High resilient flexible urethane foam and flexible molded foams based on allophanate modified isocyanates

• US 6,271,279 B1
• Filed: 07/10/2000
• Issued: 08/07/2001
• Est. Priority Date: 07/10/2000
• Status: Expired due to Fees

• Current Assignee: Bayer Materialscience LLC (Covestro AG)
• Original Assignee: Bayer Corporation (Bayer AG)
• Inventors: Haider, Karl W., Slack, William E., Nodelman, Neil H.
• Primary Examiner(s): Cooney, Jr., John M.
• Application Number:
  US09/613,366
• Time in Patent Office: 393 Days
• Field of Search: 521/159, 521/170, 521/172, 521/174, 521/155
• US Class Current: 521/159
• CPC Class Codes: C08G 18/4072 Mixtures of compounds of group C08G18/63 with other macromolecular compounds
• CPC Class Codes: C08G 18/6685 with compounds of group C08G18/3225 or polyamines of C08G18/38
• CPC Class Codes: C08G 18/7837 containing allophanate groups
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/005 < 50kg/m3
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent

Abstract

This invention relates to a process for the preparation of a flexible foam. This process comprising reacting a liquid, storage stable, allophanate-modified polyisocyanate having an NCO group content of about 20 to about 42%, with an isocyanate-reactive component, in the presence of a blowing agent and at least one catalyst, wherein the relative amounts of the polyisocyanate and the isocyanate-reactive component are such that the NCO index if from about 70 to about 130.

Claims

1. A process for the production of a flexible foam comprising

(A) reacting

(1) a liquid, storage stable, allophanate-modified polyisocyanate having an NCO group content of from about 20 to about 42%, and which comprises the reaction product of

(a) a polyisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol;

with

(2) an isocyanate-reactive component comprising at least one compound which contains isocyanate-reactive groups;

in the presence of

(3) a blowing agent; and

(4) at least one catalyst;

wherein the reaction is conducted at an isocyanate index of from about 75 to about 115.

2. The process of claim 1, wherein (A)(1) said liquid, storage stable, allophanate-modified polyisocyanate has an NCO group content of from about 23 to about 38%, and comprises the reaction product of:

(a) an aromatic diisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol.

3. The process of claim 2, wherein (A)(1) has an NCO group content of from about 30 to about 38% by weight, and comprises the reaction product of:

(a) toluene diisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol.

4. The process of claim 1, wherein (2) said isocyanate-reactive component comprises at least one compound which contains isocyanate-reactive groups having a molecular weight of from about 1,000 to about 10,000, a functionality of from about 1.5 to about 6.0 and an OH number of from about 11 to about 350.

5. The process of claim 4, wherein (2) said isocyanate-reactive component comprises at least one compound which contains isocyanate-reactive groups having a molecular weight of from about 2,000 to about 6,000, a functionality of from about 1.8 to about 4.0 and an OH number of from about 15 to about 115.

6. The process of claim 1, wherein (3) said blowing agent comprises water.

7. The process of claim 1, wherein said isocyanate index is from about 80 to about 110.

8. A flexible foam comprising the reaction product of:

(1) a liquid, storage stable, allophanate-modified polyisocyanate having an NCO group content of from about 20 to about 42%, and which comprises the reaction product of;

(a) a polyisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol;

with

(2) an isocyanate-reactive component comprising at least one compound which contains isocyanate-reactive groups;

in the presence of

(3) a blowing agent; and

(4) at least one catalyst;

wherein said components are present in quantities such that the isocyanate index is from about 75 to about 115.

9. The flexible foam of claim 8, wherein (A)(1) said liquid, storage stable, allophanate-modified polyisocyanate has an NCO group content of from about 23 to about 38%, and comprises the reaction product of:

(a) an aromatic diisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol.

10. The flexible foam of claim 9, wherein (A)(1) has an NCO group content of from about 30 to about 38% by weight, and comprises the reaction product of:

(a) toluene diisocyanate, and

(b) a compound selected from the group consisting 1,2-propylene glycol and 1,3-butanediol.

