Polyurethane based on hydroxyl-containing polymer polyol and process for making the same

Claim 2

A process for producing a cellular or noncellular polyurethane having improved rigidity and heat resistance, which comprises reacting at least one organic polyisocyanate with a polyol component, at least a part of the polyol component being a pendant hydroxyl radical-containing polymer polyol having a polymer content of at least 30% by weight, said polymer polyol being derived from at least one polyol having an equivalent weight of 200-4,000 and unsaturated monomers, the polymer portion of said polymer polyol comprisng monomer units of (a) 5-90% of at least one hydroxyl radical-containing monomer, selected from the group consisting of (1) esters of an ethylenically unsaturated carboxylic acid with a glycol, (2) polymerizable unsaturated aliphatic alcohols, (3) furfuryl alcohol, and (4) N-alkylol acrylamides; (b) 5-90% of at least one unsaturated nitrile; (c) 0-60% of at least one epoxy radical-containing monomer; and (d) 0-60% of at least one other monomer, based on the total weight of monomers, wherein the total amount of said epoxy radical-containing monomer and said other monomer is 0-60%.

Claim 3

The process of claim 1, wherein said hydroxyl radical-containing monomer is at least one ester selected from the group consisting of (1-i) esters of at least one ethylenically unsaturated carboxylic acid selected from the group consisting of acrylic, methacrylic, crotonic, maleic, fumaric, itaconic, citraconic, mesaconic, methylenemalonic, aconitic, cinnamic and vinyl benzoic acids, with at least one glycol selected from C 2 -C 6 alkylene glycols and polyglycols, and (1-ii) mixed esters of at least one ethylenically unsaturated carboxylic acid selected from the group consisting of acrylic, methacrylic, crotonic, maleic, fumaric, itaconic, citraconic, mesaconic, methylenemalonic, aconitic, cinnamic and vinyl benzoic acids, with at least one glycol selected from the group consisting of C 2 -C 6 alkylene glycols and polyglycols, and at least one mono-ol selected from the group consisting of C 1 -C 20 monohydric alcohols and alkylene oxide adducts thereof containing generally 1-20 oxyalkylene units per mole.

Claim 4

The process of claim 2, wherein said carboxylic acid is selected from the group consisting of acrylic and methacrylic acids.

Claim 5

The process of claim 1, wherein said hydroxyl-containing monomer is selected from the group consisting of hydroxyethyl acrylate, hydroxypropyl acrylate, hydroxyethyl methacrylate, and hydroxypropyl methacrylate.

Claim 6

The process of claim 1, wherein said hydroxyl-containing monomer is of the formula (I): CH.sub.2 ═CR--COO(A--O).sub.n H (I) wherein R is H or methyl; A is ethylene or propylene, or combination thereof; and n is an integer of 2-20.

Claim 7

The process of claim 1, wherein said unsaturated aliphatic alcohol is selected from the group consisting of vinyl alcohol, allyl alcohol, methallyl alcohol, crotyl alcohol, isocrotyl alcohol, butene mono-ols, butuene diols; propargyl alcohol, and alkylene oxide adducts of these alcohols containing 1-20 oxyalkylene units per mole.

Claim 8

The process of claim 1, wherein units of said hydroxyl-containing monomer are formed by polymerization of a precursor therefor containing a hydroxyl radical-forming group to obtain a polymer polyol containing hydroxyl radical-forming groups, followed by converting the hydroxyl radical-forming groups into hydroxyl radicals.

Claim 9

The process of claim 7, wherein said precursor is at least one member selected from the group consisting of esters of said unsaturated aliphatic alcohols with C 1 -C 20 fatty acids.

Claim 10

The process of claim 1, wherein said nitrile is selected from the group consisting of acrylonitrile and methacrylonitrile.

Claim 11

The process of claim 1, wherein said epoxy-containing monomer is at least one compound selected from the group consisting of unsaturated hydrocarbon oxides, and unsaturated ethers, esters, urethanes, amides or acetals, which contain one or more epoxy radicals selected from the group consisting of 1,2-, 1,3-, 1,4- and 1,5-epoxide radicals.

