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

• US 20030236316A1
• 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: Heumen, Jeffrey D. van, Pepic, Petar, Duley, John A.
• Application Number:
  US10/352,190
• Publication Number:
  US 20030236316A1
• 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 18/6564 with compounds of group C08G18/3203
• CPC Class Codes: C08G 2110/0016 semi-rigid
• CPC Class Codes: C08G 2110/0025 rigid
• CPC Class Codes: C08G 2110/005 < 50kg/m3
• CPC Class Codes: C08G 2110/0075 prepared with an isocyanate index of 60 or lower
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent

Abstract

In one of its aspects, the invention relates to a foamed isocyanate-based polymer having a compression force deformation of greater than about 130 kPa at 10% deflection when measured pursuant to ASTM 1621 and a flexural displacement at yield of greater than about 5 mm when measured pursuant to ASTM D790-00. The present foamed polymer has a novel combination of hardness/stiffness and a flexibility.

Claims

1. A foamed isocyanate-based polymer having a compression force deformation of greater than about 130 kPa at 10% deflection when measured pursuant to ASTM 1621 and a flexural displacement at yield of greater than about 5 mm when measured pursuant to ASTM D790-00.

2. The foamed isocyanate-based polymer foam defined in claim 1, wherein the foam has a compression force deformation of at least about 140 kPa at 10% deflection when measured pursuant to ASTM 1621.

3. The foamed isocyanate-based polymer foam defined in claim 1, wherein the foam has a compression force deformation in the range of from about 150 to about 250 kPa at 10% deflection when measured pursuant to ASTM 1621.

4. The foamed isocyanate-based polymer foam defined in claims 1, wherein the foam has a flexural displacement at yield in the range of from about 5 mm to about 7 mm when measured pursuant to ASTM D790-00.

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

6. The foamed isocyanate-based polymer foam defined in claim 5, wherein at least 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.

7. The foamed isocyanate-based polymer foam defined in claim 5, wherein the reaction mixture is characterized by one or more of the following:

an isocyanate index greater than about 110, the presence of a solids-polyol dispersion and the presence of a high functionality, low molecular weight polyhydroxy compound.

8. The foamed isocyanate-based polymer foam defined in claim 5, wherein:

(i) the reaction mixture is characterized by one or more of the following;

an isocyanate index greater than about 110, the presence of a solids-polyol dispersion and the presence of a high functionality, low molecular weight polyhydroxy compound (e.g., such a compound having a functionality of at least about 3 and a molecular weight of less than about 2000 g/mol); and

(ii) 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.

9. The foamed isocyanate-based polymer foam defined in claim 5, wherein the reaction mixture comprises an isocyanate index greater than about 110.

10. The foamed isocyanate-based polymer foam defined in claim 5, wherein the reaction mixture comprises a solids-polyol dispersion.

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

contacting an isocyanate, 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;

(i) the reaction mixture is characterized by one or more of the following;

an isocyanate index greater than about 110, the presence of a solids-polyol dispersion and the presence of a high functionality, low molecular weight polyhydroxy compound; and

(ii) 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.

12. The process defined in claim 11, wherein the isocyanate comprises a prepolymer.

13. The process defined in claim 11, wherein the isocyanate is selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.

14. The process defined in claim 11, wherein the isocyanate is selected from the group comprising 2,4′

-diphenylmethane diisocyanate, 4,4′

-diphenylmethane diisocyanate and mixtures thereof.

15. The process defined in claim 11, wherein the isocyanate is selected from the group comprising 2,4′

-diphenylmethane diisocyanate, 4,4′

-diphenylmethane diisocyanate and mixtures thereof; and

(ii) mixtures of (i) with an isocyanate selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.

16. The process defined in claim 11, wherein the active hydrogen-containing compound is selected from the group comprising polyols, polyamines, polyamides, polyamines and polyolamines.

17. The process defined in claim 11, wherein the active hydrogen-containing compound comprises a polyol.

18. The process defined in claim 17, wherein the polyol comprises a polyether polyol.

19. The process defined in claim 11, wherein the blowing agent comprises water.

20. The process defined in claim 11, 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.

21. The process defined in claim 20, 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.

22. The process defined in claim 20, 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 25 to 35 mg KOH/g to form a stable liquid at 23°

C.

23. The process defined in claim 20, 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 20, wherein the active hydrogen is present in the macromolecule in the form of one or more mercapto moieties.

25. The process defined in claim 20, wherein the active hydrogen is present in the macromolecule in the form of one or more primary amino moieties.

26. The process defined in claim 20, wherein the active hydrogen is present in the macromolecule in the form of one or more secondary amino moieties.

27. The process defined in claim 20, wherein the active hydrogen is present in the macromolecule in the form of one or more hydroxyl moieties.

28. The process defined in claim 20, wherein the active hydrogen is present in the macromolecule in the form of two or more of a mercapto moiety, a primary amino moiety, a secondary amino moiety and a hydroxyl moiety.

29. The process defined in claim 20, wherein the active hydrogen content of the macromolecule is in the range of from about 3.8 to about 10 mmol/g.

30. The process defined in claim 20, wherein the active hydrogen content of the macromolecule is in the range of from about 3.8 to about 7.0 mmol/g.

31. The process defined in claim 20, wherein the active hydrogen content of the macromolecule is in the range of from about 4.4 to about 5.7 mmol/g.

32. The process defined in claim 20, wherein the active hydrogen functionality in the macromolecule is in the range of from about 8 to about 70.

33. The process defined in claim 20, wherein the active hydrogen functionality in the macromolecule is in the range of from about 10 to about 60.

34. The process defined in claim 20, wherein the active hydrogen functionality in the macromolecule is in the range of from about 15 to about 35.

35. The process defined in claim 20, wherein the active hydrogen functionality in the macromolecule is in the range of from about 20 to about 30.

36. The process defined in claim 20, 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.

37. The process defined in claim 20, 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.

38. The process defined in claim 20, 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.

39. The process defined in, claim 20, wherein the macromolecule has an inherently branched structure comprising primarily an ester moiety, optionally combined with an ether moiety.

40. The process defined in claim 20, wherein the macromolecule has an inherently branched structure comprising primarily an ether moiety, optionally combined with an ester moiety.

41. The process defined in claim 20, wherein the macromolecule has an inherently branched structure comprising primarily an ester moiety, optionally combined with an ether moiety.

42. The process defined in claim 38, wherein the macromolecule further comprises nucleus to which the inherently branched structure is chemically bonded.

43. The process defined in claim 38, wherein a plurality of inherently branched structures are chemically bonded to one another.

44. The process defined in claim 38, wherein the inherently branched structure further comprises at least one chain stopper moiety chemically bonded thereto.

45. The process defined in claim 38, wherein the inherently branched structure further comprises at least two different chain stopper moieties chemically bonded thereto.

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

47. The process defined in claim 46, wherein the spacing chain extender is monomeric.

48. The process defined in claim 46, wherein the spacing chain extender is polymeric.

49. An energy absorbing device comprising a foamed isocyanate-based polymer having a compression force deformation of greater than about 130 kPa at 10% deflection when measured pursuant to ASTM 1621 and a flexural displacement at yield of greater than about 5 mm when measured pursuant to ASTM D790-00.

50. A vehicular headliner comprising a foamed isocyanate-based polymer having a compression force deformation of greater than about 130 kPa at 10% deflection when measured pursuant to ASTM 1621 and a flexural displacement at yield of greater than about 5 mm when measured pursuant to ASTM D790-00.