US4377645A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Dimensionally-stable polyurethane sponge and sponge-forming prepolymer
Assignee: Hampshire Chemical Corp
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Filing: 1981-10-26
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Granted: 1983-03-22
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Expires: 2001-10-26
Abstract
Abstract An MDI based polyurethane foam having cellulose foam properties is produced by mixing together an aqueous phase which can optionally contain reinforcing fibers and surfactants and a resin phase comprising a prepolymer derived from a poly(oxy C2-4 alkylene)diol, an MDI containing isocyanate product having a functionality greater than 2.0 made of a mixture of MDI and isocyanate containing derivatives of MDI, and a monomeric polyol cross-linking agent having 3 or 4 hydroxyl equivalents per mole. The preferred polyol is trimethylolpropane and the preferred diol is Carbowax 1000. The diol and the polyol, such as trimethylolpropane, are present in a mole ratio in the range of 4:1 to 8:1 while the ratio of the isocyanate equivalents to the total hydroxyl equivalents is in the range of 3:1 to 4:1. The isocyanate containing product comprises more than 50% by weight of the prepolymer and Isonate 143L is the preferred isocyanate product. The foam has a minimal swell when wet and it does not curl upon drying.
Inventors
- 👤 James L. Guthrie
- 👤 Suze E. Arquette
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 02:57
CPC Classifications
C; C08; C08G; C08G18/00; C08G18/06; C08G18/70; C08G18/72; C08G18/77; C08G18/78; C08G18/79; C08G18/797; C08G18/28; C08G18/40; C08G18/48; C08G18/4833; C08G18/65; C08G18/66; C08G18/6666; C08G18/667; C08G18/6674; C08G18/6677; C08G18/6681; C08G18/6688; C08G18/721; C08G18/725; C08G2110/00; C08G2110/0008; C08G2110/0041; C08G2110/005; C08G2110/0058; C08G2110/0083; Y; Y10; Y10S; Y10S521/00; Y10S521/901; Y10S521/905; Y10S521/914
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
172 words
A foamed sponge having minimal swell when wet and which does not curl upon drying made by mixing together and reacting an aqueous phase and a resin phase comprising a prepolymer derived from (a) a poly(oxy C 2-4 alkylene) diol having at least about 50% by weight of oxyethylene groups and a nominal number average molecular weight of about at most 1100, said diol having nominally two hydroxyl equivalents per mole, (b) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of a major amount of pure diphenylmethane diisocyanate and minor amounts of carbodiimides and trifunctional cycloadducts of diphenylmethane diisocyanate, and (c) a monomeric polyol cross-linking agent having 3 or 4 hydroxyl equivalents per mole, said isocyanate product comprising more than 50% by weight of the prepolymer, said diol and polyol cross-linking agent being present in a mole ratio in the range of 4:1 to 8:1, and the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 3:1 to 4:1.
Claim 2
Dependent Claim
172 words
A foamed sponge having minimal swell when wet and which does not curl upon drying made by mixing together and reacting an aqueous phase and a resin phase comprising a prepolymer derived from (a) a poly(oxy C 2-4 alkylene) diol having at least about 50% by weight of oxyethylene groups and a nominal number average molecular weight of about at most 1100, said diol having nominally two hydroxyl equivalents per mole, (b) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of a major amount of pure diphenylmethane diisocyanate and minor amounts of carbodiimides and trifunctional cycloadducts of diphenylmethane diisocyanate, and (c) a monomeric polyol cross-linking agent having 3 or 4 hydroxyl equivalents per mole, said isocyanate product comprising more than 50% by weight of the prepolymer, said diol and polyol cross-linking agent being present in a mole ratio in the range of 4:1 to 8:1, and the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 3:1 to 4:1.
Claim 3
Dependent Claim
38 words
A foamed sponge according to claim 1, wherein the nominal number average molecular weight of the poly(oxy C 2-4 alkylene) diol is between 600 and 1100 and the diol has at least 80% by weight of oxyethylene groups.
