Basf Corporation

Thomas B Lee

Thomas L Fishback

Curtis J Reichel

David C Krueger

Donald L Christman

James A Mullins

Walter R White, Iii

Andreas H Rothacker

Keith McLellan

Ronald J Wierzbicki

Theodore Michael Smiecinski

Raymond A Neff

Wassana Apichatachutapan

Eric J Lind

Roeland Tuinman

Manfred L Genz

Michele L Lee

The subject invention provides a viscoelastic polyurethane foam being flame retardant and having a density of greater than two and a half pounds per cubic foot that comprises a reaction product of an isocyanate component, an isocyanate-reactive blend, and a chain extender. The isocyanate-reactive blend includes a first isocyanate-reactive component and a second isocyanate-reactive component. The first isocyanate-reactive component includes at least 60 parts by weight of ethylene oxide (EO) based on 100 parts by weight of the first isocyanate-reactive component and the second isocyanate-reactive component includes at most 30 parts by weight of EO based on 100 parts by weight of the second isocyanate-reactive component. The chain extender is reactive with the isocyanate component and has a backbone chain with from two to eight carbon atoms and is present in an amount of from 5 to 50 parts by weight based on 100 parts by weight of the foam. A composition useful in making the viscoelastic polyurethane foam is also disclosed.

Viscoelastic polyurethane foam

The present invention discloses a method for the formation of and a flexible slabstock polyurethane foam having substantially improved indentation force deflection and resilience characteristics while maintaining the other physical properties. The method comprises the steps of: forming a polyol blend having a nominal functionality of at least 2.3 by combining at least one polyether polyol having a plurality of terminal ethylene oxide caps of from 5 to 25% by weight based on the total weight of the polyether polyol, a molecular weight of greater than or equal to 4000 Daltons, and an unsaturation of greater than 0.04 meq/g KOH; at least one graft polyether polyol having an equivalent weight of greater than 1000 Daltons, a solids content of at least 28%, and a plurality of terminal ethylene oxide caps of from 5 to 25% by weight based on the total weight of the graft polyether polyol; and at least one very low unsaturated polyether polyol having an unsaturation of less than or equal to 0.018 meq/g KOH and a plurality of terminal ethylene oxide caps of from 5 to 25% by weight based on the total weight of the polyether polyol; providing at least one polyisocyanate component; providing a catalyst; providing water as a blowing agent at a level of between 3 to 7% by weight; and combining the polyol blend with the polyisocyanate component, the catalyst and the water to form a slabstock polyurethane foam.

Use of low unsaturated polyether polyols in high resilience slabstock foam applications

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

Compositions of polytetramethylene ether glycols and polyoxy alkylene

A polyol composition is provided which when reacted with and organic isocyanate, has good flow characteristics and makes an all water blown rigid polyurethane foam having good dimensional stability at low core densities of 1.1 pcf to 2.0 pcf. The polyol composition has a polyol component which must have present a polyoxyalkylene polyether polyol having an equivalent weight of 130 or less, an average functionality of 3.1 or greater, and a hydroxyl number of 400 or more, a polyoxyalkylene polyether polyol having an average functionality from 1.5 to 3.1 and a viscosity of less than 800 cP at 25.degree. C., and a polyoxyalkylene polyether polyol having an average functionality of greater than 3.1 and an equivalent weight of greater than 130. The polyol composition also has water as the blowing agent, and further contains a blow catalyst, a delayed action gel catalyst, and preferably a cure catalyst and a surfactant.

Polyol compositions having good flow and water blown rigid polyurethane

A polyol composition is provided which when reacted with an organic isocyanate, has good flow characteristics and makes a rigid polyurethane foam having good dimensional stability at low densities. The polyol composition has a polyol component which must have present a polyoxyalkylene polyether polyol having an equivalent weight of 130 or less and a hydroxyl number of 400 or more, a polyoxyalkylene polyether polyol having an average functionality from 1.5 to 3.1 and a viscosity of less than 800 cP at 25.degree. C., and a polyoxyalkylene polyether polyol having an average functionality of greater than 3.1 and a viscosity of 5,000 cp or less at 25.degree. C. The polyol composition also has formic acid or a mixture of formic acid and water as blowing agents, and further contains a delayed action blow catalyst and a delayed action gel catalyst.