Claim 12

The process of claim 1, wherein said epoxy-containing monomer is at least one compound selected from the group consisting of glycidyl acrylates and glycidyl methacrylate.

Claim 13

The process of claim 1, wherein said other monomer is selected from the group consisting of unsaturated hydrocarbon monomers, substituted styrenes, acrylic and substituted acrylic monomers, vinyl esters, vinyl ethers, vinyl ketones, other substituted vinyl monomers, unsaturated dicarboxylic acid and esters thereof.

Claim 14

The process of claim 1, wherein said monomer units comprise 10-80% of said hydroxyl radical-containing monomer, 10-80% of said unsaturated nitrile, and 0-60% of said epoxy radical-containing monomer plus said other monomer, based on the total weight of monomers.

Claim 15

A process for producing a cellular or noncellular polyurethane having improved rigidity and heat resistance, which comprises reacting at least one organic polyisocyanate with a polyol component, at least a part of the polyol component being a pendant hydroxyl radical-containing polymer polyol having a polymer content of 10-70% by weight, said polymer polyol being derived from at least one polyol having an equivalent weight of 200-4,000 and unsaturated monomers, the polymer portion of said polymer polyol comprising monomer units of (a) 5-90% of at least one hydroxyl radical-containing monomer, selected from the group consisting of (1) esters of an ethylenically unsaturated carboxylic acid with a glycol, (2) polymerizable unsaturated aliphatic alcohols, (3) furfuryl alcohol, and (4) N-alkylol acrylamides; (b) 5-90% of at least one unsaturated nitrile; (c) 5-90% of at least one epoxy radical-containing monomer; and (d) 0-60% of at least one other monomer, based on the total weight of monomers; and bringing about ring-opening reaction of epoxy radicals of said epoxy radical-containing monomer units of said polymer polyol, in the presence of an epoxy curing agent, simultaneously with, before or after the urethane-forming reaction.

Claim 16

A process for producing a cellular or noncellular polyurethane having improved rigidity and heat resistance, which comprises reacting at least one organic polyisocyanate with a polyol component, at least a part of the polyol component being a pendant hydroxyl radical-containing polymer polyol having a polymer content of 10-70% by weight, said polymer polyol being derived from at least one polyol having an equivalent weight of 200-4,000 and unsaturated monomers, the polymer portion of said polymer polyol comprising monomer units of (a) 5-90% of at least one hydroxyl radical-containing monomer, selected from the group consisting of (1) esters of an ethylenically unsaturated carboxylic acid with a glycol, (2) polymerizable unsaturated aliphatic alcohols, (3) furfuryl alcohol, and (4) N-alkylol acrylamides; (b) 5-90% of at least one unsaturated nitrile; (c) 5-90% of at least one epoxy radical-containing monomer; and (d) 0-60% of at least one other monomer, based on the total weight of monomers; and bringing about ring-opening reaction of epoxy radicals of said epoxy radical-containing monomer units of said polymer polyol, in the presence of an epoxy curing agent, simultaneously with, before or after the urethane-forming reaction.

Claim 17

A process for producing a cellular or noncellular polyurethane having improved rigidity and heat resistance, which comprises reacting at least one organic polyisocyanate with a polyol component, at least a part of the polyol component being [A] 10-90% by weight of a pendant hydroxyl radical-containing polymer polyol having a polymer content of 10-70% by weight, said polymer polyol being derived from at least one polyol having an equivalent weight of 200-4,000 and unsaturated monomers, the polymer portion of said polymer polyol comprising monomer units of (a) 5-95% of at least one hydroxyl radical-containing monomer, selected from the group consisting of (1) esters of an ethylenically unsaturated carboxylic acid with a glycol, (2) polymerizable unsaturated aliphatic alcohols, (3) furfuryl alcohol and (4) N-alkylol acrylamides, (b) 5-95% of at least one unsaturated nitrile, and (d) 0-60% of at least one other monomer, based on the total weight of monomers; and [B] 10-90% by weight of an epoxy radical-containing polymer polyol having a polymer content of 10-70% by weight, said polymer polyol being derived from at least one polyol having an equivalent weight of 200-4,000 and unsaturated monomers, the polymer portion of said polymer polyol comprising monomer units of (b) 5-95% of at least one unsaturated nitrile, (c) 5-95% of at least one epoxy radical-containing monomer, and (d) 0-60% of at least one other monomer, based on the total weight of monomers; and bringing about ring-opening reaction of epoxy radicals of said epoxy radical-containing monomer units of said epoxy radical-containing polymer polyol [B], in the presence of an epoxy curing agent, simultaneously with, before or after the urethane-forming reaction.

