Process of making a sulfur containing foam and product obtained therefrom

Claim 2

A process for producing sulfur foam containing at least 50 weight percent sulfur, which comprises contacting and reacting molten sulfur with .001 to 1.0 g. mole acid equivalents of an organic protonic acid per 100 grams of sulfur wherein the organic protonic acid is reactive with molten sulfur so as to incorporate the organic acid with sulfur to form a sulfur-organic acid adduct containing protonic acid groups, and then contacting and reacting the protonic acid groups of the adduct with an organic polyisocyanate to obtain sulfur foam and wherein said contacting and reacting are carried out in the liquid phase.

Claim 3

A PROCESS FOR PRODUCING SULFUR FOAM CONTAINING AT LEAST 50 WEIGHT PERCENT SULFUR, WHICH COMPRISES CONTACTING AND REACTING MOLTEN SULFUR WITH .001 RO 1.0 G. MOLE ACID EQUIVALENTS OF AN ORGANIC PROTONIC ACID PER 100 GRAMS OF SULFUR WHEREIN THE ORGANIC PROTONIC ACID IS REACTIVE WITH MOLTEN SULFUR SO AS TO INCORPORATE THE ORGANIC ACID WITH SULFUR TO FORM A SULFUR-ORGANIC ACID ADDUCT CONTAINING PROTONIC ACID GROUPS, AND THEN CONTACTING AND REACTING THE PROTONIC ACID GROUPS OF THE ADDUCT WITH AN ORGANIC POLYISOCYANATE TO OBTAIN SULFUR FOAM AND WHEREIN SAID CONTACTING AND REACTING ARE CARRIED OUT IN THE LIQUID PHASE.

Claim 4

A PROCESS FOR PRODUCING SULFUR FOAM CONTAINING AT LEAST 50 WEIGHT PERCENT SULFUR, WHICH COMPRISES CONTACTING AND REACTING MOLTEN SULFUR WITH .001 RO 1.0 G. MOLE ACID EQUIVALENTS OF AN ORGANIC PROTONIC ACID PER 100 GRAMS OF SULFUR WHEREIN THE ORGANIC PROTONIC ACID IS REACTIVE WITH MOLTEN SULFUR SO AS TO INCORPORATE THE ORGANIC ACID WITH SULFUR TO FORM A SULFUR-ORGANIC ACID ADDUCT CONTAINING PROTONIC ACID GROUPS, AND THEN CONTACTING AND REACTING THE PROTONIC ACID GROUPS OF THE ADDUCT WITH AN ORGANIC POLYISOCYANATE TO OBTAIN SULFUR FOAM AND WHEREIN SAID CONTACTING AND REACTING ARE CARRIED OUT IN THE LIQUID PHASE.

Claim 5

A process in accordance with claim 1 wherein the organic acid is a carboxylic acid.

Claim 6

A process in accordance with claim 2 wherein the organic acid is an unsaturated acid, a dithio acid, or a mercapto acid.

Claim 7

A process in accordance with claim 2 wherein the organic acid is an unsaturated aliphatic carboxylic acid containing from three to 30 carbon atoms.

Claim 8

A process in accordance with claim 2 wherein the organic acid is acrylic acid.

Claim 9

A process in accordance with claim 2 wherein the polyisocyanate is an aryl isocyanate containing two or three isocyanate groups.

Claim 10

A process for producing a sulfur foam containing at least 50 weight percent sulfur, which comprises contacting and reacting molten sulfur with an organic plasticizer which is reactive with molten sulfur so as to incorporate the plasticizer with sulfur to thereby obtain a modified sulfur compound which is more plastic at a given temperature than is elemental sulfur; contacting and reacting the modified sulfur compound with .005 to .15 g. mole acid equivalents of an organic protonic acid per 100 grams of sulfur wherein the organic protonic acid is reactive with the sulfur of said compound so as to incorporate the organic acid with said compound and form a modified sulfur-organic acid adduct containing protonic acid groups; and then contacting and reacting the protonic acid groups of the adduct with an organic polyisocyanate to obtain a sulfur foam and wherein said contacting and reacting are carried out in the liquid phase.

Claim 11

A process for producing a sulfur foam containing at least 50 weight percent sulfur, which comprises contacting and reacting molten sulfur with an organic plasticizer which is reactive with molten sulfur so as to incorporate the plasticizer with sulfur to thereby obtain a modified sulfur compound which is more plastic at a given temperature than is elemental sulfur; contacting and reacting the modified sulfur compound with .005 to .15 g. mole acid equivalents of an organic protonic acid per 100 grams of sulfur wherein the organic protonic acid is reactive with the sulfur of said compound so as to incorporate the organic acid with said compound and form a modified sulfur-organic acid adduct containing protonic acid groups; and then contacting and reacting the protonic acid groups of the adduct with an organic polyisocyanate to obtain a sulfur foam and wherein said contacting and reacting are carried out in the liquid phase.

