Polymer polyol dispersion from alpha, beta-ethylenically unsaturated dicarboxylic acid anhydrides

Abstract: Stable, fluid polymer polyols, which form stable, acrylonitrile-­ free dispersions and which may be used in the production of polyurethanes, are made by the free radical polymerization of a monomer mixture of an α, β -ethylenically unsaturated dicarboxylic acid anhydride and a co­ polymerizable monomer in an organic polyol medium of secondary hydroxyl terminated polyol.

Description: This invention relates to polymer polyols used in the preparation of polyurethane polymers, to their production and to their use in the production of polyurethane polymers. In one of its more specific aspects, this invention pertains to stable, fluid polymer polyols made by the free radical polymerization of a monomer mixture of an α, β - ethylenically unsaturated acid anhydride and a copolymerizable monomer in an organic polyol medium of secondary hydroxyl terminated polyol. In one embodiment, the polymer polyols of this invention form stable, acrylonitrile-free dispersions. Graft copolymer dispersions prepared from vinyl mononers and polyether polyols and their use in the preparation of polyurethane polymers are well known. The pioneer patents in the field of polymer polyols are U.S. Pat. Nos. 3,304,273; 3,383,351; Re 28,715; Re 29,118; and 3,523,093 to Stamberger, and U.S. Pat No. 3,652,639 to Pizzini, et al. In the patents to Stamberger, the method involves the in situ polymerization of a nitrile monomer (e.g., acrylonitrile and methacrylonitrile) in high molecular weight ethylene oxide tipped polyols. Pizzini, et al.'s method involves incorporating unsaturation into a polyol to increase the resultant level of grafting onto the polyol. The unsaturated polyol is typically prepared by the reaction of a saturated primary polyol with maleic anhydride followed by capping with ethylene oxide to reduce acidity. Although the polymer polyols that found initial commercial acceptance were primarily produced from polyols and acrylonitrile, more recently, mixtures of polymer polyols produced from polyols, acrylonitrile, and styrene have been used commercially. U.S. Pat. No. 4,198,488 to Drake, et al. equivalent to EP-A-0 006 605, teaches a further improvement to the method of Stamberger and involves the addition of a small amount (preferably 2.5 to 6 weight percent) of maleic anhydride to an acrylonitrile/styrene monomer feed. The maleic anhydride units are polymerized into the polymer backbone and also must undergo a separate esterification reaction with the hydroxyl groups of the primary polyol; and, accordingly, only small amounts of maleic anhydride can be employed without increasing the acid numbers of the polymer polyols formed. Acid numbers in excess of about 1.5 mg KOH/g are taught to be undesirable. The present invention provides a stable polymer polyol dispersion from an α,β -ethylenically unsaturated dicarboxylic acid anhydride monomer such as maleic anhydride. The polymer polyol of the invention can be prepared in the absence of a nitrile monomer and without using modified (unsaturated) polyols. The advantage of a process which facilitates the production of a polymer polyol in the absence of acrylonitrile is obvious due to its high toxicity and its tendency to produce discolored dispersions resulting in scorched foams. Quite surprisingly, it was found that use of an α,β -ethylenically unsaturated dicarboxylic acid anhydride alone, without a nitrile monomer, resulted in grafting. Even more surprising was the discovery that the use of the acid anhydride resulted in a high level of grafting as compared to the use of a nitrile monomer. According to this invention, there is provided a polymer polyol comprising the reaction product prepared at a temperature within the range of from 70°C to 150°C under free radical conditions of a monomer mixture containing α,β-ethylenically unsaturated dicarboxylic acid anhydride and an organic polyol medium characterised in that (a) the monomer mixture comprises at least one α,β-ethylenically unsaturated dicarboxylic acid anhydride and at least one styrenic monomer which is polymerizable with the acid anhydride; the anhydride forms not more than 50% by weight of the monomer mixture and the monomer mixture comprises a minor proportion of the reaction mixture; and (b) the organic polyol medium comprises