Claims
- 1. In a polymer/polyol composition which is convertible by reaction with a polyisocyanate to a polyurethane product wherein said polymer/polyol composition is normally liquid at the temperature at which said composition is converted to said polyurethane product and wherein the polymer of said polymer/polyol composition is formed in situ in a polyol blend containing a polyol having a relatively low theoretical number average molecular weight by polymerizing in the blend one or more polymerizable ethylenically unsaturated monomers, the improvement comprising employing as the blend a polyol blend comprising about 55 to about 95 wt.% of a polyol having a theoretical number average molecular weight not greater than about 4000 and from about 45 to about 5 wt.% of a polyol having a theoretical number average molecular weight of not less than about 5000, in which blend said polymer is stably dispersed as small particles, said polymer being formed in the absence of any alkyl mercaptan and said monomers being substantially free of chemically bound halogen.
- 2. Composition as claimed in claim 1 wherein said polyol blend comprises about 70 to about 90 wt.% of the polyol having a theoretical number average molecular weight not greater than about 4000 and about 10 to about 30 wt.% of the polyol having a theoretical number average molecular weight of not less than about 5000.
- 3. Composition as claimed in claim 1 wherein said polyol blend comprises about 70 to about 95 wt.% of the polyol having a theoretical number average molecular weight not greater than about 4000 and about 5 to about 30 wt.% of the polyol having a theoretical number average molecular weight of not less than about 5000.
- 4. Composition as claimed in claim 1 wherein said polyol blend comprises about 80 to about 90 wt.% of the polyol having a theoretical number average molecular weight not greater than about 4000 and about 10 to about 20 wt.% of the polyol having a theoretical number average molecular weight of not less than about 5000.
- 5. Composition as claimed in claim 1 wherein the amount of polymer dispersed in said polyol blend is about 4 to about 40 wt.% based on the weights of the composition.
- 6. Composition as claimed in claim 1 wherein the amount of polymer dispersed in said polyol blend is about 15 to about 35 wt.% based on the weight of the composition.
- 7. Composition as claimed in claim 6 wherein said polymer comprises polymerized acrylonitrile.
- 8. Composition as claimed in claim 7 wherein said polymer also contains polymerized styrene.
- 9. Composition as claimed in claim 8 wherein the weight ratio of polymerized acrylonitrile to polymerized styrene in said polymer ranges from 20:80 to 100:0.
- 10. Composition as claimed in claim 9 wherein the weight ratio of polymerized acrylonitrile to polymerized styrene in said polymer ranges from 25:75 to 100:0.
- 11. Composition as claimed in claim 9 wherein the weight ratio of polymerized acrylonitrile to polymerized styrene in said polymer ranges from about 40:60 to 85:15.
- 12. Composition as claimed in claim 9 wherein the weight ratio of polymerized acrylonitrile to polymerized styrene in said polymer ranges from about 60:40 to 85:15.
- 13. Composition as claimed in claim 7 wherein said polymer also contains polymerized methyl methacrylate.
- 14. Composition as claimed in claim 1 wherein the weight ratio of polymerized acrylonitrile to polymerized methyl methacrylate to polymerized styrene is about 25 to about 25 to about 50.
- 15. Composition as claimed in claim 1 wherein the theoretical number average molecular weight of the polyol having the lower molecular weight is in the range of about 400 to about 4000 and that of the polyol having the higher molecular weight is in the range of about 5000 to about 20000.
- 16. Composition as claimed in claim 1 wherein the theoretical number average molecular weight of the polyol having the lower molecular weight is in the range of about 1000 to about 4000 and that of the polyol having the higher molecular weight is in the range of about 5000 to about 15000.
- 17. A method for producing a polyurethane foam by reacting and foaming a mixture comprising (a) the polymer/polyol composition claimed in claim 1, (b) an organic polyisocyanate, (c) a catalyst for the reaction of (a) and (b) to produce the polyurethane, (d) a blowing agent and (e) a foam stabilizer.
- 18. A method as claimed in claim 17 wherein the foam is a flexible foam, the reaction and foaming are performed by the one shot technique, the polymer/polyol composition contains an alkylene oxide adduct of a polyhydroxyalkane, the blowing agent is water and the water is used in an amount to provide a foam having a density of less than 1.75 pounds per cubic foot.
- 19. A composition as claimed in claim 1 wherein said polyol having a number average molecular weight not greater than about 4,000 consists of an alkylene oxide adduct of a polyhydroxy alkane and the polyol having a number average molecular weight of not less than about 5,000 consists of an alkylene oxide adduct of a polyhydroxy alkane.
- 20. A method for producing a polyurethane elastomer by reacting a mixture comprising (a) a polymer/polyol composition as claimed in claim 1 and (b) an organic polyisocyanate, in the presence of (c) a catalyst for the reaction of (a) and (b) to produce the polyurethane.
- 21. A method for producing a polyurethane elastomer as claimed in claim 20 wherein said polyol having a number average molecular weight not greater than about 4,000 consists of an alkylene oxide adduct of a polyhydroxy alkane and the polyol having a number average molecular weight of not less than about 5,000 consists of an alkylene oxide adduct of a polyhydroxy alkane.
- 22. In a process for producing a liquid polymer/polyol composition which is convertible by reaction with a polyisocyanate to a polyurethane product wherein said polymer/polyol composition is normally liquid at the temperature at which said composition is converted to said polyurethane product and wherein said polymer of said polymer/polyol composition is formed in situ in a polyol blend which contains a polyol having a relatively low theoretical number average molecular weight by polymerizing in the blend one or more polymerizable ethylenically unsaturated monomers, the improvement comprising employing as the blend a polyol blend comprising about 55 to 95 wt.% of a polyol having a theoretical number average molecular weight not greater than about 4000 and from about 45 to about 5 wt.% of a polyol having a theoretical number average molecular weight of not less than about 5000, in which blend said polymer is formed in situ in the absence of any alkyl mercaptan from one or more of said monomers, said monomers being substantially free of bound halogen, and said polymer is stably dispersed in said blend as small particles.
- 23. Process as claimed in claim 22 wherein said polyol blend comprises about 70 to about 95 wt.% of the polyol having a theoretical number average molecular weight not greater than about 4000 and about 5 to about 30 wt.% of the polyol having a theoretical number average molecular weight of not less than about 5000.
- 24. Process as claimed in claim 22 wherein said catalyst is 2,2'-azo-bis-isobutyronitrile.
- 25. Process as claimed in claim 22 wherein said catalyst is a peroxyester free radical catalyst.
- 26. A process as claimed in claim 22 wherein said polyol having a number average molecular weight not greater than about 4,000 consists of an alkylene oxide adduct of a polyhydroxy alkane and the polyol having a number average molecular weight of not less than about 5,000 consists of an alkylene oxide adduct of a polyhydroxy alkane.
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 699,397, filed June 24, 1976, and now abandoned.
US Referenced Citations (6)
Foreign Referenced Citations (3)
Number |
Date |
Country |
735,010 |
May 1966 |
CAX |
785,835 |
May 1968 |
CAX |
1,022,434 |
Mar 1966 |
GBX |
Non-Patent Literature Citations (2)
Entry |
Kuryla et al., Polymer Polyols, Journal of Cellular Plastics, Mar. 1966, pp. 1-3. |
Schildknecht, Vinyl and Related Polymers, John Wiley, New York (1952) pp. 26, 106 and 107. |
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
699397 |
Jun 1976 |
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