Cured unsaturated polyester-polyurethane hybrid highly filled resin foams
AssigneeEcomat, Inc.
InventorJohn N. Mushovic
Life of this patent
Estimating the term…
Abstract
The present invention is directed to a rigid, lightweight filled resin foam having voids dispersed in a continuous phase which is formed from a polyester hybrid resin having reinforcing particles dispersed therein. The hybrid resin forms a complex crosslinked network which may interact with other polymer networks in the continuous phase either by crosslinking or by forming an interpenetrating polymer network. The present invention is also directed to a process for preparing the above rigid, lightweight resin foam, and to a composition for use in this process. The foam of the present invention is useful in building materials and the like requiring high tensile and compressive strength and corrosion and thermal resistance.
Claims43
A rigid, lightweight filled resin foam, comprising:
- (A) a continuous phase having cellular voids therein, wherein said continuous phase comprises a matrix formed from a complex crosslinked network comprising an unsaturated polyester polyurethane resin which is the reaction product of an unsaturated polyester polyol, a saturated polyol, a poly- or diisocyanate, and a reactive monomer, and optionally further comprising:
- (1) polyurethane modified hybrid networks;
- (2) networks of polymerization products of reactive monomers;
- (3) networks of polymerization products of saturated polyester polyol and poly- or diisocyanates;
- (4) other networks that may form during the formation of the polyester polyurethane resin;
- or
- (5) mixtures of the above networks;
- and
- (B) fine multisize reinforcing particles dispersed in said matrix of said continuous phase, wherein the diameter of the largest of said multisize particles is no greater than about 33% of the average thickness of said walls between said cellular voids, and wherein at least a portion of said multisize particles are capable of containing and releasing a blowing agent during the formation of said polyester polyurethane resin.
Dependencies are inferred from the claim text.