polyoxyalkylene polyether polyol, consists essentially of secondary hydroxyl terminated polyol and comprises a major proportion of the reaction mixture; and wherein in the reaction product the acid anhydride is grafted to the polyol through the double bonds of the α,β-ethylenically unsaturated dicarboxylic acid anhydride and not through the hydroxyl groups of the polyol. The invention also provides a process for producing a polymer polyol which comprises polymerizing at a temperature within the range of from 70°C to 150°C in the presence of a free radical catalyst from 5 to 45 weight percent of a monomer mixture comprising at least one α,β-ethylenically unsaturated dicarboxylic acid anhydride and at least one styrenic monomer polymerizable with the acid anhydride, the anhydride forming not more than 50% by weight of the monomer mixture and monomer mixture being dispersed in 55 to 95 weight percent of an organic polyol medium comprising polyoxyalkylene polyether polyol and consisting essentially of secondary hydroxyl terminated polyol, said weight percents of the monomer mixture and the polyol medium being based on the total weight of the monomer mixture and the polyol medium, wherein said acid anhydride grafts to the polyol through the double bonds of the α,β-ethylenically unsaturated dicarboxylic acid anhydride. Further according to the invention, there is provided a method for producing an elastomeric polyurethane which comprises reacting a mixture comprising a polymer polyol as defined above, or as obtained by the process defined above, and an organic polyisocyanate in contact with a catalyst for reaction of the polymer polyol and polyisocyanate to produce a polyurethane. Also provided is a method for producing a polyurethane foam which comprises reacting a polymer polyol as defined above, or as obtained by the process defined above, and an organic polyisocyanate in contact with a catalyst for the reaction of the polymer polyol and the polyisocyanate, a blowing agent, and a foam stabiliser. In one embodiment of this invention, the essential components of the polymer polyol are an α,β -ethylenically unsaturated dicarboxylic acid anhydride, a monomer polymerizable with the acid anhydride and a polyol. The polyols suitable for use are one or more polyoxyalkylene polyether polyols which are the polymerization products of an alkene oxide or a mixture of alkene oxides with a polyhydric alcohol. The polyol must contain secondary hydroxyl groups and may contain, as is typical, small amounts of unsaturation. The molecular weight of the polyol will be within the range of from about 100 to about 5,000, preferably from about 2,000 to about 3,500. The monomer mixture according to the invention will comprise at least one α,β -ethylenically unsaturated dicarboxylic acid anhydride. Suitable anhydrides include maleic, itaconic, citraconic, 2,3-dimethylmaleic, and the like and their mixtures. Maleic anhydride is preferred. Further, the monomer mixture wiil comprise at least one additional monomer which is polymerizable with the acid anhydride. Any suitable monomer or mixture of monomers can be employed. Styrenic monomers are preferred and include styrene, substituted styrenes such as α-methylstyrene, ρ-methylstyrene, and the like, and their mixtures. Styrene is the preferred styrenic monomer. The anhydride/styrenic monomer mixture will contain at least 20 to 50 weight percent of acid anhydride, with the balance being styrenic monomer. Preferably, at least 30 weight percent of the monomer mixture will be acid anhydride. In a preferred embodiment, the anhydride/styrenic monomer mixture employed to produce the polymer polyols of this invention will contain from 45 to 50 weight percent maleic anhydride and from 50 to 55 weight percent styrene. In the practice of the invention, the monomer mixture is preferably employed in an amount within the range of from 5 to 45 weight percent, based on the total weight of the monomer mixture and the polyol. More preferably, the monomer mixture will be employed within the range of from 15 to 40 weight percent, based on the weight of the monomer mixture and the polyol. Although the monomer mixture employed to produce the polymer polyols of the invention is preferably a mixture of anhydride and styrenic monomers, the mixture can also comprise additional monomers. Additional monomers which can be incorporated