Polyethers and polysiloxane copolymers manufactured with double metal cyanide catalysts
AssigneeOSi Specialties, Inc.
InventorsMichael W. Jorgenson, Richard Budnik, Glenn A. Miller
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Abstract
The invention discloses a new class of silicone surfactants and their use for the preparation of flexible urethane foam. The surfactants incorporate high molecular weight polyethers prepared with narrower molecular weight distributions than conventional polyethers. These polyethers are prepared using a double metal cyanide (DMC) catalyst. These surfactants are better foam stabilizers than the analogous surfactants prepared from conventional polyethers.
Claims16
A process for making polyurethane foam comprising reacting a mixture of (a) a polyether or polyester polyol containing an average of more than two hydroxyl groups per molecule;
- (b) an organic isocyanate having at least two isocyanate groups per molecule;
- (c) at least one catalyst;
- (d) optionally, an auxiliary blowing agent;
- (e) water;
- and (f) a surfactant that has the generalized average formula M"D.sub.x D".sub.y M" wherein
- M" represents (CH.sub.3).sub.3 SiO.sub.1/2 or R(CH.sub.3).sub.2 SiO.sub.1/2 ;
- D represents (CH.sub.3).sub.2 SiO.sub.2/2 ;
- D" represents (CH.sub.3)(R)SiO.sub.2/2 ;
- x is from about 40 to about 220;
- and y is from about 5 to about 34;
- R are polyether-containing substituents obtained from a blend of at least two different polyethers selected from the following two groups:
- 1) --C.sub.n' H.sub.2n' O(C.sub.2 H.sub.4 O).sub.a' (C.sub.3 H.sub.6 O).sub.b' R" moieties having average molecular masses above 3000 daltons wherein the distribution of --C.sub.2 H.sub.4 O-- and --C.sub.3 H.sub.6 O-- groups is random (or contains a random block), and wherein
- n' is 3-4;
- a' and b' are positive numbers such 0.ltoreq.a'/(a'+b').ltoreq.0.6;
- R" represents --H, an alkyl group of 1-8 carbon atoms, --C(O)R"', --C(O)OR"' or --C(O)NHR"';
- R"' represents mono-functional alkyl or aryl groups;
- the random block of EO/PO of said polyether having been produced using a double metal cyanide catalyst;
- and
- 2) --C.sub.n" H.sub.2n" O(C.sub.2 H.sub.4 O).sub.a" (C.sub.3 H.sub.6 O).sub.b" R" moieties having average molecular masses in the range 300-3000 daltons wherein
- n" is 3-4;
- a" and b" are independently 0 or a positive number such that the total molecular weight of the polyether is 300 to 3000 daltons;
- and R" and R"' moieties are as defined above;
- wherein of the two different polyethers, at least one is selected from group (1) polyethers and the blend average molecular weight of the polyethers is between 1100 and 3000 daltons.
Dependencies are inferred from the claim text.