Modified Mannich condensates and manufacture of rigid polyurethane foam with alkoxylation products thereof

Claim 1

An alkoxylation product of a Mannich condensate prepared by reacting a phenolic component with 1 to 3 mols of formaldehyde and 1 to 3 mols of an amine mixture per mol of said phenolic component and thereafter reacting said Mannich condensate with from about 20 to about 50 wt.% of an alkylene oxide component, said phenolic component comprising phenol or a phenol substituted with an alkyl group containing 1 to 12 carbon atoms, said amine mixture consisting of about 90 to 99 mol percent of diethanolamine and, correspondingly, about 10 to 1 mol percent of melamine, said alkylene oxide component comprising from 90 to 100 wt.% of propylene oxide and, correspondingly, from 0 to 10 wt. percent of ethylene oxide.

Claim 5

A method of preparing a polyol composition which comprises preparing a Mannich condensate by reacting a phenolic component with formaldehyde and an amine mixture in the molar ratio of about 1 to about 3 mols of formaldehyde and from about 1 to about 3 mols of amine mixture per mol of said phenolic component, while removing by-product water of reaction, and thereafter reacting the said Mannich condensate with from about 20 to about 50 wt.% of an alkylene oxide component comprising from 100 to about 90 wt.% of propylene oxide and from 0 to about 10 wt.% of ethylene oxide, said amine mixture consisting of about 90 to about 99 mol percent of diethanolamine and from about 10 to about 1 mol percent of melamine, said phenolic component comprising phenol or an alkylphenol having an alkyl group containing 1 to 12 carbon atoms.

Claim 6

A method of preparing a polyol composition which comprises preparing a Mannich condensate by reacting a phenolic component with formaldehyde and an amine mixture in the molar ratio of about 1 to about 3 mols of formaldehyde and from about 1 to about 3 mols of amine mixture per mol of said phenolic component, while removing by-product water of reaction, and thereafter reacting the said Mannich condensate with from about 20 to about 50 wt.% of an alkylene oxide component comprising from 100 to about 90 wt.% of propylene oxide and from 0 to about 10 wt.% of ethylene oxide, said amine mixture consisting of about 90 to about 99 mol percent of diethanolamine and from about 10 to about 1 mol percent of melamine, said phenolic component comprising phenol or an alkylphenol having an alkyl group containing 1 to 12 carbon atoms.

Claim 9

A method of preparing a rigid polyurethane foam composition having improved fire retardancy properties which comprises: reacting an excess of an aromatic polyisocyanate with a polyol component in the presence of a catalyst, a blowing agent, a surfactant and a fire retardant; said polyol component comprising 100 to about 40 wt.% of an alkoxylation product of an alkylene oxide component and a Mannich condensate component, said alkoxylation product having a hydroxyl number of about 400 to about 550 and, correspondingly, from 0 to about 60 wt.% of a condensate of an initiator having 2 to 6 carbon atoms with an alkylene oxide component, said condensate having a hydroxyl number of about 200 to about 800; said Mannich Condensate Component having been prepared by reacting a phenolic component with formaldehyde and an amine mixture in the molar ratio of about 1 to about 3 mols of formaldehyde and about 1 to about 3 mols of said amine mixture per mol of phenolic component said amine mixture consisting of 90 to 99 mol percent of diethanolamine and, correspondingly, from 10 to 1 mol percent of melamine; said phenolic component comprising phenol or phenol substituted with an alkyl group constaining 1 to 12 carbon atoms, said alkylene oxide component comprising 100 to about 90 wt.% of propylene oxide and, correspondingly, from 0 to about 10 wt.% of ethylene oxide.

Claim 10

A method of preparing a rigid polyurethane foam composition having improved fire retardancy properties which comprises: reacting an excess of an aromatic polyisocyanate with a polyol component in the presence of a catalyst, a blowing agent, a surfactant and a fire retardant; said polyol component comprising 100 to about 40 wt.% of an alkoxylation product of an alkylene oxide component and a Mannich condensate component, said alkoxylation product having a hydroxyl number of about 400 to about 550 and, correspondingly, from 0 to about 60 wt.% of a condensate of an initiator having 2 to 6 carbon atoms with an alkylene oxide component, said condensate having a hydroxyl number of about 200 to about 800; said Mannich Condensate Component having been prepared by reacting a phenolic component with formaldehyde and an amine mixture in the molar ratio of about 1 to about 3 mols of formaldehyde and about 1 to about 3 mols of said amine mixture per mol of phenolic component said amine mixture consisting of 90 to 99 mol percent of diethanolamine and, correspondingly, from 10 to 1 mol percent of melamine; said phenolic component comprising phenol or phenol substituted with an alkyl group constaining 1 to 12 carbon atoms, said alkylene oxide component comprising 100 to about 90 wt.% of propylene oxide and, correspondingly, from 0 to about 10 wt.% of ethylene oxide.