during the polymerization reaction include acrylates, methacrylates, acrylamides, and their derivatives, vinyl and vinylidene halides, and nitrile derivatives such acrylonitrile and methacrylonitrile. If one or more additional monomers are present during the polymerization reaction, it is possible to reduce the minimum amount of α,β -ethylenically unsaturated acid anhydride in the monomer mixture from about 20 to about 10 weight percent. The polymer polyol of the present invention can be produced by polymerizing the monomer mixture in the selected polyol at a temperature of from 70° C. to 150° C. in the presence of a catalytically effective amount of a conventional free radical catalyst known to be suitable for the polymerization of ethylenically unsaturated monomers. The concentration of the catalyst (initiator) can vary within the range of from about 0.5 to about 5 weight percent based on the weight of the monomer mixture. However, any amount sufficient to cause grafting is satisfactory. Illustrative catalysts are the well-known free radical types; for example, hydrogen peroxide, t-butyl peroctoate, lauryl peroxide, cumene hydroperoxide, t-butyl hydroperoxide, benzoyl peroxide, and azobis(isobutyronitrile). Any conventional process for preparing polymer polyols can be employed to prepare the polymer polyols of this invention. Preferred is a process which maintains high agitation and a low monomer to polyol ratio throughout the reaction mixture during the process. Both semi-batch and continuous processes are suitable. The polymerization can also be carrried out with an inert organic solvent present. The solvent must be non-reactive with the anhydride and must not interfere with the polymerization reaction. Illustrative thereof are toluene, benzene, acetonitrile, ethyl acetate, hexane, heptane, dicyclohexane, dioxane, acetone, N,N-dimethylformamide, N,N-dimethylacetamide, and the like, including those known in the art as being suitable solvents for the polymerization of vinyl monomers. When an inert organic solvent is used, it is preferably removed by conventional means. The polymer polyols can be converted into elastomeric polyurethane and/or polyisocyanurate resins and resin foams in the known manner by reaction with polyisocyanates. Suitable methods for converting polymer polyols into polyurethane and/or polyisocyanate resins and resin foams are taught in U.S. Pat. No. 4,198,488. The invention is illustrated by the following examples. EXAMPLE 1 This example demonstrates the preparation of a graft copolymer dispersion of the invention. Into a 1 liter, 4 neck round-bottom flask equipped with a stirrer, condenser, thermometer, and addition tube, and under a blanket of nitrogen, was charged 320 parts by weight of Polyol A--a glycerin, propylene oxide, ethylene oxide adduct containing about 13% ethylene oxide and having a hydroxyl number of 56. After heating Polyol A to 110° C. and maintaining that temperature for about 30 minutes, the following monomer charge was added over a 2-hour period to give a milk-white dispersion. Monomer Charge Parts by Weight Material 60 Styrene 60 Maleic Anhydride 160 Polyol A 10 Toluene 15 Methylene chloride 3.0 Azobis(isobutyronitrile) Upon completion of the addition, the dispersion was held at 100° C. for 30 minutes, then the reaction mixture was stripped for 2.5 hours at 90° C. and 133 Pa (1 mm Hg) to yield a stable polymer polyol dispersion. The polymer polyol dispersion was found to have a viscosity of 5.564 Pas (5,564 cps) (Brookfield cone and plate viscometer spindle #CP-52, 5 rpm @ 26° C.), a solids content by hexane extraction of 29.0%, and an average particle size of 1.0 microns (Coulter N4 Particle Size Analyzer). Upon dilution, to 20% solids, the viscosity was 1.65 Pas (1,650 cps). EXAMPLES 2-20 Using substantially the procedure of Example 1, 19 additional polymer polyols (Examples 2-20) were prepared. Examples 2-8 were prepared employing various concentrations of different initiators. Examples 9-11 were prepared employing various monomer ratios of styrene to maleic anhydride. Examples 12-20 were prepared employing a third monomer, either acrylonitrile, methylmethacrylate, or acrylamide, in addition to styrene and maleic anhydride. Following Table I and Table II show the amounts of materials employed and the resulting polymer polyol dispersion properties for Examples 1-11 and Examples 