT reinforcing materials available from Skaps Industries. Woven and non-woven reinforcing materials other than fiberglass may also be used, for example woven and non-woven carbon fibers. The reinforcing filler may comprise one or more sizing agents. The reinforcing filler may be essentially free of sizing agents. By essentially free of sizing agents it is meant that the reinforcing material was not treated with a sizing agent prior to contacting the reactive mixture. [0030] The filler may be present in an amount greater than 1 , 5, 25, or 55 percent by weight percent by weight based on the total weight of the polyurethane composition. The filler may be present in an amount less than 65, 60, 40, 20, 10 or 5 percent by weight based on the total weight of the polyurethane composition. The filler may be present in an amount from about 0.001 percent by weight to about 60 percent by weight based on the total weight of the polyurethane composition.

[0031] The residues of the at least one isocyanate functional component may comprise residues of any compound having more than one isocyanate group, latent isocyanate group or mixture thereof capable of reacting with one or more isocyanate-reactive compounds to form a polyurethane. These include residues of polyisocyanate prepolymers, monomeric polyisocyanates, oligomeric polyisocyanates, polymeric polyisocyanates, blocked polyisocyanates, and mixtures thereof. These may comprise residues of aliphatic polyisocyanates and latent polyisocyanates, cycloaliphatic polyisocyanates and latent polyisocyanates, aromatic polyisocyanates and latent polyisocyanates, and mixtures thereof. Exemplary polyurethanes may include residues of aliphatic polyisocyanates such as residues of hexamethylene diisocyanate, residues of cycloaliphatic polyisocyanates such as isophorone diisocyanate and trimerized hexamethylene diisocyanate, residues of aromatic polyisocyanates such as 4,4’-diphenylmethane diisocyanate derivatives, residues of free 4,4’-diphenylmethane diisocyanate, toluene diisocyanate derivatives, free toluene diisocyanate, free bis(isocyanatophenyl)methane (MDI), MDI trimers and MDI derivatives. The residues of the at least one isocyanate functional component may be essentially free of residues of aromatic polyisocyanates and latent polyisocyanates. The residues of the polyol composition and the isocyanate functional component may be essentially free of aromatic residues of any type. Such non-aromatic polyurethane compositions may exhibit superior photostability. The disclosed polyurethane compositions may further comprise any plasticizer known in the art.

[0032] Articles comprised of the disclosed polyurethane compositions may have excellent surface appearance and exhibit outstanding strength and heat resistance. Such articles may exhibit flexural modulus greater than 3500, 3600, 3700 or 3800 Mpa, and flexural strength greater than 140, 150, 160, 170, or 180 Mpa. Articles may exhibit heat deflection temperature of greater than 110, 120, 130 or 140 °C. It may be useful in some instances to subject articles prepared using the disclosed curable compositions to an annealing step, for example annealing a molded part following its removal from a mold. Annealing may be carried out at temperatures greater than 100, 150, 200 or 250°F. Annealing may be carried out at temperatures less than 300, 250, 200, 150 or 125°F. Annealing times may be greater than 10 minutes, 30 minutes, 60 minutes, 90 minutes or 360 minutes. Annealing times may be less than 600 minutes, 300, minutes, 100, minutes, 50 minutes or 15 minutes.

[0033] The at least one polyol, the cyclic carbonate and the amounts of each included in the polyol composition may be selected to produce a low viscosity polyol composition which when reacted with the isocyanate functional component affords a high strength, heat resistant polyurethane composition. The cyclic carbonate may function as a reactive diluent which lowers the viscosity of the polyol composition but is largely or entirely consumed upon reaction with the isocyanate functional component. The at least one polyol may be present in an amount greater than 40, 60 or 80 percent by weight based on the total weight of the polyol composition. The at least one polyol may be present in an amount less than 90, 75, 60 or 45 by weight based on the total weight of the polyol composition. The at least one cyclic carbonate may be present in an amount greater than 5, 15, 20, 25 or 35 percent by weight based on the total weight of the polyol composition. The at least one cyclic carbonate may be present in an amount less than 50 , 40, 35, 20 or 10 percent by weight based on the total weight of the polyol composition. The at least one cyclic carbonate may be present in an amount from about 5 to about 40 weight percent based on the total weight of the of the polyol composition. The at least one cyclic carbonate may be present in an amount from about 10 percent to about 30 percent by weight based on the total weight of the polyol composition present in the polyurethane composition.

[0034] The polyol composition is typically a free flowing, low color, homogeneous liquid The polyol composition may have a viscosity at 150°F of less than 1000 cps. The polyol composition may have a viscosity of less than 800 cps, 600 cps, 400 cps or 200 cps at 150°F. The polyol composition may have a viscosity of greater than 100 cps, 400 cps, or 800 cps at 150°F. [0035] The polyol composition may optionally comprise at least one polyhydroxylated aromatic compound. The polyhydroxylated aromatic compound may be present as a free (meaning unbound) compound, for example monomeric bisphenol A. The polyhydroxylated aromatic compound in its free form may be present in the polyol composition in any amount that affords useful product properties. The polyol compositions may show a special utility in the preparation of high strength, heat resistant polyurethanes when the amount of polyhydroxylated aromatic compound in its free form is less than 32, 28, or 24 percent by weight based on the total weight of the polyol composition. The polyol compositions may show a special utility in the preparation of high strength, heat resistant polyurethanes when the amount of polyhydroxylated aromatic compound in its free form is greater than 10, 16, or 20 percent by weight based on the total weight of the polyol composition. Illustrative polyhydroxylated aromatic compounds include those disclosed in United States patent US10053533 which is incorporated herein by reference in its entirety for all purposes.

[0036] The at least one polyol may comprise 3 or more secondary hydroxyl groups. The at least one polyol may comprise 3 or more vicinal hydroxyl groups. The at least one polyol may comprise 3 or more vicinal hydroxyl groups. The at least one polyol may comprise six or more hydroxyl groups. The at least one polyol may comprise six or more secondary hydroxyl groups. The at least one polyol may comprise one or more carbonate groups.

[0037] Exemplary polyols include glycerol, diglycero!, triglycerol, trimethylolmethane, ditrim ethylolmethane, trlmethylolethane, ditrimethylolethane, trimethylolpropane, ditrimethylolpropane, 1 ,2,4-butanetriol, 1 ,2,3-butanetriol, 1 ,2,3-pentanetriol 2,3,4-pentanetriol, 1 ,2,4,5-pentanetetrol, 1 ,2,5.6-hexanetetrol, tris(hydroxymethyl)methyl amine, tris(hydroxyethyl)amine, tris(hydroxypropyl)amine, pentaerythritol, dipentaerythritol, bis( trimethylolpropane), tris(hydroxymethyl)isocyanurate, tris(hydroxyethyl)isocyanurate, 1 ,3,5- benznnetrimethanol, 1 ,1 ,1 -tris(4'-hydroxyphenyl)methane, 1 ,1 ,1-tris(4'-hydroxyphenyl)ethane, sugars, such as glucose, sugar derivatives, trifunctional or higher polyfunctional polyether polyols based on trihydric or higher polyhydric alcohols and ethylene oxide, ethylene carbonate, propylene oxide, 1 ,2-propylene carbonate, 1 ,3-propylene carbonate, butylene oxide, 1 , 2- butylene carbonate, 1 , 3-butylene carbonate or mixtures thereof, or polyester polyols. Of these, glycerol, trlmethylolethane, thmethylolpropane, 1 ,2,4-butanetnol pentaerythritol, dipentaerythritol and also their polyether polyols based on ethylene oxide or propylene oxide may be utilized. [0038] Polyols comprising 3 or more secondary hydroxyl groups be prepared by art recognized methods. For example, a polyol comprising three of more hydroxyl groups may be converted via alkoxylation as is known in the art with a sufficient amount of a mono-substituted oxirane such as propylene oxide, 1 , 2-butylene oxide, 1 , 2-pentylene oxide, or a cyclic carbonate such as 1 , 2- propylene carbonate, 1 , 2-butylene carbonate, or 1 , 2-pentylene carbonate, to a mixture of polyols in which the principal components are polyether polyols comprising 3 or more secondary hydroxyl groups. Such polyols are illustrated by glycerol alkoxylated with 2, 3, 4, 5, 6, or more equivalents of propylene oxide and for convenience abbreviated: glycerol 2xPO, glycerol 3xPO, glycerol 4xPO, glycerol 5xPO, glycerol 6xPO, etc. respectively; trimethylolpropane alkoxylated with 2, 3, 4, 5, 6, or more equivalents of 1 , 2-butylene oxide and for convenience abbreviated: TMP 2xBO, TMP 3xBO, TMP 4xBO, TMP 5xBO, TMP 6xBO, etc. respectively; pentaerythritol alkoxylated with 2, 3, 4, 5, 6, 7 or more equivalents of propylene oxide and for convenience abbreviated: PE 2xPO, PE 3xPO, PE 4xPO, PE 5xPO, PE 6xPO, PE 7xPO, etc. respectively; and dipentaerythritol alkoxylated with 3, 4, 5, 6, 7, 8 or more equivalents of propylene oxide and for convenience abbreviated: DiPE 3xPO, DiPE 4xPO, DiPE 5xPO, DiPE 6xPO, DiPE 7xPO, DiPE 8xPO, etc. respectively.

[0039] The polyol composition as disclosed herein may comprise one or more alkoxylated polyether polyols comprising 3 or more primary hydroxyl groups which may be prepared by art recognized methods. For example, an alkoxylated polyol comprising three of more primary or secondary hydroxyl groups may be converted via alkoxylation as is known in the art with a sufficient amount of an oxirane such as ethylene oxide or a cyclic carbonate such as ethylene carbonate to a mixture of polyols in which the principal components are alkoxylated polyether polyols comprising 3 or more primary hydroxyl groups.

[0040] As will be understood by those skilled in the art, such alkoxylated polyether polyols may be single chemical species comprising 3 or more hydroxyl groups, but are typically mixtures of related chemical species.

[0041] The polyol composition as disclosed herein may comprise one or more polyols wherein at least one polyol is tetrafunctional or greater and comprises 4 or more hydroxyl groups as is the case of pentaerythritol, dipentaerythritol and diglycerol. The tetrafunctional polyol may comprise 4 or more secondary hydroxyl groups, for example an alkoxylated pentaerythritol or an alkoxylated dipentaerythritol, an alkoxylated diglycerol or an alkoxylated C -C₆ carbohydrate. Alkoxylated polyols constitute polyether polyols and include C₂-C₄ alkoxylated polyols. The presence of secondary hydroxyl groups as opposed to primary or tertiary hydroxyl groups may beneficially control the nature and chemical properties of the polyol composition. For example, the physical properties of product polyurethanes may be favorably controlled the use of polyols comprising chiefly, or exclusively, secondary hydroxyl groups. [0042] The polyol may have a molecular weight sufficient to provide the requisite properties of both the polyol composition itself as well as polyurethanes incorporating the polyol composition. The polyol may have a molecular weight of less than 1000 grams per mole, less than 800 grams per mole, less than 600 grams per mole, less than 500 grams per mole, or less than 400 grams per mole. The polyol may have a molecular weight of greater than 50 grams per mole, greater than 450 grams per mole, greater than 700 grams per mole, or greater than 900 grams per mole. The molecular weight may be the actual molecular weight of the polyol when the polyol is predominately a single molecular species, or may represent an average molecular weight when the polyol is a mixture of structurally related polyols such as is the case of Pluracol® PEP450 polyols which are a mixture of structurally related polyols encompassing both alkoxylated homologues and diastereomers thereof. Alternatively, the molecular weight used to describe a polyol may be a nominal molecular weight of the polyol based upon a specific chemical structure assigned to such polyol. By way of example, a polyol which is a polyether polyol may be prepared by alkoxylation of a single, substantially pure base polyol (such as pentaerythritol) with propylene oxide. However, the product polyether polyol may comprise a mixture of structurally related polyols differing in molecular weight from one another by some regular amount (or multiple thereof), for example by 58 grams per mole (the group molecular weight of a propyleneoxy repeat unit). Such a product polyether polyol is defined as a polyol for purposes of this disclosure. Polyol molecular weights may be determined from its hydroxyl number obtained using ASTM E222. [0043] The at least one polyol may include polyols having structure I

I wherein R¹ and R² are independently at each occurrence a hydrogen atom, or a hydrocarbyl group such that R¹ and R², either alone or together, comprise at least 2 hydroxyl groups wherein R¹ and/or R² optionally contain an internal functional group containing a heteroatom. The hydrocarbyl group or groups may be chosen such that polyol I comprises 3 or more secondary hydroxyl groups. The hydrocarbyl group or groups may be chosen such that polyol I comprises 4 or more hydroxyl groups. The hydrocarbyl group or groups may be chosen such that polyol I comprises 4 or more secondary hydroxyl groups. The hydrocarbyl group or groups may be chosen such that polyol I comprises one or more internal functional groups containing a heteroatom. The hydrocarbyl group or groups may be chosen such that polyol I comprises one or more internal functional groups which are alkylene ether groups or polyalkylene ether groups. The hydrocarbyl group or groups may be chosen such that polyol I is an alkoxylated polyol. The hydrocarbyl group or groups may be chosen such that polyol I is an alkoxylated polyol comprising one or more C₂-C₄ alkylene oxide repeat units.

