US4458038A
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Process for the preparation of white graft polymer dispersions and flame-retardant polyurethane foams
Assignee: BASF Corp
•
Filing: 1983-03-03
•
Granted: 1984-07-03
•
Expires: 2003-03-03
Abstract
Abstract White graft polymer dispersions in polyoxyalkylene polyether polyols are employed together with flame retardant compounds to prepare flame retardant polyurethane foams. The polymer dispersions employ less than 0.1 mole of induced unsaturation per mole of polyol mixture. Improved processes for the preparation of these polymer dispersions employ either maleate or fumarate derived polyetherester polyols or polyetherester polyols prepared by reacting a polyoxyalkylene polyether polyol with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and an alkylene oxide in the presence of salts and oxides of divalent metals.
Inventors
- 👤 Gerhard G. Ramlow
- 👤 Duane A. Heyman
- 👤 Oscar M. Grace
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 17:00
CPC Classifications
C; C08; C08G; C08G63/00; C08G63/66; C08G63/668; C08G63/676; C08F; C08F283/00; C08F283/06; C08F291/00; C08F291/06; C08F291/08; C08F299/00; C08F299/02; C08F299/022; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/63; C08G18/635
Claims Analysis
Total Claims: 66
Claim 1
Independent Claim
146 words
A white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers, in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol having an equivalent weight from 100 to 10,000, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol having an equivalent weight from 100 to 10,000 with a compound selected from the group consisting of maleic acid, maleic anhydride, and fumaric acid, wherein the polyol mixture contains from 0.001 to 0.09 mole of induced unsaturation per mole of polyol mixture.
Claim 2
Dependent Claim
146 words
A white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers, in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol having an equivalent weight from 100 to 10,000, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol having an equivalent weight from 100 to 10,000 with a compound selected from the group consisting of maleic acid, maleic anhydride, and fumaric acid, wherein the polyol mixture contains from 0.001 to 0.09 mole of induced unsaturation per mole of polyol mixture.
Claim 3
Dependent Claim
36 words
The polymer dispersion of claim 1 wherein the monomer is selected from the group consisting of at least 50 weight percent styrene, and the remainder selected from methylstyrene, vinyl toluene, methyl methacrylate, methacrylonitrile, divinylbenzene and acrylonitrile.
Claim 4
Dependent Claim
22 words
The polymer dispersion of claim 1 wherein the monomer consists of styrene and acrylonitrile in the weight ratio of 9:1 to 1.05:0.95.
Claim 5
Dependent Claim
11 words
The polymer dispersion of claim 1 wherein the monomer is styrene.
Claim 6
Dependent Claim
18 words
The polymer dispersion of claim 1 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 7
Dependent Claim
28 words
The polymer dispersion of claim 5 wherein the chain transfer agent is selected from the group consisting of dodecanethiol, bromotrichloromethane, 2-butanol, 1-butanol, allyl alcohol, 2-mercaptoethanol and octadecyl mercaptan.
Claim 8
Dependent Claim
18 words
The polymer dispersion of claim 2 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 9
Dependent Claim
18 words
The polymer dispersion of claim 3 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 10
Dependent Claim
18 words
The polymer dispersion of claim 4 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 11
Dependent Claim
31 words
The polymer dispersion of claim 5 wherein the concentration of chain transfer agent is from about 0.1 weight percent to about 5 weight percent based on the weight of the monomer.
Claim 12
Dependent Claim
136 words
A process for the preparation of a white, stable, low viscosity graft polymer dispersion which comprises (a) a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid, (b) polymerizing an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers, in the presence of a free radical initiator in, from about 25 to about 75 weight percent based on the total weight of the dispersion, said polyol mixture, wherein the polyol mixture has an induced unsaturation from 0.001 to 0.09 mole per mole of polyol mixture.
Claim 13
Dependent Claim
136 words
A process for the preparation of a white, stable, low viscosity graft polymer dispersion which comprises (a) a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid, (b) polymerizing an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers, in the presence of a free radical initiator in, from about 25 to about 75 weight percent based on the total weight of the dispersion, said polyol mixture, wherein the polyol mixture has an induced unsaturation from 0.001 to 0.09 mole per mole of polyol mixture.
Claim 14
Dependent Claim
35 words
The process of claim 11 wherein the monomer is selected from the group consisting of at least 50 weight percent styrene, and the remainder selected from methylstyrene, vinyl toluene, methyl methacrylate, methacrylonitrile, divinylbenzene and acrylonitrile.
Claim 15
Dependent Claim
22 words
The process of claim 11 wherein the monomer mixture consists of styrene and acrylonitrile in the weight ratio of 9:1 to 1.05:0.95.
Claim 16
Dependent Claim
10 words
The process of claim 11 wherein the monomer is styrene.
Claim 17
Dependent Claim
17 words
The process of claim 5 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 18
Dependent Claim
33 words
The process of claim 11 wherein the polymerization occurs in the presence of a chain transfer agent selected from the group consisting of dodecanethiol, bromotrichloromethane, 2-butanol, 1-butanol, allyl alcohol, 2-mercaptoethanol and octadecyl mercaptan.
