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US 2003/0232899 A1Published application
Syntactic foams with improved water resistance, long pot life and short demolding times
AssigneeBayer Aktiengesellschaft
InventorsPeter H. Markusch, Ralf Guether, Tom L. Sekelik
Life of this patent
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Abstract
This invention relates to syntactic foams comprising the reaction product of a liquid diphenylmethane diisocyanate component, with an isocyanate-reactive component, a filler having a density of less than 1 g/cm 3, and at least one organo-metallic catalyst. This invention also relates to the use of these syntactic foams for insulating pipes.
Claims18
A syntactic foam comprising the reaction product of:
- (1) a liquid diphenylmethane diisocyanate having an NCO group content of from about 10 to about 33.6% and a viscosity from about 10 to about 5,000 mPa·s @ 25° C.,
- with
- (2) an isocyanate-reactive component comprising:
- (a) at least 10% by weight of one or more polyether polyols having a functionality of 2 to 4, a molecular weight of 200 to 8,000, and a hydroxyl number of 14 to 1,120, wherein at least one amine group is present in the starter for said polyether polyol, and the starter being alkoxylated by 100% by weight of propylene oxide;
- (b) at least 20% by weight of one or more low unsaturation polyether polyols having an OH functionality of about 2, a molecular weight of 250 to 8,000, and a hydroxyl number of 14 to 448, wherein the starter for said low unsaturation polyether polyol comprises water or an organic component containing two hydroxyl groups, and the starter being alkoxylated with 100% by weight of propylene oxide,
- (c) at least 20% by weight of one or more polyether polyols having an OH functionality of about 3 to 6, a molecular weight of about 400 to about 3,000, and an hydroxyl number of about 56 to about 840, wherein the starter for said polyether polyol comprises an organic compound containing at least three hydroxyl groups, and the starter being alkoxylated with 100% by weight of propylene oxide;
- and, optionally,
- (d) up to 10% by weight of one or more low molecular weight diols and/or triols having an equivalent weight of from 31 to 99;
- wherein the %'s by weight of (2)(a), (2)(b), (2)(c) and (2)(d) totals 100% by weight of component (2);
- (3) from 10 to 70% by weight, based on the combined weight of components (1), (2) and (3), of a filler having a density of less than 1 g/cm3;
- and
- (4) at least one organo-metallic catalyst in the amount of about 0.001 to about 1% by weight, based on 100% by weight of (2);
- wherein the relative amounts of components (1) and (2) are such that the isocyanate index is from about 90 to about 120.
10 more elements
A process for preparing a syntactic foam, comprising reacting:
- (1) a liquid diphenylmethane diisocyanate having an NCO group content of from about 10 to about 33.6% and a viscosity from about 10 to about 5,000 mPa·s @ 25° C.,
- with
- (2) an isocyanate-reactive component comprising:
- (a) at least 10% by weight of one or more polyether polyols having a functionality of 2 to 4, a molecular weight of 200 to 8,000, and a hydroxyl number of 14 to 1,120, wherein at least one amine group is present in the starter for said polyether polyol, and the starter being alkoxylated by 100% by weight of propylene oxide;
- (b) at least 20% by weight of one or more low unsaturation polyether polyols having an OH functionality of about 2, a molecular weight of 250 to 8,000, and a hydroxyl number of about 14 to 448, wherein the starter for said low unsaturation polyether polyol comprises water or an organic component containing two hydroxyl groups, and the starter being alkoxylated with 100% by weight of propylene oxide;
- (c) at least 20% by weight of one or more poiyether polyols having an OH functionality of about 3 to 6, a molecular weight of about 400 to about 3,000, and an hydroxyl number of about 56 to about 840, wherein the starter for said polyether polyol comprises an organic compound containing at least three hydroxyl groups, and the starter being alkoxylated with 100% by weight of propylene oxide;
- and, optionally,
- (d) up to 10% by weight of one or more low molecular weight diols and/or triols having an equivalent weight of from 31 to 99;
- wherein the %'s by weight of (2)(a), (2)(b), (2)(c) and (2)(d) totals 100% by weight of component (2);
- (3) from 10 to 70% by weight, based on the combined weight of components (1), (2) and (3), of a filler having a density of less than 1 g/cm3;
- and
- (4) at least one organo-metallic catalyst in the amount of about 0.001 to about 1% by weight, based on 100% by weight of component (2);
- wherein the relative amounts of components (1) and (2) are such that the isocyanate index is from about 90 to about 120.
10 more elements
A process for preparing a pipe insulated with a syntactic foam, comprising:
- (I) placing a steel pipe in the center of a cylindrical mold with the diameter of the mold being larger than the diameter of the pipe, wherein the difference in diameter between the pipe and the mold determines the thickness of the syntactic foam to be applied;
- (II) pouring a liquid polyurethane reaction mixture containing a filler around the steel pipe in the mold, wherein said liquid polyurethane reaction mixture is formed by:
- (A) blending (3) a filler having a density of less than 1 g/cm3 with (1) a liquid diisocyanate component and/or (2) an isocyanate-reactive component,
- (B) adding (4) an organo-metallic catalyst to the isocyanate-reactive component which may or may not contain a filler;
- and
- (C) mixing the liquid diisocyanate component with the isocyanate-reactive component, wherein:
- (1) said liquid diisocyanate component comprises liquid diphenylmethane diisocyanate having an NCO group content of from about 10 to about 33.6% and a viscosity from about 10 to about 5,000 mPa·s @ 25° C.,
- with
- (2) an isocyanate-reactive component comprising:
- (a) at least 10% by weight of one or more polyether polyols having a functionality of 2 to 4, a molecular weight of 200 to 8,000, and a hydroxyl number of 14 to 1,120, wherein the starter for said polyether polyol comprises at least one amine group, and said starter being alkoxylated by 100% by weight of propylene oxide;
- (b) at least 50% by weight of one or more low unsaturation polyether polyols having an OH functionality of about 2, a molecular weight of 250 to 8,000, and a hydroxyl number of 14 to 448, wherein the starter comprises water or an organic component containing at least two hydroxyl groups, and said starter being alkoxylated with 100% by weight of propylene oxide;
- (c) at least 20% by weight of one or more polyether polyols having an OH functionality of about 3 to about 6, a molecular weight of about 400 to about 3,000, and an hydroxyl number of about 56 to about 840, wherein the starter for said polyether polyol comprises an organic compound containing at least three hydroxyl groups, and said starter being alkoxylated with 100% by weight of propylene oxide;
- and, optionally,
- (d) up to 10% by weight of one or more low 30 molecular weight diols and/or triols having an equivalent weight of from 31 to 99,
- wherein the %'s by weight of (2)(a), (2)(b), (2)(c) and (2)(d) totals 100% by weight of component (2);
- (III) allowing the liquid polyurethane reaction mixture containing the filler cure to form a solid polyurethane containing a filler, which encapsulates the steel pipe;
- and
- (IV) demolding the polyurethane encapsulated steel pipe, thereby yielding a syntactic foam insulated pipe.
15 more elements
Dependencies are inferred from the claim text.