U.S. patent application number 09/917235 was filed with the patent office on 2002-05-23 for foamed isocyanate-based polymer having improved hardness properties and process for production thereof.
Invention is credited to Farkas, Paul V., Stanciu, Romeo, Van Heumen, Jeffrey D..
Application Number | 20020061936 09/917235 |
Document ID | / |
Family ID | 22828126 |
Filed Date | 2002-05-23 |
United States Patent
Application |
20020061936 |
Kind Code |
A1 |
Van Heumen, Jeffrey D. ; et
al. |
May 23, 2002 |
Foamed isocyanate-based polymer having improved hardness properties
and process for production thereof
Abstract
In one of its aspects, the present invention relates to foamed
isocyanate-based polymer derived from a reaction mixture comprising
an isocyanate, an active hydrogen-containing compound, a dendritic
macromolecule and a blowing agent; wherein at least a 15% by weight
of the dendritic macromolecule may be mixed with a polyether polyol
having an OH number less than about 40 mg KOH/g to form a stable
liquid at 23.degree. C. The dendritic macromolecule confers
advantageous load building characteristics to the foamed
isocyanate-based polymer and may be used to partially or fully
displace the use of conventional copolymer polyols used. A process
for production of a foam isocyanate-based polymer and a process for
conferring loading building properties to a foamed isocyanate-based
polymer are also described.
Inventors: |
Van Heumen, Jeffrey D.;
(Guelph, CA) ; Farkas, Paul V.; (Willowdale,
CA) ; Stanciu, Romeo; (Toronto, CA) |
Correspondence
Address: |
PATENT ADMINSTRATOR
KATTEN MUCHIN ZAVIS
SUITE 1600
525 WEST MONROE STREET
CHICAGO
IL
60661
US
|
Family ID: |
22828126 |
Appl. No.: |
09/917235 |
Filed: |
July 30, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60221511 |
Jul 28, 2000 |
|
|
|
Current U.S.
Class: |
521/155 |
Current CPC
Class: |
C08G 18/4283 20130101;
C08G 2110/005 20210101; C08G 18/4018 20130101; C08G 2110/0083
20210101; C08G 2101/00 20130101; C08G 18/4072 20130101; C08L
101/005 20130101 |
Class at
Publication: |
521/155 |
International
Class: |
C08J 009/00 |
Claims
What is claimed is:
1. A foamed isocyanate-based polymer derived from a reaction
mixture comprising an isocyanate, an active hydrogen-containing
compound, a dendritic macromolecule and a blowing agent; wherein at
least a 15% by weight of the dendritic macromolecule may be mixed
with a polyether polyol having an OH number less than about 40 mg
KOH/g to form a stable liquid at 23.degree. C.
2. A foamed isocyanate-based polymer derived from an isocyanate and
an active hydrogen-containing compound, the polymer having a
cellular matrix comprising a plurality of interconnected struts,
the active hydrogen-containing compound conferring to the cellular
matrix a load efficiency of at least about 15 Newtons/weight %
active hydrogen-containing compound.
3. The foamed isocyanate-based polymer defined in claim 2, wherein
the active hydrogen-containing compound confers to the cellular
matrix a load efficiency of at least in the range of from about 15
to about 50 Newtons/weight % active hydrogen-containing
compound.
4. The foamed isocyanate-based polymer defined in claim 2, wherein
the active hydrogen-containing compound confers to the cellular
matrix a load efficiency of at least in the range of from about 20
to about 45 Newtons/weight % active hydrogen-containing
compound.
5. The foamed isocyanate-based polymer defined in claim 2, wherein
the active hydrogen-containing compound confers to the cellular
matrix a load efficiency of at least in the range of from about 25
to about 35 Newtons/weight % active hydrogen-containing
compound.
6. A foamed isocyanate-based polymer having a cellular matrix
derived from an active hydrogen-containing compound and comprising
a plurality of interconnected struts, the cellular matrix: (i)
having a load efficiency of at least about 15 Newtons/weight %
active hydrogen-containing compound., and (ii) being substantially
free of particulate material.
7. The foamed isocyanate-based polymer defined in claim 6, wherein
the active hydrogen-containing compound confers to the cellular
matrix a load efficiency of at least in the range of from about 15
to about 50 Newtons/weight % active hydrogen-containing
compound.
8. The foamed isocyanate-based polymer defined in claim 6, wherein
the active hydrogen-containing compound confers to the cellular
matrix a load efficiency of at least in the range of from about 20
to about 45 Newtons/weight % active hydrogen-containing
compound.
9. The foamed isocyanate-based polymer defined in claim 6, wherein
the active hydrogen-containing compound confers to the cellular
matrix a load efficiency of at least in the range of from about 25
to about 35 Newtons/weight % active hydrogen-containing
compound.
10. A foamed isocyanate-based polymer derived from a reaction
mixture comprising an isocyanate, an active hydrogen-containing
compound, a dendritic macromolecule and a blowing agent; the foamed
isocyanate-based polymer having an Indentation Force Deflection
loss when measured pursuant to ASTM D3574 which is less than that
of a reference foam produced by substituting a copolymer polyol for
the dendritic macromolecule in the reaction mixture, the foamed
isocyanate-based polymer and the reference foam having
substantially the same density and Indentation Force Deflection
when measured pursuant to ASTM D3574.
11. A foamed isocyanate-based polymer derived from a reaction
mixture comprising an isocyanate, an active hydrogen-containing
compound, a dendritic macromolecule and a blowing agent; the foamed
isocyanate-based polymer having thickness loss when measured
pursuant to ASTM D3574 which is less than that of a reference foam
produced by substituting a copolymer polyol for the dendritic
macromolecule in the reaction mixture, the foamed isocyanate-based
polymer and the reference foam having substantially the same
density and Indentation Force Deflection when measured pursuant to
ASTM D3574.
12. A process for producing a foamed isocyanate-based polymer
comprising the steps of: contacting an isocyanate, an active
hydrogen-containing compound, a dendritic macromolecule and a
blowing agent to form a reaction mixture; and expanding the
reaction mixture to produce the foamed isocyanate-based polymer;
wherein at least a 15% by weight of the dendritic macromolecule may
be mixed with a polyether polyol having an OH number less than
about 40 mg KOH/g to form a stable liquid at 23.degree. C.
13. The process defined in claim 12, wherein the active
hydrogen-containing compound is selected from the group comprising
polyols, polyamines, polyamides, polyimines and polyolamines.
14. The process defined in claim 12, wherein the active
hydrogen-containing compound comprises a polyol.
15. The process defined in claim 14, wherein the polyol comprises a
hydroxyl-terminated backbone of a member selected from the group
comprising polyether, polyesters, polycarbonate, polydiene and
polycaprolactone.
16. The process defined in claim 14, wherein the polyol is selected
from the group comprising hydroxyl-terminated polyhydrocarbons,
hydroxyl-terminated polyformals, fatty acid triglycerides,
hydroxyl-terminated polyesters, hydroxymethyl-terminated
polyesters, hydroxymethyl-terminated perfluoromethylenes,
polyalkyleneether glycols, polyalkylenearyleneether glycols,
polyalkyleneether triols and mixtures thereof.