Claim 18

A process for producing a cellular or noncellular polyurethane having improved rigidity and heat resistance, which comprises reacting at least one organic polyisocyanate with a polyol component, at least a part of the polyol component being [A] 10-90% by weight of a pendant hydroxyl radical-containing polymer polyol having a polymer content of 10-70% by weight, said polymer polyol being derived from at least one polyol having an equivalent weight of 200-4,000 and unsaturated monomers, the polymer portion of said polymer polyol comprising monomer units of (a) 5-95% of at least one hydroxyl radical-containing monomer, selected from the group consisting of (1) esters of an ethylenically unsaturated carboxylic acid with a glycol, (2) polymerizable unsaturated aliphatic alcohols, (3) furfuryl alcohol and (4) N-alkylol acrylamides, (b) 5-95% of at least one unsaturated nitrile, and (d) 0-60% of at least one other monomer, based on the total weight of monomers; and [B] 10-90% by weight of an epoxy radical-containing polymer polyol having a polymer content of 10-70% by weight, said polymer polyol being derived from at least one polyol having an equivalent weight of 200-4,000 and unsaturated monomers, the polymer portion of said polymer polyol comprising monomer units of (b) 5-95% of at least one unsaturated nitrile, (c) 5-95% of at least one epoxy radical-containing monomer, and (d) 0-60% of at least one other monomer, based on the total weight of monomers; and bringing about ring-opening reaction of epoxy radicals of said epoxy radical-containing monomer units of said epoxy radical-containing polymer polyol [B], in the presence of an epoxy curing agent, simultaneously with, before or after the urethane-forming reaction.

Claim 19

The process of claim 1, wherein said polyol having an equivalent weight of 200-4,000 is at least one selected from the group consisting of polyether polyols, polyester polyols, urethane polyols and vinyl-modified polyols.

Claim 20

The process of claim 1, wherein the polyol component comprises at least 20% by weight of said polymer polyol and 0-80% of at least one other active hydrogen atom-containing compound selected from the group consisting of (i) high molecular weight polyols, having equivalent weight of 200-4,000, selected from the group consisting of polyether polyols, polyester polyols, urethane polyols and vinyl-modified polyols; (ii) high molecular weight polyamines, having equivalent weight of 200-4,000; (iii) low molecular weight active hydrogen atom-containing compounds selected from the group consisting of low molecular weight polyols and amines, having equivalent weight of at least 30 and less than 200; and (iv) combinations of two or more of them.

Claim 21

The process of claim 1, wherein the content of polymer moiety of said polymer polyol is 5-70% based on the weight of the whole active hydrogen atom-containing compounds.

Claim 22

The process of claim 1, wherein the polyurethane is produced in the presence of at least one additive selected from the group consisting of surfactants, flame retardants, retarders, colorants, internal mold release agents, age resistors, antioxidants, plasticizers, germicides and fillers.

Claim 23

The process of claim 1, wherein NCO index in the urethane-forming reaction is 65-120.

Claim 24

The process of claim 1, wherein NCO index in the urethane-forming reaction is 300-1,000 or more to produce isocyanurate rings in the polyurethane.

Claim 25

The process of claim 1, wherein said polyisocyanate is reacted with said polyol component by Reaction Injection Molding method, or by conditioning them to a temperature of 25°-90° C., intimately mixing said components under a pressure of 100-200 kg/cm 2 g, injecting said mixture into a mold preheated to a temperature 30°-120° C., and thereafter demolding the resulting article.

Claim 26

The process of claim 1, wherein the resulting product is after-cured at a temperature of 120°-140° C. for 1-30 hours.

