Hydrophilic polyurethane/polyurea sponge

Claim 2

A polymeric sponge comprising a polymer comprising a plurality of units having the formula ##STR10## wherein R is an organic group having a valence of 2, 3, or 4, selected from linear and branched aliphatic groups having 2 to 12 carbon atoms, 5- and 6-membered aliphatic and aromatic carbocyclic groups having 5 to 50 carbon atoms, each R 1 independently a linear or branched aliphatic group having a valence of (b+1) consisting of a chain of up to 110 carbon atoms in units selected from linear groups C n H 2n and C n H 2n-2 in which n is 2 to 12, 5- or 6-membered carbocylic groups, and aromatic groups of 5 to 20 carbon atoms, which are separated by individual oxygen atoms, ##STR11## the aliphatic group having a molecular weight of up to 2000, wherein b is an integer of 1, 2, or 3; and R 2 has a valence of d+2 and is an arenepolyyl group (polyvalent arene group) having 6 to 20 carbon atoms or an alkanepolyyl (polyvalent alkane) group having 2 to 20 carbon atoms, wherein d is a number 1, 2, or 3, X is independently --O-- or --NH--, and M is a cation, wherein said polymer contains at least one sulfonate equivalent per 20,000 molecular weight units.

Claim 3

The sponge according to claim 1 further comprising a plurality of units selected from the group consisting of ##STR12## wherein R 3 is a linear or branched aliphatic group having 2 to 50 carbon atoms or an aromatic group of 5 to 50 carbon atoms having a valence of c in which c is a number having a value of 2 to 5, the group optionally containing 1 to 20 nonperoxidic oxygen atoms, ##STR13## or R 3 is a 5- or 6-membered cycloaliphatic group or aromatic group having 5 to 20 carbon atoms.

Claim 4

A sponge comprising the reaction product of (a) an isocyanate-terminated sulfopolyurethane/urea comprising in its backbone linear or branched organic groups selected from the group consisting of (1) aliphatic, cycloaliphatic or aromatic ether groups and (2) aliphatic, cycloaliphatic, or aromatic ester groups, and a central arenepolyyl or alkanepolyyl group containing 1 to 3 pendant sulfonate groups, that are end-capped with isocyanate groups, and (b) coreactants which include at least one of (1) water, (2) a polyol plus a blowing agent, and (3) a polyamine plus a blowing agent.

Claim 5

A sponge comprising the reaction product of (a) an isocyanate-terminated sulfopolyurethane/urea comprising in its backbone linear or branched organic groups selected from the group consisting of (1) aliphatic, cycloaliphatic or aromatic ether groups and (2) aliphatic, cycloaliphatic, or aromatic ester groups, and a central arenepolyyl or alkanepolyyl group containing 1 to 3 pendant sulfonate groups, that are end-capped with isocyanate groups, and (b) coreactants which include at least one of (1) water, (2) a polyol plus a blowing agent, and (3) a polyamine plus a blowing agent.

Claim 6

The sponge according to claim 3 wherein said isocyanate-terminated sulfopolyurethane/urea comprises a compound having the formula ##STR14## and, optionally, at least one of compounds having the formulae ##STR15## wherein R is an organic group having a valence of (a+1) selected from linear and branched groups having 2 to 12 carbon atoms, 5- and 6-membered carbocyclic groups having 5 to 50 carbon atoms; a is a number having a value of 1, 2 or 3; R 1 is independently selected from a linear or branched organic group having a valence of (b+1) comprising a saturated or unsaturated chain of up to 110 carbon atoms selected from linear groups C n H 2n and C n H 2n-2 in which n is 2 to 12, aromatic groups of 5 to 20 carbon atoms, and 5- or 6-membered carbocyclic groups, which optionally are separated by individual oxygen atoms, ##STR16## the organic group having a molecular weight of up to 2000, wherein b is an integer of 1, 2, or 3; R 2 has a valence of d+2 and is an arenepolyyl group (polyvalent arene group) having 6 to 20 carbon atoms or an alkanepolyyl (polyvalent alkane) group having 2 to 20 carbon atoms, and d is a number having a value 1, 2, or 3; X is independently --O-- or --NH--; and M is a cation.

Claim 7

A sponge comprising the reaction product of (a) an isocyanate-terminated sulfopolyurethane/urea having at least one of the formulae ##STR17## (b) a polyisocyanate having the formula OCNR(NCO) a , (c) an isocyanate-terminated polyurethane/urea having the formula ##STR18## wherein R is an organic group having a valence of (a+1) selected from linear and branched groups having 2 to 12 carbon atoms, 5- and 6-membered carbocyclic groups having 5 to 20 carbon atoms; a is a number having a value of 1, 2 or 3; R 1 is independently selected from a linear or branched organic group having a valence of (b+1) comprising a saturated or unsaturated chain of up to 110 carbon atoms selected from linear groups C n H 2n and C n H 2n-2 in units of 2 to 12 in which n is 2 to 12, aromatic groups of 5 to 20 carbon atoms, and 5- or 6-membered carbocyclic groups, which optionally can be separated by individual oxygen atoms, ##STR19## the organic group having a molecular weight of up to 2000, wherein b is an integer of 1, 2, or 3; R 2 has a valence of d+2 and is an arenepolyyl group (polyvalent arene group) having 6 to 20 carbon atoms or an alkanepolyyl (polyvalent alkane) group having 2 to 20 carbon atoms, and d is a number having a value 1, 2, or 3, X is independently --O-- or --NH--, M is a cation, and (d) a compound selected from the group consisting of (1) water, and (2) a polyol or a polyamine plus a blowing agent.

