The Dow Chemical Company

John L Nafziger

Steven B Lowenkron

Charles E Koehler

Larry W Mobley

Mark A Snyder

Bruce N Stevens

Franciszek Olstowski

Debkumar Bhattacharjee

Mark J Hazelrigg

John M Motes

Rory D Daussin

Irwin J Seward, Jr

Laura A Rader

Rebond polyurethane foams can be prepared by coating shredded polyurethane foam with a prepolymer binder formulation which includes toluene diisocyanate distillation bottoms, compressing the binder coated foam, and the curing the binder with steam. The toluene diisocyanate distillation bottoms can be used in place of more expensive prepolymer formulation components such as toluene diisocyanate or methylene diphenyldiisocyanate. The toluene diisocyanate distillation bottoms can also improve elongation and tear resistance properties of the resultant rebond foams prepared therewith.

Flexible polyurethane rebond foam having improved tear resistance and

A method of preparing viscosity-stabilized toluene diisocyanate distillation residues comprising contacting toluene diisocyanate distillation residue with a material suitable for purging chloride-containing vapors under reaction conditions suitable to remove chloride-containing vapors from the toluene diisocyanate distillation residues. The material may be, for example, an aromatic solvent and/or a gas which associates, physically, chemically, or a combination thereof, with the vapors but not with significant amount of other components that may be present in the toluene diisocyanate distillation residue. The viscosity-stabilized and reactive residue can then be used alone or blended with one or more other isocyanate products, such as polymeric methylene diphenylisocyanate, to prepare materials such as polyurethane, polyisocyanurate, polyurethane-polyurea or polyurea compositions including, for example, foams.

Process for preparing viscosity-stabilized reactive toluene diisocyanate

This invention is a process for removing volatile impurities from a crude isocyanate compound which is prepared in the phosgenation of a primary amine, comprising heating said crude isocyanate compound to a temperature to volatilize said volatile impurities in the presence of an acidic material containing a plurality of strong acid groups. The process permits faster, more complete removal of hydrolyzable chloride impurities than conventional processes.

Process for reducing the quantity of hydrolyzable chlorides in

A method of treating toluene diisocyanate distillation residues comprising reacting the residues with at least about 0.5 equivalents, based on hydrolyzable chloride concentration of the residues, of an epoxy compound at a temperature of from about 155 to about 220.degree. C. to produce a treated distillation residue having a hydrolyzable chloride level of less than about 800 parts per million (ppm) is taught. The product of the method is useful, for instance, in producing rigid foams with low K Factors.

Rigid foams prepared from treated toluene diisocyanate residue

Polyamines are prepared from aromatic amines and aliphatic aldehydes or ketones using cationic or acid ion exchange resins as a catalyst in an essentially oxygen-free atmosphere with the aromatic amines being distilled and protected from the atmosphere.

Process for preparing polyamines with ion exchange resin catalysts

Flexible polyurethane foams having improved flame resistance and 'guide factor' are prepared by reacting a copolymer polyahl, isocyanate-terminated prepolymer containing a cotrimer of MDI and a blowing agent.

Flexible polyurethane foams prepared from cotrimers of alkylene-bridged

Trimerized isocyanates having improved solubility in polyisocyanates are prepared by reacting a polyisocyanate with a low equivalent weight polyol to form a first prepolymer, forming a cotrimer from said first prepolymer by reaction of same with diphenylmethane diisocyanate or polymeric derivatives thereof, and forming a second isocyanate terminated prepolymer by reacting said cotrimer with a second low equivalent weight polyol. The resulting cotrimer can be diluted in a polyisocyanate and used to prepare polymers, particularly polyurethane foams, having excellent properties.

Process for preparing stable solutions of trimerized isocyanates in

The invention describes an improved process for preparing polyols by reacting a mono-epoxy compound such as propylene oxide with a hydroxyl-containing initiator compound such as glycerine in the presence of a catalyst, the improvement being that the catalyst is added in the form of a calcium, strontium or barium salt of an organic acid such as acetic acid. Polyols prepared by this process can be employed to prepare polyurethanes without removing the catalyst.

Process for preparing polyols

Polyisocyanates are stabilized against discoloration by the addition of certain hindered phenols such as o,o-di-n-octadecyl-3,5-di-tert-butyl-4-hydroxyl benzyl phosphonate.

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Lake Jackson, TX, United States of America

John L Nafziger