CA2493102A1 - Process for preparing closed-cell water-blown rigid polyurethane foams having improved mechanical properties - Google Patents

Process for preparing closed-cell water-blown rigid polyurethane foams having improved mechanical properties Download PDF

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Publication number
CA2493102A1
CA2493102A1 CA 2493102 CA2493102A CA2493102A1 CA 2493102 A1 CA2493102 A1 CA 2493102A1 CA 2493102 CA2493102 CA 2493102 CA 2493102 A CA2493102 A CA 2493102A CA 2493102 A1 CA2493102 A1 CA 2493102A1
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CA
Canada
Prior art keywords
polyol
lbs
mixture
foam
solid
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA 2493102
Other languages
French (fr)
Other versions
CA2493102C (en
Inventor
Karl W. Haider
Neil H. Nodelman
John P. Forsythe
Brian R. Suddaby
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Covestro LLC
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2493102A1 publication Critical patent/CA2493102A1/en
Application granted granted Critical
Publication of CA2493102C publication Critical patent/CA2493102C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/409—Dispersions of polymers of C08G in organic compounds having active hydrogen
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/4009—Two or more macromolecular compounds not provided for in one single group of groups C08G18/42 - C08G18/64
    • C08G18/4072—Mixtures of compounds of group C08G18/63 with other macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0025—Foam properties rigid
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0041—Foam properties having specified density
    • C08G2110/0058—≥50 and <150kg/m3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0083—Foam properties prepared using water as the sole blowing agent
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31573—Next to addition polymer of ethylenically unsaturated monomer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31573—Next to addition polymer of ethylenically unsaturated monomer
    • Y10T428/31583—Nitrile monomer type [polyacrylonitrile, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31573—Next to addition polymer of ethylenically unsaturated monomer
    • Y10T428/31587—Hydrocarbon polymer [polyethylene, polybutadiene, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31605—Next to free metal

Abstract

The present invention is directed to a process for preparing water~blown rig id polyurethane foams having at least an 80% closed-cell content which involves reacting a) at least one polyol mixture which is composed of (i) at least on e polymer polyol; (ii) at least one polyol having a hydroxyl value within the range of from about 200 to about 800; and (iii) optionally, at least one polyol having a hydroxyl value within the range of from about 25 to about 11 5; with b) at least one polymeric isocyanate and/or a prepolymer thereof; in th e presence of c) optionally, at least one catalyst; d) water; and e) optionall y, at least one additive or auxiliary agent. The present invention is also directed to the closed-cell water blown rigid polyurethane foams produced by the process of the present invention. The invention is further directed to a polyurethane-foam forming mixture which is used to produce the water-blown rigid polyurethane foams of the present invention. Foams produced according to the present invention have reduced friability and acceptable adhesion to substrates as well as acceptable compressive strength.

Claims

WHAT IS CLAIMED IS:

1. A process for preparing a water-blown rigid polyurethane foam having at least an 80% closed-cell content comprising reacting:
(a) at least one polyol mixture comprising:
(i) at least one polymer polyol;
(ii) at least one polyol having a hydroxyl value within the range of from about 200 to about 800; and (iii) optionally, at least one polyol having a hydroxyl value within the range of from about 25 to about 115;
with (b) at least one polymeric isocyanate and/or a prepolymer thereof;
in the presence of (c) optionally, at least one catalyst;
(d) water; and (e) optionally, at least one additive or auxiliary agent.

2. The process according to Claim 1 in which polymer polyol (i) is comprised of at least one solid which is the reaction product of a mixture of 2,4- and 2,6-toluene diisocyanate and hydrazine polymerized in situ in a polyether polyol.

3. The process according to Claim 1 in which polymer polyol (i) is comprised of at least one solid which is a styrene/acrylonitrile mixture polymerized in situ in a polyether polyol.

4. The process according to Claim 1 in which polymer polyol (i) has from about 10 to about 60 weight percent, based on the total weight of the polymer polyol, of at least one polymer solid as a dispersed phase.

5. A rigid polyurethane foam produced by the process of Claim 1.

6. The foam of Claim 5 which has a perpendicular compressive strength within the range of from about 35 to about 150 lbs/in2.

7. The foam of Claim 5 which has from about 1 to about 30 weight percent, based on the total weight of the foam, of at least one solid from a polymer polyol.

