Copolyester polyol resins, foamable blends comprising the same, and resultant polyisocyanurate foams

Claim 2

A hydroxyl terminated copolyester polyol resin having a functionality between about 2 and about 3 comprising the reaction product of: (i) an aromatic component selected from phthalic anhydride; phthalic acid isomers; di-lower alkanol esters of phthalic acids; di-, and tri-carbomethoxy substituted diphenyls, benzyl esters, toluenes, benzenes, or benzophenones; or mixtures thereof, and (ii) at least one aliphatic component selected from succinic, glutaric, or adipic acids, esters, anhydrides, or mixtures thereof, (iii) at least one primary hydroxyl glycol, and (iv) at least one secondary hydroxyl glycol; the mole ratios of the components being: (i) glycols to aromatic plus aliphatic component of from about 1.3 to 2:1, (ii) aliphatic component to aromatic component of from about 0.3 to 1.7:1, and (iii) primary glycol to secondary glycol being from about 0.6 to 2.5:1, where the charged mole ratios are the same as the final mole ratios since no removal of glycols is made during the reaction.

Claim 3

The copolyester polyol resin of claim 1 wherein the aromatic component is a mixture of dimethylterephthalate, monomethyl terephthalate, terephthalic acid, heavy metal salts of aromatic carboxylic acids, mono-, di-, and tri-carbomethoxy substituted diphenyls, toluenes, benzenes, benzophenones, and benzyl esters and acids.

Claim 4

The copolyester polyol resin of claim 1 wherein the aromatic component is a mixture of dimethyl orthophthalate, dimethyl isophthalate, dimethyl terephthalate, 4-carboxymethyl benzaldehyde, and related single benzene ring mono- and difunctional acids and esters.

Claim 5

The copolyester polyol resin of claim 1 wherein the aromatic component is a phthalic isomer selected from phthalic anhydride; a di-lower alkanol ester or acid of isophthalic acid; a di-lower alkanol ester or acid of terephthalic acid; or mixtures thereof.

Claim 6

The copolyester polyol resin of claim 1 wherein the aliphatic component is a blend of di-lower alkanol esters of succinic, glutaric, and adipic acid.

Claim 7

The copolyester polyol resin of claim 1 wherein the glycol component is comprised of propylene glycol and a glycol selected from ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, and polyethylene glycol 200, or mixtures thereof.

Claim 8

The copolyester polyol resin of claims 1, 2, 3, 4, 5, or 6 wherein the finished mole ratios of the components are: (i) glycols to aromatic plus aliphatic components of about 1.4 to 1.5:1, (ii) aliphatic component to aromatic component of about 1.0 to 1.5:1, and (iii) primary glycol to secondary glycol of about 1.0 to 1.5:1.

Claim 9

The copolyester polyol resin of claims 1, 2, 3, 4, 5, or 6 wherein the hydroxyl number of the polyol is between about 150 and 200.

Claim 10

The copolyester polyol resin of claims 1, 2, 3, 4, 5, or 6 wherein the Brookfield viscosity is below 10,000 centipoise at 25° C.

Claim 11

A foamable copolyester polyol blend comprising: (a) A hydroxyl terminated copolyester polyol resin having a functionality between about 2 and about 3 comprising the reaction product of: (i) at least one aromatic component selected from phthalic anhydride; phthalic acid isomers; di-lower alkanol esters of phthalic acids; mono-, di-, and tri-carbomethoxy substituted diphenyls, benzyl esters, toluenes, benzenes, benzophenones; or mixtures thereof, and (ii) at least one aliphatic component selected from succinic, glutaric, or adipic acids, esters, anhydrides, or mixtures thereof, (iii) at least one primary hydroxyl glycol, and (iv) at least one secondary hydroxyl glycol; the mole ratios of the components being: (i) glycols to aromatic plus aliphatic component of from about 1.3 to 2:1, (ii) aliphatic component to aromatic component of from about 0.3 to 1.7:1, and (iii) primary glycol to secondary glycol being from about 0.6 to 2.5:1, where the charged mole ratios are the same as the final mole ratios since no removal of glycols is made during the reaction. (b) A catalyst suitable for preparing a polyisocyanurate foam; (c) A foaming agent suitable for preparing a polyisocyanurate foam; and, optionally, (d) A surfactant suitable for controlling foam cell size and shape.

Claim 12

A foamable copolyester polyol blend comprising: (a) A hydroxyl terminated copolyester polyol resin having a functionality between about 2 and about 3 comprising the reaction product of: (i) at least one aromatic component selected from phthalic anhydride; phthalic acid isomers; di-lower alkanol esters of phthalic acids; mono-, di-, and tri-carbomethoxy substituted diphenyls, benzyl esters, toluenes, benzenes, benzophenones; or mixtures thereof, and (ii) at least one aliphatic component selected from succinic, glutaric, or adipic acids, esters, anhydrides, or mixtures thereof, (iii) at least one primary hydroxyl glycol, and (iv) at least one secondary hydroxyl glycol; the mole ratios of the components being: (i) glycols to aromatic plus aliphatic component of from about 1.3 to 2:1, (ii) aliphatic component to aromatic component of from about 0.3 to 1.7:1, and (iii) primary glycol to secondary glycol being from about 0.6 to 2.5:1, where the charged mole ratios are the same as the final mole ratios since no removal of glycols is made during the reaction. (b) A catalyst suitable for preparing a polyisocyanurate foam; (c) A foaming agent suitable for preparing a polyisocyanurate foam; and, optionally, (d) A surfactant suitable for controlling foam cell size and shape.

