Novel foam compositions

• US 4,892,891 A
• Filed: 12/02/1988
• Issued: 01/09/1990
• Est. Priority Date: 12/02/1988
• Status: Expired due to Term

• Current Assignee: Syn-Coat Enterprises Incorporated
• Original Assignee: Syn-Coat Enterprises Incorporated
• Inventors: Close, Donald S.
• Primary Examiner(s): Welsh, Maurice J.
• Application Number:
  US07/279,408
• Time in Patent Office: 403 Days
• Field of Search: 521/69, 521/100, 521/101, 521/110, 521/114, 521/112, 521/122, 428/423.1
• US Class Current: 521/69
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 22/143 Calcium-sulfate
• CPC Class Codes: C04B 2201/20 for the density
• CPC Class Codes: C04B 24/00 Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
• CPC Class Codes: C04B 24/282 Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 24/36 Bituminous materials, e.g. tar, pitch C04B24/243 takes precedence
• CPC Class Codes: C04B 26/16 Polyurethanes
• CPC Class Codes: C04B 28/14 containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 38/0067 characterised by the density of the end product
• CPC Class Codes: C04B 38/02 by adding chemical blowing agents
• CPC Class Codes: C04B 38/10 by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: C08G 18/10 Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
• CPC Class Codes: C08G 18/289 containing silicon
• CPC Class Codes: C08G 18/3284 containing four hydroxy groups
• CPC Class Codes: C08G 18/3895 Inorganic compounds, e.g. aqueous alkalimetalsilicate solutions; Organic derivatives thereof containing no direct silicon-carbon bonds
• CPC Class Codes: C08G 18/54 : Polycondensates of aldehydes
• CPC Class Codes: C08G 18/58 : Epoxy resins C08G18/42, C08G18/48 take precedence; reaction products of epoxy resins with at least equivalent amounts of compounds containing active hydrogen C08G18/6407, with at least equivalent amounts of amines C08G18/6415; polymeric products of isocyanates or isothiocyanates with epoxy compounds having no active hydrogen C08G18/003
• CPC Class Codes: C08G 18/64 : Macromolecular compounds not provided for by groups C08G18/42 - C08G18/63
• CPC Class Codes: C08G 18/6476 : Bituminous materials, e.g. asphalt, coal tar, pitch; derivatives thereof
• CPC Class Codes: C08G 18/831 : by oxygen-containing compounds inclusive of carbonic acid halogenides, carboxylic acid halogenides and epoxy halides by aldehydes C08G18/84, by peroxides C08G18/86
• CPC Class Codes: C08G 2110/0083 : prepared using water as the sole blowing agent
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

Foam compositions with improved physical characteristics are from urethane prepolymers in the presence of various modifying agents. Blowing agents employed in the presence of surfactants make it possible to obtain either open or closed cell structures, and the degree of foam stiffness may be desirably controlled with polyols, as well as with polymeric polymethylene polyphenylisocyanates. Suitable modifying agents include asphalts, portland cement, epichlorohydrin, other epoxidized compounds, additional polymers, and various other materials.

Claims

1. A product obtained by the process comprising reacting polymerizable components which include a polyurethane prepolymer in the presence of a blowing agent, and at least one modifying agent, said modifying agent including portland cement, asphalt, epichlorohydrin, a silicone, or mixtures of at least two of the preceding.

2. A product according to claim 1 wherein said polyurethane prepolymer is a polyisocyanate terminated polyether.

3. A product according to claim 1 wherein one of said polymerizable components is a polyol containing at least one amine group.

4. A product according to claim 1 wherein one of the polymerizable components is a polymethylene polyphenylisocyanate that contains di-para-phenylene phenylisocyanate.

5. A product according to claim 1 wherein during the reaction there is also present an acrylic-containing emulsion.

6. A product according to claim 1 wherein said blowing agent is water.

7. A process comprising reacting polymerizable components which include a polyurethane prepolymer in the presence of a blowing agent, and at least one modifying agent, said modifying agent including portland cement, asphalt, epichlorohydrin, a silicone, or mixtures of at least two of the preceding.

8. The process according to claim 7 wherein said polyurethane prepolymer is a polyisocyanate polyether.

9. The process of claim 7 wherein said blowing agent is water, and said modifying agent is portland cement.

10. The process of claim 7 wherein said blowing agent is water and said modifying agent is asphalt.

11. A non-water soluble polyurethane foam, said foam being the reaction product in the presence of a blowing agent of an organic polyisocyanate and water soluble polyalkylene ether polyol which normally gives a water swellable foam but said reaction product is modified by reacting said organic polyisocyanate and said polyalkylene polyol in the presence of a modifying agent to form a foam which is not water swellable.

12. The non-water swellable polyurethane foam of claim 11 wherein the polyalkylene ether polyol contains alkylene groups having 2 to 3 carbon atoms with the proviso that when some of the alkylene groups contain 3 carbon atoms the rest must contain 2 carbon atoms in the amount of at least 45%.

13. The foam of claim 12 wherein the organic polyisocyanate is selected from the class consisting of toluene diisocyanate and methane di(phenylene isocyanate).

16. The non-water swellable polyurethane foam of claim 11 wherein the organic polyisocyanate is a diisocyanate and the polyol contains less than 10% by weight of a tri or high functional polyol.

17. The non-water swellable polyurethane foam of claim 11 wherein the modifying agent is bitumen.

14. A laminated foam product having at least one surface of a polyurethane foam adhered to essentially a planular member, said polyurethane foam being a reaction product of a water soluble polyalkylene ether polyol and an organic polyisocyanate in the presence of a blowing agent and a modifying agent to change the foam from a highly water swellable one to one that is non water swellable.

15. The laminated foam product of claim 14 wherein the planular member is a sheet or film of a plastic, metal or cellulose.

18. A laminate composed of at least one planular member bonded to a polyurethane foam that has had its ability to swell in water, changed by the organic polyisocyanate reacting with a reactive hydrogen containing material by reacting in the presence of sufficient modifying agent to render the foam essentially non-water swellable in water at about 75°

F. for 10 minutes.

19. The laminate of claim 18 wherein the foam does not exhibit water swellability after one hour in water.

20. The laminate of claim 18 wherein the polyurethane foam is the reaction product of a polyalkylene ether polyol whose alkylene group is at least 40% ethylene groups, an excess organic polyisocyanate and water.

21. The laminate of claim 20 wherein the modifying agent is selected from the class of fly ash, cement and bitumens.