17. The process defined in claim 14, wherein the polyol is selected
from the group comprising adipic acid-ethylene glycol polyester,
poly(butylene glycol), poly(propylene glycol) and
hydroxyl-terminated polybutadiene.
18. The process defined in claim 14, wherein the polyol is a
polyether polyol.
19. The process defined in claim 18, wherein the polyether polyol
has a molecular weight in the range of from about 200 to about
10,000.
20. The process defined in claim 18, wherein the polyether polyol
has a molecular weight in the range of from about 2000 to about
7,000.
21. The process defined in claim 18, wherein the polyether polyol
has a molecular weight in the range of from about 2,000 to about
6,000.
22. The process defined in claim 12, wherein the active
hydrogen-containing compound is selected from group comprising a
polyamine and a polyalkanolamine.
23. The process defined in claim 22, wherein the polyamine is
selected from the group comprising primary and secondary amine
terminated polyethers.
24. The process defined in claim 12, wherein the polyether have a
molecular weight of greater than about 230.
25. The process defined in claim 12, wherein the polyether have a
functionality of from about 2 to about 6.
26. The process defined in claim 12, wherein the polyether have a
molecular weight of greater than about 230 and a functionality of
from about 1 to about 3.
27. The process defined in claim 12,wherein the isocyanate is
represented by the general formula: Q(NCO).sub.i wherein i is an
integer of two or more and Q is an organic radical having the
valence of i.
28. The process defined in claim 12, wherein the isocyanate is
selected from the group comprising hexamethylene diisocyanate,
1,8-diisocyanato-p-methane, xylyl diisocyanate,
(OCNCH.sub.2CH.sub.2CH.su- b.2OCH.sub.2O).sub.2,
1-methyl-2,4-diisocyanatocyclohexane, phenylene diisocyanates,
tolylene diisocyanates, chlorophenylene diisocyanates,
diphenylmethane-4,4'-diisocyanate, naphthalene-1,5-diisocyanate,
triphenylmethane-4,4',4"-triisocyanate,
isopropylbenzene-alpha-4-diisocya- nate and mixtures thereof.
29. The process defined in claim 12, wherein the isocyanate
comprises a prepolymer.
30. The process defined in claim 12, wherein isocyanate is selected
from the group comprising 1,6-hexamethylene diisocyanate,
1,4-butylene diisocyanate, furfurylidene diisocyanate, 2,4-toluene
diisocyanate, 2,6-toluene diisocyanate, 2,4'-diphenylmethane
diisocyanate, 4,4'-diphenylmethane diisocyanate,
4,4'-diphenylpropane diisocyanate, 4,4'-diphenyl-3,3 '-dimethyl
methane diisocyanate, 1,5-naphthalene diisocyanate,
1-methyl-2,4-diisocyanate-5-chlorobenzene,
2,4-diisocyanato-s-triazine, 1-methyl-2,4-diisocyanato cyclohexane,
p-phenylene diisocyanate, m-phenylene diisocyanate, 1,4-naphthalene
diisocyanate, dianisidine diisocyanate, bitolylene diisocyanate,
1,4-xylylene diisocyanate, 1,3-xylylene diisocyanate,
bis-(4-isocyanatophenyl)methane,
bis-(3-methyl-4-isocyanatophenyl)methane- , polymethylene
polyphenyl polyisocyanates and mixtures thereof.
31. The process defined in claim 12, wherein the isocyanate is
selected from the group comprising 2,4-toluene diisocyanate,
2,6-toluene diisocyanate and mixtures thereof.
32. The process defined in claim 12, wherein the isocyanate is
selected from the group consisting essentially of (i)
2,4'-diphenylmethane diisocyanate, 4,4'-diphenylmethane
diisocyanate and mixtures thereof; and (ii) mixtures of (i) with an
isocyanate selected from the group comprising 2,4-toluene
diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.
33. The process defined in claim 12, wherein the blowing agent
comprises water.
34. The process defined in claim 33, wherein the water is used in
an amount in the range of from about 0.5 to about 40 parts by
weight per 100 parts by weight of active hydrogen-containing
compound used in the reaction mixture.
35. The process defined in claim 33, wherein the water is used in
an amount in the range of from about 1.0 to about 10 parts by
weight per 100 parts by weight of active hydrogen-containing
compound used in the reaction mixture.
36. The process defined in claim 12, wherein dendritic
macromolecule has the following characteristics: (i) an active
hydrogen content of greater than about 3.8 mmol/g; (ii) an active
hydrogen functionality of at least about 8; and (iii) at least a
15% by weight of the dendritic macromolecule may be mixed with a
polyether polyol having an OH number less than about 40 mg KOH/g to
form a stable liquid at 23.degree. C.
37. The process defined in claim 36, wherein from about 15% to
about 30% by weight of the dendritic macromolecule may be mixed
with a polyether polyol having an OH number less than about 40 mg
KOH/g to form a stable liquid at 23.degree. C.
38. The process defined in claim 36, wherein at least a 15% by
weight of the dendritic macromolecule may be mixed with a polyether
polyol having an OH number in the range of from about 25 to 35 mg
KOH/g to form a stable liquid at 23.degree. C.
39. The process defined in claim 36, wherein at least a 15% by
weight of the dendritic macromolecule may be mixed with a polyether
polyol having an OH number in the range of from about 28 to 32 mg
KOH/g to form a stable liquid at 23.degree. C.
40. The process defined in claim 36, wherein the active hydrogen is
present in the macromolecule in the form of one or more mercapto
moieties.
41. The process defined in claim 36, wherein the active hydrogen is
present in the macromolecule in the form of one or more primary
amino moieties.
42. The process defined in claim 36, wherein the active hydrogen is
present in the macromolecule in the form of one or more secondary
amino moieties.
43. The process defined in claim 36, wherein the active hydrogen is
present in the macromolecule in the form of one or more hydroxyl
moieties.
44. The process defined in claim 36, wherein the active hydrogen is
present in the macromolecule in the form of two or more of a
mercapto moiety, a primary amino moiety, a secondary amino moiety
and a hydroxyl moiety.
45. The process defined in claim 36, wherein the active hydrogen
content of the macromolecule is in the range of from about 3.8 to
about 10 mmol/g.
46. The process defined in claim 36, wherein the active hydrogen
content of the macromolecule is in the range of from about 3.8 to
about 7.0 mmol/g.
47. The process defined in claim 36, wherein the active hydrogen
content of the macromolecule is in the range of from about 4.4 to
about 5.7 mmol/g.
48. The process defined in claim 36, wherein the active hydrogen
functionality in the macromolecule is in the range of from about 8
to about 70.
49. The process defined in claim 36, wherein the active hydrogen
functionality in the macromolecule is in the range of from about 10
to about 60.
50. The process defined in claim 36, wherein the active hydrogen
functionality in the macromolecule is in the range of from about 15
to about 35.
51. The process defined in claim 36, wherein the active hydrogen
functionality in the macromolecule is in the range of from about 20
to about 30.
52. The process defined in claim 36, wherein from about 15% to
about 50% by weight of the dendritic macromolecule may be mixed
with a polyether polyol having an OH number less than about 40 mg
KOH/g to form a stable liquid at 23.degree. C.
