# US 5,344,852 A · Unsaturated polyester-polyurethane hybrid resin foam compositions > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,344,852 A - Document ID: US5344852A - Status: Granted - Kind: A - Application number: 08/021,716 - Filed: 1993-02-24 - Granted: 1994-09-06 - Earliest claimed: 1992-01-16 - Assignees: Aristech Chemical Corporation - Inventors: Gary T. Brooks; Harold R. Edwards, Jr.; Kathy J. Thrash; Donald E. Rubis; David P. Sinclair - Web page: https://patentgrep.com/patent/US5344852A ## CPC - C08G 18/68: Unsaturated polyesters - C08G 18/6529: {Compounds of group C08G18/3225 or polyamines of C08G18/38} - C08G 2110/0025: rigid - C08G 2110/0041: having specified density - C08G 2110/0075: prepared with an isocyanate index of 60 or lower - C08G 2110/0083: prepared using water as the sole blowing agent - C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS ## Abstract Water blown, thermosetting unsaturated polyester-polyurethane hybrid foam compositions are formed by the reaction of an A side composition and a B side composition. The A side composition comprises a polyfunctional isocyanate compound and a free radical initiator. The B side composition comprises a mixture of: (i) an ethylenically unsaturated monomer solution having dissolved therein about 30-90 weight percent of a polyester polyol having at least one ethylenically unsaturated group per molecule which has predominantly hydroxyl end groups; (ii) an amine compound having two or more primary or secondary amine groups in an amount effective to react with the A side composition to form small urea domains finely dispersed within a continuous polyester-polyurethane hybrid phase; and (iii) about 25 to about 150 equivalents water based on 100 equivalents of active hydrogen in the B side. When the A and B side compositions are reacted, the composition will have a ratio of active NCO groups of the isocyanate to active NH groups of the amine compound of between about 10:1 and about 50:1. and an isocyanate index, NCO:(NH+OH+COOH+HOH), of between about 0.5 and about 2.0. ## Claims ### Claim 1 A water blown, thermosetting, unsaturated polyesterpolyurethane hybrid foam resin composition formed by contacting: (a) an A side composition comprising a polyfunctional isocyanate compound and a free radical initiator; and (b) a B side composition comprising a mixture of: (i) an ethylenically unsaturated monomer having dissolved therein about 30-90 weight percent of a polyester polyol having at least one ethylenically unsaturated group per molecule which has predominantly hydroxyl end groups; (ii) an amine compound having two or more primary or secondary amine groups in an amount effective to react with the A side composition to form a first urea phase comprising small urea domains finely dispersed within a second polyester-polyurethane hybrid phase; and (iii) about 25 to about 150 equivalents water based on 100 equivalents of active hydrogen in the B side, not including active hydrogen from water; said composition having a ratio of active NCO groups of the isocyanate to active NH groups of the amine compound of between about 10:1 and about 50:1, and an isocyanate index, NCO:(NH+OH+COOH+HOH), of between about 0.5 and about 2.0. ### Claim 2 (depends on 1) The foam composition of claim 1, having a density of about 10 lbs/ft.sup.3 or less. ### Claim 3 (depends on 1) The foam composition of claim 1, wherein the urea domains comprise particles which average about 3 microns or less in diameter. ### Claim 4 (depends on 1) The foam composition of claim 1, wherein the closed cell content is about fifty percent or greater. ### Claim 5 (depends on 1) The foam composition of claim 1, wherein the composition comprises about 20-40 weight percent isocyanate, about 50-80 weight percent polyester polyol in monomer solution and about 1-10 weight percent amine compound. ### Claim 6 (depends on 1) The foam composition of claim 1, wherein the amine compound comprises an aromatic amine. ### Claim 7 (depends on 6) The foam composition of claim 6, wherein the aromatic amine compound is diethyltoluenediamine. ### Claim 8 (depends on 1) The foam composition of claim 1, wherein the amine compound is dissolved in an amine solvent. ### Claim 9 (depends on 1) The foam composition of claim 1, wherein the ethylenically unsaturated monomer solution comprises styrene. ### Claim 10 (depends on 1) The foam composition of claim 1, wherein the polyester polyol comprises a reaction product of at least one of a saturated di- or polycarboxylic acid or anhydride and an unsaturated di- or polycarboxylic acid or anhydride with a polyhydric alcohol, glycol or mixture thereof. ### Claim 11 (depends on 10) The foam composition of claim 10, wherein the saturated di- or polycarboxylic acid or anhydride comprises isophthalic acid, the unsaturated di- or polycarboxylic acid or anhydride comprises maleic anhydride, and the polyhydric alcohol or glycol is selected from the group consisting of diethylene glycol, ethylene