Foamed isocyanate-based polymer having improved hardness properties and process for production thereof

Abstract

In one of its aspects, the present invention relates to foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent; wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C. The dendritic macromolecule confers advantageous load building characteristics to the foamed isocyanate-based polymer and may be used to partially or fully displace the use of conventional copolymer polyols used. A process for production of a foam isocyanate-based polymer and a process for conferring loading building properties to a foamed isocyanate-based polymer are also described.

What is claimed is:  
     
         1 . A foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent; wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.  
     
     
         2 . A foamed isocyanate-based polymer derived from an isocyanate and an active hydrogen-containing compound, the polymer having a cellular matrix comprising a plurality of interconnected struts, the active hydrogen-containing compound conferring to the cellular matrix a load efficiency of at least about 15 Newtons/weight % active hydrogen-containing compound.  
     
     
         3 . The foamed isocyanate-based polymer defined in  claim 2 , wherein the active hydrogen-containing compound confers to the cellular matrix a load efficiency of at least in the range of from about 15 to about 50 Newtons/weight % active hydrogen-containing compound.  
     
     
         4 . The foamed isocyanate-based polymer defined in  claim 2 , wherein the active hydrogen-containing compound confers to the cellular matrix a load efficiency of at least in the range of from about 20 to about 45 Newtons/weight % active hydrogen-containing compound.  
     
     
         5 . The foamed isocyanate-based polymer defined in  claim 2 , wherein the active hydrogen-containing compound confers to the cellular matrix a load efficiency of at least in the range of from about 25 to about 35 Newtons/weight % active hydrogen-containing compound.  
     
     
         6 . A foamed isocyanate-based polymer having a cellular matrix derived from an active hydrogen-containing compound and comprising a plurality of interconnected struts, the cellular matrix: (i) having a load efficiency of at least about 15 Newtons/weight % active hydrogen-containing compound., and (ii) being substantially free of particulate material.  
     
     
         7 . The foamed isocyanate-based polymer defined in  claim 6 , wherein the active hydrogen-containing compound confers to the cellular matrix a load efficiency of at least in the range of from about 15 to about 50 Newtons/weight % active hydrogen-containing compound.  
     
     
         8 . The foamed isocyanate-based polymer defined in  claim 6 , wherein the active hydrogen-containing compound confers to the cellular matrix a load efficiency of at least in the range of from about 20 to about 45 Newtons/weight % active hydrogen-containing compound.  
     
     
         9 . The foamed isocyanate-based polymer defined in  claim 6 , wherein the active hydrogen-containing compound confers to the cellular matrix a load efficiency of at least in the range of from about 25 to about 35 Newtons/weight % active hydrogen-containing compound.  
     
     
         10 . A foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent; the foamed isocyanate-based polymer having an Indentation Force Deflection loss when measured pursuant to ASTM D3574 which is less than that of a reference foam produced by substituting a copolymer polyol for the dendritic macromolecule in the reaction mixture, the foamed isocyanate-based polymer and the reference foam having substantially the same density and Indentation Force Deflection when measured pursuant to ASTM D3574.  
     
     
         11 . A foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent; the foamed isocyanate-based polymer having thickness loss when measured pursuant to ASTM D3574 which is less than that of a reference foam produced by substituting a copolymer polyol for the dendritic macromolecule in the reaction mixture, the foamed isocyanate-based polymer and the reference foam having substantially the same density and Indentation Force Deflection when measured pursuant to ASTM D3574.  
     
     
         12 . A process for producing a foamed isocyanate-based polymer comprising the steps of: 
 contacting an isocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent to form a reaction mixture; and    expanding the reaction mixture to produce the foamed isocyanate-based polymer;    wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.    
     
     
         13 . The process defined in  claim 12 , wherein the active hydrogen-containing compound is selected from the group comprising polyols, polyamines, polyamides, polyimines and polyolamines.  
     
     
         14 . The process defined in  claim 12 , wherein the active hydrogen-containing compound comprises a polyol.  
     
     
         15 . The process defined in  claim 14 , wherein the polyol comprises a hydroxyl-terminated backbone of a member selected from the group comprising polyether, polyesters, polycarbonate, polydiene and polycaprolactone.  
     
     
         16 . The process defined in  claim 14 , wherein the polyol is selected from the group comprising hydroxyl-terminated polyhydrocarbons, hydroxyl-terminated polyformals, fatty acid triglycerides, hydroxyl-terminated polyesters, hydroxymethyl-terminated polyesters, hydroxymethyl-terminated perfluoromethylenes, polyalkyleneether glycols, polyalkylenearyleneether glycols, polyalkyleneether triols and mixtures thereof.  
     