53. The process defined in claim 36, wherein from about 15% to
about 40% by weight of the dendritic macromolecule may be mixed
with a polyether polyol having an OH number less than about 40 mg
KOH/g to form a stable liquid at 23.degree. C.
54. The process defined in claim 36, wherein the macromolecule has
an inherently branched structure comprising at least one of an
ester moiety, an ether moiety, an amine moiety, an amide moiety and
any mixtures thereof.
55. The process defined in claim 36, wherein the macromolecule has
an inherently branched structure comprising primarily an ester
moiety, optionally combined with an ether moiety.
56. The process defined in claim 36, wherein the macromolecule has
an inherently branched structure comprising primarily an ether
moiety, optionally combined with an ester moiety.
57. The process defined in claim 36, wherein the macromolecule has
an inherently branched structure comprising primarily an ester
moiety, optionally combined with an ether moiety.
58. The process defined in claim 54, wherein the macromolecule
further comprises a nucleus to which the inherently branched
structure is chemically bonded.
59. The process defined in claim 54, wherein a plurality of
inherently branched structures are chemically bonded to one
another.
60. The process defined in claim 54, wherein the inherently
branched structure further comprises at least one chain stopper
moiety chemically bonded thereto.
61. The process defined in claim 54, wherein the inherently
branched structure further comprises at least two different chain
stopper moieties chemically bonded thereto.
62. The process defined in claim 54, wherein the inherently
branched structure further comprises at least one spacing chain
extender chemically bonded thereto.
63. The process defined in claim 62, wherein the spacing chain
extender is monomeric.
64. The process defined in claim 62, wherein the spacing chain
extender is polymeric.
65. A process for conferring loading building properties to a
foamed isocyanate-based polymer derived from a mixture comprising
an isocyanate, an active hydrogen-containing compound and a blowing
agent comprising the step of incorporating a dendritic
macromolecule in the reaction mixture; wherein at least a 15% by
weight of the dendritic macromolecule may be mixed with a polyether
polyol having an OH number less than about 40 mg KOH/g to form a
stable liquid at 23.degree. C.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit under 35 U.S.C.
.sctn.119(e) of provisional patent application Ser. No. 60/221,511,
filed Jul. 28, 2000, the contents of which are hereby incorporated
by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] In one of its aspects, the present invention relates to a
foamed isocyanate-based polymer having improved hardness
properties. In another of its aspects, the present invention
relates to a process for the production of such a foamed
isocyanate-based polymer. In yet another of its aspects, the
present invention relates to a method for improving the hardness
characteristics of an isocyanate-based foam. In yet another of its
aspects, the present invention relates to a dispersion of a
dendritic macromolecule and an active hydrogen-containing compound
useful in the production of foamed isocyanate-based polymer.
[0003] 2. Description of the Prior Art
[0004] Isocyanate-based polymers are known in the art. Generally,
those of skill in the art understand isocyanate-based polymers to
be polyurethanes, polyureas, polyisocyanurates and mixtures
thereof.
[0005] It is also known in the art to produce foamed
isocyanate-based polymers. Indeed, one of the advantages of
isocyanate-based polymers compared to other polymer systems is that
polymerization and foaming can occur in situ. This results in the
ability to mould the polymer while it is forming and expanding.
[0006] One of the conventional ways to produce a polyurethane foam
is known as the "one-shot" technique. In this technique, the
isocyanate, a suitable polyol, a catalyst, water (which acts as a
reactive "blowing" agent and can optionally be supplemented with
one or more physical blowing agents) and other additives are mixed
together at once using, for example, impingement mixing (e.g., high
pressure). Generally, if one were to produce a polyurea, the polyol
would be replaced with a suitable polyamine. A polyisocyanurate may
result from cyclotrimerization of the isocyanate component.
Urethane modified polyureas or polyisocyanurates are known in the
art. In either scenario, the reactants would be intimately mixed
very quickly using a suitable mixing technique.
[0007] Another technique for producing foamed isocyanate-based
polymers is known as the "prepolymer" technique. In this technique,
a prepolymer is produced by reacting polyol and isocyanate (in the
case of a polyurethane) in an inert atmosphere to form a liquid
polymer terminated with reactive groups (e.g., isocyanate moieties
and active hydrogen moieties). To produce the foamed polymer, the
prepolymer is thoroughly mixed with a lower molecular weight polyol
(in the case of producing a polyurethane) or a polyamine (in the
case of producing a modified polyurea) in the presence of a curing
agent and other additives, as needed.
[0008] Regardless of the technique used, it is known in the art to
include a filler material in the reaction mixture. Conventionally,
filler materials have been introduced into foamed polymers by
loading the filler material into one or both of the liquid
isocyanate and the liquid active hydrogen-containing compound
(i.e., the polyol in the case of polyurethane, the polyamine in the
case of polyurea, etc.). Generally, incorporation of the filler
material serves the purpose of conferring so-called loaded building
properties to the resulting foam product.
[0009] The nature and relative amounts of filler materials used in
the reaction mixture can vary, to a certain extent, depending on
the desired physical properties of the foamed polymer product, and
limitations imposed by mixing techniques, the stability of the
system and equipment imposed limitations (e.g., due to the particle
size of the filler material being incompatible with narrow
passages, orifices and the like of the equipment).
[0010] One known technique of incorporating a solid material in the
foam product for the purpose of improving hardness properties
involves the use of a polyol-solids dispersion, particularly one in
the form of a graft copolymer polyol. As is known in the art, graft
copolymer polyols are polyols, preferably polyether polyols, which
contain other organic polymers. It is known that such graft
copolymer polyols are useful to confer hardness (i.e., load
building) to the resultant polyurethane foam compared to the use of
polyols which have not been modified by incorporating the organic
polymers. Within graft copolymer polyols, there are two main
categories which may be discussed: (i) chain-growth copolymer
polyols, and (ii) step-growth copolymer polyols.
[0011] Chain-growth copolymer polyols generally are prepared by
free radical polymerization of monomers in a polyol carrier to
produce a free radical polymer dispersed in the polyol carrier.
Conventionally, the free radical polymer can be based on
acrylonitrile or styrene-acrylonitrile (SAN). The solids content of
the polyol is typically up to about 60%, usually in the range of
from about 15% to about 40%, by weight of the total weight of the
composition (i.e., free radical polymer and polyol carrier).
Generally, these chain-growth copolymer polyols have a viscosity in
the range of from about 2,000 to about 8,000 centipoise. When
producing such chain-growth copolymer polyols, it is known to
induce grafting of the polyol chains to the free-radical
polymer.