glycol, neopentyl glycol and mixtures thereof. ### Claim 12 (depends on 1) The foam composition of claim 1, wherein the polyester polyol comprises a reaction product of an unsaturated di- or polycarboxylic acid or anhydride with a polyhydric alcohol, glycol or mixture thereof. ### Claim 13 (depends on 1) The foam composition of claim 1, wherein the B side further comprises a urethane foam catalyst. ### Claim 14 (depends on 1) The foam composition of claim 1, wherein the B side further comprises a peroxide promoter. ### Claim 15 (depends on 1) The foam composition of claim 1, wherein the B side further comprises a silicone surfactant. ### Claim 16 (depends on 1) The foam composition of claim 1, wherein the B side further comprises a filler. ### Claim 17 (depends on 16) The foam composition of claim 16, having a density of about 35 lbs/ft.sup.3 or less. ### Claim 18 (depends on 1) The foam composition of claim 1, wherein the B side further comprises a chain extender. ### Claim 19 (depends on 1) The foam composition of claim 1, wherein the B side further comprises a urethane catalyst. ### Claim 20 (depends on 1) The foam composition of claim 1, wherein the ratio of NCO to NH is between about 10:1 and about 30:1, and the isocyanate index NCO:(NH+OH COOH+HOH) is between about 0.8 and about 1.3. ### Claim 21 (depends on 1) The foam composition of claim 1, wherein the first urea phase has a glass transition or melting temperature higher than that of the second polyester-polyurethane phase. ### Claim 22 (depends on 1) The foam composition of claim 1, wherein the urea domains comprise particles which average about 1 micron or less in diameter. ### Claim 23 (depends on 1) A foam product made by the process of claim 1. ### Claim 24 (depends on 1) The B side composition useful in preparing the foam composition of claim 1. ### Claim 25 A process for making a water blown, thermosetting, unsaturated polyester-polyurethane hybrid resin foam composition comprising reacting: (a) an A side composition comprising a polyfunctional isocyanate and a free radical initiator, with (b) a B side composition comprising a mixture of: (i) An ethylenically unsaturated monomer having dissolved therein about 30-90 weight percent of an unsaturated polyester polyol having at least one ethylenically unsaturated group per molecule which has predominantly hydroxyl end groups; (ii) an amine compound having two or more primary or secondary amine groups in an amount effective to react with the A side composition to form a first urea phase comprising small urea domains finely dispersed within a second polyester-polyurethane hybrid phase; and (iii) about 25 to about 150 equivalents water based on 100 equivalents of active hydrogen in the B side, not including active hydrogen from water; wherein the hybrid resin foam composition has a ratio of active NCO groups of the isocyanate to active NH groups of the amine compound of between about 10:1 and about 50:1 and an isocyanate index, NCO:(NH+OH+COOH+HOH), of between about 0.5 and about 2.0. ### Claim 26 (depends on 25) The foam product of claim 25. ### Claim 27 (depends on 26) The foam product of claim 26 wherein the product comprises about 20-40 weight percent isocyanate, about 50-80 weight percent polyester polyol in monomer solution, and about 1-10 weight percent amine compound; the ethylenically unsaturated monomer solution comprises styrene; the polyester polyol comprises a reaction product of at least one of a saturated di- or polycarboxylic acid or anhydride and an unsaturated di- or polycarboxylic acid or anhydride with a polyhydric alcohol, glycol or mixture thereof; wherein the density of the foam product is about 10 lbs/ft.sup.3 or less; the urea domains comprise particles which average about 3 microns or less in diameter; the closed cell content is about fifty percent or greater; the first urea phase has a glass transition or melting temperature higher than that of the second polyester-polyurethane phase; and the B side further comprises a urethane foam catalyst, a peroxide promoter, and a silicone surfactant. ### Claim 28 (depends on 26) The foam product of claim 26, wherein the B side further comprises a filler. ### Claim 29 (depends on 26) The foam product of claim 26, having a density of about 35 lbs/ft.sup.3 or less. ### Claim 30 (depends on 26) The foam product of claim 26, wherein the B side further comprises a chain extender. ### Claim 31 (depends on 26) The foam product of claim 26, wherein the ratio of NCO to NH is between about 10:1 and about 30:1, and the isocyanate index NCO:(NH+OH+COOH+HOH) is between about 0.8 and about 1.2. ### Claim 32 (depends on 26) The foam product of claim 26, wherein the saturated di- or polycarboxylic acid or anhydride comprises isophthalic acid, the unsaturated di- or polycarboxylic acid or anhydride comprises maleic anhydride, and the polyhydric alcohol or glycol is selected from the group consisting of diethylene glycol, ethylene glycol, neopentyl glycol and mixtures thereof.