Process for the preparation of polyurethane foams
AssigneeBASF Wyandotte Corporation
InventorsArthur L. Austin, William W. Levis, Jr., Louis C. Pizzini, Robert J. Hartman
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Abstract
An oxyalkylated product useful for making polyurethane foams is prepared by reacting an alkylene oxide with a heated mixture of a phenol and a non-phenolic active hydrogen compound, at least one of which can be halogenated, in the presence of a catalyst complex of a phenol and an iron or aluminum substance. The mixture can also include a neutral phosphorus compound and/or acid anhydrides to enhance flame retardant properties. Optionally, also, the oxyalkylation reaction can be terminated by adding a tri (lower alkyl) amine and alkylene oxide to react with residual phenolic hydrogen in the mixture.
Claims20
In a process for preparing a polyurethane foam which comprises mixing and reacting a polyol, a polyarylpolyalkylene polyisocyanate, a polymerization catalyst, a wetting agent and a blowing agent, the improvement which comprises using as a polyol therein, based on the total weight of the ingredients,
- 20 to about 100 parts of an oxyalkylation polyol product prepared by the process of
- 1. providing a reaction mixture containing
- a. a phenol, at least in an amount sufficient to form a complex with aluminum or iron substances in the mixture,
- b. a non-phenolic active hydrogen compound having from 2 to 8 active hydrogens per molecule and having an average molecular weight below about 10,000, and
- c. a substance containing aluminum or iron which will form a complex with the phenol a), in an amount sufficient to form a complex with the phenol a),
- 2. heating the mixture to a temperature in the range of from about 80.degree. C. to about 250.degree. C., and
- 3. oxyalkylating the heated mixture by adding thereto sufficient alkylene oxide having from 2 to 12 carbon atoms to form an oxyalkylated polyol product, per
- 40 to about 60 parts of a polyarylpolyalkylene polyisocyanate having a functionality of about 2.2 to about 3.3 or of an isocyanate-terminated prepolymer derived from the reaction of a stoichiometric excess of said polyarylpolyalkylene polyisocyanate with said oxyalkylation polyol,
- 0.2 to about 2 parts of a polymerization catalyst,
- 0.15 to about 3 parts of a wetting agent, and
- 5 to about 30 parts of a blowing agent.
Dependencies are inferred from the claim text.