[0044] R¹ and R² may be independently at each occurrence a hydrogen atom, a Ci-C₆o aliphatic radical, a C₅-C₃₀ cycloaliphatic radical, a C₆-C₃o aromatic radical, or R¹ and R² may together form a C₅-C₃₀ cycloaliphatic radical or a C₆-C₃₀ aromatic radical; with the proviso that R¹ and R², either alone or together, comprise at least 2 hydroxyl groups, wherein R¹ and/or R² optionally contain an internal functional group containing a heteroatom.

[0045] R¹ and R² may be independently at each occurrence a hydrogen atom, a Ci-C₄o aliphatic radical, a C₅-C₂₅ cycloaliphatic radical, or a C₆-C₂₅ aromatic radical, or R¹ and R² may together form a C₅-C₃₀ cycloaliphatic radical or a C₆-C₃₀ aromatic radical; with the proviso that R¹ and R², either alone or together, comprise at least two hydroxyl groups, wherein R¹ and/or R² optionally contain an internal functional group containing a heteroatom.

[0046] R¹ and R² may be independently at each occurrence a hydrogen atom, or a Ci-C₆o aliphatic radical; with the proviso that R¹ and R², either alone or together, comprise at least two hydroxyl groups, wherein R¹ and/or R² optionally contain an internal functional group containing a heteroatom which is an oxygen atom, a sulfur atom or a nitrogen atom.

[0047] Specific examples of polyols I are given in Table 1 .

Table 1 Illustrative Polyols I

[0048] Illustrative monomeric polyols I are represented by aliphatic polyols, entries la -Iv. For convenience and simplicity, the fixed structures for polyols illustrated in Table I and throughout this disclosure may include structurally related homologues where the polyol represents an alkoxylated structure as in, for example, monomeric polyols which are polyether polyols la-lb, Ih- Ij, Im, lo-lp and It-lv. Base polyols to which 1 or more of the illustrated polyether polyols may relate are; le pentaerythritol, If trimethylolpropane, Ig trimethylolethane and glycerol. Polyols Ik 2,4,6-trihydroxyheptane, II 3,5-diihydroxy-1-pentanol and Is 2,3,4,5-tetrahydroxy-1-pentanol illustrate base polyols which may be converted via alkoxylation to monomeric polyether polyols. Polyols comprising hydroxyl groups present in the base polyol; Id, Ig, lo, Iq, Ir and It-lv may represent mono- or polyether polyols resulting from partial alkoxylation of the base polyol. Polythioether polyol lc illustrates a sulfur-containing polyol. Illustrative polyols include Pluracol triols and tetrols available from BASF: triols; Pluracol TP440, Pluracol GP730, Pluracol GP430, Pluracol 945, Pluracol 858, Pluracol 816, Pluracol 1016, Pluracol 1026, Pluracol 1070, Pluracol 1135i, Pluracol 1158, Pluracol 1421 , Pluracol 1538, Pluracol 1603, Pluracol 2009, Pluracol 2019/1 , Pluracol 2086, Pluracol 2090, Pluracol 2097, Pluracol 2100, Pluracol 220, Pluracol 380, Pluracol 4156, Pluracol 593, Pluracol 726 having molecular weights ranging from 180 to 6500 g/mol and viscosities ranging from 258 to 3400 cps at 25°C and tetrols; Pluracol 922, Quadrol PM, Pluracol SG-360, Pluracol PEP550, Pluracol 1168, Pluracol 1578, and Pluracol 736; and more highly functional polyols; Pluracol SG-470 and the like and having molecular weights ranging from 292 to 740 g/mol and viscosities ranging from 1600 to 56,000 cps at 25°C.

[0049] The at least one polyol used in the disclosed method may be a mixture of one or more tetrols and one or more triols. For example the polyol may be a blend comprising greater than 20, 40, 60 or 80 percent by weight of a trifunctional polyol and less than 90, 60, 40 or 20 percent by weight of tetrafunctional polyol. Such polyol blends are a useful means of adjusting the viscosity of the polyol composition as well as a means of enhancing the physical properties of the curable polyurethane-forming compositions and cured polyurethane compositions prepared from them. [0050] The polyol may be a higher polyol represented by either of (a) structure

wherein R¹ and R² are as disclosed herein; X¹ is independently at each occurrence a carbonate group or an ether group; Q is independently at each occurrence a residue of a polyol I within a polyol structure comprising at least 2 additional residues of the same or different polyols I; and z is an integer from 1 to 5. [0051] Polyols having structures II and III incorporate residues of 2 or more constituent polyols having structure I. Specific examples of higher polyols having structure II are given in Table 2.

Table 2 Illustrative Polyols II

[0052] Illustrative polyols I la-1 It represent aliphatic higher polyols in which residues of 2 polyols having structure I are linked by a carbonate group (X¹ = OCOO) or an ether group (X¹ = O). Such residues may be residues of the same or different polyols having structure I. Each of illustrative polyols lla-llt is a linear polyol since each comprises 2 and only 2 terminal residues of at least 2 constituent polyols having structure I.

[0053] Specific examples of polyols having structure III are given in Table 3.

Table 3 Illustrative Polyols III

[0054] Illustrative polyols llla-lllo represent aliphatic higher polyols III comprising 3 residues of polyol I (z =1) which may be the same or different and in which X¹ is a carbonate group or an ether group. Illustrative polyols lllp-lllr represent aliphatic polyols III comprising residues of more than 3 polyols having structure I (z = 2 or more) which may be the same or different and in which X¹ is a carbonate group or an ether group. Each of illustrative polyols llla-lllr is a linear polyol since each comprises 2 and only 2 terminal residues of a monomeric polyol I.

[0055] Additional illustrative polyols are disclosed in Tables 2, 3 and 4 and text of United States patent US10053533 incorporated herein by reference above.

[0056] The at least one cyclic carbonate may comprise at least one hydroxyl group on a ring position of a cyclic carbonate ring and/or at least one hydroxyl group not on a ring position of a cyclic carbonate ring. Any cyclic carbonate comprising at least 1 hydroxyl group capable of reaction with the isocyanate functional component may be used. The at least one cyclic carbonate may comprise one or more cycloaliphatic and/or aromatic carbonate groups. The at least one cyclic carbonate may comprise one or more aliphatic radicals comprising one or more hydroxy groups which may include hydroxylated alkyl groups. The at least one cyclic carbonate may comprise one or more hydroxymethyl groups. The at least one cyclic carbonate may comprise a single cyclic carbonate group or more than one cyclic carbonate groups. The at least one cyclic carbonate may comprise one or more five, six or seven membered ring cyclic carbonate groups or a mixture of two or more thereof. The at least one cyclic carbonate may comprise glycerol carbonate, trimethylolpropane carbonate or a mixture thereof.

[0057] Illustrative cyclic carbonates include those represented by structure IV

wherein R³ is independently at each occurrence a hydrogen atom, a hydrocarbyl group an aliphatic radical, a cycloaliphatic radical, an aromatic radical, a hydroxyl group, two R³ groups may together represent a carbonyl group, or two or more R³ groups may together form an aliphatic radical, a cycloaliphatic radical or aromatic radical and n is an integer, with the proviso that at least one R³ group represents a hydroxyl group or comprises a hydroxyl group. [0058] R³ is independently at each occurrence a hydrogen atom, a C₁-C₆₀ aliphatic radical, a C₅- C₃₀ cycloaliphatic radical, a C₆-C₃₀ aromatic radical, a hydroxyl group, two R³ groups may together form a carbonyl group, or two or more R³ groups may together form a C₁-C₆₀ aliphatic radical, a C₅-C₃₀ cycloaliphatic radical or a C₆-C₃₀ aromatic radical, n is an integer from 0 to 10, with the proviso that at least one R³ group is a hydroxyl group or comprises a hydroxyl group.

[0059] R³ is independently at each occurrence a hydrogen atom, a C₁-C₃₀ aliphatic radical, a C₅- C₂₀ cycloaliphatic radical, a C₆-C₂₀ aromatic radical, a hydroxyl group, two R³ groups may together form a carbonyl group, two or more R³ groups may together form a C₁-C₃₀ aliphatic radical, a C₅- C₂₀ cycloaliphatic radical or a C₆-C₂₀ aromatic radical, n is an integer from 0 to 5, with the proviso that at least one R³ group is a hydroxyl group or comprises a hydroxyl group.

[0060] R³ is independently at each occurrence a hydrogen atom, a C₁-C₁₃ aliphatic radical, a C₅- C₁₄ cycloaliphatic radical, a C₆-C₁₃ aromatic radical, a hydroxyl group, two R³ groups may together form a carbonyl group, or two or more R³ groups may together form a C₁-C₁₃ aliphatic radical, a C₅-C₁₄ cycloaliphatic radical or a C₆-C₁₃ aromatic radical, n is an integer from 0 to 3, with the proviso that at least one R³ group is a hydroxyl group or comprises a hydroxyl group.

[0061] Specific examples of illustrative cyclic carbonates IV are given in Table 4.

Table 4 Illustrative Cyclic Carbonates IV



[0062] Illustrative cyclic carbonates IVa-IVw represent cyclic carbonates comprising one or more hydroxyl groups. Cyclic carbonates IVd and IVh comprise at least one hydroxyl group on a ring position of a cyclic carbonate ring. Cyclic carbonates IVa-IVc, IVe-IVg, and IVi-IVw comprise at least one hydroxyl group not on a ring position of a cyclic carbonate ring. Cyclic carbonates IVa- IVr and IVu-IVw comprise cycloaliphatic carbonate groups. Cyclic carbonates IVs and IVt comprise aromatic carbonate groups. Cyclic carbonates IVa-IVc, IVe-IVf, IVi-IVk, IVm-IVn, IVp- IVr and IVu-IVv comprise one or more aliphatic radicals comprising one or more hydroxyl groups. For example, cyclic carbonate IVa (glycerol carbonate) relates to generic structure IV in which n is 0, one of the R³ groups is the aliphatic radical CH₂OH, and three of the R³ groups are hydrogen. Aklyidene cyclic carbonate IVp relates to generic structure IV in which n is 0, two R³ groups together form a C₃ aliphatic radical comprising a hydroxyl group, and two R³ groups are hydrogen. Cyclic carbonates IVg, IVI and IVo comprise one or more cycloaliphatic radicals comprising one or more hydroxyl groups. For example, cyclic carbonate IVo relates to generic structure IV in which n is 0, one of the R³ groups is a C₁₄ cycloaliphatic radical comprising two cyclic carbonate rings and a hydroxyl group, and three of the R³ groups are hydrogen. Cyclic carbonates IVs and IVt comprise one or more aromatic radicals comprising one or more hydroxyl groups. For example, cyclic carbonate IVs relates to generic structure IV in which n is 0 and four of the R³ groups together form a C₆ aromatic radical comprising a hydroxyl group. Cyclic carbonate IVw is a dicarbonate of hexitol, mannitol dicarbonate, glucitol dicarbonate, allitol dicarbonate, iditol dicarbonate, galactitol dicarbonate or altritol dicarbonate.