12-20, respectively. Amounts of polyols and monomers are in parts by weight. EXAMPLE 21 This example demonstrates that in the polymer polyols of this invention, the acid anhydride is grafted to the polyol through the double bonds of the α,β -ethylenically unsaturated dicarboxylic acid anhydride. First, the hydroxy groups of a sample of Polyol A employed in Example 1 were reacted with acetyl chloride to produce a hydroxyl free, acetate terminated polyol. Analysis found less than 1% (0.004 meq./gm) of remaining or uncapped hydroxyl groups. Next, using substantially the procedure of Example 1, a styrene-maleic anhydride dispersion was prepared in the hydroxyl-free, acetate terminated polyol. The resulting polymer polyol was tested and found to possess the same stable, low viscosity properties as the dispersion of Example 1. This example confirms that according to the invention, the grafting of the α,β -ethylenically unsaturated dicarboxylic acid anhydride occurs through the α,β -unsaturated double bond and not through esterification of the anhydride groups. It will be evident from the foregoing that various modifications can be made to this invention. Such, however, are considered as being within the scope of the invention.

Claims: Claims for the following Contracting States : BE, FR, GB, IT, NE, DE A polymer polyol comprising the reaction product prepared at a temperature within the range of from 70°C to 150°C under free radical conditions of a monomer mixture containing α,β-ethylenically unsaturated dicarboxylic acid anhydride and an organic polyol medium characterised in that (a) the monomer mixture comprises at least one α,β-ethylenically unsaturated dicarboxylic acid anhydride and at least one styrenic monomer which is polymerizable with the acid anhydride; the anhydride forms not more than 50% by weight of the monomer mixture and the monomer mixture comprises a minor proportion of the reaction mixture; and (b) the organic polyol medium comprises polyoxyalkylene polyether polyol, consists essentially of secondary hydroxyl terminated polyol and comprises a major proportion of the reaction mixture; and wherein in the reaction product the acid anhydride is grafted to the polyol through the double bonds of the α,β-ethylenically unsaturated dicarboxylic acid anhydride and not through the hydroxyl groups of the polyol. The polymer polyol of claim 1 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is selected from maleic anhydride, itaconic anhydride, citraconic anhydride, 2,3-dimethyl maleic anhydride, and mixtures of two or more of these anhydrides. The polymer polyol of claim 1 or claim 2 in which said styrenic monomer is selected from styrene, α-methylstyrene, p-methylstyrene and mixtures of two or more of said monomers. The polymer polyol of any one of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an amount of from 10 to 50 weight percent of the monomer mixture. The polymer polyol of any one of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an mount of from 20 to 50 weight percent of the monomer mixture. The polymer polyol of any of of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an amount of from 30 to 50 weight percent of the monomer mixture. The polymer polyol of any one of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an amount of from 45 to 50 weight percent of the monomer mixture. The polymer polyol of any one of claims 1 to 7 in which said monomer mixture is employed in an amount of from 5 to 45 weight percent based on the total weight of the monomer mixture and organic polyol. The polymer polyol of any one of claims 1 to 7 in which said monomer mixture is employed in an amount of from 15 to 40 percent based on the total weight of the monomer mixture and organic polyol. A process for producing a polymer polyol which comprises polymerizing at a temperature within the range of from 70°C to 150°C in the presence of a free radical catalyst from 5 to 45 weight percent of a monomer mixture comprising at least one α,β-ethylenically unsaturated dicarboxylic acid anhydride and at least one styrenic monomer polymerizable with the acid anhydride, the anhydride forming not more than 50% by weight of the monomer mixture and monomer mixture being dispersed in 55 to 95 weight percent of an organic polyol medium comprising polyoxyalkylene polyether polyol and consisting essentially of secondary hydroxyl