Claim 12

A process in accordance with claim 7 wherein the organic acid is a carboxylic acid.

Claim 13

A process in accordance with claim 7 wherein the organic acid is an unsaturated acid, a dithio acid or a mercapto acid.

Claim 14

A process in accordance with claim 7 wherein the organic acid is an unsaturated aliphatic carboxylic acid containing from three to 30 carbon atoms.

Claim 15

A process in accordance with claim 7 wherein the organic acid is acrylic acid.

Claim 16

A process in accordance with claim 8 wherein the plasticizer is styrene.

Claim 17

A process in accordance with claim 8 wherein the plasticizer is dicyclopentadiene.

Claim 18

A product produced by the process of claiM 1.

Claim 19

A product produced by the process of claim 4.

Claim 20

A product produced by the process of claim 8.

Claim 21

A product produced by the process of claim 1.

Claim 22

A process for producing a sulfur foam containing at least 50 weight percent sulfur, which comprises contacting and reacting molten sulfur with a plasticizer and .005 to .15 g. mole acid equivalents of an organic protonic acid per 100 grams of sulfur wherein the plasticizer and organic protonic acid are reactive with sulfur, to thereby obtain a modified sulfur-organic acid adduct containing protonic acid groups; and then contacting and reacting the protonic acid groups of the adduct with an organic polyisocyanate to obtain a sulfur foam and wherein said contacting and reacting are carried out in the liquid phase.

Claim 23

A process for producing a sulfur foam containing at least 50 weight percent sulfur, which comprises contacting and reacting molten sulfur with a plasticizer and .005 to .15 g. mole acid equivalents of an organic protonic acid per 100 grams of sulfur wherein the plasticizer and organic protonic acid are reactive with sulfur, to thereby obtain a modified sulfur-organic acid adduct containing protonic acid groups; and then contacting and reacting the protonic acid groups of the adduct with an organic polyisocyanate to obtain a sulfur foam and wherein said contacting and reacting are carried out in the liquid phase.

Claim 24

A process in accordance with claim 18 wherein the organic acid is a carboxylic acid.

Claim 25

A process in accordance with claim 18 wherein the organic acid is an unsaturated acid, a dithio acid or a mercapto acid.

Claim 26

A process in accordance with claim 18 wherein the organic acid is an unsaturated aliphatic carboxylic acid containing from 3 to 30 carbon atoms.

Claim 27

A process in accordance with claim 18 wherein the organic acid is acrylic acid.

Claim 28

A process in accordance with claim 19 wherein the plasticizer is styrene.

Claim 29

A process in accordance with claim 19 wherein the plasticizer is dicyclopentadiene.

Claim 30

A process for producing a sulfur foam containing at least 50 weight percent sulfur, which comprises contacting and reacting molten sulfur with .005 to .15 g. mole acid equivalents of an organic protonic acid per 100 grams of sulfur wherein the organic protonic acid is reactive with the sulfur so as to form a sulfur-organic acid compound and reacting the sulfur-organic acid compound with a plasticizer which is reactive with molten sulfur so as to incorporate the plasticizer with the sulfur-organic acid compound to thereby obtain a modified sulfur-organic acid adduct containing protonic acid groups, and then contacting and reacting the protonic acid groups of the adduct with an organic polyisocyanate to obtain a sulfur foam and wherein said contacting and reacting are carried out in the liquid phase.

Claim 31

A process for producing a sulfur foam containing at least 50 weight percent sulfur, which comprises contacting and reacting molten sulfur with .005 to .15 g. mole acid equivalents of an organic protonic acid per 100 grams of sulfur wherein the organic protonic acid is reactive with the sulfur so as to form a sulfur-organic acid compound and reacting the sulfur-organic acid compound with a plasticizer which is reactive with molten sulfur so as to incorporate the plasticizer with the sulfur-organic acid compound to thereby obtain a modified sulfur-organic acid adduct containing protonic acid groups, and then contacting and reacting the protonic acid groups of the adduct with an organic polyisocyanate to obtain a sulfur foam and wherein said contacting and reacting are carried out in the liquid phase.

Claim 32

A process in accordance with claim 25 wherein the organic acid is a carboxylic acid.

Claim 33

A process in accordance with claim 25 wherein the organic acid is an unsaturated acid, a dithio acid or a mercapto acid.

Claim 34

A process in accordance with claim 25 wherein the organic acid is an unsaturated aliphatic carboxylic acid containing from three to 30 carbon atoms.

Claim 35

A process in accordance with claim 25 wherein the organic acid is acrylic acid.

Claim 36

A process in accordance with claim 26 wherein the plasticizer is an aromatic compound.

Claim 37

A process in accordance with claim 30 wherein the plasticizer is styrene.

Claim 38

A process in accordance with claim 25 wherein the plasticizer is dicyclopentadiene.