Basf Corporation

Richard P Harrison

Edward Michael Dexheimer

Richard C Rossio

David Ho

Bari W Brown

Gladys M Aviles

Thirumurti L Narayan

Michael Scarpati

Joseph Ogonowski

Jon P Pavlinac

Blair J Zagata

L Patrick Chang

Valeri L Valoppi

Michael J Krupa

Vechelle R Onufrak

Lori R Everitt

Edward A Sliwka

Thomas M Lynch

A resin composition and an article formed therefrom are disclosed. The resin composition comprises a halogenated polyol, a brominated polyol different from the halogenated polyol, and a flame retardant. The resin composition may further comprise other components, such as supplemental polyols, catalysts, adhesion promoters, surfactants, blowing agents, additives, or combinations thereof. The article comprises the reaction product of an isocyanate, the halogenated polyol, and the brominated polyol in the presence of the flame retardant, a blowing agent, and optionally, one of more of the other components. Typically, the article is defined as a polyurethane foam. The article exceeds Class I flammability requirements, such as flame spread index, smoke density, and convective flame spread parameter according to ASTM E-84 and FM 4880 testing. In addition, the article exhibits excellent dimensional stability and adhesion strength, and may be used to form building materials, such as insulation, wall, and ceiling panels.

Resin composition and an article formed therefrom

The aromatic polyurethane elastomers of the present invention are particularly suited for methods of making objects in a mold cavity. The objects generally include an elastomeric layer formed from an aromatic polyurethane and a foam layer which is subsequently applied to the elastomer. The aromatic elastomer of the present invention lends itself to being precoated with an in-mold coating or being painted after demolding the resulting part.

Decorative components having an elastomeric outer surface and methods of making such components

The method of the present invention is particularly suited for making decorative objects in a mold cavity. The method enables one to form a decorative component having an outer elastomeric layer that is integral with an inner layer of foam. Because the chemical formulation for the outer layer and the inner layer is identical, other than the inner layer includes a foaming agent, the decorative component does not suffer from the drawbacks of the previous methods such as, for example, poor adhesion between the elastomeric layer and the foam layer causing delamination of the two layers, sinks or holes in the foam layer leading to imperfections in the elastomeric layer, and bleed through to the elastomeric layer from the foam layer. The method permits the mold to be pre-coated with an in-mold paint prior to the molding process. Coatings can also be applied after demolding the resulting part.

Method for producing decorative components having an outer elastomeric layer that is integral with an inner foam layer

The invention relates to compositions and method for producing energy absorbing, water blown, rigid polyurethane foams. The resulting polyurethane foams are low density, predominately open celled foams which exhibit a relatively constant consistency of compressive strength over deflectors. Such foams are suitable as lightweight alternatives to traditional energy absorbing applications.

Energy absorbing, water blown, rigid polyurethane foam

The invention provides polyurethane components and compositions capable of providing internal mold release properties in SRIM applications. The polyol composition of the invention has an isocyanate reactive polyol (A) having a number average molecular weight from 100 to about 10,000 and an effective amount of internal mold release composition (B) having a silicon-containing polymer (a) and an epoxidized ester (b). The invention further provides an SRIM polyurethane composition useful in the preparation of molded polyurethane articles having internal mold release properties, the composition comprising an isocyanate component (I) and the isocyanate reactive polyol composition (Component (II)) disclosed above. In another aspect of the invention, the invention provides methods of using the claimed compositions as well as the rigid cellular polyurethane SRIM articles resulting from such processes.

Polyurethane SRIM compositions having internal mold release properties

The invention provides polyurethane components and compositions capable of providing internal mold release properties in SRIM applications. The polyol composition of the invention has an isocyanate reactive polyol (A) having a number average molecular weight from 100 to about 10,000 and an effective amount of internal mold release composition (B) having a silicon-containing polymer (a) and an epoxidized ester (b). The invention further provides an SRIM polyurethane composition useful in the preparation of molded polyurethane articles having internal mold release properties, the composition comprising an isocyanate component (I) and the isocyanate reactive polyol composition (component (II)) disclosed above. In another aspect of the invention, the invention provides methods of using the claimed compositions as well as the rigid cellular polyurethane SRIM articles resulting from such processes.