Claim 4
Dependent Claim
27 words
A foamed sponge according to claim 1, wherein the polyol cross-linking agent is selected from the group consisting of trimethylolpropane, trimethylolethane, glycerol, triethanolamine, pentaerythritol, and mixtures thereof.
Claim 5
Dependent Claim
14 words
A foamed sponge according to claim 3, wherein the polyol cross-linking agent is trimethylolpropane.
Claim 6
Dependent Claim
15 words
A foamed sponge according to claim 1, wherein the aqueous phase further comprises a surfactant.
Claim 7
Dependent Claim
40 words
A foamed sponge according to claim 5, wherein the surfactant is a diol made by capping poly(oxypropylene) of molecular weight of about 1750 with ethylene oxide such that the resultant liquid product contains about 20% by weight of ethylene oxide.
Claim 8
Dependent Claim
11 words
A foamed sponge according to claim 1, further comprising reinforcing fibers.
Claim 9
Dependent Claim
23 words
A foamed sponge according to claim 7, wherein the reinforcing fibers are polyester fibers of a length of about 1/2 inch or less.
Claim 10
Dependent Claim
14 words
A foamed sponge according to claim 8, further comprising a thickening or suspending agent.
Claim 11
Dependent Claim
20 words
A foamed sponge according to claim 9, wherein the thickening or suspending agent is a high molecular weight polycarboxylic acid.
Claim 12
Dependent Claim
23 words
A foamed sponge according to claim 10, wherein the polycarboxylic acid is a polyacrylic acid polymer having an approximate molecular weight of 1,250,000.
Claim 13
Dependent Claim
13 words
A foamed sponge according to claim 10, wherein the polycarboxylic acid is neutralized.
Claim 14
Dependent Claim
16 words
A foamed sponge according to claim 12, wherein the polycarboxylic acid is neutralized with ammonium hydroxide.
Claim 15
Dependent Claim
153 words
A prepolymer, for use in making a foamed sponge, comprising the reaction product of (a) a poly(oxy C 2-4 alkylene) diol having at least about 50% by weight of oxyethylene groups and a nominal number average molecular weight of about at most 1100, said diol having nominally two hydroxyl equivalents per mole, (b) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of a major amount of pure diphenylmethane diisocyanate and minor amounts of carbodiimides and trifunctional cycloadducts of diphenylmethane diisocyanate, and (c) a monomeric polyol cross-linking agent having 3 or 4 hydroxyl equivalents per mole, said isocyanate product comprising more than 50% by weight of the prepolymer, said diol and polyol cross-linking agent being present in a mole ratio in the range of 4:1 to 8:1, and the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 3:1 to 4:1.
Claim 16
Dependent Claim
153 words
A prepolymer, for use in making a foamed sponge, comprising the reaction product of (a) a poly(oxy C 2-4 alkylene) diol having at least about 50% by weight of oxyethylene groups and a nominal number average molecular weight of about at most 1100, said diol having nominally two hydroxyl equivalents per mole, (b) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of a major amount of pure diphenylmethane diisocyanate and minor amounts of carbodiimides and trifunctional cycloadducts of diphenylmethane diisocyanate, and (c) a monomeric polyol cross-linking agent having 3 or 4 hydroxyl equivalents per mole, said isocyanate product comprising more than 50% by weight of the prepolymer, said diol and polyol cross-linking agent being present in a mole ratio in the range of 4:1 to 8:1, and the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 3:1 to 4:1.
Claim 17
Dependent Claim
34 words
A prepolymer according to claim 14, wherein the molecular weight of the poly(oxy C 2-4 alkylene) diol is between 600 and 1100 and the diol has at least 80% by weight of oxyethylene groups.
Claim 18
Dependent Claim
26 words
A prepolymer according to claim 15, wherein the polyol cross-linking agent is selected from the group consisting of trimethylolpropane, trimethylolethane, glycerol, triethanolamine, pentaerythritol, and mixtures thereof.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-03-21 | 1986-09-20 | 1987-03-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-03-21 | 1990-09-20 | 1991-03-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-03-21 | 1994-09-20 | 1995-03-22 | $7700.00 | Window Closed / Lapsed |