Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Cellular products or processes of preparing a cellular...
Patent
1998-03-19
1999-11-23
Marquis, Melvyn I.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Cellular products or processes of preparing a cellular...
528 21, 528 24, 524730, 526279, C08J 900
Patent
active
059901853
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to a polymer polyols and a process for the preparation thereof, and preformed stabilizer used for the preparation of polymer polyols.
Polymer polyols suitable for the preparation of polyurethane foams and elastomers are well known and are widely used on commercial scale. Polyurethane foams made from polymer polyols have a wide variety of uses. The two major types of polyurethane foams are slabstock and moulded foam. Polyurethane slabstock foams are used in carpet, furniture and bedding applications. Moulded polyurethane foams are used in the automotive industry for variety of applications.
Polymer polyols are produced by polymerizing one or more ethylenically unsaturated monomers dissolved or dispersed in a polyol in the presence of a free radical catalyst to form a stable dispersion of a polymer particles in the polyol. Initially, polymer polyols producing polyurethane foams having higher load-bearing properties than those produced from unmodified polyols were prepared using acrylonitrile monomer; however, many of these polymer polyols had undesirably high viscosity.
Presently, polyurethane foams having high load-bearing properties are predominantly produced using polymer polyols which are prepared using a high styrene content monomer mixture (e.g., 65 to 75 percent styrene). However, polymer polyols produced from such high styrene monomer mixture often do not satisfy the ever-increasing industry needs, including acceptable viscosity, strict stability requirements and increased load-bearing properties.
Stability and low viscosity of polymer polyols is of increasing importance to polyurethane foam manufacturers due development of sophisticated, high speed and large volume equipment and systems for handling, mixing and reacting polyurethane-forming ingredients. Polymer polyols must meet certain minimum polymer particles size requirements to avoid filters, pumps and other parts of such foam processing equipment becoming plugged or fouled in relatively short periods of time,
Numerous attempts have been made to produce polymer polyols which will meet foam processing and load-bearing properties required by polyurethane foam industry.
U.S. Pat. No. 4,242,249 (Van Cleve et al) describes polymer polyols prepared by using certain preformed dispersants or stabilizers. These polymer polyols provide stability satisfactory for commercial production, and use of at least one of (i) high amounts of styrene or other comonomer with acrylonitrile, (ii) higher solids contents or (iii) the use of lower molecular weight polyols. The particular stabilizer used and the concentration used vary with respect to the monomer system used in the preparation of polymer polyols.
U.S. Pat. No. 4,652,589 (Simroth et al) describes stabilizer precursors for polymer polyols. Stabilizer A is made by reacting a 34 hydroxyl number, 15 weight percent ethylene oxide capped polyoxypropylene triol with maleic anhydride and subsequently with ethylene oxide. Stabilizer A has a hydroxyl number of 32, an unsaturation of 0.1 meq/g, with the unsaturation being 30/70 maleate/fumarate. Stabilizer B is made by reacting a 28 hydroxyl number sorbitol started polyol, containing 10 percent internal ethylene oxide, with maleic anhydride, and subsequently with propylene oxide. Stabilizer B has a hydroxyl number of 28 and an unsaturation of approximately 0.07 meq/g, with the unsaturation being of the fumarate type.
U.S. Pat. No. 5,196,476 (Simroth) describes: (a) a high potency preformed stabilizer; (b) the use of same in the manufacture of polymer polyols having high solids content, lower viscosity and excellent product stability; and (c) a polyurethane made using such polymer polyol. The preformed stabilizer is the free radical polymerization product of at least one free radically polimerizable ethylenically unsaturated monomer and at least one polyhydric alcohol adduct comprising a polyhydric alcohol residue and a residue of a compound having fumaric or maleic type unsaturation.
U.S. Pat. No. 5,364,906 (Critchfield et al) describes a
REFERENCES:
patent: 4723026 (1988-02-01), Cloetens et al.
patent: 4831076 (1989-05-01), Lidy et al.
patent: 4883832 (1989-11-01), Cloetens et al.
Marquis Melvyn I.
Milstead Mark W.
The Dow Chemical Company
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