Patent GB-1015614-A (GB)
Title: Improvements in or relating to the manufacture of polyurethane foams
Inventor: CHAPMAN JOHN FREDERICK
IPC: C08G18/40
Filed: 1962-12-21
Abstract: A process for the manufacture of substantially open-celled rigid polyurethane foams comprises interacting (a) an organic polyisocyanate, (b) a mixture of hydroxyl-group-containing resins which are liquids at the initial interaction temperature, said mixture containing from 30% to 70% by weight of a highly branched resin, i.e. one containing at least 3 hydroxyl groups per 1000 units of molecular weight, the remainder being a linear resin, i.e. one with 2 hydroxy groups per molecule or a lightly branched resin, i.e. one which contains not more than 3 hydroxyl groups per 1500 units of molecular weight, the last two resins being incompatible with the highly branched resin; and (c) at least 6% by weight of water based on the highly branched resin, in the presence of a low boiling point liquid which is inert towards the polyurethane foam forming ingredients.  Highly branched hydroxyl group-containing resins which are used are polyesters, polyesteramides and oxyalkylation products of active hydrogen-containing compounds.  Examples of polyesters and polyesteramides are those made from polycarboxylic acids especially dicarboxylic acids, e.g. glutaric and terephthalic acids, and polyhydric alcohols e.g. glycols such as ethylene glycol, 1:3-butylene glycol; polyhydric alcohols of higher functionality such as trimethylol propane and pentaerythritol; with minor proportions of polyamines or amino alcohols such as ethylene diamine, tolylene diamine and diethanolamine. Oxyalkylation products include polyethers prepared by the polymerization of an alkylene oxide in the presence of a basic catalyst and a substance with more than two active hydrogen atoms per molecule e.g. ammonia, and polyhydroxy compounds such as glycerol, trimethylolpropane, sorbitol, amino alcohols such as ethanolamine and polyamines such as ethylene diamine and diaminodiphenylmethane. Suitable alkylene oxides are e.g. ethylene oxide, 1:2 butylene oxide and epichlorohydrin. Alkylene oxides can also be polymerized with e.g. diepoxides, glycidol and 3-hydroxymethyloxacyclobutane.  Mixtures of highly branched resins can be used.  Linear and lightly branched resins used are hydroxyl group-containing polyesters and polyamides made from e.g. dicarboxylic acids and glycols with minor proportions of diamines and aminoalcohols. To introduce a slight degree of branching minor amounts of compounds having more than two ester- or amide-forming groups can be incorporated in the mixture.  Linear polyethers include hydroxyl-ended polymers and co-polymers of cyclic oxides e.g. 1:2 alkylene oxide, oxacyclobutane and tetrahydrofuran, made by polymerizing the alkylene oxide with a compound having two active hydrogen atoms per molecule e.g. water, glycols and monoamines, in the presence of a basic catalyst. Lightly branched polyethers are prepared by polymerizing alkylene oxides in the presence of polyhydric alcohols and polyamines. Inert low boiling point compounds are halogenated hydrocarbons. Additives such as cross-linking agents, foam stabilizing agents, surface active agents, colouring matter, fillers, plasticizers, flame retardants and anti-oxidants may be added.