Formulated waterborne polyurethane dispersion composition for stable ambient-dried foams

Patent metadata

Field	Value
Publication number	US-11713368-B2
Application number	US-201916695890-A
Country	US
Kind code	B2
Filing date	Nov 26, 2019
Priority date	Nov 30, 2018
Publication date	Aug 1, 2023
Grant date	Aug 1, 2023

Abstract

Foamable waterborne dispersions which form stable flexible foams under ambient cure conditions are disclosed, said foamable waterborne dispersions comprising: a polyurethane polymer formed from one or more aliphatic or cycloaliphatic polyisocyanate and at least two different polymeric polyol components selected from polyether polyol, polyester polyol, and polycarbonate polyol; wherein the ambient cure conditions include a temperature of from 4° C. to 32° C., and a humidity of 0% relative humidity to 90% relative humidity. Also disclosed are the flexible foams produced from the foamable waterborne dispersions, as well as methods of providing a space filling layer or space filling volume adjacent to or on a surface, said methods comprising applying to said surface a foamed sample of the foamable waterborne dispersions, and allowing the foamed sample of foamable waterborne dispersion to dry under ambient conditions to yield a stable flexible foam.

First claim

What is claimed:

1. A method of providing a space filling volume adjacent to or on a surface in a gap in a building envelope, the method comprising:
(a) applying to said surface a foamed sample of a foamable waterborne dispersion, wherein said foamable waterborne dispersion comprises:
a polyurethane polymer formed from isophorone diisocyanate, and
at least two different polyol components that comprise one or more polyether polyol and one or more polyester polyol; and

(b) allowing the foamed sample of foamable waterborne dispersion to dry under ambient conditions of 4° C. to 32° C. and 0% to 90% relative humidity to yield a stable foam;
and
wherein the stable foam provides a space filling volume adjacent to or on the surface in the gap in a building envelope to block air transmission,
wherein the stable foam will not collapse at conditions of 32° C. and 90% relative humidity, and can be compressed to less than 30% of its original height with a pressure of 15 psi or less.

2. The method of claim 1 , wherein the step of applying the foamed sample of the foamable waterborne dispersion is performed by dispensing the foamable waterborne dispersion from a pressurized container.

3. The method of claim 1 , wherein the stable foam produced has a density of from 0.04 to 0.4 g/cm 3 .

4. The method of claim 3 , wherein the height of the stable foam is greater than 3 mm.

5. The method of claim 1 , wherein the stable foam is compressed between two surfaces and acts as a gasket.

6. The method of claim 1 , wherein the foamable waterborne dispersion comprises less than 0.3%, by weight in relation to the entire foamable waterborne dispersion, of ionic surfactants, soaps, or waxes.

7. The method of claim 1 , wherein the weight ratio of polyether polyol to polyester polyol is from 5:95 to 90:10.

Assignees

• Ddp Specialty Electronic Mat Us Inc
• Ddp Specialty Electronic Materials Us Llc

Inventors

• Broderick Adam Howlett

Classifications

• C08G18/48 Primary

  Polyethers · CPC title

• C08G18/4018

  Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48 · CPC title

• C08G18/44

  Polycarbonates · CPC title

• C08G18/755

  and at least one isocyanate or isothiocyanate group linked to a secondary carbon atom of the cycloaliphatic ring, e.g. isophorone diisocyanate · CPC title

• C08G2110/005

  < 50kg/m3 · CPC title