Claim 13

The foamable copolyester polyol blend of claim 10 wherein the hydroxyl terminated copolyester polyol resin comprises: (i) the aromatic component of claims 2, 3, or 4, (ii) the aliphatic component of claim 5, (iii) the glycols of claim 6, (iv) the respective mole ratios of claim 7, (v) the hydroxyl number of claim 8, and (vi) the viscosity of claim 9.

Claim 14

The foamable copolyester polyol blend of claim 10 wherein said foaming agent is fluorotrichloromethane and said foaming agent comprises from about 1 to 30 weight percent of the blend.

Claim 15

The foamable copolyester polyol blend of claim 10 wherein the catalyst is potassium octoate in combination with 2,4,6, tris (dimethyl aminomethyl) phenol, or a quaternary ammonium salt.

Claim 16

The foamable copolyester polyol blend of claim 10 wherein the surfactant is a polydimethylsiloxane-polyoxyalkylene block copolymer.

Claim 17

A polyisocyanurate foam comprising the reaction product of: (a) A polymethylene polyphenylisocyanate, (b) A hydroxyl terminated copolyester polyol resin having a functionality between about 2 and about 3 comprising the reaction product of: (i) an aromatic component selected from phthalic anhydride; phthalic acid isomers; di-lower alkanol esters of phthalic acids; mono-, di-, and tri-carbomethoxy substituted diphenyls, benzyl esters, toluenes, benzenes, benzophenones, or mixtures thereof, (ii) at least one aliphatic component selected from succinic, glutaric, or adipic acids, esters, anhydrides, or mixtures thereof, (iii) at least one primary hydroxyl glycol, and (iv) at least one secondary hydroxyl glycol; the mole ratios of the components being: (i) glycols to aromatic plus aliphatic component of from about 1.3 to 2:1, (ii) aliphatic component to aromatic component of from about 0.3 to 1.7:1, and (iii) primary glycol to secondary glycol being from about 0.6 to 2.5:1; where the charged mole ratios are the same as the final mole ratios since no removal of glycols is made during the reaction. (c) A catalyst suitable for preparing a polyisocyanurate foam, (d) A foaming agent suitable for preparing a polyisocyanurate foam, and, optionally, (e) A surfactant suitable for controlling foam cell size and shape.

Claim 18

A polyisocyanurate foam comprising the reaction product of: (a) A polymethylene polyphenylisocyanate, (b) A hydroxyl terminated copolyester polyol resin having a functionality between about 2 and about 3 comprising the reaction product of: (i) an aromatic component selected from phthalic anhydride; phthalic acid isomers; di-lower alkanol esters of phthalic acids; mono-, di-, and tri-carbomethoxy substituted diphenyls, benzyl esters, toluenes, benzenes, benzophenones, or mixtures thereof, (ii) at least one aliphatic component selected from succinic, glutaric, or adipic acids, esters, anhydrides, or mixtures thereof, (iii) at least one primary hydroxyl glycol, and (iv) at least one secondary hydroxyl glycol; the mole ratios of the components being: (i) glycols to aromatic plus aliphatic component of from about 1.3 to 2:1, (ii) aliphatic component to aromatic component of from about 0.3 to 1.7:1, and (iii) primary glycol to secondary glycol being from about 0.6 to 2.5:1; where the charged mole ratios are the same as the final mole ratios since no removal of glycols is made during the reaction. (c) A catalyst suitable for preparing a polyisocyanurate foam, (d) A foaming agent suitable for preparing a polyisocyanurate foam, and, optionally, (e) A surfactant suitable for controlling foam cell size and shape.

Claim 19

The polyisocyanurate foam of claim 15 wherein said polyphenylisocyanate has a functionality between about 2.1 and 3.2, and an equivalent weight between 130 and 145.

Claim 20

The polyisocyanurate foam of claim 15 wherein the hydroxyl terminated copolyester polyol resin used is the resin of claims 2, 3, 4, 5, or 6.

Claim 21

The polyisocyanurate foam of claim 15 wherein the catalyst is potassium octoate in combination with 2,4,6 tris (dimethyl aminomethyl) phenol or a quarternary ammonium salt and the surfactant is a polydimethylsiloxane-polyoxyalkylene block copolymer.

Claim 22

The polyisocyanurate foam of claims 15, 16, 17, or 18 wherein the ratio of active isocyanate groups (--NCO) to active hydroxyl (--OH) groups is between about 3.0 to about 4.5:1.

Claim 23

The polyisocyanurate foam of claims 15, 16, 17, or 18 wherein the ratio of active isocyanate groups (--NCO) to active hydroxyl (--OH) groups is between about 3.5 to 4.2:1.