[0012] Step-growth copolymer polyols generally are characterized as
follows: (i) PHD (Polyharnstoff Disperion) polyols, (ii) PIPA (Poly
Isocyanate Poly Addition) polyols, and (iii) epoxy dispersion
polyols. PHD polyols are dispersions of polyurea particles in
conventional polyols and generally are formed by the reaction of a
diamine (e.g., hydrazine) with a diisocyanate (e.g., toluene
diisocyanate) in the presence of a polyether polyol. The solids
content of the PHD polyols is typically up to about 50%, usually in
the range of from about 15% to about 40%, by weight of the total
weight of the composition (i.e., polyurea particles and polyol
carrier). Generally, PHD polyols have a viscosity in the range of
from about 2,000 to about 6,000 centipoise. PIPA polyols are
similar to PHD polyols but contain polyurethane particles instead
of polyurea particles. The polyurethane particles in PIPA polyols
are formed in situ by reaction of an isocyanate and alkanolamine
(e.g., triethanolamine). The solids content of the PIPA polyols is
typically up to about 80%, usually in the range of from about 15%
to about 70%, by weight of the total weight of the composition
(i.e., polyurethane particles and polyol carrier). Generally, PIPA
polyols have a viscosity in the range of from about 4,000 to about
50,000 centipoise. See, for example, U.S. Pat. Nos. 4,374,209 and
5,292,778. Epoxy dispersion polyols are based on dispersions of
cured epoxy resins in conventional based polyols. The epoxy
particles are purportedly high modulus solids with improved
hydrogen bonding characteristics.
[0013] Further information regarding useful graft copolymer polyols
may be found, for example, in Chapter 2 of "Flexible Polyurethane
Foams" by Herrington and Hock (1997) and the references cited
therein.
[0014] Despite the advances made in the art, there exists a
continued need for the development of novel load building
techniques. Specifically, many of the prior art approaches
discussed hereinabove involve the use of relatively expensive
materials (e.g., the graft copolymer polyols described above) which
can be complicated to utilize in a commercial size facility. Thus,
it would be desirable to have a load building technique which could
be conveniently applied to polyurethane foam as an alternative to
conventional load building techniques. It would be further
desirable if the load building technique: was relatively
inexpensive and/or improved other properties of the polyurethane
foam and/or could be incorporated into an existing production
scheme without great difficulty.
SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to provide a novel
isocyanate-based polymer foam which obviates or mitigates at least
one of the above-mentioned disadvantages of the prior art.
[0016] It is another object of the present invention to provide a
novel approach to conferring load building properties to an
isocyanate-based polymer foam.
[0017] It is yet another object of the present invention to provide
a novel process for production of an isocyanate-based polymer
foam.
[0018] Accordingly, in one of its objects, the present invention
provides a foamed isocyanate-based polymer derived from a reaction
mixture comprising an isocyanate, an active hydrogen-containing
compound, a dendritic macromolecule and a blowing agent; wherein at
least a 15% by weight of the dendritic macromolecule may be mixed
with a polyether polyol having an OH number less than about 40 mg
KOH/g to form a stable liquid at 23.degree. C.
[0019] In another of its aspects, the present invention provides a
foamed isocyanate-based polymer derived from an isocyanate and an
active hydrogen-containing compound, the polymer having a cellular
matrix comprising a plurality of interconnected struts, the active
hydrogen-containing compound conferring to the cellular matrix a
load efficiency of at least about 15 Newtons (preferably from about
15 to about 50 Newtons, more preferably from about 20 to about 45
Newtons, most preferably from about 25 to about 35 Newtons).
[0020] In yet another of its aspects, the present invention
provides a foamed isocyanate-based polymer having a cellular matrix
comprising a plurality of interconnected struts, the cellular
matrix: (i) having a load efficiency of at least about 15 Newtons,
and (ii) being substantially free of particulate material.
[0021] In yet another of its aspects, the present invention
provides a process for producing a foamed isocyanate-based polymer
comprising the steps of:
[0022] contacting an isocyanate, an active hydrogen-containing
compound, a dendritic macromolecule and a blowing agent to form a
reaction mixture; and
[0023] expanding the reaction mixture to produce the foamed
isocyanate-based polymer;
[0024] wherein at least a 15% by weight of the dendritic
macromolecule may be mixed with a polyether polyol having an OH
number less than about 40 mg KOH/g to form a stable liquid at
23.degree. C.
[0025] In yet another of its aspects, the present invention
provides a foamed isocyanate-based polymer derived from a reaction
mixture comprising an isocyanate, an active hydrogen-containing
compound, a dendritic macromolecule and a blowing agent; the foamed
isocyanate-based polymer having an Indentation Force Deflection
loss when measured pursuant to ASTM D3574 which is less than that
of a reference foam produced by substituting a copolymer polyol for
the dendritic macromolecule in the reaction mixture, the foamed
isocyanate-based polymer and the reference foam having
substantially the same density and Indentation Force Deflection
when measured pursuant to ASTM D3574 (50 in.sup.2 indentor;
15".times.15".times.4" sample size; 25.degree. C., 50% relative
humidity.
[0026] In yet another of its aspects, the present invention
provides a foamed isocyanate-based polymer derived from a reaction
mixture comprising an isocyanate, an active hydrogen-containing
compound, a dendritic macromolecule and a blowing agent; the foamed
isocyanate-based polymer having thickness loss when measured
pursuant to ASTM D3574 which is less than that of a reference foam
produced by substituting a copolymer polyol for the dendritic
macromolecule in the reaction mixture, the foamed isocyanate-based
polymer and the reference foam having substantially the same
density and Indentation Force Deflection when measured pursuant to
ASTM D3574.
[0027] As used throughout this specification, the term
"isocyanate-based polymer" is intended to mean, inter alia,
polyurethane, polyurea and polyisocyanurate. Further, the terms
"dendritic polymer" and "dendritic macromolecule" are used
interchangeably throughout this specification. These materials are
generally known in the art. See, for example, any one of:
[0028] Tomalia et al in Angew. Chem. Int. Ed. Engl. 29 pages
138-175 (1990);
[0029] U.S. Pat. No. 5,418,301 [Hult et al (Hult)]; and
[0030] U.S. Pat. No. 5,663,247 [Sorensen et al (Sorensen)].
[0031] The present inventors have surprisingly and unexpectedly
discovered that a sub-group of dendritic macromolecules is
particularly advantageous to confer load building properties in an
isocyanate-based foam. Indeed, as will be developed in the Examples
hereinbelow, its possible to utilize the sub-group of dendritic
macromolecules to partially or fully displace copolymer polyols
conventionally used to confer load building characteristics to
isocyanate-based polymer foams. The sub-group of dendritic
macromolecules is described in detail in copending U.S. patent
application Ser. No. 60/221,512, filed on Jul. 28, 2000 in the name
of Pettersson et al. and the contents of which are hereby
incorporated by reference.
[0032] Preferred aspects of the present invention relate to the
ability to mix at least about 15% by weight of the dendritic
macromolecule with a polyether polyol having an OH number less than
about 40 mg KOH/g to form a stable liquid at 23.degree. C. As used
throughout this specification, the term "stable liquid", when used
in connection with this solubility parameter of the dendritic
macromolecule, is intended to mean that the liquid formed upon
mixing the dendritic macromolecule and the polyol has a substantial
constant light transmittance (transparent at one extreme and opaque
at the other extreme) for at least 2 hours, preferably at least 30
days, more preferably a number of months, after production of the
mixture. Practically, in one embodiment, the stable liquid will be
in the form a clear, homogeneous liquid (e.g., a solution) which
will remain as such over time. In another embodiment, the stable
liquid will be in the form an emulsion of (at least a portion of)
the dendritic macromolecule in the polyol which will remain as such
over time - i.e., the dendritic macromolecule will not settle out
over time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The present invention is related to foamed isocyanate-based
polymer and to a process for production thereof. Preferably, the
isocyanate-based polymer is selected from the group comprising
polyurethane, polyurea, polyisocyanurate, urea-modified
polyurethane, urethane-modified polyurea, urethane-modified
polyisocyanurate and urea-modified polyisocyanurate. As is known in
the art, the term "modified", when used in conjunction with a
polyurethane, polyurea or polyisocyanurate means that up to 50% of
the polymer backbone forming linkages have been substituted.
