Fine particle, high concentration, polyisocyanate polyaddition/polyurethane-urea polyols

Patent metadata

Field	Value
Publication number	US-2016264716-A1
Application number	US-201615161660-A
Country	US
Kind code	A1
Filing date	May 23, 2016
Priority date	May 9, 2011
Publication date	Sep 15, 2016
Grant date	—

Abstract

Embodiments of the invention include a method of producing polymer polyol dispersions is. The method includes providing at least one reaction system, and the reaction system includes:
a) at least one polyol, b) at least one seed population, c) at least one catalyst,
at least one co-reactant having an equivalent weight of up to 400 and at least one active hydrogen attached to a nitrogen or oxygen atom, and
e) at least one polyisocyanate.

The at least one seed population includes less than about 5% by weight of the total weight of the at least one reaction system and includes seed particles having diameters of less than 5 μm. The at least one reaction mixture reacts to form at least one of a polyurea and polyurethane-urea particle population in the at least one polyol without the addition of any catalysts comprising tin. The polymer polyol dispersion has a solids content of at least 15% of the weight of the polymer polyol dispersion.

First claim

1 - 19 . (canceled)

20 . A method of producing a polymer polyol dispersion, the method comprising:
forming a first composition by providing at least one polyol and providing isocyanate-reactive seed particles in an amount less than about 5% by weight of the at least one polyol, the suspended seed particles exhibiting a chemical reaction when combined with an isocyanate and having maximum particle diameters of less than 5 μm; adding to the at least one polyol at least one co-reactant that has an equivalent weight of up to 400 and at least one active hydrogen attached to a nitrogen or oxygen atom, the at least one co-reactant being added to the at least one polyol in a concentration between 5% to 15% by weight, the at least one polyol, the isocyanate-reactive seed particles, and the at least one co-reactant forming a second composition; and adding at least one polyisocyanate to the second composition to form the polymer polyol dispersion having a solids content of at least 15% of the weight of the polymer polyol dispersion, the at least one polyisocyanate reacting to form at least one of a polyurea, polyurethane, and polyurethane-urea particle population in the at least one polyol without the addition of any catalysts comprising tin.

21 . The method of claim 20 , wherein at least 90% by weight the particles of the at least one of a polyurea, polyurethane, and polyurethane-urea particle population particles have a diameter of less than 10 μm.

22 . The method of claim 20 , wherein the co-reactant is pre-blended with a metal salt catalyst and then added to the first composition.

23 . The method claim 20 , wherein the co-reactant is pre-blended with a metal salt catalyst, and added to the first composition whereby the at least one polyol, an amine catalyst, and the at least one seed population was already pre-blended.

24 . The method of claim 20 , wherein the at least one seed population comprises particles of at least one of polyurea particles, polyurethane, polyurethane-urea, polyisocyanate polyaddition particle, which contain reactive hydrogens, able to react with the polyisocyanate during the formation of polyurea, polyurethane or polyurethane-urea particles.

25 . The method of claim 20 , wherein the at least one of a polyurea, polyurethane, and polyurethane-urea particle population is formed in the presence of at least one of a tin free metal catalyst, a tertiary amine catalyst, or a combination of the tin free metal catalyst and the tertiary amine catalyst.

26 . The method of claim 25 , wherein the tertiary amine catalyst is at least one of triethylenediamine, bis-(dimethylaminopropyl) methylamine, or a combination of both.

27 . The method of claim 25 , wherein the tin free metal salt catalyst is present and comprises one or more of a zinc, bismuth, zirconium, copper, chromium, nickel, iron, and cobalt catalyst.

28 . The method of claim 27 , wherein the tin free metal salt catalyst is at least one of zinc ricinoleate, zinc octoate, and bismuth neodecanoate.

29 . The method of claim 20 , wherein the co-reactant comprises at least one of a primary or secondary amine or an alkanolamine.

30 . The method of claim 20 , wherein the isocyanate-reactive seed particles comprises particles of at least one of polyurea particles and polyisocyanate polyaddition particles.

31 . The method of claim 20 , wherein:
the polymer polyol dispersion is a polyisocyanate polyaddition polyol, the at least one polyol comprises a polyether polyol having an equivalent weight per hydroxyl group of from 800 to 1750, the at least one seed population comprises polyisocyanate polyaddition particles, and the at least one co-reactant comprises monoethanolamine, diethanolamine, triethanolamine, triisopropanolamine, 2-(2-aminoethoxyethanol), hydroxyethylpiperazine, monoisopropanolamine, diisopropanolamine, or mixtures thereof.

32 . A method of forming a polyurethane foam, comprising:
preparing a polymer polyol dispersion using the method of claim 20 , and reacting the polymer polyol dispersion with at least one polyisocyanate.

Assignees

• Dow Global Technologies Llc

Inventors

• Cookson Paul
• Borella Ricco B
• Hoehener Daniel
• Casati Francois M

Classifications

• C08G18/3819

  having nitrogen · CPC title

• C08G2101/00

  Manufacture of cellular products · CPC title

• C08G18/7862

  containing cyano groups or aldimine or ketimine groups · CPC title

• C08G18/14

  Manufacture of cellular products · CPC title

• C08G18/1833

  having ether, acetal, or orthoester groups · CPC title