Claim 27

A cellular or noncellular polyurethane, having a density of 0.01 to 1.4 g/cm 3 , obtained by the process of claim 1.

Claim 28

The polyurethane of claim 24, having a density of 0.8 to 1.4 g/cm 3 .

Claim 29

The polyurethane of claim 24, having a flexural modulus of at least 7,000 Kg/cm 2 .

Claim 30

The polyurethane of claim 24, having a notched Izod impact strength of at least 10 Kgcm/cm at 23° C.

Claim 31

A crosslinked polyurethane, obtained by the process of claim 14.

Claim 32

A crosslinked polyurethane, obtained by the process of claim 15.

Claim 33

A process for producing a pendant hydroxyl radical-containing polymer polyol, which comprises polymerizing unsaturated monomers in situ in at least one polyol having an equivalent weight of 200-4,000, said monomers being used in an amount of 50-250 parts per 100 parts of said polyol, said monomers comprising (a) 5-90% of at least one hydroxyl radical-containing monomer or precursor thereof, selected from the group consisting of (1) esters of an ethylenically unsaturated carboxylic acid with a glycol, (2) polymerizable unsaturated aliphatic alcohols, or fatty acid esters thereof, (3) furfuryl alcohol, and (4) N-alkylol acrylamides; (b) 5-90% of at least one unsaturated nitrile; (c) 0-90% of at least one epoxy radical-containing monomer; and (d) 0-60% of at least one other monomer, based on the total weight of monomers.

Claim 34

A process for producing a pendant hydroxyl radical-containing polymer polyol, which comprises polymerizing unsaturated monomers in situ in at least one polyol having an equivalent weight of 200-4,000, said monomers being used in an amount of 50-250 parts per 100 parts of said polyol, said monomers comprising (a) 5-90% of at least one hydroxyl radical-containing monomer or precursor thereof, selected from the group consisting of (1) esters of an ethylenically unsaturated carboxylic acid with a glycol, (2) polymerizable unsaturated aliphatic alcohols, or fatty acid esters thereof, (3) furfuryl alcohol, and (4) N-alkylol acrylamides; (b) 5-90% of at least one unsaturated nitrile; (c) 0-90% of at least one epoxy radical-containing monomer; and (d) 0-60% of at least one other monomer, based on the total weight of monomers.

Claim 35

The process of claim 30, which comprises polymerizing monomers containing a fatty acid ester of an unsaturated aliphatic alcohol to obtain a polymer polyol containing hydrolyzable ester groups, followed by converting at least a part of the ester groups of the resulting polymer polyol to hydroxyl radicals by hydrolysis or alcoholysis in the presence of a basic or acidic catalyst.

Claim 36

The process of claim 31, wherein the basic catalyst is at least one compound selected from the group consisting of cycloamidines and diazabicycloalkenes, having the general formula: ##STR2## wherein R 1 is H or an alkyl group having 1-8 carbon atoms, R 2 is an alkyl group having 1-8 carbon atoms, or R 1 and R 2 may be joined to form a ring having 2-11 methylene groups, n is an integer of 2-6, and each of the methylene groups may carry a lower alkyl substituent.

Claim 37

The process of claim 32, wherein the compound is 1,8-diazabicyclo[5,4,0]-7-undecene.

Claim 38

A polymer polyol composition comprising the product of the in situ polymerization of said monomers in said polyol produced in accordance with the process of claim 30.

Claim 39

The process of claim 1, wherein said other monomers is at least one selected from the group consisting of styrene and methyl methacrylate.

Claim 40

The process of claim 1, wherein said reacting step is preformed in the presence of a blowing agent.

Claim 41

The process of claim 14, wherein said reacting step is performed in the presence of a blowing agent.

Claim 42

The process of claim 15, wherein said reacting step is performed in the presence of a blowing agent.

Claim 43

The process of claim 14, wherein said ring-opening reaction is performed with an epoxy curing accelerator.

Claim 44

The process of claim 15, wherein said ring-opening reaction is performed with an epoxy curing accelerator.

Claim 45

The composition of claim 34, having a polymer content of at least 40% by weight.