[0034] The present foamed isocyanate-based polymer is produced from
a reaction mixture which comprises an isocyanate and an active
hydrogen-containing compound.
[0035] The isocyanate suitable for use in the reaction mixture is
not particularly restricted and the choice thereof is within the
purview of a person skilled in the art. Generally, the isocyanate
compound suitable for use may be represented by the general
formula:
Q(NCO).sub.i
[0036] wherein i is an integer of two or more and Q is an organic
radical having the valence of i. Q may be a substituted or
unsubstituted hydrocarbon group (e.g., an alkylene or arylene
group). Moreover, Q may be represented by the general formula:
Q.sup.1-Z-Q.sup.1
[0037] wherein Q.sup.1 is an alkylene or arylene group and Z is
chosen from the group comprising --O--, --O--Q.sup.1--, --CO--,
--S--, --S--Q.sup.1--S-- and --SO.sub.2--. Examples of isocyanate
compounds which fall within the scope of this definition include
hexamethylene diisocyanate, 1 ,8-diisocyanato-p-methane, xylyl
diisocyanate, (OCNCH.sub.2CH.sub.2CH.sub.2CH.sub.2O).sub.2,
1-methyl-2,4-diisocyanatocy- clohexane, phenylene diisocyanates,
tolylene diisocyanates, chlorophenylene diisocyanates,
diphenyhnethane-4,4'-diisocyanate, naphthalene-1,5-diisocyanate,
triphenylmethane-4,4',4"-triisocyanate and
isopropylbenzene-alpha-4-diisocyanate.
[0038] In another embodiment, Q may also represent a polyurethane
radical having a valence of i. In this case Q(NCO).sub.i is a
compound which is commonly referred to in the art as a prepolymer.
Generally, a prepolymer may be prepared by reacting a
stoichiometric excess of an isocyanate compound (as defined
hereinabove) with an active hydrogen-containing compound (as
defined hereinafter), preferably the polyhydroxyl-containing
materials or polyols described below. In this embodiment, the
polyisocyanate may be, for example, used in proportions of from
about 30 percent to about 200 percent stoichiometric excess with
respect to the proportion of hydroxyl in the polyol. Since the
process of the present invention may relate to the production of
polyurea foams, it will be appreciated that in this embodiment, the
prepolymer could be used to prepare a polyurethane modified
polyurea.
[0039] In another embodiment, the isocyanate compound suitable for
use in the process of the present invention may be selected from
dimers and trimers of isocyanates and diisocyanates, and from
polymeric diisocyanates having the general formula:
[Q"(NCO).sub.i].sub.j
[0040] wherein both i and j are integers having a value of 2 or
more, and Q" is a polyfunctional organic radical, and/or, as
additional components in the reaction mixture, compounds having the
general formula:
L(NCO).sub.i
[0041] wherein i is an integer having a value of 1 or more and L is
a monofunctional or polyfunctional atom or radical. Examples of
isocyanate compounds which fall with the scope of this definition
include ethylphosphonic diisocyanate, phenylphosphonic
diisocyanate, compounds which contain a .dbd.Si--NCO group,
isocyanate compounds derived from sulphonamides (QSO.sub.2NCO),
cyanic acid and thiocyanic acid.
[0042] See also for example, British patent number 1,453,258, for a
discussion of suitable isocyanates.
[0043] Non-limiting examples of suitable isocyanates include:
1,6-hexamethylene diisocyanate, 1,4-butylene diisocyanate,
furfurylidene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene
diisocyanate, 2,4'-diphenylmethane diisocyanate,
4,4'-diphenylmethane diisocyanate, 4,4'-diphenylpropane
diisocyanate, 4,4'-diphenyl-3,3'-dimethyl methane diisocyanate,
1,5-naphthalene diisocyanate, 1-methyl-2,4-diisocyanate-5-c-
hlorobenzene, 2,4-diisocyanato-s-triazine,
1-methyl-2,4-diisocyanato cyclohexane, p-phenylene diisocyanate,
m-phenylene diisocyanate, 1,4-naphthalene diisocyanate, dianisidine
diisocyanate, bitolylene diisocyanate, 1,4-xylylene diisocyanate,
1,3-xylylene diisocyanate, bis-(4-isocyanatophenyl)methane,
bis-(3-methyl-4-isocyanatophenyl)methane- , polymethylene
polyphenyl polyisocyanates and mixtures thereof. A more preferred
isocyanate is selected from the group comprising 2,4-toluene
diisocyanate, 2,6-toluene diisocyanate and mixtures thereof, for
example, a mixture comprising from about 75 to about 85 percent by
weight 2,4-toluene diisocyanate and from about 15 to about 25
percent by weight 2,6-toluene diisocyanate. Another more preferred
isocyanate is selected from the group comprising
2,4'-diphenylmethane diisocyanate, 4,4'-diphenyhnethane
diisocyanate and mixtures thereof. The most preferred isocyanate is
a mixture comprising from about 15 to about 25 percent by weight
2,4'-diphenylmethane diisocyanate and from about 75 to about 85
percent by weight 4,4'-diphenylmethane diisocyanate.
[0044] If the process is utilized to produce a polyurethane foam,
the active hydrogen-containing compound is typically a polyol. The
choice of polyol is not particularly restricted and is within the
purview of a person skilled in the art. For example, the polyol may
be a hydroxyl-terminated backbone of a member selected from the
group comprising polyether, polyester, polycarbonate, polydiene and
polycaprolactone. Preferably, the polyol is selected from the group
comprising hydroxyl-terminated polyhydrocarbons,
hydroxyl-terminated polyformals, fatty acid triglycerides,
hydroxyl-terminated polyesters, hydroxymethyl-terminated
polyesters, hydroxymethyl-terminated perfluoromethylenes,
polyalkyleneether glycols, polyalkylenearyleneether glycols and
polyalkyleneether triols. More preferred polyols are selected from
the group comprising adipic acid-ethylene glycol polyester,
poly(butylene glycol), poly(propylene glycol) and
hydroxyl-terminated polybutadiene--see, for example, British patent
number 1,482,213, for a discussion of suitable polyols. Preferably,
such a polyether polyol has a molecular weight in the range of from
about 200 to about 10,000, more preferably from about 2,000 to
about 7,000, most preferably from about 2,000 to about 6,000.
[0045] If the process is utilized to produce a polyurea foam, the
active hydrogen-containing compound comprises compounds wherein
hydrogen is bonded to nitrogen. Preferably such compounds are
selected from the group comprising polyamines, polyamides,
polyimines and polyolamines, more preferably polyamines.
