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US 2003/0203984 A1Published application
Fire retardant silicone surfactants for use in inert gas blown polyurethane foams
OwnerBrian L. Hilker, Lee F. Lawler +1inventors
InventorsBrian L. Hilker, Lee F. Lawler, Susan B. McVey
Life of this patent
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Abstract
Silicone surfactants for use in inert gas blown polyurethane foams comprise low to moderate molecular weight comb-type flame-retardant silicone copolymers possessing no high ethylene oxide content branches. The silicone surfactants yield Dissolved Gas Technology foams having improved consistency as compared to other surfactant compositions.
Claims30
A method of producing a polyurethane foam comprising:
- A) preparing a mixture comprising:
- (1) a polyether polyol containing an average of more than two hydroxyl groups per molecule,
- (2) an organic polyisocyanate,
- (3) at least one catalyst for the production of polyurethane foams,
- (4) water, and
- (5) a surfactant;
- wherein the surfactant comprises a silicone/polyether composition of the formula:
- R—Si(CH3)2O—{Si(CH3)2O—}x—{SiCH3R1O—}a—{SiCH3R2O—}b—{SiCH3R3O—}c—{SiCH3R4O—}d—Si(CH3)2—R;
- or the formula:
- R—Si(CH3)2O—{SiCH3RO}m—(SiCH3{O—(SiCH3RO)m—Si(CH3)2R}O)n—{SiCH3RO}m—Si(CH3)2—R
- wherein:
- R1, R2, and R3 are polyalkylene oxide polyethers of the formula
- —B—CnH2nO—(C2H4O)e—(C3H6O)f(C4H8O)gZ,
- where
- R1 has a blend average molecular weight in the range of from about 3000 to about 6000 grams/mole and ethylene oxide is from about 20 to about 60 weight percent of the alkylene oxide content of the polyether;
- R2 has a blend average molecular weight in the range of from about 800 to about 2900 and ethylene oxide is from about 20 to about 60 weight percent of the alkylene oxide content of the polyether;
- R3 has a blend average molecular weight in the range of from about 130 to about 800 grams/mole and ethylene oxide is from 0 to about 75 weight percent of the alkylene oxide content of the polyether;
- R4 is an substituted or unsubstituted alkyl, alkaryl, or aryl group of C1 to C12;
- B is derived from a moiety capable of undergoing hydrosilation;
- Z is selected from the group consisting of hydrogen, C1-C8 alkyl or aralkyl moieties, —C(O)Z1, —C(O)OZ1, and —C(O)NHZ1,
- where Z1 represents mono-functional C1-C8 alkyl or aryl moieties;
- each R is independently selected from the group consisting of R1, R2, R3, and R4;
- x is 40 to 150;
- y is 5 to 40 and equals a+b+c+d,
- where b or c, but not both, may be 0,
- d/(a+b+c)=0 to 1, and
- a+b>0;
- x/y≦10;
- m=10 to 100;
- n≦4;
- and
- e, f, and g are defined by the molecular weight required by the polyether;
- with the proviso that the total ethylene oxide content of the surfactant structure is less than 37% by weight;
- and
- B) blowing the polyurethane foam with a pressurized inert gas.
32 more elements
A polyurethane foam prepared by a method comprising:
- A) preparing a mixture comprising:
- (1) a polyether polyol containing an average of more than two hydroxyl groups per molecule,
- (2) an organic polyisocyanate,
- (3) at least one catalyst for the production of polyurethane foams,
- (4) water, and
- (5) a surfactant;
- wherein the surfactant comprises a silicone/polyether composition of the formula:
- R—Si(CH3)2O—{Si(CH3)2O—}x—SiCH3R1O—}a—{SiCH3R2O—}b—{SiCH3R3O—}c—{SiCH3R4O—}d—Si(CH3)2—R;
- or the formula:
- R—Si(CH3)2O—{SiCH3RO}m—(SiCH3{O—(SiCH3RO)m—Si(CH3)2R}O)n—{SiCH3RO}m—Si(CH3)2—R
- wherein:
- R1, R2, and R3 are polyalkylene oxide polyethers of the formula
- —B—CnH2nO—(2H4O)e—(C3H6O)f(C4H8O)gZ,
- where
- R1 has a blend average molecular weight in the range of from about 3000 to about 6000 grams/mole and ethylene oxide is from about 20 to about 60 weight percent of the alkylene oxide content of the polyether;
- R2 has a blend average molecular weight in the range of from about 800 to about 2900 and ethylene oxide is from about 20 to about 60 weight percent of the alkylene oxide content of the polyether;
- R3 has a blend average molecular weight in the range of from about 130 to about 800 grams/mole and ethylene oxide is from 0 to about 75 weight percent of the alkylene oxide content of the polyether;
- R4 is an substituted or unsubstituted alkyl, alkaryl, or aryl group of C1 to C12;
- B is derived from a moiety capable of undergoing hydrosilation;
- Z is selected from the group consisting of hydrogen, C1-C8 alkyl or aralkyl moieties, —C(O)Z1, —C(O)OZ1, and —C(O)NHZ1,
- where Z1 represents mono-functional C1-C8 alkyl or aryl moieties;
- each R is independently selected from the group consisting of R1, R2, R3, and R4;
- x is 40 to 150;
- y is 5 to 40 and equals a+b+c+d,
- where b or c, but not both, may be 0,
- d/(a+b+c)=0 to 1, and
- a+b>0;
- x/y≦10;
- m=10 to 100;
- n≦4;
- and
- e, f, and g are defined by the molecular weight required by the polyether;
- with the proviso that the total ethylene oxide content of the surfactant structure is less than 37% by weight;
- and
- B) blowing the polyurethane foam with a pressurized inert gas.
32 more elements
Dependencies are inferred from the claim text.