[0063] The isocyanate functional component of the compositions disclosed herein may be in the form of isocyanate functional prepolymers, blocked polyisocyanates, monomers or oligomers and polymers having on average greater than 1 isocyanate group, and preferably 2 or more isocyanate groups. The isocyanate functional prepolymers can be any prepolymers prepared by reaction of an isocyanate functional compound with one or more compounds having on average more than one isocyanate reactive functional groups, such as hydroxyl, amine, thiol, carboxyl and the like, under conditions such that the prepolymers prepared have on average more than one isocyanate group per molecule. The isocyanate functional component may be any art recognized monomeric polyisocyanate, for example monomeric methylene diphenyl diisocyanate (MDI), monomeric hexamethylene diisocyanate, isophorone diisocyanate, or mixtures thereof. The isocyanate functional blocked polyisocyanate may be any art recognized blocked polyisocyanate. The isocyanate functional oligomer may be any art recognized oligomeric polyisocyanate, for example oligomeric methylene diphenyl diisocyanate (oligomeric MDI). Oligomeric aromatic polyisocyanates useful in the preparation of polyurethanes as disclosed herein include those available from The Dow Chemical Company under the trademarks PAPI and VORANATE, such as VORANTE M220, PAPI 27 and PAPI 20 polymeric isocyanates. The isocyanate functional components are present the composition in a sufficient amount to form a cured component when exposed to curing conditions. Exemplary polyisocyanates useful in the invention and in preparing isocyanate functional prepolymers include any aliphatic, cycloaliphatic, araliphatic, heterocyclic or aromatic polyisocyanates, or mixtures thereof. The polyisocyanates used may have an average isocyanate functionality of about 2.0 or greater and an equivalent weight of about 80 or greater. The isocyanate functionality of the polyisocyanates may be about 2.0 or greater, about 2.2 or greater, or about 2.4 or greater; and may be about 4.0 or less, about 3.5 or less, or about 3.0 or less. Higher functionality may be used, but may cause excessive cross-linking and result in a curable composition which is too viscous to handle and apply easily, and can cause the cured composition to be too brittle. The equivalent weight of the polyisocyanates may be about 80 or greater, about 110 or greater, or about 120 or greater; and may be about 300 or less, about 250 or less, or about 200 or less. Exemplary aliphatic polyisocyanates include those disclosed by Wu, U.S. Pat. No. 6,512,033 at column 3, line 3 to line 49, incorporated herein by reference. Exemplary polyisocyanates include, tetramethylxylene diisocyanate (aromatic), hexamethylene diisocyanate (aliphatic) and oligomeric and polymeric derivatives thereof, bis(4-isocyanatocylohexyl)methane, and trimethyl hexamethylene diisocyanate. Examples of cycloaliphatic isocyanates include trimers of hexamethylene diisocyanate, such as those available from Bayer under the trademark and designation DESMODUR N3300, DESMODUR N3400, DESMODUR N-100. Exemplary aromatic polyisocyanates may include those disclosed by Wu, U.S. Pat. No. 6,512,033 at column 3, line 3 to line 49, incorporated herein by reference. Aromatic isocyanates may include oligomeric and polymeric derivatives of MDI and TDI.

[0064] Illustrative polyisocyanates include those having structure V, and polyisocyanate prepolymers, mixed-latent polyisocyanates containing free and blocked isocyanate groups, oligomeric polyisocyanates, polymeric polyisocyanates, and mixtures thereof or may be latent polyisocyanates comprising residues thereof,

wherein R⁴ is a hydrocarbyl group and m is an integer, to form useful polyurethane materials.

[0065] R⁴ is a C₂-C₃₀ aliphatic radical, a C₅-C₂₀ cycloaliphatic radical, or a C₆-C₃o aromatic radical and m is an integer from 2 to 6. R⁴ may be a C₂-C₂₅ aliphatic radical, a C₅-C₁₅ cycloaliphatic radical, or a C₆-C₂₅ aromatic radical and m is an integer 2 or greater and 4 or less, or 3 or less. R⁴ may be a C₂-C₁₇ aliphatic radical, a C₅-C₁₃ cycloaliphatic radical, or a C₆-C₂₂ aromatic radical and m is an integer 2 or greater and 3 or less.

[0066] Specific examples of polyisocyanates having structure V are given in Table 5 and include aliphatic polyisocyanates Va-Ve, cycloaliphatic polyisocyanates Vf-Vk, and aromatic polyisocyanates Vl-Vp.

Table 5 Illustrative Polyisocyanates V

[0067] The components of the disclosed curable compositions and their proportions may include any of the components; polyols, cyclic carbonates, isocyanate functional components, catalysts, fillers, and other additives and their proportions disclosed herein or known in the art. The disclosed curable compositions include 2-part compositions which cure upon contact of the polyol composition with the isocyanate functional component to form a polyurethane product. Such compositions may be employed as a kit in which the polyol composition and the isocyanate functional component are separately compartmentalized until contacted. The disclosed curable compositions include one-part compositions in which the polyol composition and the isocyanate functional component are not separately compartmentalized, but the cure reaction is held in abeyance by one or more art recognized techniques, for example the isocyanate functional component may be a polyisocyanate or latent polyisocyanate which reacts with the polyol composition only under certain conditions, such as a temperature threshold or the presence of a catalyst. Illustrative polyisocyanates and latent polyisocyanates include sterically hindered polyisocyanates and blocked polyisocyanates as are known in the art. Such one-part polyurethane forming compositions may advantageously include one or more latent catalysts as are known in the art and allow for on-command polymerization. It may be useful to subject one or more of the components of the curable composition to a purification step prior to its conversion to a polyurethane. Purification steps may include distillation, vacuum transfer or evaporative removal of volatile components, filtration, microfiltration, nanofiltration, ultrafiltration, centrifugation, low temperature recrystallization, low temperature zone refining and trituration. [0068] The disclosed curable compositions may comprise one or more compounds having 2 or more isocyanate reactive groups and a hydrocarbon backbone wherein the backbone may further comprise one or more heteroatoms. Such compounds may be of any molecular weight which provides useful physical characteristics in the polyurethane composition, and may be chain extenders. Such compounds may be difunctional, or crosslinkers having greater than 2 active hydrogen groups per compound. The chain extender may be a lower molecular weight, moderate molecular weight or higher molecular weight diamine; for example, ethylene diamine, 1 ,3- propylene diamine, 1 ,4 butylene diamine, N,N’-dimethyl hexamethylene diamine; Jeffamine 400, Jeffamine 1000; Jeffamine 2000 and Jeffamine 4000, mixtures therof; and the like. The compound having 2 or more isocyanate reactive groups may be a triamine such as bishexamethylene triamine, Jeffamine T-403, Jeffamine T5000, mixtures thereof, and the like. The heteroatoms in the backbone may be oxygen, sulfur, nitrogen or a mixture thereof; oxygen, nitrogen or a mixture thereof; or oxygen. The molecular weight of such compounds having 2 or more isocyanate reactive groups and a hydrocarbon backbone wherein the backbone may further comprise one or more heteroatoms, may be about 4000 or less, about 2000 or less, about 1000 or less, about 500 or less, or about 200 grams per mole or less. Such compounds having 2 or more isocyanate reactive groups and a hydrocarbon backbone wherein the backbone may comprise one or more multifunctional alcohols, multifunctional alkanol amines, one or more adducts of multifunctional alcohol and an alkylene oxide, one or more adducts of a multifunctional alkanol amine and an alkylene oxide or a mixture thereof. Exemplary multifunctional alcohols and multifunctional alkanol amines include ethane diol, propane diol, butane diol, hexane diol, heptane diol, octane diol, neopentyl glycol, diethanol amine, di-isopropanol amine, triisopropanol amine, and the like. Blends of such compounds having 2 or more isocyanate reactive groups may be used. The compound having 2 or more isocyanate reactive groups may be a component of the polyol composition. Such compounds may be present in the composition in an amount of about 2, 3, or 4 percent by weight or greater based on the total weight of the polyurethane forming composition. Such compounds may be present in the composition in an amount of about 16, 12, 10 percent by weight or less based on the total weight of the polyurethane forming composition.

[0069] The curable compositions may comprise a catalyst for the reaction of hydroxyl groups with isocyanate groups. Illustrative catalysts include any polyurethane catalysts known in the art which allow for control of the rate of polyurethane formation from the curable composition and which do not negatively affect the stability of the product polyurethane. Among exemplary catalysts are organotin compounds, metal alkanoates and tertiary amines. Mixtures of classes of catalysts may be used, such as a mixture of a tertiary amine and one or more of organotin compounds or metal alkanoates. Such a mixture may include tertiary amines, such as dimorpholino diethyl ether, and a metal alkanoate, such as bismuth octoate. Included in organotin compounds are alkyl tin oxides, stannous alkanoates, dialkyl tin carboxylates and tin mercaptides. Stannous alkanoates include stannous octoate. Alkyl tin oxides include dialkyl tin oxides, such as dibutyl tin oxide and its derivatives. Exemplary organotin compounds are dialkyltin dicarboxylates and dialkyltin dimercaptides. Dialkyl tin dicarboxylates with lower total carbon atoms are preferred as they are more active catalysts in the compositions. Exemplary dialkyl dicarboxylates include 1 ,1 - dimethyltin dilaurate, 1 ,1-dibutyltin diacetate and 1 ,1-dibutyltin dimaleate. Metal alkanoates may include bismuth octoate and bismuth neodecanoate. The organo tin compounds or metal alkanoates may be present in an amount of about 60 parts per million or greater based on the weight of the composition, about 90 parts by million or greater or about 120 parts by million or greater. The organo tin compounds or metal alkanoates may be present in an amount of about 1 .0 percent or less based on the weight of the composition, about 0.5 percent by weight or less or about 0.2 percent by weight or less. Exemplary tertiary amine catalysts include dimorpholinodialkyl ether, a di((dialkyl-morpholino)alkyl)ether, bis-(2-dimethylaminoethyl)ether, triethylene diamine, pentamethyldi-ethylene triamine, N,N-dimethylcyclohexylamine, N,N- dimethyl piperazine, 4-methoxyethyl morpholine, N-methylmorpholine, N-ethyl morpholine, diazabicyclo compounds and mixtures thereof. An exemplary dimorpholinodialkyl ether is dimorpholinodiethyl ether. An exemplary di((dialkylmorpholino)alkyl)ether is (di-(2-(3,5- dimethylmorpholino)ethyl)-ether). Exemplary diazabicyclo compounds include diazabicycloalkanes and diazabicyclo alkene salts. Exemplary diazabicycloalkanes include diazabicyclooctane, available from Air Products under the trademark and designations, DABCO, DABCO WT, DABCO DC 1 , DABCO DC 2, and DABCO DC 21 . Diazabicycloalkene salts include diazabicycloundecene in the phenolate, ethylhexoate, oleate and formate salt forms, available from Air Products under the trademark and designations, POLYCAT SA 1 , POLYCAT SA 1/10, POLYCAT SA 102 and POLYCAT SA 610. Tertiary amines may be employed in about 0.01 , 0.05, 0.1 , 0.2, or 2.0 percent by weight or greater based on the total weight of the composition. Tertiary amines may be employed in about 1 .5, 1 .2, or 1 percent by weight or less based on the total weight of the composition.

