Polyisocyanate Polyaddition Polyol Manufacturing Process Using Stabilizers

Patent metadata

Field	Value
Publication number	US-2016194431-A1
Application number	US-201414916987-A
Country	US
Kind code	A1
Filing date	Sep 11, 2014
Priority date	Sep 13, 2013
Publication date	Jul 7, 2016
Grant date	—

Abstract

PIPA polyols are made by reacting a low equivalent weight polyol with a polyisocyanate in the presence of a stabilizer. Low amounts, if any, of water are present. Useful stabilizers include functionalized linear or branched polyethers having at least one polyether segment having a molecular weight of 200 to 8000, wherein the functionalized polyether is terminated at one end with one or more isocyanate groups or with one or more isocyanate-reactive groups linked to the polyether through one or more urea and/or urethane groups, and further wherein all or a portion of such functionalized polyether contains one or more biuret, isocyanurate, urea or allophonate groups.

First claim

1 . A process for preparing a dispersion of polyisocyanate polyaddition particles in a base polyol, comprising forming an agitated mixture of a low equivalent weight polyol having a hydroxyl equivalent weight of up to 80 and 2 to 6 hydroxyl groups per molecule, one or more polyisocyanate compounds, a stabilizer which is a functionalized polyether based on a reaction product of a polyether and a starting polyisocyanate, which stabilizer is not a polyisocyanate polyaddition (PIPA) polyol and is not a silicone compound, and a base polyether polyol having a hydroxyl equivalent weight of at least 200, and reacting the low equivalent weight polyol with the polyisocyanate compound(s) in the presence of the base polyether polyol, the stabilizer, 0 to 2.0% by weight water based on the combined weight of the water, base polyol, low equivalent weight polyol, stabilizer and polyisocyanate compound(s), to form the dispersion of polyisocyanate polyaddition particles in the base polyol.

2 - 5 . (canceled)

6 . A process for preparing a dispersion of polyisocyanate polyaddition particles in a base polyol, comprising forming an agitated mixture of a low equivalent weight polyol having a hydroxyl equivalent weight of up to 80, one or more polyisocyanate compounds, a stabilizer, a base polyether polyol having a hydroxyl equivalent weight of at least 200, and reacting the low equivalent weight polyol with the polyisocyanate compound(s) in the presence of the base polyether polyol and the stabilizer, to form the dispersion of polyisocyanate polyaddition particles in the base polyol, wherein the stabilizer includes one or more functionalized linear or branched polyether compounds having at least one polyether segment that have a molecular weight of 200 to 8000, wherein the functionalized linear or branched polyether compounds are terminated at one end with one or more isocyanate groups or with one or more isocyanate-reactive groups linked to the polyether through one or more urea and/or urethane groups, and further wherein all or a portion of such functionalized linear or branched polyether compounds contain one or more biuret, isocyanurate, urea or allophonate groups.

7 . The process of claim 6 wherein the functionalized linear or branched polyether compound(s) are a reaction product of a monofunctional polyether having a molecular weight of 700 to 8000 and a polyisocyanate having an isocyanate equivalent weight of up to 300.

8 . The process of claim 7 , wherein all or a portion of the functionalized linear or branched polyether compound(s) contain one or more isocyanurate groups.

9 . The process of claim 6 , wherein the functionalized linear or branched polyether compound(s) containing one or more isocyanurate groups have a structure represented by

where each R represents the residue, after removal of isocyanate groups, from a starting polyisocyanate compound having the structure R—(NCO) x ; each x is a number from 2 to 6 representing the number of isocyanate groups on the starting polyisocyanate compound, PE represents a polyether chain of 700 to 8000 molecular weight, each X independently is —O— or —NH—, and each A is independently

or —N═C═O.

10 . The process of claim 6 wherein the stabilizer contains 3 to 15% by weight isocyanate groups.

11 . The process of claim 6 wherein 92 to 100% of the hydroxyl groups of the base polyol are secondary hydroxyl groups.

12 . The process of claim 6 wherein the aminoalcohol is triethanolamine or a mixture of 75-99.9 weight-% triethanolamine and 0.1 to 25 weight-% of another low equivalent weight polyol.

13 - 19 . (canceled)

20 . A dispersion of polyisocyanate polyaddition particles in a base polyether polyol made in accordance with the process of claim 1 .

21 . A polyurethane made by reacting the dispersion of claim 20 with a polyisocyanate.

22 . The polyurethane of claim 21 which is a flexible polyurethane foam prepared in a slabstock process.

23 . A dispersion of polyisocyanate polyaddition particles in a base polyether polyol made in accordance with the process of claim 6 .

24 . A polyurethane made by reacting the dispersion of claim 23 with a polyisocyanate.

25 . The polyurethane of claim 24 which is a flexible polyurethane foam prepared in a slabstock process.

Assignees

• Dow Global Technologies Llc

Inventors

• Amici-Kroutilova Irena
• Cookson Paul
• Borella Ricco
• Hoenhener Daniel
• Casati Francois

Classifications

• C08G18/222

  metal compounds not provided for in groups C08G18/225 - C08G18/26 · CPC title

• C08G18/1875

  containing ammonium salts or mixtures of secondary of tertiary amines and acids · CPC title

• C08G18/409

  Dispersions of polymers of C08G in organic compounds having active hydrogen · CPC title

• C08G18/7621

  being toluene diisocyanate including isomer mixtures · CPC title

• C08G18/3281

  containing three hydroxy groups · CPC title