     
         17 . The process defined in  claim 14 , wherein the polyol is selected from the group comprising adipic acid-ethylene glycol polyester, poly(butylene glycol), poly(propylene glycol) and hydroxyl-terminated polybutadiene.  
     
     
         18 . The process defined in  claim 14 , wherein the polyol is a polyether polyol.  
     
     
         19 . The process defined in  claim 18 , wherein the polyether polyol has a molecular weight in the range of from about 200 to about 10,000.  
     
     
         20 . The process defined in  claim 18 , wherein the polyether polyol has a molecular weight in the range of from about 2000 to about 7,000.  
     
     
         21 . The process defined in  claim 18 , wherein the polyether polyol has a molecular weight in the range of from about 2,000 to about 6,000.  
     
     
         22 . The process defined in  claim 12 , wherein the active hydrogen-containing compound is selected from group comprising a polyamine and a polyalkanolamine.  
     
     
         23 . The process defined in  claim 22 , wherein the polyamine is selected from the group comprising primary and secondary amine terminated polyethers.  
     
     
         24 . The process defined in  claim 12 , wherein the polyether have a molecular weight of greater than about 230.  
     
     
         25 . The process defined in  claim 12 , wherein the polyether have a functionality of from about 2 to about 6.  
     
     
         26 . The process defined in  claim 12 , wherein the polyether have a molecular weight of greater than about 230 and a functionality of from about 1 to about 3.  
     
     
         27 . The process defined in  claim 12 ,wherein the isocyanate is represented by the general formula:  
       Q(NCO) i    
       wherein i is an integer of two or more and Q is an organic radical having the valence of i.  
     
     
         28 . The process defined in  claim 12 , wherein the isocyanate is selected from the group comprising hexamethylene diisocyanate, 1,8-diisocyanato-p-methane, xylyl diisocyanate, (OCNCH 2 CH 2 CH 2 OCH 2 O) 2 , 1-methyl-2,4-diisocyanatocyclohexane, phenylene diisocyanates, tolylene diisocyanates, chlorophenylene diisocyanates, diphenylmethane-4,4′-diisocyanate, naphthalene-1,5-diisocyanate, triphenylmethane-4,4′,4″-triisocyanate, isopropylbenzene-alpha-4-diisocyanate and mixtures thereof.  
     
     
         29 . The process defined in  claim 12 , wherein the isocyanate comprises a prepolymer.  
     
     
         30 . The process defined in  claim 12 , wherein isocyanate is selected from the group comprising 1,6-hexamethylene diisocyanate, 1,4-butylene diisocyanate, furfurylidene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 2,4′-diphenylmethane diisocyanate, 4,4′-diphenylmethane diisocyanate, 4,4′-diphenylpropane diisocyanate, 4,4′-diphenyl-3,3 ′-dimethyl methane diisocyanate, 1,5-naphthalene diisocyanate, 1-methyl-2,4-diisocyanate-5-chlorobenzene, 2,4-diisocyanato-s-triazine, 1-methyl-2,4-diisocyanato cyclohexane, p-phenylene diisocyanate, m-phenylene diisocyanate, 1,4-naphthalene diisocyanate, dianisidine diisocyanate, bitolylene diisocyanate, 1,4-xylylene diisocyanate, 1,3-xylylene diisocyanate, bis-(4-isocyanatophenyl)methane, bis-(3-methyl-4-isocyanatophenyl)methane, polymethylene polyphenyl polyisocyanates and mixtures thereof.  
     
     
         31 . The process defined in  claim 12 , wherein the isocyanate is selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.  
     
     
         32 . The process defined in  claim 12 , wherein the isocyanate is selected from the group consisting essentially of (i) 2,4′-diphenylmethane diisocyanate, 4,4′-diphenylmethane diisocyanate and mixtures thereof; and (ii) mixtures of (i) with an isocyanate selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.  
     
     
         33 . The process defined in  claim 12 , wherein the blowing agent comprises water.  
     
     
         34 . The process defined in  claim 33 , wherein the water is used in an amount in the range of from about 0.5 to about 40 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         35 . The process defined in  claim 33 , wherein the water is used in an amount in the range of from about 1.0 to about 10 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         36 . The process defined in  claim 12 , wherein dendritic macromolecule has the following characteristics: 
 (i) an active hydrogen content of greater than about 3.8 mmol/g;    (ii) an active hydrogen functionality of at least about 8; and    (iii) at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.    
     
