US 6,617,368 B2Granted

Isotropic rigid foams

AssigneeBayer Aktiengesellschaft

InventorsDavid D. Steppan, Alan D. Bushmire, Edward E. Ball

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Abstract

This invention relates to a process for the preparation of an isotropic rigid foam comprising the step of reacting: (A) an organic polyisocyanate component selected from the group consisting of: (1) a polymethylene poly(phenylisocyanate) and (2) an NCO-terminated prepolymer, and comprising the reaction product of: (a) a polyester comprising the reaction product of (i) pure ortho-phthalic acid or phthalic anhydride and (ii) a glycol and (b) a polymethylene poly(phenylisocyanate); with (B) an isocyanate-reactive component comprising: (1) a liquid OH-terminated prepolymer having a viscosity of more than about 100,000 mPa·s at 25° C., and which comprises the reaction product of: (a) an organic aromatic polyisocyanate component; and (b) an amine initiated polyether polyol component; (2) at least one polyether polyol and optionally (3) at least one aromatic polyester polyol; in the presence of: (C) at least one catalyst; and (D) at least one blowing agent; wherein the relative amounts of components present is such that the Isocyanate Index is from 90 to 170. This invention also relates to the isotropic rigid foams prepared thereby.

Claims34

Dependent claims

A process for the preparation of a rigid foam comprising the step of reacting:

(A) an organic polyisocyanate component selected from the group consisting of:
(1) a polymethylene poly(phenylisocyanate) having an NCO group content of 30.5% to 33.0%, and a monomer content of 42 to 48%, wherein:
(i) less than about 0.5% comprises the 2,2′-isomer,
(ii) from about 2 to about 4% comprises the 2,4′-isomer,
(iii) from about 40 to about 46% comprises the 4,4′-isomer, and
(iv) from about 52 to about 58% by weight comprises higher ring homologues of the MDI series;
with the %'s by weight of (A)(1)(i), (A)(1)(ii), (A)(1)(iii) and (A)(1)(iv) totaling 100% by weight of the component (A)(1);
and
(2) an NCO-terminated prepolymer having an NCO group content of about 26.0% to about 30.0%, and comprising the reaction product of:
(a) a polyester comprising the reaction product of
(i) pure ortho-phthalic acid or phthalic anhydride;
and
(ii) a glycol;
and
(b) a polymethylene poly(phenylisocyanate) having an NCO group content of about 30.5% to 33.0% and a monomer content of about 42 to about 48%, wherein:
(i) less than about 0.5% by weight comprises the 2,2′-isomer,
(ii) from about 2 to about 4% by weight of the 2,4′-isomer,
(iii) from about 40 to 46% by weight of the 4,4′-isomer;
and
(iv) from about 52 to about 58% by weight of higher ring homologues of the diphenylmethane diisocyanate series,
with the %'s by weight of (A)(2)(b)(i), (A)(2)(b)(ii), (A)(2)(b)(iii) and (A)(2)(b)(iv) totaling 100% by weight of (A)(2)(b) the polyisocyanate component;
with
(B) an isocyanate-reactive component comprising:
(1) from 2 to 20% by weight, based on 100% by weight of (B), of a liquid OH-terminated prepolymer having a viscosity of at least about 100,000 mPa·s at 25° C., and which comprises the reaction product of:
(a) an organic aromatic polyisocyanate component;
and
(b) an amine initiated polyether polyol component;
(2) from 50 to 98% by weight, based on 100% by weight of component (B), of at least one polyether polyol having a molecular weight of from 280 to 1,120, a functionality of from 2 to 6, and an OH number of from 300 to 800;
and
(3) from 0 to 30% by weight, based on 100% by weight of (B), of at least one aromatic polyester polyol having an OH number of from 100 to 400, and a functionality of 1.8 to 2.5;
in the presence of:
(C) at least one catalyst;
and
(D) at least one blowing agent;
wherein the relative amounts of components present is such that the Isocyanate Index is from 90 to 170.

32 more elements

A rigid foam comprising the reaction product of:

(A) an organic polyisocyanate component selected from the group consisting of:
(1) a polymethylene poly(phenylisocyanate) having an NCO group content of 30.5% to 33.0%, and a monomer content of 42 to 48%, wherein the polyisocyanate comprises:
(i) less than about 0.5% by weight of the 2,2′ isomer of MDI,
(ii) from about 2 to 4% by weight of the 2,4′-isomer of MDI,
(iii) from about 40 to about 46% by weight of the 4,4′-isomer of MDI, and
(iv) from about 52 to about 58% by weight of higher ring homologues of the diphenylmethane series,
with the %'s by weight of (A)(1)(i), (A)(1)(ii), (A)(1)(iii) and (A)(1)(iv) totaling 100% by weight of the (A)(1) the polyisocyanate;
and
(2) an NCO-terminated prepolymer having an NCO group content of about 26.0% to about 30.0%, and comprising the reaction product of:
(a) a polyester comprising the reaction product of:
(i) pure ortho-phthalic acid or phthalic anhydride;
and
(ii) a glycol;
and
(b) a polymethylene poly(phenylisocyanate) having an NCO group content of about 30.5% to 33.0% and a monomer content of about 42 to about 48% by weight, wherein the polyisocyanate comprises:
(i) less than about 0.5% by weight of the 2,2′-isomer of MDI,
(ii) from about 2 to about 4% by weight of the 2,4′-isomer of MDI,
(iii) from about 40 to about 46% by weight of the 4,4′-isomer of MDI, and
(iv) from about 52 to about 58% by weight of higher ring homologues of the diphenylmethane diisocyanate series,
with the %'s by weight of (A)(2)(b)(i), (A)(2)(b)(ii), (A)(2)(b)(iii) and (A)(2)(b)(iv) totaling 100% by weight of (A)(2)(b) the polyisocyanate;
with
(B) an isocyanate-reactive component comprising:
(1) from 2 to 20% by weight, based on 100% by weight of (B), of a liquid OH-terminated prepolymer having a viscosity of at least about 100,000 mPa·s at 25° C., and which comprises the reaction product of:
(a) an organic aromatic polyisocyanate component;
and
(b) an amine initiated polyether polyol component;
(2) from 50 to 98% by weight, based on 100% by weight of component (B), of at least one polyether polyol having a molecular weight of from 280 to 1,120, a functionality of from 2 to 6, and an OH number of from 300 to 800;
and
(3) from 0 to 30% by weight, based on 100% by weight of (B), of at least one aromatic polyester polyol having an OH number of from 100 to 400, and a functionality of 1.8 to 2.5;
in the presence of:
(C) at least one catalyst;
and
(D) at least one blowing agent;
wherein the relative amounts of components present is such that the Isocyanate Index is from 90 to 170.

31 more elements

Dependencies are inferred from the claim text.

Facts

Application: 10/008,551Filed 13 Nov 2001
Published: US 2003/0134923 A117 Jul 2003
Granted: 9 Sep 2003
Term ends: Not estimatedThe source records don’t support an estimate.

Classification6 codes

C08G 18/4018
Two or more macromolecular compounds not provided for in one single group of groups C08G18/42 - C08G18/64: mixtures of compounds of group…
C08G 18/5027
Containing primary and/or secondary amino groups: directly linked to carbocyclic groups
C08G 2110/0025
Foam properties: rigid
C08G 2110/005
Having specified density: < 50kg/m3