terminated polyol, said weight percents of the monomer mixture and the polyol medium being based on the total weight of the monomer mixture and the polyol medium, wherein said acid anhydride grafts to the polyol through the double bonds of the α,β-ethylenically unsaturated dicarboxylic acid anhydride. A method for producing an elastomeric polyurethane which comprises reacting a mixture comprising a polymer polyol as claimed in any one of claims 1 to 9, or as obtained by the process claimed in claim 10, and an organic polyisocyanate in contact with a catalyst for the reaction of the polymer polyol and polyisocyanate to produce a polyurethane. A method for producing a polyurethane foam which comprises reacting a polymer polyol as claimed in any one of claims 1 to 9, or as obtained by the process claimed in claim 10, and an organic polyisocyanate in contact with a catalyst for the reaction of the polymer polyol and the polyisocyanate, a blowing agent, and a foam stabiliser. Claims for the following Contracting State : ES A process for producing a polymer polyol which comprises polymerizing, at a temperature within the range of from 70°C to 150°C and in the presence of a free radical catalyst, a monomer mixture containing α,β-ethylenically unsaturated dicarboxylic acid anhydride and an organic polyol medium characterised in that: (a) the monomer mixture comprises at least one α,β-ethylenically unsaturated dicarboxylic acid anhydride and at least one styrenic monomer which is polymerizable with the acid anhydride; the anhydride forms not more than 50% by weight of the monomer mixture and the monomer mixture comprises a minor proportion of the reaction mixture; and (b) the organic polyol medium comprises polyoxyalkylene polyether polyol, consists essentially of secondary hydroxyl terminated polyol and comprises a major portion of the reaction mixture; and wherein the acid anhydride is grafted to the polyol through the double bonds of the α,β-ethylenically unsaturated dicarboxylic acid anhydride and not through the hydroxyl groups of the polyol. A process as claimed in claim 1 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is selected from maleic anhydride, itaconic anhydride, citraconic anhydride, 2,3-dimethyl maleic anhydride, and mixtures of two or more of these anhydrides. A process as claimed in claim 1 or claim 2 in which said styrenic monomer is selected from styrene, α-methylstyrene, p-methylstyrene and mixtures of two or more of said monomers. A process as claimed in any one of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an amount of from 10 to 50 weight percent of the monomer mixture. A process as claimed in any one of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an amount of from 20 to 50 weight percent of the monomer mixture. A process as claimed in any one of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an amount of from 30 to 50 weight percent of the monomer mixture. A process as claimed in any one of claims 1 to 3 in which said α,β-ethylenically unsaturated dicarboxylic acid anhydride is employed in an amount of from 45 to 50 weight percent of the monomer mixture. A method as claimed in any one of claims 1 to 7 in which said monomer mixture is employed in an amount of from 5 to 45 weight percent based on the total weight of the monomer mixture and organic polyol. A method as claimed in any one of claims 1 to 7 in which said monomer mixture is employed in an amount of from 15 to 40 weight percent based on the total weight of the monomer mixture and organic polyol. A method for producing an elastomeric polyurethane which comprises reacting a mixture comprising a polymer polyol obtained by the process claimed in any one of claims 1 to 9 and an organic polyisocyanate in contact with a catalyst for the reaction of the polymer polyol and the polyisocyanate to produce a polyurethane. A method for producing a polyurethane foam which comprises reacting a polymer polyol obtained by the process claimed in any one of claims 1 to 9 and an organic polyisocyanate in contact with a catalyst for the reaction of the polymer polyol and the polyisocyanate, a blowing agent, and a foam stabilizer.

Inventors: GASTINGER ROBERT G, HAYES JOHN E, GASTINGER, ROBERT G., HAYES, JOHN E.
Applicants: ARCO CHEM TECH, ARCO CHEMICAL TECHNOLOGY, L.P.
Application year: 1988
Main classification: C08G18
IPC codes: C08G18