[0070] The curable compositions may comprise one or more fillers which enhance the performance characteristics of the product polyurethanes without unduly affecting the physical characteristics of the curable composition. Either or both of the isocyanate functional component and the polyol composition may contain a filler. Fillers may include fillers disclosed herein and those known in the art. Fillers may impart the appropriate viscosity and rheology to the curable composition and strike a balance between cost and the desired properties of the curable composition and the cost of the product polyurethane composition. Reinforcing fillers, such as one or more carbon blacks, one or more clays, non-pigmented fillers, treated and untreated talc, calcium carbonate and combinations thereof may be used. Clays include kaolin, surface treated kaolin, calcined kaolin, aluminum silicates and surface treated anhydrous aluminum silicates. Fillers are used in a sufficient amount to impart an acceptable balance of viscosity and cost to the curable composition and to achieve the desired properties of the product polyurethane composition. The one or more fillers may be present in an amount from greater than 0.001 % to less than 60 % by weight of the total weight of the curable composition. The one or more fillers may be present in an amount from greater than 0.001 % to less than 5 % by weight of the total weight of the curable composition. The filler may comprise an electrically conductive material. The filler may include one or more nano-particulate materials as exemplified nano clays, organic nano clays, nano-particulate silica, nano-particulate titania, nano-particulate zirconia and nano particulate boron nitride. The filler may comprise an electrically conductive material comprising carbon nanotubes. The filler may comprise single wall carbon nanotubes such as those offered commercially under the tradename T uball™. The curable composition may comprise fillers which function as thixotropes. Such thixotropes are well known and include fumed silica and the like. Fumed silicas include organically modified fumed silicas. The thixotrope may be added to the curable composition in a sufficient amount to give the desired rheological properties. Additional fillers include glass flake, glass fibers carbon fibers and basalt fiber.

[0071 ] The filler may be present in about 10, 20, 30, or 40 percent by weight or greater based on the total weight of the curable composition. The filler may be present in about 60, 40, 20, or 10 percent by weight or less based on the total weight of the curable composition.

[0072] Composite materials incorporating polyurethane compositions disclosed herein may be prepared using art recognized techniques such as are disclosed in Applicants’ co-pending application W02020086470A1 filed October 21 , 2019 and which is incorporated herein by reference in its entirety for all purposes.

[0073] The curable compositions may contain plasticizers in either or both of the isocyanate functional component and the polyol composition. Exemplary plasticizers include straight and branched alkylphthalates, such as diisononyl phthalate, dioctyl phthalate and dibutyl phthalate, a partially hydrogenated terpene commercially available as ‘ΉB-40”, trioctyl phosphate, alkylsulfonic acid esters of phenol, toluene sulfamide, adipic acid esters, castor oil, xylene, 1- methyl-2-pyrrolidinone and toluene. Exemplary plasticizers are branched plasticizers, such as branched chain alkyl phthalates for example di-isononyl phthalates (available under the Trademark PLATINOL N from BASF. The amount of plasticizer used is that amount sufficient to give the desired rheological properties and disperse the components in the curable composition. The plasticizer may be present in about 1 , 5, or 10 percent by weight or greater based on the total weight of the curable composition. The plasticizer may be present in about 50, 40, 30, 15, or 5 percent by weight or less based on the total weight of the curable composition.

[0074] Other components commonly used in curable compositions may be used in the compositions. Such materials are well known to those skilled in the art and may include ultraviolet stabilizers, antioxidants, mold release compounds, both external or internal, and the like.

[0075] The curable compositions disclosed herein may be processed into polyurethane containing parts using one or more known processing techniques including Pultrusion, Reaction Injection Molding (RIM), Compression Molding, Resin Transfer Molding, Poured Open Molding, Filament Winding, Vacuum Infusion, Vacuum Assisted Resin Transfer Molding (VARTM) and Sprayed Open Molding.

[0076] The relatively low viscosity of the polyol compositions makes it possible to manufacture such polyurethanes in relatively low-cost and high throughput manufacturing equipment, such as meter mixing equipment and reaction injection molding equipment. Such equipment types are ill suited for use with viscous polyol compositions which may require specialized pumping and higher temperature handling capabilities. The lower viscosity of the polyol compositions allows (1 ) more complete mixing of a composition comprising a first part containing the disclosed polyol composition, and a second part containing the at least one isocyanate functional component , and (2) delivery to a mold or die at lower temperature than would be required in systems in which the first part comprises a more viscous polyol composition. This in turn may moderate the in-mold exotherm arising as the polyurethane-forming formulation cures inside a mold. Lower in-mold peak exotherm temperatures in turn make the use of FRP tooling more efficient by extending the useful life of such tooling. Similarly, cycle times may be reduced as a result of lower in-mold peak exotherm temperatures.

[0077] The polyurethane materials and articles containing them may be prepared using the techniques disclosed herein as well as art-recognized polyurethane polymer preparation and processing techniques such as those disclosed in E.N. Doyle’s The Development and Use of Polyurethane Products (McGraw-Hill, Inc. 1971), Saunders’ et al. Polyurethanes Chemistry and Technology, Parts I - II (Interscience Publishers), Saunders’ Organic Polymer Chemistry (Chapman and Hall), J.M. Burst’s Developments in Polyurethanes (Applied Science Publishers) and the Kirk Othmer Encyclopedia of Chemical Technology which are incorporated herein by reference in their entirety for all purposes. Experimental Part

General

[0078] Examples describing the preparation of polyol compositions and their conversion into polyurethane materials are presented. Polyol viscosities are measured on a TA Instruments (New Castle, Delaware) Discovery Hybrid Rheometer at steady state shear and variable temperature sweep using a 25 mm diameter parallel-plate geometry and a 1000 micron gap to provide viscosity values as a function of temperature according to the standard instrument operating protocols furnished by the manufacturer. Mechanical analysis performed is carried out using a 3-point flexural (ASTM D790 03 Procedure B) protocol with a 0.1 inch/inch/minute strain rate and 16:1 spa thickness ratio. The test specimens are 0.5 inch x 5.5 inch x 0.125 inch bars cut from plaques of the product materials and are tested 24 hours after molding. The test instrument is a 5969 Instron Universal Mechanical Analyzer. Heat distortion temperatures are measured according to ASTM D648 at loads of 0.45 or 1 8MPa.

[0079] Exemplary polyol compositions include the monomeric polyol Pluracol PEP 450 (PEP 450) and higher polyols containing PEP 450 residues. PEP 450 has a nominal molecular weight of 368.46 g/mol but its average molecular weight is approximately 404 g/mol as determined from its reported hydroxyl number of 540-570 mg KOH/g. PEP 450 has a hydroxyl group content of about 16.8 % by weight. Hydroxyl number is determined by ASTM E222 and is expressed as mg KOH per gram PEP 450. Dividing the molecular weight of KOH expressed in mg/mol (56,100 mg/mol) by the hydroxyl number taken here to be 555 mg/mol affords an equivalent weight of 101 g PEP 450 per equivalent of OH group. Multiplying the equivalent weight by the number of OH equivalents (4 per mol of PEP 450) affords a molecular weight of 404 g/mol.

Mol Wt PEP 450 = (Mol Wt KOH (mg/mol)/ (OH Number (mg KOH/g PEP)) x 4 =404 g/mol.

[0080] As a precaution, polyol compositions were heated under a stream of nitrogen at 175°C for 15 minutes to remove traces of water and methanol prior to polyurethane formation. Pluracol^® PEP 450, hereinafter “PEP 450” was obtained from BASF. Glycerol carbonate was obtained from Alichem. Baydur^® 486, hereinafter “Baydur 486” was obtained from Covestro.

Example 1 : Preparation of Polyol Composition Comprising Polyol and Cyclic Carbonate and Polyurethane Product Therefrom [0081] To a 2-liter glass reactor equipped with a mechanical agitator, overhead vent and nitrogen purge line is added the polyol la (PEP 450, 636.5 g, 1 .56 mole), and (147.5 g, 1 .25 moles) glycerol carbonate lla. The contents of the reactor are stirred at 175°C for 15 minutes to produce a colorless polyol composition having a viscosity significantly less than 1000 cps at 150°F and a hydroxyl number of 519. The proton NMR spectrum is consistent with a mixture of glycerol carbonate and polyol la. A portion (132.8 g) of the polyol composition is transferred to a beaker and degassed in a vacuum oven at 180°F at a pressure of approximately 23 inches of mercury for one hour. Baydur 486 polyisocyanate is charged to a separate beaker and degassed at 140°F in a vacuum oven at approximately 23 inches of mercury for 1 hour. The degassed polyol composition is then heated briefly in a microwave oven to raise its temperature to 220°F. The isocyanate functional component, Baydur 486 (217.2 g, 27.3 % NCO), at 140°F is then added to the polyol composition and the mixture is thoroughly mixed for 20 seconds at 1 ,000 RPM to afford a curable polyurethane-forming composition comprising the polyol, glycerol carbonate and the polyisocyanate and having an isocyanate to hydroxyl group index of 1 .1 . The curable composition is then poured into a mold held at 250°F and cured for 30 minutes to afford a product polyurethane having excellent homogeneity and surface appearance, a flexural modulus of 3653.74 ± 68.11 and a flexural strength of 173.49 ± 1 .63 MPa.

Comparative Example 1 :

[0082] PEP 450 (130.7 g, 0.32 mole) and Baydur 486 polyisocyanate are degassed in separately in open beakers as in Example 1 . The degassed polyol is briefly heated as in Example 1 to 220°F. The polyisocyanate (219.3 g, 27.3 % NCO) at 140°F is then added to the polyol and the mixture is thoroughly mixed for 20 seconds at 1 ,000 RPM to afford a polyurethane-forming composition comprising the polyol and the isocyanate functional component. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having a flexural modulus of 3100.46 ± 40.92 and a flexural strength of 144.84 ± 1 .57 MPa.

Example 2: Preparation of Polyol Composition Comprising Cyclic Carbonate and Polyurethane Product Therefrom

[0083] To a 2-liter glass reactor equipped as in Example 1 is added PEP 450 (636.5 g, 1 .56 mole) and glycerol carbonate (147.5g, 1.25 mole). The contents of the reactor are stirred at 175°C for 15 minutes to produce a master polyol composition. To a portion (122 g) of the master polyol composition is added glycerol (38 g, 0.414 moles) and PEP 450 (84 g, 0.207 moles). A portion of this polyol composition (107.3 g) (hydroxyl number of 619) and Baydur 486 polyisocyanate are degassed as in Example 1 . The degassed polyol composition is heated to 220°F as in Example 1 . The polyisocyanate (242.7 g, 27.3 % NCO) at 140°F is then added to the polyol composition at 220°F and mixed as in Example 1 to afford a curable polyurethane-forming composition comprising the polyols PEP 450 and glycerol, the cyclic carbonate, glycerol carbonate, and the polyisocyanate. The curable polyurethane-forming composition is then poured into a mold held at 250°F and cured for 30 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3637.8 ± 125.04 and a flexural strength of 172.84 ± 4.85 MPa.

Comparative Example 2:

[0084] To a 1 -liter glass reactor equipped as in Example 1 is added polyol PEP 450 (408 g, 1 mole) and glycerol (92 g, 1 mole). The contents of the reactor are stirred at 180°C for 10 minutes under nitrogen to produce a colorless polyol mixture. A portion (103 g) of this polyol mixture and Baydur 486 (246.92 g, 27.3 % NCO) are degassed and mixed as in Example 1 to afford a polyurethane-forming composition. The composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having flexural modulus of 3323.11 ± 33.83 and a flexural strength of 159.40 ± 1.16 MPa.