The invention relates to water blown integral skin polyurethane foams made with a particular isocyanate quasi-prepolymer and resin side ingredients to yield a foam having good overall mechanical roperties. The isocyanate quasi-prepolymer component of the present invention comprises from 0.5 weight percent to 30.0 weight percent or less uretonimine-carbodiimide-modified diphenylmethane diisocyanate, from 50 weight percent to 80 weight percent 4,4'-diphenylmethane diisocyanate and reacted with from 15 weight percent to 40 weight percent of a polyether polyol containing predominately secondary hydroxy groups and having an average molecular weight from about 2,000 to 10,000, an average functionality from 1.5 to about 3.2, and a hydroxyl number from about 20 to 60. The resin side component comprises a high molecular weight polyether polyol with an average functionality from 1.5 to about 3.2, water as a blow agent, and optionally an mono- or di-functional alcohol composition having from 8 to about 30 carbon atoms. The components, when injected or poured into a preheated mold, can tolerate mold temperatures from 105.degree. F. to 135.degree. F. and can be demolded in less than 150 seconds to yield and integral skin foam having little or no bubbles or pores visible to the eye. The foam produced thereby has a compression set of 30 percent or less, high tensile strength, and high tear strength.

Water-blown polyurethane integral skin foam

The invention relates to water blown integral skin polyurethane foams made with a particular isocyanate quasi-prepolymer and resin side ingredients to yield a foam having good overall mechanical properties. The isocyanate quasi-prepolymer component of the present invention comprises from 0.5 weight percent to 30.0 weight percent or less uretonimine-carbodiimide-modified diphenylmethane diisocyanate, from 50 weight percent to 80 weight percent 4,4'-diphenylmethane diisocyanate and reacted with from 15 weight percent to 40 weight percent of a polyether polyol containing predominately secondary hydroxyl groups and having an average molecular weight from about 2,000 to 10,000, an average functionality from 1.5 to about 3.2, and a hydroxyl number from about 20 to 60, and optionally with a low molecular weight diol in an amount of from 1.0 weight percent to 10 weight percent, the weight percentages based on the weight of the quasi-prepolymer reactants. The resin side component comprises a high molecular weight polyether compound having isocyanate reactive hydrogens and average molecular weights from about 2,000 to about 10,000 and an average functionality from 1.5 to about 3.2, water as a blowing agent in an amount of from 0.25 weight percent to 3 weight percent, an effective amount of polyurethane and/or polyurea promoting catalyst, a surfactant, and a chain extender, and optionally a mono- or di- functional alcohol composition having from 8 to about 30 carbon atoms. The components, when injected or poured into a preheated mold, can tolerate mold temperatures from 105.degree. F. to 135.degree. F. and can be demolded in less than 150 seconds to yield an integral skin foam having little or no bubbles or pores visible to the eye. The foam produced thereby has a compression set of 30 percent or less, high tensile strength, and high tear strength.

It was found that a combination of thermoplastic microspheres containing a volatile hydrocarbon and water could be used as effective co-blowing/density reducing agents in low density, integral skin polyurethane foams.

Low density flexible integral skin polyurethane systems using

The invention relates to water blown integral skin polyurethane foams made with a particular isocyanate quasi-prepolymer and resin side ingredients to yield a foam having good overall mechanical properties. The isocyanate quasi-prepolymer component of the present invention comprises from 0.5 weight percent to 30.0 weight percent or less uretonimine-carbodiimide-modified diphenylmethane diisocyanate, from 50 weight percent to 80 weight percent 4,4'-diphenylmethane diisocyanate and reacted with from 15 weight percent to 40 weight percent of a polyether polyol containing predominately secondary hydroxyl groups and having an average molecular weight from about 2,000 to 10,000, an average functionality from 1.5 to about 3.2, and a hydroxyl number from about 20 to 60, and optionally with a low molecular weight diol in an amount of from 1.0 weight percent to 10 weight percent, the weight percentages based on the weight of the quasi-prepolymer reactants. The resin side component comprises a high molecular weight polyether compound having isocyanate reactive hydrogens and average molecular weights from about 2,000 to about 10,000 and an average functionality from 1.5 to about 3.2, water as a blowing agent in an amount of from 0.25 weight percent to 3 weight percent, an effective amount of polyurethane and/or polyurea promoting catalyst, a surfactant, and a chain extender, and optionally a mono- or di- functional alcohol composition having from 8 to about 30 carbon atoms.

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Lincoln Park, MI, United States of America

Richard P Harrison