Non-limiting examples of such compounds include primary and
secondary amine terminated polyethers. Preferably such polyethers
have a molecular weight of greater than about 230 and a
functionality of from 2 to 6. Such amine terminated polyethers are
typically made from an appropriate initiator to which a lower
alkylene oxide is added with the resulting hydroxyl terminated
polyol being subsequently aminated. If two or more alkylene oxides
are used, they may be present either as random mixtures or as
blocks of one or the other polyether. For ease of amination, it is
especially preferred that the hydroxyl groups of the polyol be
essentially all secondary hydroxyl groups. Typically, the amination
step replaces the majority but not all of the hydroxyl groups of
the polyol.
[0046] The reaction mixture used to produce the present foamed
isocyanate-based polymer typically will further comprise a blowing
agent. As is known in the art water can be used as an indirect or
reactive blowing agent in the production of foamed isocyanate-based
polymers. Specifically, water reacts with the isocyanate forming
carbon dioxide which acts as the effective blowing agent in the
final foamed polymer product. Alternatively, the carbon dioxide may
be produced by other means such as unstable compounds which yield
carbon dioxide (e.g., carbamates and the like). Optionally, direct
organic blowing agents may be used in conjunction with water
although the use of such blowing agents is generally being
curtailed for environmental considerations. The preferred blowing
agent for use in the production of the present foamed
isocyanate-based polymer comprises water.
[0047] It is known in the art that the amount of water used as an
indirect blowing agent in the preparation of a foamed
isocyanate-based polymer is conventionally in the range of from
about 0.5 to as high as about 40 or more parts by weight,
preferably from about 1.0 to about 10 parts by weight, based on 100
parts by weight of the total active hydrogen-containing compound
content in the reaction mixture. As is known in the art, the amount
of water used in the production of a foamed isocyanate-based
polymer typically is limited by the fixed properties expected in
the foamed polymer and by the tolerance of the expanding foam
towards self structure formation.
[0048] The reaction mixture used to produce the present foamed
isocyanate-based polymer typically will further comprise a
catalyst. The catalyst used in the reaction mixture is a compound
capable of catalyzing the polymerization reaction. Such catalysts
are known, and the choice and concentration thereof in the reaction
mixture is within the purview of a person skilled in the art. See,
for example, U.S. Pat. Nos. 4,296,213 and 4,518,778 for a
discussion of suitable catalyst compounds. Non-limiting examples of
suitable catalysts include tertiary amines and/or organometallic
compounds. Additionally, as is known in the art, when the objective
is to produce an isocyanurate, a Lewis acid must be used as the
catalyst, either alone or in conjunction with other catalysts. Of
course it will be understood by those skilled in the art that a
combination of two or more catalysts may be suitably used.
[0049] In a preferred aspect of the present invention a dendritic
macromolecule is incorporated in the present foamed
isocyanate-based polymer. Preferably, the dendritic macromolecule
has the following characteristics:
[0050] (i) an active hydrogen content of greater than about 3.8
mmol/g, more preferably greater than about 4.0 mmol/g, even more
preferably in the range of from about 3.8 to about 10 mmol/g; even
more preferably in the range of from about 3.8 to about 7.0 mmol/g;
even more preferably in the range of from about 4.0 to about 8.0
mmol/g; most preferably in the range of from about 4.4 to about 5.7
mmol/g;
[0051] (ii) an active hydrogen functionality of at least about 8;
more preferably at least about 16; even more preferably in the
range of from about 16 to about 70; even more preferably in the
range of from about 18 to about 60; even more preferably in the
range of from about 17 to about 35; most preferably in the range of
from about 20 to about 30;
[0052] (iii) at least about 15%, more preferably from about 15% to
about 50%, even more preferably from about 15% to about 40%, even
more preferably from about 15% to about 30%, by weight of the
dendritic macromolecule may be mixed with a polyether polyol having
an OH number less than about 40, more preferably from about 25 to
about 35, mg KOH/g to form a stable liquid at 23.degree. C.
[0053] Further details on the dendritic macromolecule may be
obtained from copending U.S. patent application Ser. No.
60/221,512, filed on Jul. 28, 2000 and from International patent
application PCT/SE.cndot./.cndot. filed on Jun. 29, 2001 (claiming
priority from the '512 application), both in naming Pettersson et
al.
[0054] As will be clearly understood by those of skill in the art,
it is contemplated that conventional additives in the polyurethane
foam art can be incorporated in the reaction mixture created during
the present process. Non-limiting examples of such additives
include: surfactants (e.g., organo-silicone compounds available
under the tradename L-540 Union Carbide), cell openers (e.g.,
silicone oils), extenders (e.g., halogenated paraffins commercially
available as Cereclor S45), cross-linkers (e.g., low molecular
weight reactive hydrogen-containing compositions), pigments/dyes,
flame retardants (e.g., halogenated organo-phosphoric acid
compounds), inhibitors (e.g., weak acids), nucleating agents (e.g.,
diazo compounds), anti-oxidants, and plasticizers/stabilizers
(e.g., sulphonated aromatic compounds). The amounts of these
additives conventionally used would be within the purview of a
person skilled in the art.
[0055] The following Examples illustrate the use of the dendritic
polymer in a typical isocyanate-based high resilience (HR) based
foam. In each Example, the isocyanate-based foam was prepared by
the pre-blending of all resin ingredients including polyols,
copolymer polyols, catalysts, water, and surfactants as well as the
dendritic macromolecule of interest. The isocyanate was excluded
from this mixture. The resin blend and isocyanate were then mixed
at an isocyanate index of 100 using a conventional two-stream
mixing technique and dispensed into a preheated mold (65.degree.
C.) having the dimensions 38.1 cm.times.38.1 cm.times.10.16 cm. The
mold was then closed and the reaction allowed to proceed until the
total volume of the mold was filled. After approximately 6 minutes,
the isocyanate-based foam was removed and, after proper
conditioning, the properties of interest were measured. This
methodology will be referred to in the following Examples as the
General Procedure.
[0056] In the Examples, the following materials were used:
[0057] E837, base polyol, commercially available from Lyondell;
[0058] E850, a 43% solids content copolymer(SAN)polyol,
commercially available from Lyondell;
[0059] HBP, a dendritic macromolecule produced in Example A
hereinbelow and discussed in more detail in copending U.S. patent
application Ser. No. 60/221,512, filed on Jul. 28, 2000 in the name
of Pettersson et al.;
[0060] DEAO LF, diethanolamine, a cross-linking agent commercially
available from Air Products;
[0061] Glycerin, a cross-linking agent, commercially available from
Van Waters & Rogers;
[0062] Water, indirect blowing agent;
[0063] Dabco 33LV, a gelation catalyst, commercially available from
Air Products;
[0064] Niax A-1, a blowing catalyst, commercially available from
Witco;
[0065] DC 5169, a surfactant, commercially available from Air
Products;
[0066] Y-10184, a surfactant, commercially available from Witco;
and
[0067] Lupranate T80, isocyanate (TDI), commercially available from
BASF.
[0068] Unless otherwise stated, all parts reported in the Examples
are parts by weight.