Claim 19
Dependent Claim
17 words
The process of claim 14 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 20
Dependent Claim
33 words
The process of claim 12 wherein the polymerization occurs in the presence of a chain transfer agent selected from the group consisting of dodecanethiol, bromotrichloromethane, 2-butanol, 1-butanol, allyl alcohol, 2-mercaptoethanol and octadecyl mercaptan.
Claim 21
Dependent Claim
17 words
The process of claim 13 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 22
Dependent Claim
33 words
The process of claim 14 wherein the polymerization occurs in the presence of a chain transfer agent selected from the group consisting of dodecanethiol, bromotrichloromethane, 2-butanol, 1-butanol, allyl alcohol, 2-mercaptoethanol and octadecyl mercaptan.
Claim 23
Dependent Claim
33 words
A polyurethane foam prepared by reacting the (a) polymer dispersion of claim 2, (b) an organic polyisocyanate, (c) a blowing agent, (d) a urethane forming catalyst, (e) foam stabilizers, and (f) flame retardants.
Claim 24
Dependent Claim
33 words
A polyurethane foam prepared by reacting the (a) polymer dispersion of claim 3, (b) an organic polyisocyanate, (c) a blowing agent, (d) a urethane forming catalyst, (e) foam stabilizers, and (f) flame retardants.
Claim 25
Dependent Claim
33 words
A polyurethane foam prepared by reacting the (a) polymer dispersion of claim 4, (b) an organic polyisocyanate (c) a blowing agent, (d) a urethane forming catalyst, (e) form stabilizers, and (f) flame retardants.
Claim 26
Dependent Claim
33 words
A polyurethane foam prepared by reacting the (a) polymer dispersion of claim 5, (b) an organic polyisocyanate, (c) a blowing agent, (d) a urethane forming catalyst, (e) foam stabilizers, and (f) flame retardants.
Claim 27
Dependent Claim
33 words
A polyurethane foam prepared by reacting the (a) polymer dispersion of claim 6, (b) an organic polyisocyanate, (c) a blowing agent, (d) a urethane forming catalyst, (e) foam stabilizers, and (f) flame retardants.
Claim 28
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer dispersion of claim 2, (b) an organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
Claim 29
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer dispersion of claim 3, (b) an organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
Claim 30
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer dispersion of claim 4, (b) an organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
Claim 31
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer dispersion of claim 5, (b) an organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
Claim 32
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer despersion of claim 6, (b) and organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
Claim 33
Dependent Claim
33 words
A polyurethane foam prepared by reacting the (a) polymer dispersion of claim 1, (b) an organic polyisocyanate, (c) a blowing agent, (d) a urethane forming catalyst, (e) foam stabilizers, and (f) flame retardants.
Claim 34
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer dispersion of claim 1, (b) an organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
Claim 35
Dependent Claim
139 words
A white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid, and optionally an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced isomerized fumarate unsaturation per mole of polyol mixture.
Claim 36
Dependent Claim
139 words
A white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid, and optionally an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced isomerized fumarate unsaturation per mole of polyol mixture.
Claim 37
Dependent Claim
36 words
The polymer dispersion of claim 33 wherein the monomer is selected from the group consisting of at least 50 weight percent styrene, and the remainder selected from methylstyrene, vinyl toluene, methyl methacrylate, methacrylonitrile, divinylbenzene and acrylonitrile.
Claim 38
Dependent Claim
23 words
The polymer dispersion of claim 33 wherein the monomer mixture consists of styrene and acrylonitrile in the weight ratio of 9:1 to 1.05:0.95.
Claim 39
Dependent Claim
18 words
The polymer dispersion of claim 33 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 40
Dependent Claim
31 words
The polymer dispersion of claim 33 wherein the concentration of chain transfer agent is from about 0.1 weight percent to about 5 weight percent based on the weight of the monomer.
Claim 41
Dependent Claim
28 words
The polymer dispersion of claim 33 wherein the chain transfer agent is selected from the group consisting of dodecanethiol, bromotrichloromethane, 2-butanol, 1-butanol, allyl alcohol, 2-mercaptoethanol and octadecyl mercaptan.
Claim 42
Dependent Claim
165 words
A white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and optionally an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced unsaturation per mole of polyol mixture and wherein the macromer is prepared in the presence of an effective amount of a catalyst selected from the group consisting of salts and oxides of divalent metals.
Claim 43
Dependent Claim
165 words
A white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and optionally an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced unsaturation per mole of polyol mixture and wherein the macromer is prepared in the presence of an effective amount of a catalyst selected from the group consisting of salts and oxides of divalent metals.
Claim 44
Dependent Claim
36 words
The polymer dispersion of claim 39 wherein the monomer is selected from the group consisting of at least 50 weight percent styrene, and the remainder selected from methylstyrene, vinyl toluene, methyl methacrylate, methacrylonitrile, divinylbenzene and acrylonitrile.
Claim 45
Dependent Claim
23 words
The polymer dispersion of claim 39 wherein the monomer mixture consists of styrene and acrylonitrile in the weight ratio of 9:1 to 1.05:0.95.
