Basf Corporation

Basf Wyandotte Corporation

Duane A Heyman

Gerhard G Ramlow

Oscar M Grace

James A Gallagher

Curtis J Reichel

John E Davis

Thomas L Fishback

Donald Charles Mente

Steven D Gagnon

Steven E Wujcik

Robert J Hartman

Richard A Moore

Adam J Jaglowski

Theodore Michael Smiecinski

Raymond A Neff

Jay G Otten

John R Murphy

Mao-Yao Huang

Joseph R Gregoria

Disclosed is a process for preparation of final graft polyols via a continuous process. In, addition, a final graft polyol formed by the process is disclosed. The process includes the steps of reacting a plurality of ethylenically unsaturated monomers and a reaction moderator with a macromer having induced unsaturation in the presence of a carrier polyol, a free radical polymerization initiator, and a first graft polyol. The process provides for the preparation of a final graft polyol having a solids level of from 30 to 70% in a continuous process. The final graft polyol produced by the process has a lower viscosity over a range of solids levels, a reduced amount of very large irregularly shaped particles, a reduced viscosity change in response to a change in reaction temperature compared to a typical graft polyol, a reduced tendency to foul the continuous reactor, and a broader particle size distribution compared to an identical graft polyol prepared by a semi-batch process.

Graft polyols prepared by a continuous process

Polyols initiated with a first initiator having a relatively high functionality averaging greater than eight and comprising a range of species of different functionality, and optionally a second initiator, having low functionality, i.e. a two to eight nominal functionality initiator molecule. Another aspect of the invention is a process for making the polyol. The invention is also directed to a process for producing polyurethane foam by reacting the polyol of the invention with isocyanates, and the foam produced thereby.

Polyether polyol for foam applications

Compositions of polytetramethylene ether glycols and polyoxy alkylene polyether polyols having a low degree of unsaturation

The present invention relates to graft polyols employing a t-amyl peroxy compound as free radical initiator. The novel graft polyols are made by polymerizing at least one monomer in a polyol composition in the presence of a free radical initiator and preferably a chain transfer agent. The resulting graft polyols are in turn useful in reactions with polyisocyanates to make polyurethane products.

Process for making graft polyols using t-amyl peroxy free radical initiator

Thus, there is provided according to the present invention polyol compositions comprising

Composition of polytetramethylene ether glycols and polyoxy alkylene

There is a provided a stable low viscosity graft polymer dispersion comprising from 25 to 60 weight percent based on the total weight of the polymer dispersion of at least three ethylenically unsaturated monomers polymerized in the presence of a reaction moderator and a free radical initiator in a polyol mixture initially containing less than 0.1 moles of induced unsaturation per mole of said polyol mixture. One of the monomers in the mixture of ethylenically unsaturated monomers is a hydroxylfunctional or aminofunctional C.sub.2 -C.sub.6 alkyl methacrylate.

Graft polymer dispersion having a third monomer and polyurethane foams

A flexible open-cell polyurethane is described that is the reaction product of a mixture comprising

Flexible open-cell polyurethane foam

The flame retardancy of flexible polyurethane foams is increased by incorporation into the foam forming reactants of a low molecular weight, high primary hydroxyl trifunctional polyether polyol having a hydroxyl number between 300 and 500 and a primary hydroxyl content greater than 50 percent.

Polyurethane foams of increased flame retardancy

Macromers for use in preparing stable, low viscosity graft polymer polyols of high solids content are disclosed. These macromers are easily made in high yield with short cycle times, and may be used to prepare graft dispersions containing amine based polyols.

Macromers for graft polyols and the polyols prepared therefrom

Graft polymer dispersions in polyoxyalkylene polyether polyols are employed together with flame retardant compounds to prepare flame retardant polyurethane foams. The polymer dispersions employ less than 0.1 mole of induced unsaturation per mole of polyol mixture. Processes for the preparation of these polymer dispersions employ fumarate derived polyetherester polyols or polyetherester polyols prepared by reacting a polyoxyalkylene polyether polyol with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and an alkylene oxide in the presence of salts and oxides of divalent metals. The polymer dispersions are prepared in the presence of a reaction moderator and employ 50 weight percent or more of acrylonitrile.

Process for the preparation of graft polymer dispersions and

White graft polymer dispersions in polyoxyalkylene polyether polyols are employed together with flame retardant compounds to prepare flame retardant polyurethane foams. The polymer dispersions employ less than 0.1 mole of induced unsaturation per mole of polyol mixture. Improved processes for the preparation of these polymer dispersions employ either maleate or fumarate derived polyetherester polyols or polyetherester polyols prepared by reacting a polyoxyalkylene polyether polyol in the presence of a chain transfer agent with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and an alkyklene oxide in the presence of salts and oxides of divalent metals.

Process for the preparation of white graft polymer dispersions and

Graft polymer dispersions in a polyol are prepared by a continuous process employing in situ free radical polymerization of an ethylenically unsaturated monomer in a polyol containing from about 0.001 to 0.09 mole of induced unsaturation per mole of polyol in the presence of an effective amount of a chain transfer agent. Products prepared by this process have uniform viscosity with resulting product uniformity. Polyurethane foams incorporating flame retardants prepared from these dispersions readily pass the California No. 117 Flame Test.

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Monroe, MI, United States of America

Duane A Heyman