Comparative Example 3:

[0085] A polyol mixture comprising PEP 450 (408 g, 1 mole), and glycerol (138 g, 1.5 moles) glycerol is prepared as in Comparative Example 2. A portion (95.53 g) of the polyol mixture and Baydur 486 (254.47 g, 27.3 % NCO) are degassed and mixed as in Example 1 to afford a polyurethane-forming composition. The composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having flexural modulus of 3278.46 ± 113.84 and a flexural strength of 104.83 ± 42.03 MPa.

Comparative Example 4:

[0086] To a 1 -liter glass reactor equipped as in Example 1 is added PEP 450 (404 g, 1 mole) and ethylene carbonate (Sigma-Aldrich) (106 g, 1.2 moles). The contents of the reactor are stirred and heated to 175°C for 15 minutes to produce a colorless mixture of the polyol and ethylene carbonate. A portion of the mixture (150 g) and Baydur 486 (200 g, 27.2 % NCO groups) are degassed and mixed as in as in Example 1 to afford a polyurethane-forming composition. The curable composition is then poured into a mold held at 266°F and cured for 45 minutes to afford a product polyurethane having a first pass glass transition temperature Tg1 of 89°C and a second pass glass transition temperature Tg2 of 92°C. The relatively low glass transition temperatures indicate that replacement of the cyclic carbonate comprising one or more hydroxyl groups with a cyclic carbonate comprising no hydroxyl groups results in significant plasticization of the product polyurethane.

Comparative Example 5:

[0087] To a 2 -liter glass reactor equipped as in Example 1 is added PEP 450 (636.5 g, 1 .56 mole) and propylene carbonate (127.6 g, 1.25 mole) (Acros), CAS No. 108-32-7. The contents of the reactor are stirred and heated as in Example 1 to produce a colorless mixture of the polyol and propylene carbonate. A portion of the mixture (131 g) and Baydur 486 (229 g, 27.3 % NCO) are degassed and mixed as in Example 1 to afford a polyurethane-forming composition which is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having a flexural modulus of 3453.93 ± 31.51 MPa and a flexural strength of 153.77 ± 0.90 MPa. The product polyurethane exhibited a glass transition temperature of 78°C as measured by differential scanning calorimetry (DSC) indicating significant plasticization of the product polyurethane.

Examples 3-6 Preparation of Polyol Composition Comprising Cyclic Carbonate and Polyurethane Product Therefrom

Example 3: 1 :1 Molar Ratio Cyclic Carbonate to Polyol

[0088] A polyol composition containing PEP 450 (608.9 g, 1 .49 moles) and glycerol carbonate (176.1 g, 1.49 moles) is prepared as in Example 1. A portion of the polyol composition (133.3 g) and Baydur 486 (216.7 g) are then degassed and mixed as in Example 1 to afford a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having flexural modulus of 3588.64 ± 59.79 and a flexural strength of 168.42 ± 4.16 MPa.

Example 4: 1 .2:1 Molar Ratio Cyclic Carbonate to Polyol

[0089] A polyol composition containing PEP 450 (582.75 g, 1 .43 moles) and glycerol carbonate (202.25 g, 1.71 moles) is prepared as in Example 1. A portion of the polyol composition (133.6 g) is then degassed and combined with Baydur 486™ polyisocyanate (216.4 g) as in Example 1 to afford a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having flexural modulus of 3840.13 ± 18.17 and a flexural strength of 185.94 ± 1.99 MPa.

Example 5: 1 .67:1 Molar Ratio Cyclic Carbonate to Polyol

[0090] A polyol composition containing PEP 450 (529.7 g, 1 .30 moles) and glycerol carbonate (255.3 g, 2.17 moles) is prepared as in Example 1. A portion of the polyol composition (134.4 g) is then degassed and combined with Baydur 486 (215.6 g) as in Example 1 to afford a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having flexural modulus of 3819.26 ± 43.60 and a flexural strength of 180.73 ± 2.01 MPa.

Example 6: 2:1 Molar Ratio Cyclic Carbonate to Polyol

[0091] A polyol composition containing PEP 450 (497.3 g,1 .22 moles) (BASF) and glycerol carbonate (287.7 g, 2.44 moles) is prepared as in Example 1 . A portion of the polyol composition (134.9 g) is then degassed and combined with Baydur 486™ polyisocyanate (215.1 g) as in Example 1 to afford a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having flexural modulus of 3939.80 ± 72.83 and a flexural strength of 134.99 ± 31.13 MPa.

Examples 7-10 Preparation of Polyol Composition Comprising Cyclic Carbonate and Polyurethane Product Therefrom

Example 7: 0.5:1 :1.67 Molar Ratio Triol:Tetrol:Cyclic Carbonate

[0092] To a 2 -liter glass reactor equipped with a mechanical agitator, overhead vent and nitrogen purge line is added PEP 450 (529.7 g, 1.30 moles) and glycerol carbonate (255.3 g, 2.17 moles). The contents of the reactor are stirred and heated at 175°C for 15 minutes to produce a colorless master polyol composition. To a portion of this master polyol composition (185.87 g) is added glycerol (14.13 g, 0.154 moles) to afford a polyol composition containing glycerol, PEP 450 and glycerol carbonate in a 0.5 to 1 to 1.67 molar ratio. A portion (121.3 g) of this polyol composition and Baydur 486 (228.7g, 27.3 % NCO) are degassed and combined as in Example 1 to form a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3871 .18 ± 42.87 MPa and a flexural strength of 189.202 ± 2.02 MPa. An infrared spectrum of the product polyurethane is shown in FIG. 2. The peak at 1796 cnr¹ indicates the presence of residues of the cyclic carbonate wherein the cyclic carbonate ring structure remains intact. The peak at 2276 cnr¹ indicates residual intact isocyanate groups.

Example 8: 1 :1 :1.67 Molar Ratio T riol:T etrol: Cycl ic Carbonate [0093] To a portion (173.6 g) of the master polyol composition prepared in Example 7 is added glycerol (26.40 g, 0.287 moles) to afford a polyol composition containing glycerol, PEP 450 and glycerol carbonate in a 1 to 1 to 1 .67 molar ratio. A portion (111 .9 g) of this polyol composition and Baydur 486 (238.1 g, 27.3 % NCO) are degassed and combined as in Example 1 to form a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3792 ± 50.74 MPa and a flexural strength of 185.79 ± 1.75 MPa.

Example 9: 1 .5:1 :1 .67 Molar Ratio Triol:Tetrol:Cyclic Carbonate

[0094] To a portion (162.85 g) of the master polyol composition prepared in Example 7 is added glycerol (37.14 g, 0.4.04 moles) to afford a polyol composition containing glycerol, PEP 450 and glycerol carbonate in a 1 .5 to 1 to 1 .67 molar ratio. A portion (111 .9 g) of this polyol composition and Baydur 486 (238.1 g, 27.3 % NCO) are degassed and combined as in Example 1 to form a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3771 ± 60.05 MPa and a flexural strength of 184.35 ± 1.75 MPa.

Examples 10-13 Preparation of Polyol Composition Comprising Cyclic Carbonate and Polyurethane Product Therefrom With Variations in Isocyanate Index

Example 10: Isocyanate Index 1.0

[0095] A polyol composition containing PEP 450 (582.75 g, 1 .43 moles) and glycerol carbonate (202.25 g, 1.71 moles) is prepared as in Example 1. To a portion (461.38 g) of this polyol composition at 180°F is added glycerol (38.62 g, 0.42 moles) to afford a master polyol composition containing glycerol, PEP 450 and glycerol carbonate in a 0.5 to 1.0 to 1.2 molar ratio and having a viscosity significantly less than 1000 cps at 150°F. A portion of this master batch (127 g) and Baydur 486 (223 g, 27.3 % NCO) are degassed and combined as in Example 1 to form a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3712 MPa and a flexural strength of 178 MPa.

Example 11 Isocyanate Index 1.1

[0096] A portion (120 g) of the master polyol composition prepared in Example 10 and Baydur 486 (230 g) are degassed and combined as in Example 1 to form a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3784 MPa and a flexural strength of 182 MPa.

Example 12 Isocyanate Index 1.2

[0097] A portion (113 g) of the master polyol composition prepared in Example 10 and Baydur 486 (237 g) are degassed and combined as in Example 1 to form a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3784 MPa and a flexural strength of 182 MPa.

Example 13 Isocyanate Index 1.3

[0098] A portion (107 g) of the master polyol composition prepared in Example 10 and Baydur 486 (237 g) are degassed and combined as in Example 1 to form a curable composition. The curable composition is then poured into a mold held at 275°F and cured for 45 minutes to afford a product polyurethane having excellent homogeneity and surface appearance and having a flexural modulus of 3753 MPa and a flexural strength of 145 MPa.

Comparative Example 6: Modified Prepolymer Comprising Cyclic Carbonate Residues

[0099] Glycerol carbonate (104 g, 0.88 moles) and Baydur 486 polyisocyanate (651 g, 27.3 % NCO, 4.21 mole equivalents) are combined at room temperature in a glass reactor equipped as in Example 1 . The mixture is stirred for 30 minutes and then heated to 50°C at which point a modest exotherm is observed which reaches 100°C after about 50 minutes. The mixture is then allowed to cool to provide a glycerol carbonate modified prepolymer containing residues of glycerol carbonate, residues of the polyisocyanate, and unreacted polyisocyanate. The glycerol carbonate modified prepolymer was noticeably viscous at 100°C, and at room temperature was highly viscous to the point of being resistant to flow under the influence of gravity.

Comparative Example 7: Polyurethane from Modified Prepolymer of Comparative Example 6

[0100] A portion of the modified prepolymer prepared in Comparative Example 6 (250 g) is warmed to 175 °F and added to PEP450 (100 g) which is heated to 200 °F and the two are mixed for 30 seconds with an air driven blade. The prepolymer is highly viscous and does not appear to mix well with the PEP450. A test plaque is molded as in Example 1. The test plaque is noticeably brittle, contains numerous voids, exhibits a flexural strength of 139 MPa and a first glass transition temperature Tg1 of 99°C and an unchanged second pass glass transition temperature Tg2 of 99°C. A photograph of the test plaque is shown in Fig. 3.

Comparative Example 8: Polyurethane from Modified Prepolymer of Comparative Example 6

[0101 ] PEP450 (100 g) which is heated to 200 °F is added to a portion of the modified prepolymer prepared in Comparative Example 6 (250 g) warmed to 200 °F and the two are mixed for 30 seconds with an air driven blade. The two components appear to mix more thoroughly than in Comparative Example 7, however, a test plaque prepared as in Example 1 is noticeably brittle, contains numerous voids, exhibits a flexural strength of 101 MPa and first and second pass glass transition temperatures Tg1 and Tg2 of 114°C and 115 °C respectively.

Table 6: Physical Properties of Product Polyurethanes

[0102] Examples 1 -13 illustrate the preparation and properties of useful curable compositions prepared from low viscosity polyol compositions comprising both a polyol comprising 3 or more hydroxyl groups and a cyclic carbonate comprising at least one hydroxyl group. Polyurethanes prepared from these compositions exhibit both high modulus and high strength. Comparative Examples 1 -3 highlight the need for a cyclic carbonate in the polyol composition. Comparative Examples 4-5 highlight the need for a cyclic carbonate comprising at least one hydroxyl group in the polyol composition. Comparative Examples 7-8 highlight the need for a low viscosity polyol composition.