Claim 8

A sponge comprising the reaction product of (a) an isocyanate-terminated sulfopolyurethane/urea having at least one of the formulae ##STR17## (b) a polyisocyanate having the formula OCNR(NCO) a , (c) an isocyanate-terminated polyurethane/urea having the formula ##STR18## wherein R is an organic group having a valence of (a+1) selected from linear and branched groups having 2 to 12 carbon atoms, 5- and 6-membered carbocyclic groups having 5 to 20 carbon atoms; a is a number having a value of 1, 2 or 3; R 1 is independently selected from a linear or branched organic group having a valence of (b+1) comprising a saturated or unsaturated chain of up to 110 carbon atoms selected from linear groups C n H 2n and C n H 2n-2 in units of 2 to 12 in which n is 2 to 12, aromatic groups of 5 to 20 carbon atoms, and 5- or 6-membered carbocyclic groups, which optionally can be separated by individual oxygen atoms, ##STR19## the organic group having a molecular weight of up to 2000, wherein b is an integer of 1, 2, or 3; R 2 has a valence of d+2 and is an arenepolyyl group (polyvalent arene group) having 6 to 20 carbon atoms or an alkanepolyyl (polyvalent alkane) group having 2 to 20 carbon atoms, and d is a number having a value 1, 2, or 3, X is independently --O-- or --NH--, M is a cation, and (d) a compound selected from the group consisting of (1) water, and (2) a polyol or a polyamine plus a blowing agent.

Claim 9

The sponge according to claim 1 having an absorptive capacity of 10 to 50 grams of water per gram of dry sponge.

Claim 10

The sponge according to claim 1 having a rate of water absorption of 0.001 to 0.004 g/cm 2 /5 sec.

Claim 11

The sponge according to claim 1 having a density in the range of 0.01 to 0.4 g/cm 3 .

Claim 12

The sponge according to claim 1 having a percentage volumetric swell in water of 25 to 50%.

Claim 13

The sponge according to claim 1 having a percentage volumetric swell in water of less than 30%.

Claim 14

The sponge according to claim 1 wherein M is H, an alkali or alkaline earth metal cation, or a primary, secondary, tertiary, or quaternary ammonium cation.

Claim 15

A water-absorbing sponge comprising at least one of a sulfo- group containing polyurea and polyurethane, the polymer containing at least one sulfonate equivalent per 20,000 molecular weight units, said sponge further comprising adjuvants selected from the class consisting of fibers, fillers, deodorants, medicinals, insecticides, fungicides, antimicrobials, humectants, pigments, and dyes.

Claim 16

A water-absorbing sponge comprising at least one of a sulfo- group containing polyurea and polyurethane, the polymer containing at least one sulfonate equivalent per 20,000 molecular weight units, said sponge further comprising adjuvants selected from the class consisting of fibers, fillers, deodorants, medicinals, insecticides, fungicides, antimicrobials, humectants, pigments, and dyes.

Claim 17

A water-absorbing sponge comprising at least one of a sulfo- group containing polyurea and polyurethane, said polymer containing at least one sulfonate equivalent per 3,000 to 10,000 molecular weight units.

Claim 18

A water-absorbing sponge comprising at least one of a sulfo- group containing polyurea and polyurethane, said polymer containing at least one sulfonate equivalent per 3,000 to 10,000 molecular weight units.

Claim 21

The method according to claim 14 wherein said polyol or polyamine has the formulas R 3 (OH) c and R 3 (NH c ) c wherein R 3 is a linear or branched aliphatic group having 2 to 50 carbon atoms and a valence of c in which c is a number having a value of 2 to 5, the group optionally containing 1 to 20 of at least one of nonperoxidic oxygen atom, ##STR23## or R 3 is a 5- or 6-membered cycloaliphatic group or aromatic group having 5 to 20 carbon atoms.

Claim 24

The method according to claim 14 further comprising adding surfactant.

Claim 25

The method according to claim 17 wherein said surfactant is added in the range of 0.01 to 5.0 weight percent.

Claim 26

The method according to claim 17 wherein said surfactant is a nonionic alkylphenyl polyether alcohol.

Claim 27

The method according to claim 14 further comprising adding a catalyst.

Claim 28

The method according to claim 20 wherein said catalyst is added in an amount more than 0 and up to 2.0 weight percent.

Claim 29

The method according to claim 20 wherein said catalyst is N-ethylmorpholine.

Claim 30

The method according to claim 20 wherein said catalyst is a tin or urethane catalyst.

Claim 31

The sponge according to claim 1 having a wet wipe capacity of 85 to 100 percent.

Claim 32

The sponge according to claim 1 further comprising a surfactant.

Claim 33

An article comprising (a) a water-absorbing sponge comprising at least one of sulfo- group containing polyurea and polyurethane, the polymer containing at least one sulfonate equivalent per 20,000 molecular weight units, and (b) a backing laminated to said sponge.

Claim 34

An article comprising (a) a water-absorbing sponge comprising at least one of sulfo- group containing polyurea and polyurethane, the polymer containing at least one sulfonate equivalent per 20,000 molecular weight units, and (b) a backing laminated to said sponge.

Claim 35

The article according to claim 26 wherein said backing is a fabric.

Claim 36

The article according to claim 27 wherein said fabric is nonwoven.

Claim 37

The article according to claim 26 wherein said backing is a synthetic chamois.

Claim 38

The sponge according to claim 1 further comprising adjuvants selected from the class consisting of fibers, fillers, deodorants, medicinals, insecticides, fungicides, antimicrobials, humectants, pigments, or dyes.

Claim 39

The sponge according to claim 1 wherein said polymer contains at least one sulfonate equivalent per 3,000 to 10,000 molecular weight units.