Tin free polymer polyols

Patent metadata

Field	Value
Publication number	US-9399696-B2
Application number	US-201314378189-A
Country	US
Kind code	B2
Filing date	Mar 14, 2013
Priority date	Mar 30, 2012
Publication date	Jul 26, 2016
Grant date	Jul 26, 2016

Abstract

Embodiments include polymer polyol dispersions which include a polyol liquid phase and solid particle phase. Embodiments include methods of making the polymer polyol dispersions. The polymer polyol dispersions are essentially free of tin, have a solid content of between about 20 and 50 wt % based on the total weight of the polymer polyol dispersion, and have a viscosity at 20 C. of less than 9000 mPas. The solid particle phase has more than 90% by weight of particles in the solid particle phase having a particle diameter of less than 5 μm.

First claim

The invention claimed is:

1. A method of producing a polymer polyol dispersion, the method comprising:
1) in a first step, a) combining at least one of a tin-free catalyst, at least one of a polyol, and at least one of a co-reactant, wherein the co-reactant has an equivalent weight of up to 400 and at least one active hydrogen attached to a nitrogen or oxygen atom, and b) introducing at least one polyisocyanate to create a polymer polyol having a first solid content;
2) in a second step, a) introducing at least one of a co-reactant to the polymer polyol, wherein the co-reactant has an equivalent weight of up to 400 and at least one active hydrogen attached to a nitrogen or oxygen atom, b) introducing at least one polyisocyanate to create a polymer polyol having a second solid content; and
repeating the second step at least 1 time until a final polymer polyol having a final solid content is obtained.

2. The method of claim 1 , wherein in step 1, the at least one of a tin-free catalyst is combined with the at least one of a co-reactant before being combined with the at least one of a polyol.

3. The method of claim 1 , wherein the first solid content is between 1 and 15 wt % based on the total weight of the polymer polyol having a first solid content.

4. The method of claim 3 , wherein the second solid content is between 2 and 25 wt % based on the total weight of the polymer polyol having a second solid content.

5. The method of claim 1 , wherein the final solid content is between 15 and 50 wt % based on the total weight of the polymer polyol having a final solid content.

6. The method of claim 1 , wherein more than 90% by weight of particles in the polymer polyol dispersion has a particle diameter of less than 10 μm.

7. The method of claim 5 , wherein more than 90% by weight of particles in the polymer polyol dispersion has a particle diameter of less than 5 μm.

8. The method of claim 6 , wherein more than 90% by weight of particles in the polymer polyol dispersion has a particle diameter of less than 1 μm.

9. The method of claim 1 , wherein the polymer polyol has a viscosity at 20° C of less than 15000 mPa·s.

10. The method of claim 1 , wherein the polymer polyol has a viscosity at 20° C. of less than 9000 mPa·s.

11. The method of claim 1 , wherein the co-reactant comprises at least one of a primary or secondary amine or an alkanolamine.

12. The method of claim 11 wherein the tin-free catalyst comprises 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.

13. The method of claim 12 , wherein the at least one of a tin-free metal catalyst comprises at least one of zinc ricinoleate, zinc octoate, and bismuth neodecanoate.

14. The method of claim 12 , wherein the tertiary amine catalyst comprises at least one of triethylenediamine, bis-(dimethylaminopropyl) methylamine, or a combination of both.

15. The method of producing a polymer polyol dispersion of claim 1 , wherein the polymer polyol dispersion comprises a polyol liquid phase and solid particle phase, the polymer polyol dispersion is essentially free of tin, has a solid content of between about 20 and 50 wt % based on the total weight of the polymer polyol dispersion, has a viscosity at 20° C. of less than 9000 mPas, and the solid particle phase comprises more than 90% by weight of particles in the solid particle phase having a particle diameter of less than 5 μm.

16. The method of claim 15 , wherein the solid particle phase comprises PIPA particles, PHD particles, or a combination of both.

Assignees

• Borella Ricco B
• Cookson Paul
• Hoehener Daniel
• Casati Francois M
• Dow Global Technologies Llc

Inventors

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

Classifications

• C08G18/4829

  Polyethers containing at least three hydroxy groups (C08G18/4833 - C08G18/5096 take precedence) · CPC title

• C08G18/7621 Primary

  being toluene diisocyanate including isomer mixtures · CPC title

• C08G18/242

  organometallic compounds containing tin-carbon bonds · CPC title

• C08G18/3281

  containing three hydroxy groups · CPC title

• C08G18/222

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