US 2006/0135637 A1 · Phthalic anhydride based polyester-ether polyols and double metal cyanide catalyst system for preparing same

Abstract

Disclosed are polyester-ether polyols and their use in foams, in particular rigid or flexible foams. Methods for producing such polyester-ether polyols using potassium hydroxide or double metal cyanide catalysts are disclosed, along with methods for producing urethane prepolymers. The polyester-ether polyols of the instant invention are preferably the reaction product of phthalic anhydride, diethylene glycol, and propylene oxide. These polyester-ether polyols are useful as either the primary polyol in urethane compositions or in combination with conventional auxiliary polyester- and/or polyether-based polyols. The polyester-ether polyols impart greatly improved solubility and compatibility to mixtures of either polyether and/or polyester polyols. The polyester-ether polyols of the instant invention are desirably of lower viscosity than their precursor intermediate polyester polyols and are generally soluble in either polyester- and/or polyether-based polyols.

Claims103

Dependent claims

A foam made from a blend comprising:

(a) from about 0% to about 5.0% based on the weight of the composition of a urethane catalyst;
(b) from about 10% to about 90% based on the weight of the composition of a phthalate polyester-ether polyol which is the reaction product of:
(1) about 2% to about 60% based on the weight of the polyester-ether polyol of phthalic anhydride or phthalic acid;
and
(2) about 40% to about 98% based on the weight of the polyester-ether polyol of at least one polyol of the formula:
HO—R1—OH
wherein R1 represents:
(a) alkylene groups of about 2 to about 10 carbon atoms;
(b) —CH2—R2—CH2—
where R2 represents:
(c) —(R3O)n2—R3—
where each R3 independently is an alkylene group of about 2 to about 4 carbon atoms, and n2 is an integer of from about 1-200;
and
(3) about 10% to about 80% based on the weight of the polyester-ether polyol of an alkoxylating agent;
(c) from about 0% to about 50% by weight of an auxiliary polyether polyol, polyester polyol, or a mixture thereof;
(d) from about 0% to about 10% based on the weight of the composition of a blowing agent;
and
(e) from about 0% to about 5% based on the weight of the composition of a compatibilizing surfactant;
and
wherein the blend is further reacted with an effective amount of an isocyanate, a polyisocyante, derivatives thereof, or mixtures thereof to make the foam.

17 more elements

A composition suitable for preparing foam, comprising:

(a) from about 10% to about 70% based on the weight of the composition of an isocyanate;
(b) from about 0.02% to about 5.0% based on the weight of the composition of a urethane catalyst;
and
(c) from about 50% to about 90% based on the weight of the composition of a phthalate polyester-ether polyol which is the reaction product of:
(1) about 2% to about 60% based on the weight of the polyester-ether polyol of phthalic anhydride or phthalic acid;
and
(2) about 40% to about 98% based on the weight of the polyester-ether polyol of at least one polyol of the formula:
HO—R1—OH
wherein R1 represents:
(a) alkylene groups of about 2 to about 10 carbon atoms;
(b) —CH2—R2—CH2—
where R2 represents:
(c) —(R3O)n2—R3—
where each R3 independently is an alkylene group of about 2 to about 4 carbon atoms, and n2 is an integer of from about 1-200;
and
(3) about 10% to about 80% based on the weight of the polyester-ether polyol of an alkoxylating agent selected from the group consisting essentially of ethylene oxide, propylene oxide or butylene oxide or mixtures thereof;
(d) from about 0% to about 50% based on the weight of the composition of an auxiliary polyether polyol, polyester polyol, or a mixture thereof;
(e) from about 0% to about 10% based on the weight of the composition of a blowing agent;
and
(f) from about 0% to about 5% based on the weight of the composition of a compatibilizing surfactant.

17 more elements

A method for preparing foam, comprising the steps of:

(1) preparing a phthalate polyester-ether polyol comprising the step of reacting:
(a) about 2 to about 60 weight % of phthalic anhydride or phthalic acid;
and
(b) about 40 to about 98 weight % of diethylene glycol to form an intermediate phthalate-diethylene glycol polyester polyol, wherein the weight percents of (a) and (b) are based on the weight of the intermediate polyester polyol;
and alkoxylating said intermediate polyester polyol with about 55 to about 80% of propylene oxide based on the weight of the phthalate polyester-ether polyol in the presence of a double metal cyanide complex catalyst;
(2) reacting the phthalate polyester-ether polyol with an isocyanate to prepare a foam.

3 more elements

Dependencies are inferred from the claim text.

Phthalic anhydride based polyester-ether polyols and double metal cyanide catalyst system for preparing same

Life of this patent

Phthalic anhydride based polyester-ether polyols and double metal cyanide catalyst system for preparing same

Life of this patent

Abstract

Claims103