US4411949A — Polymeric foams from transesterified by-product d…

Claim 1

Independent Claim 84 words

A polyisocyanurate foam comprising the reaction product of an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 2

Dependent Claim 84 words

A polyisocyanurate foam comprising the reaction product of an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 3

Dependent Claim 14 words

The polyisocyanurate foam of claim 1 wherein said organic polyisocyanate is a polymethylene polyphenylisocyanate.

Claim 4

Dependent Claim 30 words

The polyisocyanurate foam of claims 1 or 2 wherein said transesterifying glycol is a member selected from the group consisting of ethylene glycol, diethylene glycol, propylene glycol and dipropylene glycol.

Claim 5

Dependent Claim 13 words

The polyisocyanurate foam of claim 1 wherein said transesterifying glycol is diethylene glycol.

Claim 6

Dependent Claim 60 words

The polyisocyanurate foam of claim 1 wherein said organic polyisocyanate is a mixture of components of the formula ##STR4## wherein n is an integer from 0 to 8 inclusive, and said mixture has: (a) a functionality of 2.1 to 3.2, (b) an equivalent weight between 120 and 180, and (c) a viscosity at 25° C. between 150 and 2500 centipoises.

Claim 7

Dependent Claim 21 words

The polyisocyanurate foam of claim 1 wherein said transesterifying glycol is an aliphatic dihydric alcohol having 2 to 16 carbon atoms.

Claim 8

Dependent Claim 98 words

The polyisocyanurate foam of claim 1 wherein said by-product fraction from the manufacture of dimethyl terephthalate comprises a mixture of (a) about 40 to 60 percent by weight of dimethyl terephthalate, (b) about 1 to 10 percent by weight of monomethyl terephthalate, (c) about 1 to 2 percent by weight of terephthalic acid, (d) about 10 to 25 percent by weight of bi-ring esters, (e) about 5 to 12 percent by weight of organic acid salts, (f) about 18 to 25 percent by weight of polymeric materials, and (g) about 1 to 4 percent by weight of ash.

Claim 9

Dependent Claim 20 words

The polyisocyanurate foam of claims 1, 2 or 6 wherein said polyol mixture includes glycol added after the transesterification reaction.

Claim 10

Dependent Claim 26 words

The polyisocyanurate foam of claims 1, 2 or 6 wherein the equivalent ratio of said organic polyisocyanate to said polyol mixture is about 1.5:1 to 6:1.

Claim 11

Dependent Claim 24 words

The polyisocyanurate foam of claim 9 wherein said transesterifying glycol is a member selected from the group consisting of ethylene glycol and diethylene glycol.

Claim 12

Dependent Claim 70 words

The polyisocyanurate foam of claim 10 wherein said transesterifying glycol is diethylene glycol and said polyol mixture is characterized by a viscosity in cps at 25° C. of about 700 to 2500, a free diethylene glycol content of from about 10 to 30 percent by weight of said mixture, a hydroxyl number within a range of from about 350 to 468, and an acid number of about 0.2 to 10.

Claim 13

Dependent Claim 97 words

The polyisocyanurate foam of claim 1 which comprises the reaction product of a polymethylene polyphenylisocyanate, a fluorocarbon blowing agent, a trimerization catalyst, and a polyol mixture prepared by the transesterification, with ethylene glycol or diethylene glycol, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 40 to 60 weight percent of dimethyl terephthalate, and about 60 to 40 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials, and the equivalent ratio of said polymethylene polyphenylisocyanate to said polyol mixture being about 1.5:1 to 6:1.

Claim 14

Dependent Claim 70 words

The polyisocyanurate foam of claim 12 wherein said transesterifying glycol is diethylene glycol and said polyol mixture is characterized by a viscosity in cps at 25° C. of about 700 to 2500, a free diethylene glycol content of from about 10 to 30 percent by weight of said mixture, a hydroxyl number within a range of from about 350 to 468, and an acid number of about 0.2 to 10.

Claim 15

Dependent Claim 25 words

The polyisocyanurate foam of claims 12 or 13 wherein said trimerization catalyst comprises a mixture of a tertiary amino phenol and an alkali metal carboxylate.

Claim 16

Dependent Claim 28 words

The polyisocyanurate foam of claim 14 wherein said trimerization catalyst comprises a mixture of 2,4,6-tris(dimethylaminomethyl) phenol and potassium-2-ethyl hexoate in an equivalent ratio of about 0.4:1 to 2.5:1.

