Dow Global Technolgoies LLC

Irena Amici-Kroutilova

David A Babb

Martin R Greaves

Francois M Casati

Paul A Cookson

Alberto Lora Lamia

Ricco B Borella

Hamideh Ahmadloo

Daniel Hoenhener

Jean-Paul Masy

Giuseppe Vairo

Van Delk

Rossella Riccio

Elena Ferrari

Daniel Hoehener

Dale Hunter

Embodiments of the present disclosure are directed towards polyol compositions including a dispersion of polyisocyanate polyaddition particles in a carrier polyol, wherein the polyisocyanate polyaddition particles have an average particle diameter from 0.1 to 10.0 microns and the dispersion has a solids content from 5 wt % to 50 wt % based upon a total weight of the dispersion, and a polyester polyol that is from 1 wt % to 98 wt % of the polyol composition based upon a total weight of the polyol composition.

Polyol compositions

Embodiments of the present disclosure are directed towards semi-flexible foam formulations that can be utilized to form semi-flexible foams. As an example, a semiflexible foam formulation can include a first polyether polyol having an average nominal hydroxyl functionality from 2 to 4 and a number average equivalent weight from 120 to 1500, a second polyether polyol having a having an average nominal hydroxyl functionality from 4 to 8 and a number average equivalent weight from 120 to 800, and a third polyether polyol having an average nominal hydroxyl functionality from 2 to 4 a number average equivalent weight from 200 to 500 and toluene diisocyanate.

Semi-flexible foam formulations

Embodiments of the present disclosure are directed towards polyether polyol compositions that can be utilized to form semi-rigid foams. As an example, a polyether polyol composition can include a first polyether polyol having an average nominal hydroxyl functionality from 2 to 4 and a number average equivalent weight from 120 to 1500, a second polyether polyol having a having an average nominal hydroxyl functionality from 4 to 8 and a number average equivalent weight from 120 to 800, and a third polyether polyol having an average nominal hydroxyl functionality from 2 to 4 a number average equivalent weight from 200 to 500.

Polyether polyol compositions

Random poly(propylene oxide-co-ethylene oxide) polymers are made by polymerizing a mixture of propylene oxide and a small amount of ethylene oxide in the presence of a starter and a double metal cyanide catalyst complex, and then feeding in a mixture of propylene oxide and ethylene oxide while increasing the ethylene oxide concentration in the mixture to at least 90%. This produces a polyol suitable for making high resiliency polyurethane foam without need for adding an ethylene oxide cap.

Method for making propylene oxide/ethylene oxide copolymers using double metal cyanide catalysts, and copolymers so made

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.

Polyisocyanate polyaddition polyol manufacturing process using stabilizers

A process for forming a combustion-modified ether (CME) polyurethane foam includes providing a polyol component including a PIPA polyol that is a dispersion having a solids content from 10 wt % to 75 wt %, based on a total weight of the PIPA polyol, providing an isocyanate component that includes at least one polyisocyanate, providing an additive component that includes at least one flame retardant, and forming a reaction mixture including the polyol component, the isocyanate component, and the additive component to form a CME polyurethane foam. The reaction mixture has an isocyanate index from 90 to 150. The PIPA polyol is a reaction product of a mixture including at least a low equivalent weight polyol having a number average hydroxyl equivalent weight of less than 80, a polyisocyanate compound having a number average isocyanate equivalent weight that is less than 225, and a liquid base poly ether polyol having a number average hydroxyl equivalent weight of at least 200 and at least 80% of secondary hydroxyl groups based on a total amount of hydroxyl groups in the liquid base polyether polyol.

PIPA based combustion-modified flexible foam

A process for forming a conventional flexible polyurethane foam includes providing a polyol component including a PIPA polyol that is a dispersion having a solids content from 10% to 75 wt %, based on a total weight of the PIPA polyol, providing an isocyanate component that includes at least one polyisocyanate, providing an additive component that includes a catalyst, and forming a reaction mixture including the polyol component, the isocyanate component, and the additive component to form a flexible polyurethane foam with a resiliency value below 45%. The reaction mixture has an isocyanate index from 90 to 150. The PIPA polyol is a reaction product of a mixture including at least a low equivalent weight polyol having a number average hydroxyl equivalent weight of less than 80, a polyisocyanate compound having a number average isocyanate equivalent weight that is less than 225, and a liquid base poly ether polyol having a number average hydroxyl equivalent weight from 200 to 1500 and at least 80% of secondary hydroxyl groups based on a total amount of hydroxyl groups in the liquid base polyether polyol.

PIPA polyol based conventional flexible foam

PIPA polyols are made in a two-step process. In the first step, a base polyether polyol and a polyisocyanate are reacted to form a mixture that contains unreacted base polyol, unreacted polyisocyanate and adducts of the base polyol and polyisocyanate. A low equivalent weight polyol is then added and reacted in a second step to form the dispersion. The process unexpectedly produces a stable dispersion of the fine PIPA particles in the base polyol, even when the base polyol contains mostly secondary hydroxyl groups. The process also permits the tuning of product viscosity by increasing or decreasing the extent of reaction in the first step.

Polyisocyanate polyaddition polyol manufacturing process and product

Thixotropic polyol dispersions are described. The dispersions contain a dispersed phase of polyurethane-isocyanurate particles. They can be made by reacting a low equivalent weight polyol with a polyisocyanate in the presence of an isocyanate trimerization catalyst while dispersed in a base polyol. These polyol dispersions are useful as the resin component of curable systems such as formulated coatings, sealants or adhesives.

Thixotropic polyol compositions containing dispersed urethane-modified polyisocyanurates

Viscoelastic foam is made by reacting an isocyanate compound with water and a polyol mixture. The polyol mixture contains a dispersion of polyurethane or polyurethane-urea particles in a carrier polyol (a PIPA polyol) and at least one other polyol that is a homopolymer of propylene oxide or a copolymer of 20 to 99.9 weight-% propylene oxide and 0.1 to 80 weight-% ethylene oxide, has 2 to 4 hydroxyl groups per molecule and has a hydroxyl equivalent weight of 200 to 400. The VE foams are characterized by high airflows and long recovery times.

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Waedenswil, Switzerland

Irena Amici-Kroutilova