Graft prestabilizing and stabilizing copolymers and their preparation, process for obtaining dispersions of polymers/polyols and process for obtaining polyurethane foams

Claim 2

A graft prestabilizing copolymer, characterized in that it comprises the product of the in situ reaction of a mixture of ethylenically unsaturated monomers containing at least one mono-unsaturated monomer containing no groups which can be alkoxylated and one unsaturated monomer containing a group which can be alkoxylated, a prepolyol of low molecular weight and a polymerization catalyst as well as an alkoxylating agent for the above mentioned reaction product chosen from the group comprising ethylene oxide, propylene oxide and their mixtures.

Claim 3

Copolymer according to claim 1, characterized in that the mixture of monomers contains at least one monomer promoting free radical grafting.

Claim 4

Copolymer according to claim 1, characterized in that the proportion by weight of the mixture of monomers is of the order of 1% to 75% relative to the prepolyol.

Claim 5

Copolymer according to claim 3, characterized in that the proportion by weight of the mixture of monomers is of the order of 20% to 60% relative to the prepolyol.

Claim 6

Copolymer according to claim 1, characterized in that the prepolyol has a molecular weight of less than 5,000.

Claim 7

Copolymer according to claim 5, characterized in that the molecular weight of the prepolyol is between 500 and 2,000.

Claim 8

Copolymer according to claim 2, characterized in that the mixture of ethylenically unsaturated monomers contains about 1 to 20 moles of unsaturated monomer containing a group which can be alkoxylated and 1 to 25 moles of monomer promoting free radical grafting per 100 moles of mono-unsaturated monomer which does not contain groups which can be alkoxylated.

Claim 9

Copolymer according to claim 1, characterized in that the mono-unsaturated monomer which does not contain groups which can be alkoxylated is chosen from the groups comprising styrene, α-methylstyrene, methylstyrene, 2,4-dimethylstyrene, ethylstyrene, isopropylstyrene, butylstyrene, phenylstyrene, cyclohexylstyrene, benzylstyrene, chlorostyrene, 2,5-dichlorostyrene, bromostyrene, cyanostyrene, nitrostyrene, N,N,-dimethylaminostyrene, acetoxystyrene, methyl 4-vinylbenzoate, phenoxystyrene, acrylonitrile, methacrylonitrile, methyl acrylate, methyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, benzyl acrylate, benzyl methacrylate, isopropyl acrylate, isopropyl methacrylate, octyl acrylate, octyl methacrylate, methyl, α-chloroacrylate, ethyl α-ethoxyacrylate, butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, phenyl acrylate, phenyl methacrylate, α-chloroacrylonitrile, N,N-dimethylacrylamide or N,N-dibenzylacrylamide, vinylidene chloride, vinyl bromide, vinyl chloride, vinyl fluoride, vinylidene fluoride, vinyl acetate, vinyl chloroacetate, isopropenyl acetate, vinyl formate, vinyl methoxyacetate, vinyl benzoate, methyl vinyl ether, ethyl vinyl ether, propyl vinyl ether, butyl vinyl ether, phenyl vinyl ether, methyl vinyl ketone, vinylpyridine, ethyl vinyl ketone, phenyl vinyl ketone, N-vinylpyrrolidone, dimethyl fumarate or dimethyl maleate.

Claim 10

Copolymer according to claim 1, characterized in that the unsaturated monomer containing a group which can be alkoxylated is chosen from the group comprising allyl alcohol, 2-butene-1,4-diol, 3-butene-1,2-diol, glycerol monoallyl ether, trimethylolpropane monoallyl ether, hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, hydroxypropyl methacrylate, glycerol monoacrylate and glycerol monomethacrylate, monoethanolamine, diethanolamine, triethanolamine, acrylic acid, methacrylic acid, fumaric acid, itaconic acid, crotonic acid, maleic anhydride, acrylamide methacrylamide, N-butylacrylamide, glycidyl acrylate, glycidyl methacrylate, allylglycidyl ether, butadiene monoepoxide and vinylcyclohexane-3,4-epoxide.