Methods 1 -7 Preparation of Polyol Compositions Comprising Polyols Comprising Carbonate Linking Groups

Method 1

[0103] To a 20-L reactor equipped with a mechanical agitator, overhead vent and nitrogen purge line is added PEP 450 (BASF), (8123.00 g, 22.05 mol, 67.48%), and a 20% solution of potassium hydroxide (4.2 g, 0.03%) in methanol. The contents of the reactor are stirred and heated to 150°C. A second polyol, pentaerythritol, (534.00 g, 3.92 mol, 4.44%) is added to the reactor with continued stirring. The pentaerythritol substantially dissolves within a 2 minute period. The mechanical agitator shaft speed is maintained at approximately 5000 rpm which corresponds to a linear velocity of the mixing blade of approximately 100 feet per second. Bisphenol A polycarbonate powder (3200.00 g, 26.59%), LEXAN^R105 (Sabic), is then added over a 7 minute period. After 25 minutes no polycarbonate powder remains visible in the reactor. After approximately 32 minutes the rate of agitation is lowered to approximately 1000 rpm and the reaction mixture is allowed to cool. When the reaction mixture reaches approximately 50°C, a phosphoric acid alkyl ester weakly acidic catalyst, Nacure 4000 (5.90 g, 0.05%) is added under stirring to quench any remaining potassium hydroxide and other basic species in the reaction mixture. After further cooling the entire contents of the reactor representing the product polyol composition are transferred to a storage vessel. The product polyol composition has a viscosity of 770 cps at 150°F.

Method 2

[0104] The polyol of Method 1 (200 g) containing 22-24% by weight free bisphenol A is dissolved in methylene chloride and transferred into a separatory funnel and washed 5 times with 300 mL portions of a stock solution prepared from 40 g sodium hydroxide and 2 L of water and the phases are separated. The pH of the aqueous phase is monitored after each wash to assure adequate deprotonation and extraction of the free bisphenol A. The methylene chloride phase is then washed 5 times with 1% hydrochloric acid and 5 times with deionized water. The methylene chloride phase is then dried over sodium sulfate, filtered and the methylene chloride is removed on a rotary evaporator and then dried on a vacuum manifold to constant weight. The product polyol composition contains a statistical mixture of the unreacted PEP-450 and product polyols containing 2-5 residues of PEP-450 linked by 1 -4 carbonate linkages, all of which product polyols are present in the starting polyol composition of Method 1 . The product polyol composition is essentially free of free bisphenol A, is suitable for use in the preparation of polyurethanes and foamed polyurethanes and contains about 13.5% by weight OH groups.

Method 3

[0105] PEP 450 (1000 g, 2.47 mol, PEP 450), diethyl carbonate (131 .12 g, 1.11 mol) and catalyst (KOH or K₂C0₃, (250 ppm)) are charged to a glass reactor equipped with a stirrer, reflux condenser, and internal thermometer. The mixture is heated to a temperature in a range from about 120° C to about 140° C. As the carbonate exchange reaction between diethyl carbonate and PEP 450 takes place ethanol is formed and reflux ensues. The reflux condenser is subsequently replaced with a still head and ethanol is distilled from the reaction mixture. The temperature of the reaction mixture is slowly raised to 160° C. The pressure is then slowly lowered to about 10 Torr. After approximately 1 hr heating is discontinued and the product polyol composition is allowed to cool. When the reaction mixture reaches approximately 50°C an amount of Nacure 4000 sufficient to quench the basic catalyst is added under stirring. The product polyol composition contains a statistical mixture of the unreacted PEP 450 and linear product polyols containing 2-5 residues of PEP 450 linked by 1-4 carbonate linkages and about 12.5 % by weight hydroxyl groups. The product polyol is essentially free of aromatic components and is suitable for use in the preparation of polyurethanes and foamed polyurethanes.

Method 4

[0106] To the polyol composition prepared in Method 3 (500 g) is added glycerol carbonate (125 g) and PEP 450 (100 g). The mixture is stirred warmed to produce a homogeneous polyol composition comprising glycerol carbonate, the monomeric polyol PEP-450 and the higher polyol components comprising 2-5 residues of PEP-450 linked by 1-4 carbonate linkages which is suitable for use in the preparation of polyurethanes and foamed polyurethanes. The polyol composition contains approximately 13.4 % by weight hydroxyl groups.

Method 5

[0107] To a polyol composition prepared as in Method 3 (500 g) is added glycerol carbonate (150 g) and PEP 450 (50 g). The mixture is stirred warmed to produce a homogeneous polyol composition comprising glycerol carbonate, the monomeric polyol PEP-450 and the higher polyol components comprising 2-5 residues of PEP-450 linked by 1-4 carbonate linkages and is suitable for use in the preparation of polyurethanes and foamed polyurethanes. The polyol composition contains approximately 13.2 % by weight OH groups.

Method 6

[0108] PEP-450 (200.00 g, 0.49 mol) and biscarbonate 1 (CAS No. 412312-38-0) (62.92 g, 0.24 mol) and catalyst (KOH or K₂C0₃, (50 ppb)) are charged to a glass reactor equipped with a mechanical stirrer, nitrogen inlet and exit ports and an internal thermometer. The mixture is stirred and heated to a temperature in a range from about 100° C to about 180° C for 2 hr to produce a polyol composition comprising unconsumed PEP 450, a suite of linear carbonate-containing dimers, trimers, tetramers and pentamers comprising from 2 to 5 residues of PEP-450 as a statistical mixture together with glycerol carbonate liberated as carbonate groups are transferred from biscarbonate 1 to PEP 450 and product polyols comprising residues of PEP 450 linked by 1 or more carbonate groups. The catalyst is quenched with Nacure 4000 under stirring at 50°C. The product polyol composition contains about 12.8 % by weight hydroxyl groups and 21 % by weight glycerol carbonate. The product polyol is essentially free of aromatic components and is suitable for use in the preparation of polyurethanes and foamed polyurethanes.

Method 7

[0109] Following the protocol of Method 3, PEP 450 (200 g, 0.49 mol) and di-t-butyl dicarbonate 2 (52.34 g, 0.24 mol) and a catalyst (KOH or K₂C0₃, (250 ppm)) are charged to a glass reactor equipped with stirrer, reflux condenser, and internal thermometer. The mixture is stirred and heated to a temperature in a range from about 100° C to about 140°C. As the reaction takes place carbon-dioxide and t-butanol are formed and reflux of the t-butanol ensues. The reflux condenser is subsequently replaced with a still head and t-butanol is distilled from the reaction mixture. The temperature of the reaction mixture is slowly raised to 160° C. The pressure is then slowly lowered to about 5 Torr. Heating is then discontinued and the product polyol composition is allowed to cool. The catalyst is quenched by the addition of Nacure 4000 under stirring at 50°C. The product polyol composition contains a statistical mixture of the unconsumed polyol PEP-450 and linear product polyols containing 2-5 residues of PEP-450 linked by 1-4 carbonate linkages. The product polyol composition contains about 16.2 % by weight hydroxyl groups, is essentially free of aromatic components and is suitable for use in the preparation of polyurethanes and foamed polyurethanes. Numbered Embodiments

1 . A curable composition comprising:

(a) a polyol composition comprising:

(i) at least one polyol comprising three or more hydroxyl groups;

(ii) at least one cyclic carbonate comprising one or more hydroxyl groups;

(b) at least one isocyanate functional component comprising isocyanate groups, latent isocyanate groups, or a mixture thereof; and optionally

(c) a catalyst; wherein the composition when subjected to conditions sufficient to cause the polyol composition and the isocyanate functional component to react, the composition cures by reaction of at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate with the isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form urethane linkages of a polyurethane composition.

2. The composition of embodiment 1 , wherein the isocyanate functional component comprises a polyisocyanate, a latent polyisocyanate, or a mixture thereof.

3. The composition of any of embodiments 1-2, wherein a latent catalyst is present in the composition.

4. The composition of any of embodiments 1-3, wherein both a latent catalyst and a latent polyisocyanate are present in the composition.

5. The composition of any of embodiments 1-4, wherein the cyclic carbonate is present in about 5 percent to about 40 percent by weight based on the total weight of the polyol composition.

6. The composition of any of embodiments 1-5, wherein the polyol composition has a viscosity of less than 1000 cps at 150 °F, wherein the viscosity is determined on a rheometer as disclosed herein operated at steady state shear and variable temperature sweep according to standard instrument operating protocols furnished by the manufacturer.

7. The composition of any of embodiments 1-6, wherein the at least one polyol comprises three or more secondary hydroxyl groups. 8. The composition of any of embodiments 1-7, wherein the at least one polyol comprises one or more ether groups.

9. The composition of any of embodiments 1-8, wherein the at least one polyol is at least tetrafunctional comprising four or more hydroxyl groups.

10. The composition of any of embodiments 1 -9, wherein the at least one polyol comprises four or more secondary hydroxyl groups.

11. The composition of any of embodiments 1 -10, wherein the at least one polyol comprises a mixture of polyols having an average molecular weight of less than 500 grams per mole.

12. The composition of any of embodiments 1-11 , wherein the at least one polyol comprises an alkoxylated polyether polyol.

13. The composition of any of embodiments 1 -12, wherein the at least one polyol comprises a C₂to C₄ alkoxylated polyether polyol.

14. The composition of any of embodiments 1 -13, wherein the at least one polyol comprises three or more vicinal hydroxyl groups.

15. The composition of any of embodiments 1 -14, wherein the at least one polyol comprises glycerol.

16. The composition of any of embodiments 1 -15, wherein the at least one polyol comprises one or more carbonate groups .

17. The composition of any of embodiments 1 -16, wherein the at least one polyol comprises one or more carbonate groups and one or more ether groups.

18. The composition of any of embodiments 1 -17, wherein the at least one polyol comprises six or more secondary hydroxyl groups.

19. The composition of any of embodiments 1 -18, wherein the polyol composition further comprises a polyhydroxylated aromatic compound.

20. The composition of embodiment 19, wherein the polyhydroxylated aromatic compound comprises one or more bisphenols.

21. The composition of any of embodiments 19-20, wherein at least a portion of the at least one polyhydroxylated aromatic compound comprises bisphenol A, bisphenol S, bisphenol M, bisphenol AP or a combination thereof. 22. The composition of any of embodiments 1 -21 , wherein the cyclic carbonate comprises at least one hydroxyl group on a ring position of a cyclic carbonate ring.

23. The composition of any of embodiments 1-22, wherein the cyclic carbonate comprises at least one hydroxyl group not on a ring position of a cyclic carbonate ring.

24. The composition of any of embodiments 1-23, wherein the cyclic carbonate comprises one or more cycloaliphatic carbonate groups.

25. The composition of any of embodiments 1-24, wherein the cyclic carbonate comprises one or more aromatic carbonate groups.

26. The composition of any of embodiments 1-25, wherein the cyclic carbonate comprises one or more aliphatic radicals comprising one or more hydroxy groups.

27. The composition of any of embodiments 1-26, wherein the cyclic carbonate comprises one or more hydroxylated alkyl groups.

28. The composition of any of embodiments 1-27, wherein the cyclic carbonate comprises one or more hydroxymethyl groups.

29. The composition of any of embodiments 1-28, wherein the cyclic carbonate comprises a single cyclic carbonate group.

30. The composition of any of embodiments 1-28, wherein the cyclic carbonate comprises more than one cyclic carbonate groups.

31. The composition of any of embodiments 1 -30, wherein the cyclic carbonate comprises one or more five membered ring cyclic carbonate groups.

32. The composition of any of embodiments 1 -31 , wherein the cyclic carbonate comprises one or more six membered ring cyclic carbonate groups.

33. The composition of any of embodiments 1-32, wherein the cyclic carbonate comprises one or more seven membered ring cyclic carbonate groups.

34. The composition of any of embodiments 1-33, wherein the cyclic carbonate comprises glycerol carbonate, trimethylol carbonate or a mixture thereof.

35. The composition of any of embodiments 1-34, wherein the cyclic carbonate comprises trimethylolpropane carbonate. 36. The composition of any of embodiments 1-35, wherein the cyclic carbonate is present in from about 10 percent to about 30 percent by weight based on the total weight of the polyol composition.