8. The foam of Claim 5, when having a density which is in the range of from about 5.66 to about 5.75 lbs/ft3, has a perpendicular compressive strength greater than 62 lbs/in2, a tensile adhesion greater than 105 lbs/in2 and a closed-cell content of at least 84%.

9. The foam of Claim 5 which, when prepared with a polymer polyol (i) which is comprised of at least one solid which is a styrene/acrylonitrile mixture polymerized in situ in a polyether polyol and when having a density which is in the range of from about 5.66 to about 5.75 lbs/ft3, has a perpendicular compressive strength greater than 62 lbs/in2, a tensile adhesion greater than 105 lbs/in2, and a closed-cell content of at least 84%.

10. The foam of Claim 5 which, when prepared with a polymer polyol (i) which is comprised of at least one solid which is the reaction product of a mixture of 2,4- and 2,6-toluene diisocyanate and hydrazine polymerized in situ in a polyether polyol and when having a density of about 5.73 lbs/ft3, has a perpendicular compressive strength greater than 62 lbs/in2, a tensile adhesion greater than 105 lbs/in2 and a closed-cell content of at least 84%.

11. The foam of Claim 5, when having a density of about 3.23 lbs/ft3, has a perpendicular compressive strength greater than 24 lbs/in2 and a closed-cell content of at least 84%.

12. The foam of Claim 5 which, when prepared with a polymer polyol (i) which is comprised of at least one solid which is a styrene/acrylonitrile mixture polymerized in situ in a polyether polyol and when having a density of about 3.23 lbs/ft3, has a perpendicular compressive strength greater than 24 lbs/in2 ana a closed-cell content of at least 84%.

13. A polyurethane-foam forming mixture comprising:
(a) at least one polyol mixture comprising:
(i) at least one polymer polyol;
(ii) at least one polyol having a hydroxyl value within the range of from about 200 to about 800; and (iii) optionally, at least one polyol having a hydroxyl value within the range of from about 25 to about 115;
(b) at least one polymeric isocyanate and/or a prepolymer thereof;
(c) optionally, at least one catalyst;
(d) water; and (e) optionally, at least one additive or auxiliary agent.

14. The mixture of Claim 13 in which polymer polyol (i) is comprised of at least one solid which is the reaction product of a mixture of 2,4-and 2,6-toluene diisocyanate and hydrazine polymerized in situ in a polyether polyol.

15. The mixture of Claim 13 in which polymer polyol (i) is comprised of at least one solid which is a styrene/acrylonitrile mixture polymerized in situ in a polyether polyol.

16. The mixture of Claim 13 in which polymer polyol (i) has from about 10 to about 60 weight percent, based on the total weight of the polymer polyol, of at least one polymer solid as a dispersed phase.

17. A rigid polyurethane foam produced with the polyurethane-foam forming mixture of Claim 13.
CA 2493102 2002-07-22 2003-07-18 Process for preparing closed-cell water-blown rigid polyurethane foams having improved mechanical properties Expired - Fee Related CA2493102C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/200,532 2002-07-22
US10/200,532 US6833390B2 (en) 2002-07-22 2002-07-22 Process for preparing closed-cell water-blown rigid polyurethane foams having improved mechanical properties
PCT/US2003/022555 WO2004009667A1 (en) 2002-07-22 2003-07-18 Process for preparing closed-cell water blown rigid polyurethane foams having improved mechanical properties

Publications (2)

Publication Number Publication Date
CA2493102A1 true CA2493102A1 (en) 2004-01-29
CA2493102C CA2493102C (en) 2011-05-03

Family

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CA 2493102 Expired - Fee Related CA2493102C (en) 2002-07-22 2003-07-18 Process for preparing closed-cell water-blown rigid polyurethane foams having improved mechanical properties

Country Status (5)

Country Link
US (3) US6833390B2 (en)
AU (1) AU2003263789A1 (en)
CA (1) CA2493102C (en)
MX (1) MXPA05000864A (en)
WO (1) WO2004009667A1 (en)

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Also Published As

Publication number Publication date
US20050020705A1 (en) 2005-01-27
CA2493102C (en) 2011-05-03
US20090036562A1 (en) 2009-02-05
US6833390B2 (en) 2004-12-21
AU2003263789A1 (en) 2004-02-09
US7750058B2 (en) 2010-07-06
MXPA05000864A (en) 2005-07-29
WO2004009667A1 (en) 2004-01-29
US20040014828A1 (en) 2004-01-22

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