Claim 11

Copolymer according to claim 2, characterized in that the monomer promoting free radical grafting is chosen from the group comprising butadiene, isoprene, 1,4-pentadiene, piperylene, 1,4-hexadiene, 1,7-octadiene, allyl acrylate, allyl methacrylate, ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, 1,4-butanediol dimethacrylate, divinylbenzene, divinyl ether, divinyl sulphide, divinyl sulphone, N,N-diethylaminoethyl acrylate, vinyl laurate, vinyl isobutyrate, vinyl dodecanate, vinyl hexanoate, the bromstyrenes, the α- and β-bromostyrenes, vinylnaphthalene and vinylanthracene.

Claim 12

Copolymer according to claim 1, characterized in that the amount by weight of catalyst is of the order of 1% to 5% relative to the ethylenically unsaturated monomer.

Claim 13

Copolymer according to claim 11, characterized in that the catalyst is chosen from the group comprising dibenzoyl peroxide, benzoyl hydroperoxide, t-butyl hydroperoxide, t-butyl peroxide, diisopropyl peroxide, diisopropylbenzene hydroperoxide, cumene hydroperoxide, 2,2'-azo-bis-isobutyronitrile, 2,2'-azo-bis(2,4-dimethylvaleronitrile), 2-t-butylazo-2-cyano-4-methylpentane and 4,4'-azo-bis(4-cyano-n-pentanol).

Claim 14

Copolymer according to claim 12, characterized in that the catalyst is dibenzoyl peroxide or 2,2'-azo-bis-isobutyronitrile.

Claim 15

Copolymer according to claim 1, characterized in that the abovementioned alkoxylating agent is a mixture of ethylene oxide and propylene oxide.

Claim 16

Copolymer according to claim 14, characterized in that the mixture contains about 40% to 95% of propylene oxide and about 5% to 60% of ethylene oxide.

Claim 17

Copolymer according to claim 1, characterize din that the proportion by weight of akoxylating agent relative to the abovementioned reaction product is of the order of 20% to 85%.

Claim 18

Copolymer according to claim 16, characterized in that the proportion by weight of akoxylating agent is of the order of 50% to 75%.

Claim 19

Process for the preparation of a stabilizing graft copolymer according to claim 1, characterized in that it comprises the in situ copolymerization of the mixture of ethylenically unsaturated monomers in the prepolyol of low molecular weight in the presence of the polymerization catalyst in such a way as to form an unsaturated precursor copolymer, containing a group which can be akoxylated, in solution in the prepolyol, the alkoxylation of the said precursor copolymer and of the prepolyol in the presence of a basic catalyst in such a way as to obtain a reaction product constituted by a graft copolymer in solution in a polyol and the neutralization of the reaction product by an acid, enabling the basic catalyst to be converted to a neutral salt.

Claim 20

Process according to claim 18, characterized in that the polyol has a molecular weight of 3,000 to 7,000.

Claim 21

Process according to claim 18, characterized in that the alkoxylation is carried out at a temperature of the order of 50° C. to 200° C.

Claim 22

Process according to claim 18, characterized in that the amount of basic catalyst to be used is about 0.1% to about 10% weight relative to the weight of the precursor copolymer/prepolyol mixture subjected to the alkoxylation.

Claim 23

Process according to claim 18, characterized in that the basic catalyst used is a compound chosen from the group comprising potassium hydroxide, sodium hydroxide, potassium methylate and sodium methylate.

Claim 24

A stable dispersion of polymer/polyol, characterized in that it comprises the product of the in situ reaction of at least one ethylenically unsaturated monomer in the polyol, a graft prestabilizing copolymer according to claim 1, and a polymerization initiator.

Claim 25

Dispersion according to claim 23, characterized in that the proportion by weight of graft prestabilizing copolymer is about 1% to about 45% by weight relative to the total weight of unsaturated commoner and of polyol.

