# US 9,434,809 B2 · Isocyanate-terminated prepolymer, the method for preparing the same and the use thereof

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- Number: US 9,434,809 B2
- Document ID: US9434809B2
- Status: Granted
- Kind: B2
- Application number: 13/768,430
- Filed: 2013-02-15
- Published: 2013-06-27
- Granted: 2016-09-06
- Earliest claimed: 2009-08-24
- Assignees: Covestro Deutschland AG
- Applicants: Bayer MaterialScience AG
- Inventors: Jen-Chieh Lin; HoChien Kung; Hong Zhu
- Web page: https://patentgrep.com/patent/US9434809B2

## CPC

- C08G 18/7657: {containing two or more aromatic rings}
- C08G 18/12: using two or more compounds having active hydrogen in the first polymerisation step
- C08G 18/14: {Manufacture of cellular products}
- C08G 18/7664: {containing alkylene polyphenyl groups}
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- C08G 2110/0008: flexible
- 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

The present invention pertains to the field of polyurethane, especially relates to an isocyanate-terminated prepolymer, the method for preparing the same and the use thereof. The present invention adjusts the reaction components and the ratios thereof to obtain an isocyanate-terminated prepolymer suitable for preparing flexible polyurethane foam under a relative low mold temperature. The method for preparing flexible polyurethane foam by using the isocyanate-terminated prepolymer provided in this present invention can reduce the mold temperature, production time and energy consumption, as well as to obtain a polyurethane flexible foam processing good physical and mechanical properties.

## Claims

### Claim 1

An isocyanate-terminated prepolymer, wherein the isocyanate-terminated prepolymer comprises the reaction product of reaction components of a1, a2 and a3:
a1) 52-54% by weight of diphenylmethane diisocyanate (MDI), based on 100% by weight of the isocyanate-terminated prepolymer, wherein the diphenylmethane diisocyanate (MDI) comprises 73-79% by weight of 4,4′-diphenylmethane diisocyanate, based on 100% by weight of the diphenylmethane diisocyanate (MDI),
a2) 34-36% by weight of polymethylene polyphenyl polyisocyanate (PMDI), based on 100% by weight of the isocyanate-terminated prepolymer, wherein the polymethylene polyphenyl polyisocyanate (PMDI) has an average functionality of from 2.6 to 2.8, and
a3) 10-13% by weight of polyoxyethylene-polyoxypropylene polyol, based on 100% by weight of the isocyanate-terminated prepolymer, wherein the average functionality of the polyoxyethylene-polyoxypropylene polyol is 2-6, the average molecular weight is 2000-10000, and the average ethylene oxide content of the polyoxyethylene-polyoxypropylene polyol is 24-40% by weight, based on 100% by weight of the polyoxyethylene-polyoxypropylene polyol,
wherein, the NCO content of the isocyanate-terminated prepolymer is 27-30% by weight, based on 100% by weight of the isocyanate-terminated prepolymer.

### Claim 2 (depends on 1)

The isocyanate-terminated prepolymer as claimed in claim 1, wherein the average ethylene oxide content of the polyoxyethylene-polyoxypropylene polyol is 24-37% by weight, based on 100% by weight of the polyether polyol.

### Claim 3

A method for preparing an isocyanate-terminated prepolymer, comprising the step of reacting components of a1, a2 and a3:
a1) 52-54% by weight of diphenylmethane diisocyanate (MDI), based on 100% by weight of the isocyanate-terminated prepolymer, wherein the diphenylmethane diisocyanate (MDI) comprises 73-79% by weight of 4,4′-diphenylmethane diisocyanate, based on 100% by weight of the diphenylmethane diisocyanate (MDI),
a2) 34-36% by weight of polymethylene polyphenyl polyisocyanate (PMDI) having an average functionality of from 2.6 to 2.8, based on 100% by weight of the isocyanate-terminated prepolymer, and
a3) 10-13% by weight of polyoxyethylene-polyoxypropylene polyol, based on 100% by weight of the isocyanate-terminated prepolymer, wherein the average functionality of the polyoxyethylene-polyoxypropylene polyol is 2-6, the average ethylene oxide content of the polyoxyethylene-polyoxypropylene polyol is 24-40% by weight, based on 100% by weight of the polyoxyethylene-polyoxypropylene polyol,
wherein the NCO content of the isocyanate-terminated prepolymer is 27-30% by weight, based on 100% by weight of the isocyanate-terminated prepolymer.

### Claim 4 (depends on 3)

The method as claimed in claim 3, wherein the average ethylene oxide content of the polyoxyethylene-polyoxypropylene polyol is 24-37% by weight, based on 100% by weight of the polyether polyol.

### Claim 5 (depends on 1, 2)

A method for preparing a flexible polyurethane foam comprising the step of reacting components of A, B and C:
A) isocyanate-terminated prepolymer as claimed in claim 1 or 2,
B) polyol, comprising;
b1) 0.1-20 weight parts of at least a first polyoxyethylene-polyoxypropylene polyol, based on 100% by weight of B and C, wherein the functionality of the first polyoxyethylene-polyoxypropylene polyol is equal to or more than 2, the average ethylene oxide content of the first polyoxyethylene-polyoxypropylene polyol is equal to or more than 50% by weight,
b2) 30-90 weight parts of a second polyoxyethylene-polyoxypropylene polyol, based on 100% by weight of B and C, wherein the hydroxyl value of the second polyoxyethylene-polyoxypropylene polyol is 25-40 mg/KOH, the average ethylene oxide content of the second polyoxyethylene-polyoxypropylene polyol is equal to or less than 30% by weight,
b3) 5-60 weight parts of polymer polyol,
b4) 0.01-15 weight parts of chain extender,
b5) 0.01-20 weight parts of catalyst and/or foam stabilizer, and
C) 0.1-7 weight parts of water,
wherein the NCO index of the reaction is 70-120.

### Claim 6 (depends on 5)

The method as claimed in claim 5, wherein the reaction of reaction components A, B and C is carried out in a mould, and the mould temperature is 15-40° C.