Process for producing elastic polyurethane moldings with compact surfaces and cellular cores

• US 6,331,577 B1
• Filed: 04/30/1999
• Issued: 12/18/2001
• Est. Priority Date: 05/08/1996
• Status: Expired due to Fees

• Current Assignee: BASF AG (BASF SE)
• Original Assignee: BASF AG (BASF SE)
• Inventors: Volkert, Otto, Pittrich, Klaus
• Primary Examiner(s): COONEY, JOHN M
• Application Number:
  US09/171,537
• Time in Patent Office: 963 Days
• Field of Search: 521/51, 521/137, 521/159, 521/160, 521/170, 521/172, 521/174
• US Class Current: 521/159
• 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 18/48 Polyethers
• CPC Class Codes: C08G 18/4825 Polyethers containing two hydroxy groups C08G18/4833 - C08G18/5096 take precedence
• CPC Class Codes: C08G 18/4829 Polyethers containing at least three hydroxy groups C08G18/4833 - C08G18/5096 take precedence
• CPC Class Codes: C08G 18/4837 and other oxyalkylene units
• CPC Class Codes: C08G 18/7671 containing only one alkylene bisphenyl group
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/0033 having integral skins
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08G 2410/00 Soles

Abstract

Elastic polyurethane moldings having a compact surface and a cellular core are produced by reacting

a) modified organic polyisocyanates with

b) at least one relatively high molecular weight compound containing at least two reactive hydrogen atoms and, if desired,

c) low molecular weight chain extenders in the presence of

d) blowing agents,

e) catalysts and, if desired,

f) customary auxiliaries and/or additives

in a closed mold with compaction, wherein the modified organic polyisocyanate used is at least one reaction product of pure MDI and at least one polyether alcohol (polyoxyalkylene polyol), the modified organic polyisocyanate having an NCO content of <15% by weight.

Claims

1. A process for producing high elasticity polyurethane moldings having a compact surface and a cellular core comprising the step of reacting

a) modified organic polyisocyanate with

b) at least one compound containing at least two reactive hydrogen atoms and having a molecular weight of from 1000 to 8000, and optionally

c) chain extenders, in the presence of

d) blowing agents,

e) catalysts and, if desired,

f) auxiliaries and/or additives in a closed mold with compaction, wherein the modified organic polyisocyanate a) comprises the reaction product of 4,4′

-diisocyanatodiphenylmethane with at least one polyoxypropylene polyol and/or polyoxypropylene-polyoxyethylene polyol, the modified organic polyisocyanate has an NCO content of <

15% by weight, the chain extenders c) comprise diols having a molecular weight of <

400, the weight ratio of a) to the sum of the components b) to f) in the reaction is greater than 1, the blowing agent d) comprises water, and

wherein the components a) through f) are reacted in amounts sufficient to provide polyurethane moldings having a density below 400 grams per liter and a rebound resilience in accordance with DIN 53512 of at least 35%.

2. A process as claimed in claim 1, wherein the modified organic polyisocyanate a) has an NCO content of <

13% by weight.

3. A process as claimed in claim 1, wherein the modified organic polyisocyanate a) comprises the reaction product of 4,4′

-diisocyanatodiphenylmethane and at least one polyoxypropylene diol and/or triol and/or polyoxypropylene-polyoxyethylene diol and/or triol.

4. A process as claimed in claim 1, wherein the polyoxypropylene polyol and/or polyoxypropylene-polyoxyethylene polyol used for preparing the modified organic polyisocyanate a) has a molecular weight of from 1000 to 8000.

5. A process as claimed in claim 1, wherein the polyoxypropylene polyol and/or polyoxypropylene-polyoxyethylene polyol used for preparing the modified organic polyisocyanate a) has a molecular weight of from 2000 to 6000.

6. A process as claimed in claim 1, wherein the modified organic polyisocyanate a) comprises the reaction product of 4,4′

-diisocyanatodiphenylmethane and one or more diols based on polyoxypropylene having polyoxyethylene units at the chain end, wherein >

80% of the terminal hydroxyl groups are primary hydroxyl groups.

7. A process as claimed in claim 1, wherein the modified organic polyisocyanate a) comprises a reaction product of 4,4′

-diisocyanatodiphenylmethane and up to 5%, based on the weight of 4,4′

-diisocyanatodiphenylmethane, of a high functional polyisocyanate selected from the group consisting of allophanate-modified polyisocyanate, uretonimine-modified polyisocyanate, polyphenylene polymethylene polyisocyanate, and mixtures thereof, with at least one polyoxypropylene polyol or polyoxypropylene-polyoxyethylene polyol.

8. A process as claimed in claim 7, wherein the modified organic polyisocyanate a) has an NCO content of <

13% by weight.

9. A high elasticity polyurethane molding having a compact surface and a cellular core, comprising the reaction product of

a) modified organic polyisocyanate with

b) at least one compound containing at least two reactive hydrogen atoms and having a molecular weight of from 1000 to 8000, and optionally

c) chain extenders, in the presence of

d) blowing agents,

e) catalysts and, if desired,

f) auxiliaries and/or additives

in a closed mold with compaction, wherein the modified organic polyisocyanate a) comprises the reaction product of 4,4′

-diisocyanatodiphenylmethane with at least one polyoxypropylene polyol and/or polyoxypropylene-polyoxyethylene polyol, the modified organic polyisocyanate has an NCO content of <

15% by weight, the chain extenders c) comprise diols having a molecular weight of <

400, the weight ratio of a) to the sum of the components b) to f) in the reaction is greater than 1, the blowing agent d) comprises water, and

wherein said polyurethane molding has a density below 400 grams per liter and a rebound resilience in accordance with DIN 53512 of at least 35%.

10. A polyurethane molding according to claim 9, wherein the modified organic polyisocyanate a) has an NCO content of <

13% by weight.

11. A polyurethane molding according to claim 9, wherein the modified organic polyisocyanate a) comprises the reaction product of 4,4′

-diisocyanatodiphenylmethane and at least one polyoxypropylene diol and/or triol and/or polyoxypropylene-polyoxyethylene diol and/or triol.

12. A polyurethane molding according to claim 9, wherein the polyoxypropylene polyol and/or polyoxypropylene-polyoxyethylene polyol used for preparing the modified organic polyisocyanate a) has a molecular weight of from 1000 to 8000.

13. A polyurethane molding according to claim 9, wherein the polyoxypropylene polyol and/or polyoxypropylene-polyoxyethylene polyol used for preparing the modified organic polyisocyanate a) has a molecular weight of from 2000 to 6000.

14. A polyurethane molding according to claim 9, wherein the modified organic polyisocyanate a) comprises the reaction product of 4,4′

-diisocyanatodiphenylmethane and one or more diols based on polyoxypropylene having polyoxyethylene units at the chain end, wherein >

80% of the terminal hydroxyl groups are primary hydroxyl groups.

15. A polyurethane molding according to claim 9, wherein the modified organic polyisocyanate a) comprises a reaction product of 4,4′

-diisocyanatodiphenylmethane and up to 5%, based on the weight of 4,4′

-diisocyanatodiphenylmethane, of a high functional polyisocyanate selected from the group consisting of allophanate-modified polyisocyanate, uretonimine-modified polyisocyanate, polyphenylene polymethylene polyisocyanate, and mixtures thereof, with at least one polyoxypropylene polyol or polyoxypropylene-polyoxyethylene polyol.

16. A polyurethane molding according to claim 15, wherein the modified organic polyisocyanate a) has an NCO content of <

13% by weight.