EXAMPLE A
[0069] 100.0 kg of an alkoxylated pentaerythritol with a hydroxyl
value of 630 mg KOH/g, 1055 kg of 2,2-dimethylolpropionic acid
(Bis-MPA, Perstorp Specialty Chemicals) and 8.5 kg of paratoluenic
sulphonic acid were cold mixed in a reactor equipped with a heating
system with accurate temperature control, a mechanical stirrer, a
pressure gauge, a vacuum pump, a cooler, nitrogen inlet and a
receiver. The mixture was heated carefully during slow stirring to
a temperature of 140.degree. C. Slow stirring of the mixture at
this temperature was maintained at atmospheric pressure until all
2,2-dimethylopropionic acid was dissolved and the reaction mixture
formed a filly transparent solution. The stirring speed was then
significantly increased and vacuum was applied to a pressure of 30
mbar. Reaction water immediately started to form, which was
collected in the receiver. The reaction was allowed to continue for
a further 7 hours, until a final acid value of 8.9 mg KOH/g was
obtained. This corresponded to a chemical conversion of 98%.
[0070] The obtained dendritic polymer had the following
characteristics:
1 Final acid value: 8.9 mg KOH/g Final hydroxyl value: 489 mg KOH/g
Peak molecular weight: 3490 g/mole Mw (SEC): 3520 g/mole Mn (SEC):
2316 g/mole PDI (Mw/Mn): 1.52 Average hydroxyl functionality: 30.4
OH-groups/molecule
[0071] The obtained properties were in good agreement with the
expected theroretical molecular weight of 3607 g/mole at 100%
chemical conversion and a theoretical hydroxyl value of 498 mg
KOH/g, which would correspond to a OH-functionality of 32.
[0072] 25.0 kg of the dendritic polymer, 8.4 kg of an aliphatic
acid with nine carbons with an acid value of 363 mg KOH/g and 3.3
kg of xylene were charged to a reactor equipped with a heating
system with accurate temperature control, a mechanical stirrer, a
pressure gauge, a vacuum pump, a dean-stark device for azeotropic
removal of water, a cooler, nitrogen inlet and a receiver. The
mixture was heated under stirring with a nitrogen flow of 500-600
l/h through the reaction mixture from room temperature up to
170.degree. C. At this temperature all xylene was refluxing and the
reaction water which started to form was removed by azeotropic
distillation. The reaction was allowed to continue for a further
1.5 hours at 170.degree. C., after which the reaction temperature
was increased to 180.degree. C. The reaction mixture was kept at
this temperature for a further 2.5 hours until an acid value of 5.7
mg KOH/g was obtained. Full vacuum was then applied to the reactor
to remove all xylene from the final product.
[0073] The obtained derivatized dendritic polymer had the following
characteristics:
2 Final acid value: 6.2 mg KOH/g Final hydroxyl value: 293 mg KOH/g
Peak molecular weight: 4351 g/mole Mw (SEC): 4347 g/mole Mn (SEC):
1880 g/mole PDI (Mw/Mn): 2.31 Average hydroxyl functionality: 22.7
OH-groups/molecule
[0074] The obtained properties were in good agreement with the
expected theoretical molecular weight of 4699 g/mole at 100%
chemical conversion and a theoretical hydroxyl value of 287 mg
KOH/g, which would correspond to a OH-functionality of 24.
EXAMPLES 1-4
[0075] In Examples 1-4, isocyanate-based foams based on the
formulations shown in Table 1 were produced using the General
Procedure referred to above. In these Examples, isocyanate-based
foams were prepared having a copolymer polyol concentration of 7%
(Examples 1 and 3) and 11% (Examples 2 and 4) by weight of resin
and having a % H.sub.2O concentration of 3.80% which results in an
approximate foam core density of 31 kg/m.sup.3. For each level of
copolymer polyol concentration, the dendritic macromolecule
concentration was increased from 2% by weight of resin (Examples 1
and 2) to 5% by weight of resin (Examples 3 and 4).
[0076] Also reported in Table 1 for each foam is the density and
Indentation Force Deflection (IFD) at 50% deflection, measured
pursuant to ASTM D3574. As shown, the introduction of the dendritic
macromolecule to the isocyanate-based polymer matrix resulted in a
70 N hardness increase for foam containing 7% copolymer (Examples 1
and 3) and a 100N hardness increase for the foam containing 11%
copolymer polyol (Examples 2 and 4).
[0077] By this analysis, a "load efficiency", having units of
Newtons/weight % dendritic macromolecule in the resin blend, for
each foam may be reported and represents the ability of the
dendritic macromolecule to generate firmness in the
isocyanate-based foam matrix. As used throughout this specification
in connection with the present invention, the term "load
efficiency" is defined as the number of Newtons of foam hardness
increase per weight % of the dendritic macromolecule added to a
base or control resin blend (i.e., typically comprising all
ingredients in the foamable composition except the iscocyanate).
The term "load efficiency", as used throughout this specification,
is intended to have the meaning set out in this paragraph.
[0078] For Examples 1 and 3, the load efficiency of the dendritic
macromolecule was determined to be 23.78 Newtons/weight % dendritic
macromolecule in the resin blend while for Examples 2 and 4, the
load efficiency was determined to be 33.42 Newtons/weight %
dendritic macromolecule in the resin blend.
EXAMPLES 5-8
[0079] In Examples 5-8, isocyanate-based foams based on
formulations shown in Table 2 were produced using the General
Procedure referred to above.
[0080] In these Examples, isocyanate-based foams were prepared
having copolymer polyol concentrations as those used in Examples
1-4 with a % H.sub.2O concentration of 3.2% which results in an
approximate core foam density of 36kg/m.sup.3. For each copolymer
polyol level used the dendritic macromolecule concentration was
increased from 2% to 5% by weight of resin.
[0081] The results of physical property testing are reported in
Table 2. As shown, in these Examples, the introduction of the
dendritic macromolecule to the isocyanate-based polymer matrix
resulted in a 61 Newtons/weight % dendritic macromolecule in the
resin blend hardness increase for the foam containing 7% copolymer
polyol and a 72 Newtons/weight % dendritic macromolecule in the
resin blend hardness increase for the foam containing 11% copolymer
polyol. The resulting load efficiency for Examples 5 and 7 was
determined to be 20.4 Newtons/weight % dendritic macromolecule in
the resin blend while for Examples 6 and 8 the load efficiency was
determined to be 23.9 Newtons/weight % dendritic macromolecule in
the resin blend.
EXAMPLES 9-11
[0082] In Examples 9-11, isocyanate-based foams based on the
formulations shown in Table 3 were produced using the General
Procedure referred to above.
[0083] In these Examples, isocyanate based foams were prepared in
the absence of any copolymer polyol. The isocyanate-based foams
were formulated with a % H.sub.2O concentration of 3.8% resulting
in an approximate foam core density of 31 kg/m.sup.3. The level of
the dendritic macromolecule was varied from 6.68% to 13.35% by
weight in the resin.
[0084] The results of physical property testing are reported in
Table 3. As shown, the introduction of the dendritic macromolecule
resulted in a foam hardness increase of 181 Newtons. The load
efficiency was calculated by plotting, for each Example, % HBP in
the resin (X-axis) versus 50% IFD (Y-axis) and using Sigma Plot.TM.
to plot the line of best fit. The slope of the resulting curve was
obtained and reported as the load efficiency, in this case: 27
Newtons/weight % dendritic macromolecule in the resin blend.
