Polyisocyanurate foam and process therefor

Claim 2

A process for producing a polyisocyanurate foam comprising: (I) admixing: (A) a polymethylene polyphenylisocyanate; (B) a polyol having the formula: ##STR1## wherein m is 0 or 1, R is hydrogen, hydroxyl, lower alkyl or a radical having the formula: H--OCH.sub.2 CH.sub.2).sub.d OCH.sub.2 --, the sum of a+b+c+d is between 2.0 and 8.0, and the equivalent ratio of A:B is 2:1 to 6:1; (C) a catalyst; (D) a blowing agent; and (E) a surfactant; and (II) recovering the polyisocyanurate foam.

Claim 3

The process of claim 1 wherein the polyol has the formula: ##STR2## wherein m is 0 or 1, R is hydrogen, lower alkyl, or a radical having the formula: H--OCH.sub.2 CH.sub.2).sub.d4 OCH.sub.2 --, and the sum of a+b+c+d is between 2.0 and 8.0.

Claim 4

The process of claim 2 wherein the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated trimethylol ethane, ethoxylated pentaerythritol and ethoxylated glycerin.

Claim 5

The process of claim 2 wherein the polymethylene polyphenylisocyanate is a mixture of polyisocyanates having the formula: ##STR3## wherein the mixture has: (a) a functionality of 2.1 to 3.2, (b) an equivalent weight between 120 and 180, (c) a viscosity at 25° C. between 150 and 2500 centipoises, and (d) n is an integer from 0 to 8 inclusive.

Claim 6

The process of claim 4 wherein the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated trimethylol ethane, ethoxylated pentaerythritol and ethoxylated glycerin.

Claim 7

The process of claim 4 wherein the polyol is ethoxylated trimethylol propane.

Claim 8

The process of claim 2 or 5 wherein the polyol has an equivalent weight of 60 to 170.

Claim 9

The process of claim 7 wherein the polyol has an equivalent weight of 75 to 125.

Claim 10

The process of claim 8 wherein the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated pentaerythritol and ethoxylated glycerin.

Claim 11

The process of claim 8 wherein the polyol is ethoxylated trimethylol propane.

Claim 12

The process of claim 1 for producing a polyisocyanurate foam comprising: (I) admixing: (A) a polymethylene polyphenylisocyanate which is a mixture of polyisocyanates having the formula: ##STR4## wherein the mixture has: (a) a functionality of 2.1 to 3.2, (b) an equivalent weight between 120 and 180, (c) a viscosity at 25° between 150 and 2500 centipoises, and (d) n is an integer from 0 to 8 inclusive; (B) a polyol which is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated trimethylol ethane, ethoxylated pentaerythritol and ethoxylated glycerin and has an equivalent weight of 75 to 125; (C) a catalyst; (D) a blowing agent; and (E) a surfactant; wherein the equivalent ratio of A:B is 2:1 to 6:1, C comprises from 1 to 5 weight percent of the reaction mixture, D comprises 5 to 20 weight percent of the reaction mixture, and E comprises 0.1 to 2 weight percent of the reaction mixture; and (II) recovering the polyisocyanurate foam.

Claim 13

The process of claim 4 or 11 wherein: (A) the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated pentaerythritol and ethoxylated glycerin and has an equivalent weight of 75 to 125; (B) the catalyst is a mixture of 2,4,6-tris(dimethylaminomethyl) phenol and potassium octoate; (C) the blowing agent is trichlorofluoromethane; and (D) the surfactant is a silicone surfactant.

Claim 14

The process of claim 12 wherein the polyol is ethoxylated trimethylol propane.

Claim 15

A polyisocyanurate foam which is the reaction product of: (A) a polymethylene polyphenylisocyanate; (B) a polyol having the formula: ##STR5## wherein m is 0 or 1, R is hydrogen, hydroxyl, lower alkyl or a radical having the formula: H--OCH.sub.2 CH.sub.2).sub.d OCH.sub.2 --, the sum of a+b+c+d is between 2.0 and 8.0, and the equivalent ratio of A:B is 2:1 to 6:1; (C) a catalyst; (D) a blowing agent; and (E) a surfactant.

