US 12,409,583 B2
Sprayed multilayer polyurea and polyurethane composites
Dustin Le, Santa Fe Springs, CA (US); and John H. Bender, Santa Fe Springs, CA (US)
Assigned to AMERICAN POLYMERS CORPORATION, Santa Fe Springs, CA (US)
Filed by American Polymers Corporation, Santa Fe Springs, CA (US)
Filed on Nov. 20, 2023, as Appl. No. 18/514,861.
Prior Publication US 2025/0162207 A1, May 22, 2025
Int. Cl. B29C 41/22 (2006.01); B29C 41/08 (2006.01); B29C 44/02 (2006.01); B29C 44/08 (2006.01); B29K 75/00 (2006.01); B29K 105/04 (2006.01); C09D 5/02 (2006.01); C09D 175/02 (2006.01); C09D 175/04 (2006.01)
CPC B29C 41/22 (2013.01) [B29C 41/08 (2013.01); B29C 44/022 (2013.01); B29C 44/08 (2013.01); C09D 5/021 (2013.01); C09D 175/02 (2013.01); C09D 175/04 (2013.01); B29K 2075/00 (2013.01); B29K 2105/04 (2013.01)] 17 Claims
 
1. A method of producing a molded composite product, the method comprising the steps of:
a) applying an aliphatic polyurea layer to a mold by spraying a first isocyanate material component and a first resin material component with a first spray system, the first spray system comprising a mechanical purge or liquid purge spray gun, the temperature of the first isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the first resin component ranging from 100° F. to 175° F. when being sprayed;
b) applying a first elastomeric layer to the aliphatic polyurea layer by spraying a second isocyanate material component and a second resin material component with a second spray system, the second spray system comprising a secondary air purge spray gun, a secondary mechanical purge spray gun, or a secondary solvent purge spray gun the temperature of the second isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the second resin component ranging from 100° F. to 175° F. when being sprayed;
c) applying a structural foam layer to the first elastomeric layer by spraying a third isocyanate material component and a third resin material component with a third spray system, the third spray system comprising a tertiary air purge spray gun, a tertiary mechanical purge spray gun, or a tertiary solvent purge spray gun, the temperature of the third isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the third resin component ranging from 100° F. to 175° F. when being sprayed;
d) applying a second elastomeric layer to the structural foam layer by spraying a fourth isocyanate material component and a fourth resin material component with a fourth spray system, the fourth spray system comprising a quaternary air purge spray gun, a quaternary mechanical purge spray gun, or a quaternary solvent purge spray gun, the temperature of the fourth isocyanate component ranging from 100° F. to 175° F. when being sprayed, the temperature of the fourth resin component ranging from 100° F. to 175° F. when being sprayed;
e) allowing the layers to cure to form the molded composite product; and
f) removing the molded composite product from the mold.