Foamed isocyanate-based polymer having improved hardness properties and process for production thereof

• US 20030236315A1
• Filed: 01/28/2003
• Published: 12/25/2003
• Est. Priority Date: 01/28/2002
• Status: Abandoned Application

• Current Assignee: Woodbridge Foam Corporation
• Original Assignee: Woodbridge Foam Corporation
• Inventors: Xie, Min, Kee, Robert A., Valentin, Ferdiemar N., Heumen, Jeffrey D. van
• Application Number:
  US10/352,182
• Publication Number:
  US 20030236315A1
• Time in Patent Office: Days
• US Class Current: 521/155
• CPC Class Codes: C08G 18/4072 Mixtures of compounds of group C08G18/63 with other macromolecular compounds
• CPC Class Codes: C08G 2110/0016 semi-rigid
• CPC Class Codes: C08G 2110/0025 rigid
• CPC Class Codes: C08G 2110/0058 ≥50 and <150kg/m3
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent

Abstract

In one of its aspects, the present invention relates to a foamed isocyanate-based polymer derived from a reaction mixture comprising toluene diisocyanate, wherein the foam has a compression force deformation of at least about 50 kPa at 30% deflection when measured pursuant to ASTM 3574 and a density of less than about 45 kg/m³. In another of its aspects, the present invention relates to a process for producing a foamed isocyanate-based polymer comprising the steps of: contacting an isocyanate comprising toluene diisocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent to form a reaction mixture; and expanding the reaction mixture to produce the foamed isocyanate-based polymer; wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.

Claims

1. A foamed isocyanate-based polymer derived from a reaction mixture comprising toluene diisocyanate, wherein the foam has a compression force deformation of at least about 50 kPa at 30% deflection when measured pursuant to ASTM 3574 and a density of less than about 45 kg/m³.

2. The foamed isocyanate-based polymer foam defined in claim 1, wherein the foam has a compression force deformation of at least about 70 kPa at 30% deflection when measured pursuant to ASTM 3574.

3. The foamed isocyanate-based polymer foam defined in claim 1, wherein the foam has a compression force deformation of at least about 120 kPa at 30% deflection when measured pursuant to ASTM 3574.

4. The foamed isocyanate-based polymer foam defined in claim 1, wherein the foam has a density in the range of from about 25 to about 45 kg/m³.

5. The foamed isocyanate-based polymer foam defined in claim 1, wherein the foam has a density in the range of from about 35 to about 45 kg/m³.

6. The foamed isocyanate-based polymer foam defined in claim 1, wherein the reaction mixture comprises toluene diisocyanate as the sole isocyanate.

7. The foamed isocyanate-based polymer foam defined in claim 1, wherein the reaction mixture comprises toluene diisocyanate and at least one other isocyanate.

8. The foamed isocyanate-based polymer foam defined in claim 7, wherein the reaction mixture comprises at least about 40% by weight toluene diisocyanate.

9. The foamed isocyanate-based polymer foam defined in claim 7, wherein the reaction mixture comprises at least about 75% by weight toluene diisocyanate.

10. The foamed isocyanate-based polymer foam defined in claim 1, wherein, the reaction mixture comprising toluene diisocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent.

11. The foamed isocyanate-based polymer foam defined in claim 10, wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23°

C.

19. The process defined in claim 2, wherein the active hydrogen-containing compound comprises a polyol.

20. The process defined in claim 19, wherein the polyol comprises a polyether polyol.

12. A process for producing a foamed isocyanate-based polymer comprising the steps of:

contacting an isocyanate comprising toluene diisocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent to form a reaction mixture; and

expanding the reaction mixture to produce the foamed isocyanate-based polymer;

wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23°

C.

13. The process defined in claim 12, wherein the toluene diisocyanate as the sole isocyanate in the reaction mixture.

14. The process defined in claim 12, wherein the isocyanate comprises toluene diisocyanate and at least one other isocyanate.

15. The process defined in claim 12, wherein the reaction mixture comprises at least about 40% by weight toluene diisocyanate.

16. The process defined in claim 12, wherein the reaction mixture comprises at least about 75% by weight toluene diisocyanate.

17. The process defined in claim 14, wherein the at least one other isocyanate is selected from the group comprising 2,4′

-diphenylmethane diisocyanate, 4,4′

-diphenylmethane diisocyanate and mixtures thereof.

18. The process defined in claim 12, wherein the toluene diisocyanate is selected from the group comprising 2,4-toluene dilsocyanate, 2,6-toluene diisocyanate and mixtures thereof.

21. The process defined in claim 12, wherein dendritic macromolecule has the following characteristics:

(i) an active hydrogen content of greater than about 3.8 mmol/g;

(ii) an active hydrogen functionality of at least about 8; and

(iii) at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23°

C.

22. The process defined in claim 21, wherein from about 15% to about 30% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23°

C.

23. The process defined in claim 21, wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number in the range of from about 28 to 32 mg KOH/g to form a stable liquid at 23°

C.

24. The process defined in claim 21, wherein the active hydrogen content of the macromolecule is in the range of from about 3.8 to about 10 mmol/g.

25. The process defined in claim 21, wherein the active hydrogen content of the macromolecule is in the range of from about 4.4 to about 5.7 mmol/g.

26. The process defined in claim 21, wherein the active hydrogen functionality in the macromolecule is in the range of from about 8 to about 70.

27. The process defined in claim 21, wherein the active hydrogen functionality in the macromolecule is in the range of from about 15 to about 35.

28. The process defined in claim 21, wherein from about 15% to about 50% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23°

C.

29. The process defined in claim 21, wherein from about 15% to about 40% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23°

C.

30. The process defined in claim 21, wherein the macromolecule has an inherently branched structure comprising at least one of an ester moiety, an ether moiety, an amine moiety, an amide moiety and any mixtures thereof.

31. The process defined in claim 21, wherein the macromolecule has an inherently branched structure comprising primarily an ester moiety, optionally combined with an ether moiety.

32. The process defined in claim 21, wherein the macromolecule has an inherently branched structure comprising primarily an ether moiety, optionally combined with an ester moiety.

33. The process defined in claim 21, wherein the macromolecule has an inherently branched structure comprising primarily an ester moiety, optionally combined with an ether moiety.

34. The process defined in claim 30, wherein the macromolecule further comprises nucleus to which the inherently branched structure is chemically bonded.

35. The process defined in claim 30, wherein a plurality of inherently branched structures are chemically bonded to one another.

36. The process defined in claim 30, wherein the inherently branched structure further comprises at least one chain stopper moiety chemically bonded thereto.

37. The process defined in claim 30, wherein the inherently branched structure further comprises at least two different chain stopper moieties chemically bonded thereto.

38. The process defined in claim 30, wherein the inherently branched structure further comprises at least one spacing chain extender chemically bonded thereto.

39. The process defined in claim 38, wherein the spacing chain extender is monomeric.

40. The process defined in claim 38, wherein the spacing chain extender is polymeric.