Claim 17

Dependent Claim 89 words

A process for producing a polyisocyanurate foam comprising reacting together under foam-forming conditions an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 18

Dependent Claim 89 words

A process for producing a polyisocyanurate foam comprising reacting together under foam-forming conditions an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 19

Dependent Claim 95 words

A laminate comprising at least one facing sheet adhered to a polyisocyanurate foam which comprises the reaction product of an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 20

Dependent Claim 95 words

A laminate comprising at least one facing sheet adhered to a polyisocyanurate foam which comprises the reaction product of an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 21

Dependent Claim 14 words

The laminate of claim 17 wherein said polyisocyanurate foam is reinforced by glass fibers.

Claim 22

Dependent Claim 100 words

A process for producing a laminate comprising (a) contacting a facing sheet with a polyisocyanurate foam-forming mixture comprising an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials, and (b) foaming said foam-forming mixture.

Claim 23

Dependent Claim 100 words

A process for producing a laminate comprising (a) contacting a facing sheet with a polyisocyanurate foam-forming mixture comprising an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials, and (b) foaming said foam-forming mixture.

Claim 24

Dependent Claim 98 words

In a polyurethane foam which comprises the reaction product of an organic polyisocyanate, a blowing agent, a catalyst and a polyol, the improvement comprising about 20 to 50 percent of the weight of said polyol being a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 25

Dependent Claim 98 words

In a polyurethane foam which comprises the reaction product of an organic polyisocyanate, a blowing agent, a catalyst and a polyol, the improvement comprising about 20 to 50 percent of the weight of said polyol being a polyol mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 26

Dependent Claim 64 words

A polyol mixture comprising the reaction product obtained by transesterifying, with a glycol of molecular weight from about 60 to 400, a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 27

Dependent Claim 64 words

A polyol mixture comprising the reaction product obtained by transesterifying, with a glycol of molecular weight from about 60 to 400, a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials.

Claim 28

Dependent Claim 13 words

The polyisocyanurate foam of claim 1 wherein said blowing agent is a halohydrocarbon.

Claim 29

Dependent Claim 12 words

The laminate of claim 17 wherein said blowing agent is a halohydrocarbon.

Claim 30

Dependent Claim 28 words

The polyol mixture of claim 21 wherein said transesterifying glycol is a member selected from the group consisting of ethylene glycol, diethylene glycol, propylene glycol and dipropylene glycol.

Claim 31

Dependent Claim 13 words

The polyol mixture of claim 21 wherein said transesterifying glycol is diethylene glycol.

Claim 32

Dependent Claim 17 words

The polyol mixture of claim 21 wherein said polyol mixture includes glycol added after the transesterification reaction.

Claim 33

Dependent Claim 70 words

The polyol mixture of claim 21 wherein said transesterifying glycol is diethylene glycol and said polyol mixture is characterized by a viscosity in cps at 25° C. of about 700 to 2500, a free diethylene glycol content of from about 10 to 30 percent by weight of said mixture, a hydroxyl number within a range of from about 350 to 468, and an acid number of about 0.2 to 10.

Claim 34

Dependent Claim 21 words

The polyol mixture of claim 21 wherein said transesterifying glycol is an aliphatic dihydric alcohol having 2 to 16 carbon atoms.

Claim 35

Dependent Claim 98 words

The polyol mixture of claim 28 wherein said by-product fraction from the manufacture of dimethyl terephthalate comprises a mixture of (a) about 40 to 60 percent by weight of dimethyl terephthalate, (b) about 1 to 10 percent by weight of monomethyl terephthalate, (c) about 1 to 2 percent by weight of terephthalic acid, (d) about 10 to 25 percent by weight of bi-ring esters, (e) about 5 to 12 percent by weight of organic acid salts, (f) about 18 to 25 percent by weight of polymeric materials, and (g) about 1 to 4 percent by weight of ash.

Claim 36

Dependent Claim 24 words

The polyol mixture of claim 29 wherein said transesterifying glycol is a member selected from the group consisting of ethylene glycol and diethylene glycol.

Claim 37

Dependent Claim 70 words

The polyol mixture of claim 30 wherein said transesterifying glycol is diethylene glycol and said polyol mixture is characterized by a viscosity in cps at 25° C. of about 700 to 2500, a free diethylene glycol content of from about 10 to 30 percent by weight of said mixture, a hydroxyl number within a range of from about 350 to 468, and an acid number of about 0.2 to 10.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1986-10-24	1987-04-25	1987-10-25	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1990-10-24	1991-04-25	1991-10-25	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1994-10-24	1995-04-25	1995-10-25	$7700.00	Window Closed / Lapsed

Polymeric foams from transesterified by-product derived from manufacture of dimethyl terephthalate and laminates therefrom

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