Claim 26

Dispersion according to claim 24, characterized in that the proportion by weight of graft prestabilizing copolymer is about 5% to 30%.

Claim 27

Dispersion according to claim 23, characterized in that the polyol is a polyetherpolyol prepared by a condensation reaction of propylene oxide and/or ethylene oxide with a polyol, such as glycerol, trimethylolpropane, pentaerythritol, sorbitol, sucrose or propylene glycol.

Claim 28

Dispersion according to claim 23, characterized in that the proportion by weight of ethylenically unsaturated monomer is of the order of 5% to 60% relative to the total weight of graft copolymer, polyol and initiator.

Claim 29

Dispersion according to claim 27, characterized in that the proportion by weight of ethylenically unsaturated monomer is of the order of 15% to 50%.

Claim 30

Dispersion according to claim 23, characterized in that the ethylenically unsaturated monomer is a substance chosen from the group comprising isoprene, butadiene, 1,4-pentadiene, styrene, methylstyrene, α-methylstyrene, p-tert-butylstyrene, acrylonitrile, acrylic acid, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, benzyl acrylate, benzyl methacrylate, isopropyl acrylate, isopropyl methacrylate, methacrylonitrile, ethyl α-ethoxyacrylate, butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, 2ethylhexyl methacrylate, phenyl acrylate, phenyl methacrylate, N,N-dimethylacrylamide, N,N-dibenzylacrylamide, N-butylacrylamide, vinyl acetate, vinyl alcohol, vinyl butylate, vinyl acrylate, vinyl methacrylate, methyl vinyl ketone, dimethyl fumarate, dimethyl maleate, maleic acid, fumaric acid, dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate, glycidyl acrylate, glycidyl methacrylate, allyl alcohol, vinylpyridine, vinylpyrrolidone, vinyl chloride, vinyl bromide and vinylidene chloride.

Claim 31

Dispersion according to claim 29, characterized in that the ethylenically unsaturated monomer is chosen from the group comprising acrylonitrile, styrene and the mixtures of acrylonitrile and styrene.

Claim 32

Dispersion according to claim 23, characterized in that the proportion by weight of initiator is of the order of 0.1% to 5% relative to the total weight of ethylenically unsaturated monomer, graft copolymer and polyol.

Claim 33

Dispersion according to claim 23, characterized in that the initiator is chosen from the group comprising benzoyl peroxide, 2,2'-azo-bis-isobutyronitrile and the mixtures of these compounds.

Claim 34

Process for the preparation of a stable dispersion of polymer/polyol according to claim 23, characterized in that it comprises the in situ polymerization of at least one ethylenically unsaturated monomer in the polyol in the presence of the prestabilizing graft copolymer, in the presence of the polymerization initiator, the unsaturated monomer being polymerized, under the effect of the initiator, into particles which are insoluble and partially grafted on the prestabilizing copolymer in the polyol and producing a graft copolymer ensuring the stabilization of the dispersion thus obtained.

Claim 35

Process according to claim 33, characterized in that a supplementary quantity of polyol is added.

Claim 36

Process according to claim 33, characterized in that the polymerization is carried out at a temperature of the order of 25° C. 170° C.

Claim 37

Process according to claim 35, characterized in that the polymerization temperature is between 80° C. and 120° C.

Claim 38

Process according to claim 33, characterized in that a chain transfer agent is added during the above mentioned polymerization.

Claim 39

Process for the preparation of a polyurethane foam, characterized in that the stable dispersion of polymer/polyol according to claim 23, is reacted with water, catalysts, surfactants and a polyisocyanate.

Claim 40

Process according to claim 38, characterized in that water, catalysts and surfactants are mixed with the dispersion of polymer/polyol before the latter is brought into contact with the polyisocyanate.

Claim 41

Polyurethane foam such as obtained by the process according to claim 39.