Polyisocyanurate foam and laminates thereof and process for producing them

Claim 2

A foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, which is the reaction product of: A. polymethylene polyphenyl isocyanate and B. a furan resin of the formula ##STR5## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C.

Claim 3

The foam of claim 1 wherein the equivalent ratio of A:B is 2:1 to 7:1.

Claim 4

The foam of claim 1 wherein the polymethylene polyphenyl isocyanate is that of the formula ##STR6## wherein n is an integer from 1 to 8 inclusive.

Claim 5

The foam of claim 1 wherein the polymethylene polyphenyl isocyanate contains less than 30 percent by weight diphenylmethane diisocyanate based on the total weight of polymethylene polyphenyl isocyanate.

Claim 6

The foam of claim 1 wherein the polymethylene polyphenyl isocyanate has an NCO equivalent weight of 136 to 142.

Claim 7

The foam of claim 1 wherein the average value of m is such that the furan resin has a viscosity of 8,000 to 45,000 centipoises at 25° C.

Claim 8

The foam of claim 1 further comprising a blowing agent in an amount sufficient to give the resultant foam the desired bulk density between 0.5 and 10 pounds per cubic foot.

Claim 9

The foam of claim 7 wherein the blowing agent comprises from 1 to 30 weight percent of the composition.

Claim 10

The foam of claim 1 further comprising 0.1 to 20 weight percent of the total composition of catalyst.

Claim 11

The foam of claim 1 further comprising 0.05 to 4 weight percent of the total composition of surfactant.

Claim 12

A foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, which is the reaction product of: A. polymethylene polyphenyl isocyanate of the formula ##STR7## wherein n is an integer from 1 to 8 inclusive, and B. a furan resin of the formula ##STR8## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C., and the equivalent ratio of A:B is 2:1 to 7:1.

Claim 13

A foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, which is the reaction product of: A. polymethylene polyphenyl isocyanate of the formula ##STR7## wherein n is an integer from 1 to 8 inclusive, and B. a furan resin of the formula ##STR8## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C., and the equivalent ratio of A:B is 2:1 to 7:1.

Claim 14

A foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, which is the reaction product of: A. polymethylene polyphenyl isocyanate of the formula ##STR9## wherein n is an integer from 1 to 8 inclusive, and B. a furan resin comprising (i) 25 to 40 weight percent of 2,5-bis hydroxymethyl furan of the formula ##STR10## (ii) the balance of the furan resin having the formula ##STR11## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C., and wherein the equivalent ratio of A:B is 2:1 to 7:1.

Claim 15

A foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, which is the reaction product of: A. polymethylene polyphenyl isocyanate of the formula ##STR9## wherein n is an integer from 1 to 8 inclusive, and B. a furan resin comprising (i) 25 to 40 weight percent of 2,5-bis hydroxymethyl furan of the formula ##STR10## (ii) the balance of the furan resin having the formula ##STR11## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C., and wherein the equivalent ratio of A:B is 2:1 to 7:1.

Claim 16

A foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, which is the reaction product of: A. polymethylene polyphenyl isocyanate of the formula ##STR12## wherein n is an integer from 1 to 8 inclusive, wherein the polymethylene polyphenyl isocyanate contains less than 30% by weight diphenylmethane diisocyanate based on the total weight of polymethylene polyphenyl isocyanate, and wherein the polymethylene polyphenyl isocyanate has an NCO equivalent weight of 136 to 142, B. a furan resin of the formula ##STR13## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity between 8,000 and 45,000 centipoises at 25° C., C. a blowing agent comprising fluorotrichloromethane in an amount sufficient to give the resultant foam a bulk density of 1 to 5 pounds per cubic foot, D. a catalyst comprising 2,4,6-tris (dimethylaminomethyl) phenol and potassium-2-ethyl hexoate in an amount necessary to give the desired reactivity profile, comprising from 0.3 to 10 weight percent of the total composition, and E. a surfactant comprising a polydimethyl siloxanepolyoxyalkylene block copolymer, comprising from 0.1 to 2 weight percent of the composition, wherein the equivalent ratio of A:B is 3:1 to 6:1.

Claim 17

A foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, which is the reaction product of: A. polymethylene polyphenyl isocyanate of the formula ##STR12## wherein n is an integer from 1 to 8 inclusive, wherein the polymethylene polyphenyl isocyanate contains less than 30% by weight diphenylmethane diisocyanate based on the total weight of polymethylene polyphenyl isocyanate, and wherein the polymethylene polyphenyl isocyanate has an NCO equivalent weight of 136 to 142, B. a furan resin of the formula ##STR13## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity between 8,000 and 45,000 centipoises at 25° C., C. a blowing agent comprising fluorotrichloromethane in an amount sufficient to give the resultant foam a bulk density of 1 to 5 pounds per cubic foot, D. a catalyst comprising 2,4,6-tris (dimethylaminomethyl) phenol and potassium-2-ethyl hexoate in an amount necessary to give the desired reactivity profile, comprising from 0.3 to 10 weight percent of the total composition, and E. a surfactant comprising a polydimethyl siloxanepolyoxyalkylene block copolymer, comprising from 0.1 to 2 weight percent of the composition, wherein the equivalent ratio of A:B is 3:1 to 6:1.