EXAMPLES 12-14
[0085] In Examples 12-14, isocyanate based foams based on the
formulations shown in Table 4 were produced using the General
Procedure referred to above.
[0086] In these Examples, isocyanate based foams were prepared in
the absence of any copolymer polyol. The isocyanate-based foams
were formulated with a %H.sub.2O concentration of 3.2% resulting in
an approximate foam core density of 36 kg/m.sup.3. The level of the
dendritic macromolecule was varied from 6.72% to 13.43% by weight
in the resin.
[0087] The results of physical property testing are reported in
Table 4. As shown, the introduction of the dendritic macromolecule
resulted in a foam hardness increase of 202.5 Newtons. The load
efficiency was obtained in the same manner as described in Examples
9-11 and was found to be 30.18 Newtons/weight % dendritic
macromolecule in the resin blend.
EXAMPLES 15-16
[0088] In Examples 15 and 16, isocyanate-based foams based on the
formulations shown in Table 5 were produced using the General
Procedure referred to above.
[0089] In these Examples, isocyanate based foams were prepared in
the absence of any dendritic macromolecule and used only copolymer
polyol as the method by which foam hardness is increased. Thus, it
will be appreciated that Examples 15 and 16 are provided for
comparative purposes only and are outside the scope of the present
invention. The isocyanate-based foams were formulated with a
%H.sub.2O concentration of 3.8% resulting in an approximate foam
core density of 31 kg/m.sup.3. The level of the copolymer polyol
was varied from 26% to 8% by weight in the resin.
[0090] The results of physical property testing are reported in
Table 4. As shown, the introduction of the copolymer polyol
resulted in a foam hardness increase of 192.1 Newtons. The
resulting load efficiency is 10.69 Newtons/weight % dendritic
macromolecule in the resin blend. As will be apparent, this is
significantly less than the load efficiency achieved in the foams
produced in Examples 1-14.
[0091] While this invention has been described with reference to
illustrative embodiments and examples, the description is not
intended to be construed in a limiting sense. Thus, various
modifications of the illustrative embodiments, as well as other
embodiments of the invention, will be apparent to persons skilled
in the art upon reference to this description. It is therefore
contemplated that the appended claims will cover any such
modifications or embodiments.
[0092] All publications, patents and patent applications referred
to herein are incorporated by reference in their entirety to the
same extent as if each individual publication, patent or patent
application was specifically and individually indicated to be
incorporated by reference in its entirety.
3 TABLE 1 Example Ingredient 1 2 3 4 E837 80.33 70.32 77.2 67.24
E850 17.52 27.53 17.44 27.4 HBP 2.15 2.15 5.36 5.36 DEOA LF 0.91
0.91 0.91 0.91 Glycerin 0.51 0.51 0.51 0.51 H.sub.2O 3.95 3.95 3.95
3.95 Dabco 33LV 0.53 0.53 0.53 0.53 Niax A-1 0.08 0.08 0.08 0.08
DC5169 0.04 0.04 0.04 0.04 Y10184 1.1 1.1 1.1 1.1 Total resin
107.13 107.13 107.13 107.13 Lupranate T80 48.72 48.72 49.33 49.33
Index 100 100 100 100 % H.sub.2O 3.8 3.8 3.8 3.8 % SAN in resin 7
11 7 11 % HBP in resin 2 2 5 5 Total dry weight (g) 504 504 510 514
Density (kg/m.sup.3) 31 31 31 31 50% IFD (N) 289 320 359 420
[0093]
4 TABLE 2 Example Ingredient 5 6 7 8 E837 80.5 70.58 77.41 67.54
E850 17.37 27.29 17.28 27.16 HBP 2.13 2.13 5.31 5.31 DEOA LF 0.91
0.91 0.91 0.91 Glycerin 0.51 0.51 0.51 0.51 H.sub.2O 3.28 3.28 3.28
3.28 Dabco 33LV 0.53 0.53 0.53 0.53 Niax A-1 0.08 0.08 0.08 0.08
DC5169 0.04 0.04 0.04 0.04 Y10184 1.1 1.1 1.1 1.1 Total resin
106.45 106.45 106.45 106.45 Lupranate T80 41.87 42.38 41.87 42.38
Index 100 100 100 100 % H.sub.2O 3.2 3.2 3.2 3.2 % SAN in resin 7
11 7 11 % HBP in resin 2 2 5 5 Total dry weight (g) 572 576 578 576
Density (kg/m.sup.3) 36 36 36 36 50% IFD (N) 294 335 355 407
[0094]
5 TABLE 3 Example Ingredient 9 10 11 E837 93.8 89.2 85.6 E850 -- --
-- HBP 7.2 10.8 14.4 DEOA LF 1.1 1.1 1.1 Glycerin 0.6 0.6 0.6
H.sub.2O 3.93 3.93 3.93 Dabco 33LV 0.411 0.452 0.492 Niax A-1 0.08
0.08 0.08 DC5169 -- -- -- Y10184 1 1 1 Total resin 107.12 107.16
107.2 Lupranate T80 51.737 53.197 54.658 Index 100 100 100 %
H.sub.2O 3.8 3.8 3.8 % SAN in resin 0 0 0 % HBP in resin 6.68 10.01
13.35 Total dry weight (g) 476 471 473 Density (kg/m.sup.3) 31 31
31 50% IFD (N) 301.6 399.9 482.6 % Hysteresis 34.9 39.3 42.6 Load
Efficiency 27.13
[0095]
6 TABLE 4 Example Ingredient 12 13 14 E837 92.8 89.2 85.6 E850 --
-- -- HBP 7.2 10.8 14.4 DEOA LF 1.1 1.1 1.1 Glycerin 0.6 0.6 0.6
H.sub.2O 3.24 3.24 3.24 Dabco 33LV 0.411 0.452 0.492 Niax A-1 0.08
0.08 0.08 DC5169 -- -- -- Y10184 1 1 1 Total resin 106.43 106.45
106.51 Lupranate T80 45.067 46.527 47.988 Index 100 100 100 %
H.sub.2O 3.2 3.2 3.2 % SAN in resin 0 0 0 % HBP in resin 6.72 10.08
13.43 Total dry weight (g) 554 554 550 Density (kg/m.sup.3) 36 36
36 50% IFD (N) 307 412.8 509.5 % Hysteresis 28.6 37.3 43.9 Load
Efficiency 30.18
[0096]
7 TABLE 5 Example Ingredient 16 16 E837 34.85 79.95 E850 65.15
20.05 HBP -- -- DEOA LF 1.1 1.1 Glycerin 0.6 0.6 H.sub.2O 3.93 3.93
Dabco 33LV 0.33 0.33 Niax A-1 0.08 0.08 DC5169 -- -- Y10184 1 1
Total resin 107.04 107.04 Lupranate T80 40.817 41.432 Index 100 100
% H.sub.2O 3.8 3.8 % SAN in resin 26 8 % HBP in resin 0 0 Total dry
weight (g) 550 556 Density (kg/m.sup.3) 31 31 50% IFD (N) 468.4
276.3 % Hysteresis 38.4 29.1 Load Efficiency 10.69
* * * * *