37. The composition of any of embodiments 1-36, wherein the isocyanate functional component is present in an amount such that a ratio of isocyanate groups, latent isocyanate groups, or a mixture thereof to hydroxyl groups of the polyol composition is 0.8 or greater.

38. The composition of any of embodiments 1-37, wherein the isocyanate functional component is present in an amount such that a ratio of isocyanate groups, latent isocyanate groups, or a mixture thereof to hydroxyl groups of the polyol composition is 1 .2 or less.

39. The composition of any of embodiments 1-38, wherein the isocyanate functional component comprises at least one polyisocyanate prepolymer, at least one blocked polyisocyanate, at least one monomeric polyisocyanate, at least one oligomeric polyisocyanate, at least one polymeric polyisocyanate, or a mixture thereof.

40. The composition of any of embodiments 1-39, wherein the isocyanate functional component comprises at least one polyisocyanate prepolymer.

41. The composition of any of embodiments 1 -40, wherein the isocyanate functional component comprises at least one monomeric polyisocyanate.

42. The composition of any of embodiments 1 -41 , wherein the isocyanate functional component comprises at least one oligomeric polyisocyanate.

43. The composition of any of embodiments 1-42, wherein the isocyanate functional component comprises at least one blocked polyisocyanate.

44. The composition of any of embodiments 1-43, wherein the isocyanate functional component comprises at least one polymeric polyisocyanate.

45. The composition of any of embodiments 1-44, wherein the isocyanate functional component comprises at least one aliphatic polyisocyanate, latent aliphatic polyisocyanate, or a mixture thereof.

46. The composition of any of embodiments 1-45, wherein the isocyanate functional component comprises hexamethylene diisocyanate, residues of hexamethylene diisocyanate or a mixture thereof. 47. The composition of any of embodiments 1-46, wherein the isocyanate functional component is essentially free of residues of aromatic polyisocyanates, latent polyisocyanates, or mixtures thereof.

48. The composition of any of embodiments 1-46 wherein the isocyanate functional component comprises residues of 4,4'-diphenylmethane diisocyanate, free 4,4’- diphenylmethane diisocyanate, or a mixture thereof.

49. The composition of any of embodiments 1-46 and 48, wherein the isocyanate functional component comprises residues of toluene diisocyanate, free toluene diisocyanate (TDI), or a mixture thereof.

50. The composition of any of embodiments 1-46 and 48-49, wherein the isocyanate functional component comprises one or more polyisocyanates comprising residues of bis(isocyanatophenyl)methane (MDI), free MDI, or a mixture thereof.

51. The composition of any of embodiments 1-50, wherein an initial ratio of isocyanate groups, latent isocyanate groups, or a mixture thereof to hydroxyl groups of the polyol composition is in a range from about 1.2 to about 0.8.

52. The composition of any of embodiments 1 -51 , further comprising a filler.

53. The composition of embodiment 52, wherein the filler comprises one or more clay fillers, glass flake fillers, glass fiber fillers, carbon black fillers, carbon fiber fillers, basalt fiber fillers, or a mixture thereof.

54. The composition of any of embodiments 52-53, wherein the filler comprises one or more of a glass or carbon continuous filament mat (CFM), a chopped strand mat (CSM), and engineered stitched mat.

55. The composition of any of embodiments 52-54, wherein the filler comprises one or more sizing agents.

56. The composition of any of embodiments 52-54, wherein the filler is essentially free of sizing agent.

57. The composition of any of embodiments 1 -18, 22-24, 26-47and 51 -56, wherein the composition is essentially free of aromatic components.

58. A polyurethane composition comprising prepared from the composition of any of embodiments 1-57. 59. An article comprising the polyurethane composition of embodiment 58, which exhibits a heat distortion temperature greater than 110 °C as measured according to ASTM D648, a flexural strength greater than 24,000 psi and a flexural modulus greater than 520,000 psi as measured according to ASTM D790 03 Procedure B as disclosed herein.

60. The article of embodiment 59, further comprising one or more of a glass or carbon continuous filament mat (CFM), a chopped strand mat (CSM), and engineered stitched mat.

61. A method comprising: contacting the composition of any of embodiments 1-57, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate to react with isocyanate groups or latent isocyanate groups of the at least one isocyanate functional component to form a polyurethane product.

62. A polyurethane composition comprising:

(a) residues of a polyol composition comprising:

(i) at least one polyol having three or more hydroxyl groups;

(ii) residues of at least one cyclic carbonate comprising one or more hydroxyl groups; and

(b) residues of at least one isocyanate functional component comprising isocyanate groups, latent isocyanate groups, or a mixture thereof; wherein at least a portion of the residues of the at least one polyol and at least a portion of the residues of the at least one cyclic carbonate are bound by one or more urethane linkages to the residues of the at least one isocyanate functional component.

63. The composition of embodiment 62, wherein the at least one isocyanate functional component comprises a polyisocyanate, a latent polyisocyanate, or a mixture thereof.

64. The composition of any of embodiments 62-63, wherein the residues of the cyclic carbonate are present in about 5 weight percent to about 40 weight percent based on the total weight of the residues of the polyol composition.

65. The composition of any of embodiments 62-64, wherein the polyol composition has a viscosity of less than 1000 cps at 150 °F, wherein the viscosity is determined on a rheometer as disclosed herein operated at steady state shear and variable temperature sweep according to standard instrument operating protocols furnished by the manufacturer.

66. The composition of any of embodiments 62-65, wherein the at least one polyol comprises three or more secondary hydroxyl groups.

67. The composition of any of embodiments 62-66, wherein the at least one polyol comprises one or more ether groups.

68. The composition of any of embodiments 62-67, wherein the at least one polyol is at least tetrafunctional comprising four or more hydroxyl groups.

69. The composition of any of embodiments 62-68, wherein the at least one polyol comprises four or more secondary hydroxyl groups.

70. The composition of any of embodiments 62-69, wherein the at least one polyol comprises a mixture of polyols having an average molecular weight of less than 500 grams per mole as determined from its hydroxyl number obtained using ASTM E222.

71. The composition of any of embodiments 62-70, wherein the at least one polyol comprises an alkoxylated polyether polyol.

72. The composition of any of embodiments 62-71 , wherein the at least one polyol comprises a C₂to C₄ alkoxylated polyether polyol.

73. The composition of any of embodiments 62-73, wherein the at least one polyol comprises both a C₂to C₄ alkoxylated polyether triol and a C₂to C₄ alkoxylated polyether tetrol.

74. The composition of any of embodiments 62-73, wherein the at least one polyol comprises three or more vicinal hydroxyl groups.

75. The composition of any of embodiments 62-74, wherein the at least one polyol comprises glycerol.

76. The composition of any of embodiments 62-75, wherein the at least one polyol comprises two or more residues of constituent polyols having structure I linked by one or more carbonate groups.

77. The composition of embodiment 76, wherein the structures of the constituent polyols I are the same.

78. The composition of embodiment 76, wherein the structures of the constituent polyols I are different. 79. The composition of any of embodiments 62-78, wherein the at least one polyol comprises one or more carbonate groups and one or more ether groups.

80. The composition of any of embodiments 62-79, wherein the at least one polyol comprises six or more secondary hydroxyl groups.

81. The composition of any of embodiments 62-80, wherein the polyol composition further comprises at least one polyhydroxylated aromatic compound.

82. The composition of embodiment 81 , wherein the polyhydroxylated aromatic compound comprises one or more bisphenols.

83. The composition of any of embodiments 81-82, wherein at least a portion of the at least one polyhydroxylated aromatic compound comprises bisphenol A, bisphenol S, bisphenol M, bisphenol AP or a combination thereof.

84. The composition of any of embodiments 62-83, wherein the cyclic carbonate comprises at least one hydroxyl group on a ring position of a cyclic carbonate ring.

85. The composition of any of embodiments 62-84, wherein the cyclic carbonate comprises at least one hydroxyl group not on a ring position of a cyclic carbonate ring.

86. The composition of any of embodiments 62-85, wherein the cyclic carbonate comprises one or more cycloaliphatic carbonate groups.

87. The composition of any of embodiments 62-86, wherein the cyclic carbonate comprises one or more aromatic carbonate groups.

88. The composition of any of embodiments 62-87, wherein the cyclic carbonate comprises one or more aliphatic radicals comprising one or more hydroxy groups.

89. The composition of any of embodiments 62-88, wherein the cyclic carbonate comprises one or more hydroxylated alkyl groups.

90. The composition of any of embodiments 62-89, wherein the cyclic carbonate comprises one or more hydroxymethyl groups.

91. The composition of any of embodiments 62-90, wherein the cyclic carbonate comprises a single cyclic carbonate group.

92. The composition of any of embodiments 62-90, wherein the cyclic carbonate comprises more than one cyclic carbonate groups. 93. The composition of any of embodiments 62-92, wherein the cyclic carbonate comprises one or more five membered ring cyclic carbonate groups.

94. The composition of any of embodiments 62-93, wherein the cyclic carbonate comprises one or more six membered ring cyclic carbonate groups.

95. The composition of any of embodiments 62-94, wherein the cyclic carbonate comprises one or more seven membered ring cyclic carbonate groups.

96. The composition of any of embodiments 62-95, wherein the cyclic carbonate comprises glycerol carbonate.

97. The composition of any of embodiments 62-96, wherein the at least one cyclic carbonate comprises trimethylolpropane carbonate.

98. The composition of any of embodiments 62-97, wherein residues of the cyclic carbonate are present in from about 10 percent to about 30 percent by weight based on the total weight of residues of the at least one polyol and the at least one cyclic carbonate.

99. The composition of any of embodiments 62-98, wherein a ratio of residues of isocyanate groups, latent isocyanate groups, or a mixture thereof to residues of hydroxyl groups of the at least one polyol and the at least one cyclic carbonate is greater than 0.8.

100. The composition of any of embodiments 62-99, wherein a ratio of residues of isocyanate groups, latent isocyanate groups, or a mixture thereof to residues of hydroxyl groups of the at least one polyol and the at least one cyclic carbonate is less than 1.2.

101. The composition of any of embodiments 62-100, wherein residues of the at least one isocyanate functional component comprise residues of at least one polyisocyanate prepolymer, at least one blocked polyisocyanate, at least one monomeric polyisocyanate, at least one oligomeric polyisocyanate, at least one polymeric polyisocyanate, or a mixture thereof.

102. The composition of any of embodiments 62-101 , wherein residues of the at least one isocyanate functional component comprise residues of at least one polyisocyanate prepolymer.

103. The composition of any of embodiments 62-102, wherein residues of the at least one isocyanate functional component comprise residues of at least one monomeric polyisocyanate.

104. The composition of any of embodiments 62-103, wherein residues of the at least one isocyanate functional component comprise residues of at least one oligomeric polyisocyanate. 105. The composition of any of embodiments 62-103, wherein residues of the at least one isocyanate functional component comprise residues of at least one blocked polyisocyanate.

106. The composition of any of embodiments 62-105, wherein residues of the at least one isocyanate functional component comprise residues of at least one polymeric polyisocyanate.

107. The composition of any of embodiments 62-106, wherein residues of the at least one isocyanate functional component comprise residues of at least one aliphatic polyisocyanate, latent aliphatic polyisocyanate, or a mixture thereof.

108. The composition of any of embodiments 62-107, wherein residues of the at least one isocyanate functional component comprise residues of hexamethylene diisocyanate.

109. The composition of any of embodiments 62-108, wherein residues of the at least one isocyanate functional component are essentially free of residues of aromatic polyisocyanates, latent polyisocyanates, or mixtures thereof.

110. The composition of any of embodiments 62-108, wherein residues of the at least one isocyanate functional component comprise residues of 4,4'-diphenylmethane diisocyanate.