Claim 46
Dependent Claim
18 words
The polymer dispersion of claim 39 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 47
Dependent Claim
31 words
The polymer dispersion of claim 39 wherein the concentration of chain transfer agent is from about 0.1 weight percent to about 5 weight percent based on the weight of the monomer.
Claim 48
Dependent Claim
29 words
The polymer dispersion of claim 39 wherein the chain transfer agent is selected from the group consisting of dodecanethiol, bromotrichloromethane, 2-butanol, bromochloromethane, 1-butanol, allyl alcohol, 2-mercaptoethanol and octadecyl mercaptan.
Claim 49
Dependent Claim
145 words
A process for the preparation of a white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and optionally an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced isomerized fumarate unsaturation per mole of polyol mixture.
Claim 50
Dependent Claim
145 words
A process for the preparation of a white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and optionally an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced isomerized fumarate unsaturation per mole of polyol mixture.
Claim 51
Dependent Claim
35 words
The process of claim 45 wherein in the monomer is selected the group consisting of at least 50 weight percent styrene, and the remainder selected from methylstyrene, vinyl toluene, methyl methacrylate, methacrylonitrile, divinylbenzene and acrylonitrile.
Claim 52
Dependent Claim
22 words
The process of claim 45 wherein the monomer mixture consists of styrene and acrylonitrile in the weight ratio of 9:1 to 1.05:0.95.
Claim 53
Dependent Claim
17 words
The process of claim 45 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 54
Dependent Claim
30 words
The process of claim 45 wherein the concentration of chain transfer agent is from about 0.1 weight percent to about 5 weight percent based on the weight of the monomer.
Claim 55
Dependent Claim
10 words
The process of claim 45 wherein the monomer is styrene.
Claim 56
Dependent Claim
169 words
A process for the preparation of a white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced unsaturation per mole of polyol mixture and the macromer is prepared in the presence of an effective amount of a catalyst selected from the group consisting of salts and oxides of divalent metals.
Claim 57
Dependent Claim
169 words
A process for the preparation of a white, stable low viscosity graft polymer dispersion formed by polymerizing in the presence of a free radical initiator (a) an ethylenically unsaturated monomer or mixture of monomers provided that in the mixture of monomers the concentration of acrylonitrile or methacrylonitrile is less than 50 weight percent of the weight of monomers in (b) from about 25 to about 75 weight percent based on the total weight of the dispersion, a polyol mixture comprising (1) a polyoxyalkylene polyether polyol, (2) a macromer containing induced unsaturation consisting essentially of the reaction product of a polyoxyalkylene polyether polyol, with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and an alkylene oxide wherein the polyol mixture has an unsaturation from 0.001 to 0.09 mole of induced unsaturation per mole of polyol mixture and the macromer is prepared in the presence of an effective amount of a catalyst selected from the group consisting of salts and oxides of divalent metals.
Claim 58
Dependent Claim
31 words
The process of claim 51 wherein the monomer is selected from the group consisting of at least 50 weight percent styrene, and methylstyrene, vinyl toluene, methyl methacrylate, methacrylonitrile, divinylbenzene and acrylonitrile.
Claim 59
Dependent Claim
21 words
The process of claim 51 the monomer mixture consists of styrene and acrylonitrile in the weight ratio of 9:1 to 1.05:0.95.
Claim 60
Dependent Claim
17 words
The process of claim 51 wherein the polymerization occurs in the presence of a chain transfer agent.
Claim 61
Dependent Claim
30 words
The process of claim 51 wherein the concentration of chain transfer agent is from about 0.1 weight percent to about 5 weight percent based on the weight of the monomer.
Claim 62
Dependent Claim
27 words
The process of claim 51 wherein the chain transfer agent is selected from the group consisting of dodecanethiol, bromotrichloromethane, 2-butanol, 1-butanol, allyl alcohol, 2-mercaptoethanol and octadecyl mercaptan.
Claim 63
Dependent Claim
33 words
A polyurethane foam, prepared by reacting the (a) polymer dispersion of claim 33, (b) an organic polyisocyanate, (c) a blowing agent, (d) a urethane forming catalyst, (e) foam stabilizers, and (f) flame retardants.
Claim 64
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer dispersion of claim 33, (b) an organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
Claim 65
Dependent Claim
32 words
A polyurethane foam prepared by reacting the polymer dispersion of claim 39 (b) an organic polyisocyanate, (c) a blowing agent, (d) a urethane forming catalyst, (e) foam stabilizers, and (f) flame retardants.
Claim 66
Dependent Claim
29 words
A polyurethane elastomer prepared by reacting the (a) polymer dispersion of claim 39, (b) an organic polyisocyanate, (c) a urethane forming catalyst, (d) foam stabilizers, and (e) flame retardants.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1987-07-03 | 1988-01-02 | 1988-07-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-07-03 | 1992-01-02 | 1992-07-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-07-03 | 1996-01-02 | 1996-07-03 | $7700.00 | Window Closed / Lapsed |