     
         37 . The process defined in  claim 36 , wherein from about 15% to about 30% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.  
     
     
         38 . The process defined in  claim 36 , wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number in the range of from about 25 to 35 mg KOH/g to form a stable liquid at 23° C.  
     
     
         39 . The process defined in  claim 36 , wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number in the range of from about 28 to 32 mg KOH/g to form a stable liquid at 23° C.  
     
     
         40 . The process defined in  claim 36 , wherein the active hydrogen is present in the macromolecule in the form of one or more mercapto moieties.  
     
     
         41 . The process defined in  claim 36 , wherein the active hydrogen is present in the macromolecule in the form of one or more primary amino moieties.  
     
     
         42 . The process defined in  claim 36 , wherein the active hydrogen is present in the macromolecule in the form of one or more secondary amino moieties.  
     
     
         43 . The process defined in  claim 36 , wherein the active hydrogen is present in the macromolecule in the form of one or more hydroxyl moieties.  
     
     
         44 . The process defined in  claim 36 , wherein the active hydrogen is present in the macromolecule in the form of two or more of a mercapto moiety, a primary amino moiety, a secondary amino moiety and a hydroxyl moiety.  
     
     
         45 . The process defined in  claim 36 , wherein the active hydrogen content of the macromolecule is in the range of from about 3.8 to about 10 mmol/g.  
     
     
         46 . The process defined in  claim 36 , wherein the active hydrogen content of the macromolecule is in the range of from about 3.8 to about 7.0 mmol/g.  
     
     
         47 . The process defined in  claim 36 , wherein the active hydrogen content of the macromolecule is in the range of from about 4.4 to about 5.7 mmol/g.  
     
     
         48 . The process defined in  claim 36 , wherein the active hydrogen functionality in the macromolecule is in the range of from about 8 to about 70.  
     
     
         49 . The process defined in  claim 36 , wherein the active hydrogen functionality in the macromolecule is in the range of from about 10 to about 60.  
     
     
         50 . The process defined in  claim 36 , wherein the active hydrogen functionality in the macromolecule is in the range of from about 15 to about 35.  
     
     
         51 . The process defined in  claim 36 , wherein the active hydrogen functionality in the macromolecule is in the range of from about 20 to about 30.  
     
     
         52 . The process defined in  claim 36 , wherein from about 15% to about 50% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.  
     
     
         53 . The process defined in  claim 36 , wherein from about 15% to about 40% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.  
     
     
         54 . The process defined in  claim 36 , wherein the macromolecule has an inherently branched structure comprising at least one of an ester moiety, an ether moiety, an amine moiety, an amide moiety and any mixtures thereof.  
     
     
         55 . The process defined in  claim 36 , wherein the macromolecule has an inherently branched structure comprising primarily an ester moiety, optionally combined with an ether moiety.  
     
     
         56 . The process defined in  claim 36 , wherein the macromolecule has an inherently branched structure comprising primarily an ether moiety, optionally combined with an ester moiety.  
     
     
         57 . The process defined in  claim 36 , wherein the macromolecule has an inherently branched structure comprising primarily an ester moiety, optionally combined with an ether moiety.  
     
     
         58 . The process defined in  claim 54 , wherein the macromolecule further comprises a nucleus to which the inherently branched structure is chemically bonded.  
     
     
         59 . The process defined in  claim 54 , wherein a plurality of inherently branched structures are chemically bonded to one another.  
     
     
         60 . The process defined in  claim 54 , wherein the inherently branched structure further comprises at least one chain stopper moiety chemically bonded thereto.  
     
     
         61 . The process defined in  claim 54 , wherein the inherently branched structure further comprises at least two different chain stopper moieties chemically bonded thereto.  
     
     
         62 . The process defined in  claim 54 , wherein the inherently branched structure further comprises at least one spacing chain extender chemically bonded thereto.  
     
     
         63 . The process defined in claim  62 , wherein the spacing chain extender is monomeric.  
     
     
         64 . The process defined in claim  62 , wherein the spacing chain extender is polymeric.  
     
     
         65 . A process for conferring loading building properties to a foamed isocyanate-based polymer derived from a mixture comprising an isocyanate, an active hydrogen-containing compound and a blowing agent comprising the step of incorporating a dendritic macromolecule in the reaction mixture; 
 wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C.