Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Cellular products or processes of preparing a cellular...
Patent
1988-05-09
1989-06-27
Welsh, Maurice J.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Cellular products or processes of preparing a cellular...
521108, 521137, 521906, 524709, 524710, 524712, 524732, C08G 1814
Patent
active
048431060
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to the preparation of novel modified polymer polyols and their use in making polyurethane foam. In particular, the present invention relates to the preparation of polymer polyols suitable for use in the manufacture of polyurethane foams which are fire resistant.
It is known to prepare polyurethane foams having improved fire resistant properties relative to conventional foams. Such improved fire resistant properties are usually achieved by adding a flame retardant directly into the polyurethane foam formulation along with the other components. Whilst such a method is applicable to flame retardants which are either liquids or solids which are soluble in the foam formulation, it is not generally suitable where the flame retardant is solid which is insoluble in the foam formulation as it is difficult to achieve homogenous dispersion of the flame retardant.
An approach to rendering polyurethane foams fire resistant has now been developed which allows a wider range of flame retardants to be used than before. The approach, which in particular relates to polyurethane foams derived from so-called polymer polyols or graft polyols, comprises incorporating the flame retardant into the polymer polyol during the polymer polyol production stage. Surprisingly, it has been observed that, by using such an approach, it is possible to carry out incorporation of the flame retardant without seriously effecting the viscosity and stability of the polymer polyol.
The approach described above is especially suitable when solid flame retardants are used, since by this method the flame retardant can be incorporated relatively homogenously into the polymer polyol and hence the foam formulation. As a consequence not only is the fire resistance improved for a given level of flame retardant but it has also been found that the quality of the foam structure is improved. The latter effect is also true if liquid retardants are incorporated during the polymer polyol production stage.
Accordingly, the present invention provides a fluid polymer polyol dispersion prepared by reacting a polyol with one or more monomers and an effective amount of a free radical polymerisation catalyst under conditions where the monomer is grafted onto the polyol characterised in that the reaction is carried out in the presence of between 1 and 30% by weight of a flame retardant.
As regards the polyol used in preparing the fluid polymer polyol dispersion, this is conveniently a polyether polyol and is optionally one with deliberately added unsaturation, as might be introduced, for example, by reaction of a polyol with an unsaturated anhydride such as maleic anhydride or the stabilisers of EP No. 162588 and EP No. 162589. Typical polyols which are contemplated by this invention are alkylene oxide adducts of (1) low molecular weight diols and triols or naturally occuring polyols (2) non reducing sugars and derivatives thereof (3) phosphoric, phosphorus, and polyphosphoric acids. Examples of such adducts are the alkylene oxide adducts of ethylene glycol, propylene glycol, glycerol, trimethylolpropane, the isomeric butanediols, hexanediols, octanediols and the like. Alkylene oxide adducts of pentaerythritol, sorbitol, arabitol, mannitol, alkyl glucoside, alkylene glycol glucosides and glycerol glucosides are also contemplated, as are adducts of alkylene diamines and hydrazine.
In general it is desirable that the alkylene oxide used to form the adduct is a 1,2 or 1,3 or 1,4 alkylene oxide having from 2 to 4 carbon atoms. Preferred examples are ethylene oxide, propylene oxide, the butylene oxides, THF, or mixtures thereof, with ethylene oxide and/or propylene oxide being the most preferred.
With such a large number of polyols available for use with the above invention, the choice of polyol will depend very much upon the application for which the polymer polyol is used. In choosing the polyol, an important consideration is its hydroxyl number, that is the average number of free hydroxyl groups per polyol molecule, since this reflects the numbe
REFERENCES:
patent: 3230193 (1966-01-01), Moulds et al.
patent: 4334031 (1982-06-01), Otten et al.
patent: 4661531 (1987-04-01), Davis et al.
Fis Joelle Y.
Lidy Werner A.
Phillips Brian D.
Thomas David B.
BP Chemicals Limited
Welsh Maurice J.
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