Claim 18

A process for producing foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability tests, said process comprising the steps of: I. forming a reaction mixture of: A. polymethylene polyphenyl isocyanate, B. a furan resin of the formula ##STR14## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C., C. a blowing agent, D. a catalyst, and E. a surfactant, and then II. permitting the reaction mixture to react thereby producing the foam.

Claim 19

A process for producing foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability tests, said process comprising the steps of: I. forming a reaction mixture of: A. polymethylene polyphenyl isocyanate, B. a furan resin of the formula ##STR14## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C., C. a blowing agent, D. a catalyst, and E. a surfactant, and then II. permitting the reaction mixture to react thereby producing the foam.

Claim 20

A process for producing foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, said process comprising the steps of: I. forming a reaction mixture of: A. polymethylene polyphenyl isocyanate of the formula ##STR15## wherein n is an integer from 1 to 8 inclusive, wherein the polymethylene polyphenyl isocyanate contains less than 30% by weight diphenylmethane diisocyanate based on the total weight of polymethylene polyphenyl isocyanate, and wherein the polymethylene polyphenyl isocyanate has an NCO equivalent weight of 136 to 142, B. a furan resin of the formula ##STR16## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the value of m is such that the furan resin has a viscosity between 8,000 and 45,000 centipoises at 25° C., C. a blowing agent comprising fluorotrichloromethane in an amount sufficient to give the resultant foam a bulk density of 1 to 5 pounds per cubic foot, D. a catalyst comprising 2,4,6-tris (dimethylaminomethyl) phenol and potassium-2-ethyl hexoate in an amount necessary to give the desired reactivity profile, comprising from 0.3 to 10 weight percent of the total composition, and E. a surfactant comprising a polydimethyl siloxanepolyoxyalkylene block copolymer, comprising from 0.1 to 2 weight percent of the composition, wherein the equivalent ratio of A:B is 3:1 to 6:1, and then, II. permitting the reaction mixture to react thereby producing the foam.

Claim 21

A process for producing foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, said process comprising the steps of: I. forming a reaction mixture of: A. polymethylene polyphenyl isocyanate of the formula ##STR15## wherein n is an integer from 1 to 8 inclusive, wherein the polymethylene polyphenyl isocyanate contains less than 30% by weight diphenylmethane diisocyanate based on the total weight of polymethylene polyphenyl isocyanate, and wherein the polymethylene polyphenyl isocyanate has an NCO equivalent weight of 136 to 142, B. a furan resin of the formula ##STR16## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the value of m is such that the furan resin has a viscosity between 8,000 and 45,000 centipoises at 25° C., C. a blowing agent comprising fluorotrichloromethane in an amount sufficient to give the resultant foam a bulk density of 1 to 5 pounds per cubic foot, D. a catalyst comprising 2,4,6-tris (dimethylaminomethyl) phenol and potassium-2-ethyl hexoate in an amount necessary to give the desired reactivity profile, comprising from 0.3 to 10 weight percent of the total composition, and E. a surfactant comprising a polydimethyl siloxanepolyoxyalkylene block copolymer, comprising from 0.1 to 2 weight percent of the composition, wherein the equivalent ratio of A:B is 3:1 to 6:1, and then, II. permitting the reaction mixture to react thereby producing the foam.

Claim 22

A laminate comprising a facing sheet having fixedly attached to one surface thereof a foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, the foam being the reaction product of: A. polymethylene polyphenyl isocyanate and B. a furan resin of the formula ##STR17## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C.

Claim 23

A laminate comprising a facing sheet having fixedly attached to one surface thereof a foam characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, the foam being the reaction product of: A. polymethylene polyphenyl isocyanate and B. a furan resin of the formula ##STR17## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C.

Claim 24

A laminate comprising a foam having facing sheets fixedly attached to its upper and lower surfaces, the foam being characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, and being the reaction product of: A. polymethylene polyphenyl isocyanate and B. a furan resin of the formula ##STR18## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C.

Claim 25

A laminate comprising a foam having facing sheets fixedly attached to its upper and lower surfaces, the foam being characterized by the presence of isocyanurate groups and by a friability of no greater than 21 percent, as measured by the ASTM C-421 friability test, and being the reaction product of: A. polymethylene polyphenyl isocyanate and B. a furan resin of the formula ##STR18## wherein R is --CH 2 -- or --CH 2 --O--CH 2 --, and the average value of m is such that the furan resin has a viscosity of up to 50,000 centipoises at 25° C.