11. The flexible foam of claim 8, wherein (2) said isocyanate-reactive component comprises at least one compound which contains isocyanate-reactive groups having a molecular weight of from about 1,000 to about 10,000, a functionality of from about 1.5 to about 6.0 and an OH number of from about 11 to about 350.

12. The flexible foam of claim 11, wherein (2) said isocyanate-reactive component coprises at least one compound which contains isocyanate-reactive groups having a m a molecular weight of from about 2,000 to about 6,000, a functionality of from about 1.8 to about 4.0 and an OH number of from about 15 to about 115.

13. The flexible foam of claim 8, wherein (3) said blowing index is from about 80 to about 110.

14. The flexible foam of claim 8, wherein said isocyanate index is from about 80 to about 110.

15. A process for the production of a flexible molded foam comprising:

(A) reacting

(1) a liquid, storage stable, allophanate-modified polyisocyanate having an NCO group content of from about 20 to about 42%, and which comprises the reaction product of;

(a) a polyisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol;

with

(2) an isocyanate-reactive component comprising at least one compound which contains isocyanate-reactive groups;

in the presence of

(3) a blowing agent; and

(4) at least one catalyst;

wherein the reaction is conducted at an isocyanate index of from about 75 to about 115.

16. The process of claim 15, wherein (A)(1) said liquid, storage stable, allophanate-modified polyisocyanate has an NCO group content of from about 23 to about 38%, and comprises the reaction product of:

(a) an aromatic diisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol.

17. The process of claim 16, wherein (A)(1) has an NCO group content of from about 30 to about 38% by weight, and comprises the reaction product of:

(a) toluene diisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol.

18. The process of claim 15, wherein (2) said isocyanate-reactive component comprises at least one compound which contains isocyanate-reactive groups having a molecular weight of from about 1,000 to about 10,000, a functionality of from about 1.5 to about 6.0 and an OH number of from about 11 to about 350.

19. The process of claim 18, wherein (2) said isocyanate-reactive component comprises at least one compound which contains isocyanate-reactive groups having a molecular weight of from about 2,000 to about 6,000, a functionality of from about 1.8 to about 4.0 and an OH number of from about 15 to about 115.

20. The process of claim 15, wherein (3) said blowing agent comprises water.

21. The process of claim 15, wherein said isocyanate index is from about 80 to about 110.

22. A flexible molded foam comprising the reaction product of:

(1) a liquid, storage stable, allophanate-modified polyisocyanate having an NCO group content of from about 20 to about 42%, and which comprises the reaction product of;

(a) a polyisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol;

with

(2) an isocyanate-reactive component comprising at least one compound which contains isocyanate-reactive groups;

in the presence of

(3) a blowing agent; and

(4) at least one catalyst;

wherein said components are present in quantities such that the isocyanate index is from about 75 to about 115.

23. The flexible molded foam of claim 22, wherien (A)(1) said liquid, storage stable, allophanate-modified polyisocyanate has an NCO group content of from about 23 to about 38%, and comprises the reaction product of:

(a) an aromatic diisocyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol.

24. The flexible molded foam of claim 23, wherein (A)(1) has an NCO group content of from about 30 to about 38% by weight, and comprises the reaction product of:

(a) toluene diisucyanate, and

(b) a compound selected from the group consisting of 1,2-propylene glycol and 1,3-butanediol.

25. The flexible molded foam of claim 22, wherein (2) said isocyanate-reactive component comprises at least one compound which contains isocyanate-reactive groups having a molecular weight of from about 1,000 to about 10,000, a functionality of from about 1.5 to about 6.0 and an OH number of from about 11 to about 115.

26. The flexible molded foam of claim 25, wherein (2) said isocyanate-reactive component comprises at least one compound which contains isocyanate-reactive groups having a molecular weight of from about 2,000 to about 6,000, a functionality of from about 1.8 to about 4.0 and an OH number of from about 15 to about 115.

27. The flexible molded foam of claim 22, wherein (3) said blowing agent comprises water.

28. The flexible molded foam of claim 22, wherein said isoxyanate index is from about 80 to about 110.