Claim 16

A polyisocyanurate foam which is the reaction product of: (A) a polymethylene polyphenylisocyanate; (B) a polyol having the formula: ##STR5## wherein m is 0 or 1, R is hydrogen, hydroxyl, lower alkyl or a radical having the formula: H--OCH.sub.2 CH.sub.2).sub.d OCH.sub.2 --, the sum of a+b+c+d is between 2.0 and 8.0, and the equivalent ratio of A:B is 2:1 to 6:1; (C) a catalyst; (D) a blowing agent; and (E) a surfactant.

Claim 17

The polyisocyanurate foam of claim 14 wherein the polyol has the formula: ##STR6## wherein m is 0 or 1, R is hydrogen, lower alkyl, or a radical having the formula: H--OCH.sub.2 CH.sub.2).sub.d OCH.sub.2 --, and the sum of a+b+c+d is between 2.0 and 8.0.

Claim 18

The polyisocyanurate foam of claim 15 wherein the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated trimethylol ethane, ethoxylated pentaerythritol and ethoxylated glycerin.

Claim 19

The polyisocyanurate foam of claim 15 wherein the polymethylene polyphenylisocyanate is a mixture of polyisocyanates having the formula: ##STR7## wherein the mixture has: (a) a functionality of 2.1 to 3.2, (b) an equivalent weight between 120 and 180, (c) a viscosity at 25° C. between 150 and 2500 centipoises, and (d) n is an integer from 0 to 8 inclusive.

Claim 20

The polyisocyanurate foam of claim 17 wherein the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated trimethylol ethane, ethoxylated pentaerythritol and ethoxylated glycerin.

Claim 21

The polyisocyanurate foam of claim 17 wherein the polyol is ethoxylated trimethylol propane.

Claim 22

The polyisocyanurate foam of claim 15 or 18 wherein the polyol has an equivalent weight of 60 to 170.

Claim 23

The polyisocyanurate foam of claim 20 wherein the polyol has an equivalent weight of 75 to 125.

Claim 24

The polyisocyanurate foam of claim 21 wherein the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated pentaerythritol and ethoxylated glycerin.

Claim 25

The polyisocyanurate foam of claim 21 wherein the polyol is ethoxylated trimethylol propane.

Claim 26

The polyisocyanurate foam of claim 14 which is the reaction product of: (A) a polymethylene polyphenylisocyanate which is a mixture of polyisocyanates having the formula: ##STR8## wherein the mixture has: (a) a functionality of 2.1 to 3.2, (b) an equivalent weight between 120 and 180, (c) a viscosity at 25° between 150 and 2500 centipoises, and (d) n is an integer from 0 to 8 inclusive; (B) a polyol which is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated trimethylol ethane, ethoxylated pentaerythritol and ethoxylated glycerin and has an equivalent weight of 75 to 125; (C) a catalyst; (D) a blowing agent; and (E) a surfactant; wherein the equivalent ratio of A:B is 2:1 to 6:1, C comprises from 1 to 5 weight percent of the reaction mixture, D comprises 5 to 20 weight percent of the reaction mixture, and E comprises 0.1 to 2 weight percent of the reaction mixture.

Claim 27

The polyisocyanurate foam of claim 17 or 24 wherein: (A) the polyol is a member selected from the group consisting of ethoxylated trimethylol propane, ethoxylated pentaerythritol and ethoxylated glycerin and has an equivalent weight of 75 to 125; (B) the catalyst is a mixture of 2,4,6-tris(dimethylaminomethyl) phenol and potassium octoate; (C) the blowing agent is trichlorofluoromethane; and (D) the surfactant is a silicone surfactant.

Claim 28

The polyisocyanurate foam of claim 25 wherein the polyol is ethoxylated trimethylol propane.