Polyol composition having good flow and formic acid blown rigid

Polyol composition having good flow and water blown rigid polyurethane

There is now provided a polyisocyanate based rigid closed cell foam made by reacting an organic isocyanate with a polyol composition in the presence of a blowing agent, where the polyol composition contains at least:

Three component polyol blend for use in insulating rigid polyurethane

There is now provided a polyisocyanate based rigid closed cell foam made by reacting an organic isocyanate with a polyol composition in the presence of a blowing agent, where the polyol composition contains at least: a) an aromatic amine initiated polyoxyalkylene polyether polyol having an hydroxyl number of 200 meq polyol/g KOH or more; b) an aliphatic amine initiated polyoxyalkylene polyether polyol having an hydroxyl number of 200 meq polyol/g KOH or more; and c) an aromatic polyester polyol having an hydroxyl number of 200 meq. polyol/g KOH or more. The blowing agent is selected from the group consisting of cyclopentane, HFC's, HCFC's, and mixtures thereof in an amount of 5.0 weight percent or more based on the weight of the polyol composition. Preferably, the blowing agent is soluble in the polyol composition without sacrificing, and advantageously improving, the thermal insulation and dimensional stability of the resulting polyurethane foam. Also disclosed are a storage stable polyol composition and methods for making a polyisocyanate based rigid closed cell foam.

There is provided a polyol composition which comprises a a) compound having at least two isocyanate reactive hydrogens, at least one of which is a polyoxyalkylene polyether polyol, b) 2-chloropropane, and, c) a C.sub.4 -C.sub.6 aliphatic hydrocarbon. There is also provided a rigid polyurethane foam made with the polyol composition. The 2-chloropropane acts to solubilize the C.sub.4 -C.sub.6 aliphatic hydrocarbon in the polyols.

Polyol compositions and rigid polyisocyanate based foams containing

There is now provided a polyisocyanate-based foam made by reacting an organic polyisocyanate with a polyol solution containing a C.sub.4 -C.sub.7 aliphatic and/or cycloaliphatic hydrocarbon as a blowing agent. The hydrocarbon blowing agent is soluble in the polyol solution having polyols with polyester linkages by using a reacted or unreacted compatibilizing agent represented by the formula: ##STR1## wherein R.sup.1 is preferentially OH, and R.sup.2 is a C.sub.6 -C.sub.24 aliphatic, branched or unbranched, hydrocarbon group.

Processability of hydrocarbon blown, polyisocyanate based foams through

A polyol composition is provided which when reacted with an organic isocyanate, has good flow characteristics and makes a rigid polyurethane foam having good dimensional stability at low densities. The polyol compostion has a polyol component which must have present a polyoxyalkylene polyether polyol having an equivalent weight of 130 or less and a hydroxyl number of 400 or more, a polyoxyalkylene polyether polyol having an average functionality from 1.5 to 3.1 and a viscosity of less than 800 cP at 25.degree. C., and a polyoxyalkylene polyether polyol having an average functionality of greater than 3.1 and a viscosity of 5,000 cp or less at 25.degree. C. The polyol composition also has formic acid or a mixture of formic acid and water as blowing agents, and further contains a delayed action blow catalyst and a delayed action gel catalyst.

There is now provided a polyisocyanate-based foam made by an organic polyisocyanate with a polyol solution containing a C.sub.4 -C.sub.7 aliphatic and/or cycloaliphatic hydrocarbon as a blowing agent. The hydrocarbon blowing agent is soluble in the polyol solution having polyols with polyester linkages by using a reacted or unreacted compatibilizing agent represented by the formula: ##STR1## wherein R.sup.1 is preferentially OH, and R.sup.2 is a C.sub.6 -C.sub.24 aliphatic, branched or unbranched, hydrocarbon group.

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Southgate, MI, United States of America

Thomas B Lee