111. The composition of any of embodiments 62-108 and 110, wherein residues of the at least one isocyanate functional component comprise residues of toluene diisocyanate (TDI).

112. The composition of any of embodiments 62-108 and 110-111 , wherein residues of the at least one isocyanate functional component comprise residues of bis(isocyanatophenyl)methane (MDI).

113. The composition of any of embodiments 62-112, wherein a ratio of residues of isocyanate groups, latent isocyanate groups, or a mixture thereof to residues of hydroxyl groups is in a range from about 1 .2 to about 0.8.

114. The composition of any of embodiments 62-113, further comprising a filler.

115. The composition of embodiment 114, wherein the filler comprises one or more clay fillers, glass flake fillers, glass fiber fillers, carbon black fillers, carbon fiber fillers, basalt fiber fillers, or mixtures thereof.

116. The composition of any of embodiments 114-115, wherein the filler comprises one or more of a glass or carbon continuous filament mat (CFM), a chopped strand mat (CSM), and engineered stitched mat. 117. The composition of any of embodiments 114-116, wherein the filler comprises one or more sizing agents.

118. The composition of any of embodiments 114-116, wherein the filler is essentially free of sizing agent.

119. A method comprising:

(a) transferring the composition of any of embodiments 1-57 into a mold; and

(b) curing the composition within the mold to afford a molded part; wherein during step (b) at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate react with one or more isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form a molded polyurethane product.

120. A curable composition comprising:

(a) a first part comprising:

(i) at least one polyol comprising three or more hydroxyl groups; and

(ii) at least one cyclic carbonate comprising one or more hydroxyl groups; and

(b) a second part comprising at least one isocyanate functional component comprising isocyanate groups, latent isocyanate groups, or a mixture thereof; and optionally

(c) a catalyst; wherein the first part and the second part when contacted cure to form the polyurethane composition by reaction of at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate with the isocyanate groups, latent isocyanate groups, or mixture thereof of the at least one isocyanate functional component.

121. A polyurethane forming kit comprising the composition of embodiment 120.

122. A polyurethane composition comprising a filler prepared by reacting, in the presence of the filler, the composition of any of embodiments 1-57, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and the at least one cyclic carbonate to react with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form urethane linkages of the product polyurethane composition.

123. A polyurethane composition comprising a filler and the residue of the composition of any of embodiments 1-57, wherein urethane linkages of the polyurethane composition are formed by reaction of at least a portion of the hydroxyl groups of the at least one polyol and the at least one cyclic carbonate with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component.

124. The composition of any of embodiments 122-123, wherein the filler is present in greater than 0.001% and less than 60% by weight based on the total weight of the composition.

125. An article comprising the composition according any of embodiments 123-124, which exhibits a heat distortion temperature greater than 130 °C as measured according to ASTM D648, a flexural strength greater than 30,000 psi and a Young’s modulus greater than

1 ,000,000 psi as measured according to ASTM D790 03 Procedure B as disclosed herein.

126. A method comprising: contacting in the presence of a filler the composition of any of embodiments 1-57, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate to react with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form a filled polyurethane product.

127. The method of embodiment 126, wherein the contacting in the presence of a filler is carried out in a mold.

128. The method of embodiment 127, wherein the mold is comprised of one or more fiber reinforced plastics (FRP).

129. The method of embodiment 127, wherein the mold is comprised of one or more metals.

130. The method of embodiment 178, wherein the mold is comprised of aluminum metal.

131. The method of any of embodiments 127-130, wherein an internal mold temperature is greater than 250°F during the contacting.

132. The method of any of embodiments 127-131 , wherein an internal mold temperature is less than 290°F during the contacting.

133. A method comprising: (a) transferring the composition of any of embodiments 1-57 into a mold containing a reinforcing filler; and

(b) curing the composition within the mold to afford a molded composite part; wherein during step (b) at least a portion of the hydroxyl groups of the at least one polyol and the at least a portion of the hydroxy groups of the at least one cyclic carbonate react with isocyanate groups, latent isocyanate groups, or a mixture thereof of the at least one isocyanate functional component, to form a polyurethane product in the presence of the reinforcing filler.

134. A composition comprising:

(a) a first part comprising the polyol composition of embodiments 1-57 comprising:

(i) at least one polyol comprising three or more hydroxyl groups; and

(ii) at least one cyclic carbonate comprising one or more hydroxyl groups; and

(b) a second part comprising an isocyanate functional component of embodiments 1-57; and optionally

(c) a catalyst; wherein either or both of the first part and the second part comprises a filler, wherein the composition cures by reaction of at least a portion of the hydroxyl groups of the polyol and the hydroxyl groups of the cyclic carbonate with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component.

Claims

Claims:

1 . A curable composition comprising:

(a) a polyol composition comprising:

(i) at least one polyol comprising three or more hydroxyl groups;

(ii) at least one cyclic carbonate comprising one or more hydroxyl groups;

2. The composition of Claim 1 , wherein both a latent catalyst and a latent polyisocyanate are present in the composition.

3. The composition of any of Claims 1-2, wherein the cyclic carbonate is present in about 5 percent to about 40 percent by weight based on the total weight of the polyol composition.

4. The composition of any of Claims 1-3, wherein the polyol composition has a viscosity of less than 1000 cps at 150 °F, wherein the viscosity is determined on a rheometer as disclosed herein operated at steady state shear and variable temperature sweep according to standard instrument operating protocols furnished by the manufacturer.

5. The composition of any of Claims 1-4, wherein the at least one polyol comprises three or more secondary hydroxyl groups.

6. The composition of any of Claims 1-5, wherein the at least one polyol comprises four or more hydroxyl groups.

7. The composition of any of Claims 1-6, wherein the at least one polyol comprises four or more secondary hydroxyl groups.

8. The composition of any of Claims 1-7, wherein the at least one polyol comprises a mixture of polyols having an average molecular weight of less than 500 grams per mole as determined from its hydroxyl number obtained using ASTM E222.

9. The composition of any of Claims 1-8, wherein the at least one polyol comprises a C₂to C₄ alkoxylated polyether polyol.

10. The composition of any of Claims 1 -9, wherein the polyol composition further comprises a polyhydroxylated aromatic compound.

11. The composition of Claim 10, wherein at least a portion of the at least one polyhydroxylated aromatic compound comprises bisphenol A, bisphenol S, bisphenol M, bisphenol AP or a combination thereof.

12. The composition of any of Claims 1-11 , wherein the cyclic carbonate comprises at least one hydroxyl group on a ring position of a cyclic carbonate ring.

13. The composition of any of Claims 1 -12, wherein the cyclic carbonate comprises at least one hydroxyl group not on a ring position of a cyclic carbonate ring.

14. The composition of any of Claims 1 -13, wherein the cyclic carbonate comprises one or more hydroxymethyl groups.

15. The composition of any of Claims 1 -14, wherein the cyclic carbonate comprises a single cyclic carbonate group.

16. The composition of any of Claims 1 -14, wherein the cyclic carbonate comprises more than one cyclic carbonate groups.

17. The composition of any of Claims 1 -16, wherein the cyclic carbonate comprises one or more five, six or seven membered ring cyclic carbonate groups.

18. The composition of any of Claims 1 -7, wherein the cyclic carbonate comprises glycerol carbonate, trimethylol carbonate or a mixture thereof.

19. The composition of any of Claims 1 -18, wherein the isocyanate functional component is present in an amount such that a ratio of isocyanate groups, latent isocyanate groups, or a mixture thereof to hydroxyl groups of the polyol composition is 0.8 or greater, or 1.2 or less.

20. The composition of any of Claims 1 -19, wherein the isocyanate functional component comprises at least one polyisocyanate prepolymer, at least one blocked polyisocyanate, at least one monomeric polyisocyanate, at least one oligomeric polyisocyanate, at least one polymeric polyisocyanate, or a mixture thereof.

21. The composition of any of Claims 1 -20, wherein the isocyanate functional component comprises hexamethylene diisocyanate, residues of hexamethylene diisocyanate or a mixture thereof.

22. The composition of any of Claims 1-21 wherein the isocyanate functional component comprises residues of 4,4'-diphenylmethane diisocyanate, free 4,4’-diphenylmethane diisocyanate, or a mixture thereof; residues of toluene diisocyanate, free toluene diisocyanate (TDI), or a mixture thereof; residues of bis(isocyanatophenyl)methane (MDI), free MDI, or a mixture thereof; or a mixture of any of the foregoing.

23. The composition of any of Claims 1-22, further comprising a filler selected from one or more clay fillers, glass flake fillers, glass fiber fillers, carbon black fillers, carbon fiber fillers, basalt fiber fillers, or a mixture thereof.

24. The composition of any of Claims 1-23, wherein the at least one polyol comprises one or more carbonate groups.

25. The composition of any of Claims 1-24, wherein the polyol composition comprises at least one polyol having structure I and at least one polyol comprising 2 or more residues of a polyol having structure I linked by one or more carbonate groups, ether groups or a combination thereof; wherein the polyol having structure I may be the same as or different from one or more polyols to which the 2 or more residues relate.

26. The composition of any of Claims 1-9, 12-21 and 23-26, wherein the composition is essentially free of aromatic components.

27. A polyurethane composition comprising prepared from the composition of any of Claims 1-26.

28. An article comprising the polyurethane composition of Claim 27, which exhibits a heat distortion temperature greater than 110 °C as measured according to ASTM D648, a flexural strength greater than 24,000 psi and a flexural modulus greater than 520,000 psi as measured according to ASTM D790 03 Procedure B as disclosed herein.

29. The article of Claim 28, further comprising one or more of a glass or carbon continuous filament mat (CFM), a chopped strand mat (CSM), and engineered stitched mat.

30. A method comprising: contacting the composition of any of Claims 1-26, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate to react with isocyanate groups or latent isocyanate groups of the at least one isocyanate functional component to form a polyurethane product.

31. A polyurethane composition comprising:

(a) residues of a polyol composition comprising:

(i) residues at least one polyol having three or more hydroxyl groups; and

32. The composition of Claim 31 , wherein the polyol composition comprises at least one polyol having structure I and at least one linear polyol comprising two or more residues of constituent polyols having structure I linked by one or more carbonate groups.

33. The composition of Claim 32, wherein the structures of the constituent polyols I are the same or different.

34. A method comprising:

(a) transferring the composition of any of Claims 1-26 into a mold; and

35. A curable composition comprising:

(a) a first part comprising: (i) at least one polyol comprising three or more hydroxyl groups; and

(ii) at least one cyclic carbonate comprising one or more hydroxyl groups; and

36. A polyurethane forming kit comprising the composition of Claim 35.

37. A polyurethane composition comprising a filler prepared by reacting, in the presence of the filler, the composition of any of Claims 1-26, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and the at least one cyclic carbonate to react with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form urethane linkages of the product polyurethane composition.

38. A polyurethane composition comprising a filler and the residue of the composition of any of Claims 1-26, wherein urethane linkages of the polyurethane composition are formed by reaction of at least a portion of the hydroxyl groups of the at least one polyol and the at least one cyclic carbonate with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component.

39. An article comprising the composition according any of Claims 37-38, which exhibits a heat distortion temperature greater than 130 °C as measured according to ASTM D648, a flexural strength greater than 30,000 psi and a Young’s modulus greater than 1 ,000,000 psi as measured according to ASTM D790 03 Procedure B as disclosed herein.

40. A method comprising: contacting in the presence of a filler the composition of any of Claims 1-26, optionally in the presence of a catalyst, under conditions sufficient to cause at least a portion of the hydroxyl groups of the at least one polyol and at least a portion of the hydroxy groups of the at least one cyclic carbonate to react with isocyanate groups, latent isocyanate groups, or a mixture thereof of the isocyanate functional component to form a filled polyurethane product.

41. A method comprising:

(a) transferring the composition of any of Claims 1-26 into a mold containing a reinforcing filler; and