Patent GB-880924-A (GB)
Title: Improvements in and relating to foamed polymers
IPC: C08G63/08
Filed: 1958-04-17
Abstract: Foamed polymers of oxyalkylene-carboxyalkylenes (produced by reaction of a polyfunctional focal compound, a lactone and a 1, 2-epoxide as described and claimed in Specification 880,923 are prepared by reacting the oxyalkylenecarboxyalkylene polymers with water and a substantial molar excess, preferably 100-700% by weight, of polyisocyanate.  A considerable number of isocyanates, including higher functional polyisocyanates, are specified.  The rigidity of the foam produced depends on the molecular weight of the oxyalkylene-carboxyalkylene polymer employed, viz. polymers of molecular weight 100-1600 for semi-rigid foams, for flexible, open-cell foams the polymer should be substantially linear and have a molecular weight of 1600-2800, and for flexible, closed-cell foams the polymer should be branched and have a molecular weight of 3500-6000.  A specified blend has 70 to 95% of a linear oxyalkylene-carboxyalkylene polymer having an average molecular weight of 1600-2800 and 30 to 50% of a branched oxyalkylene-carboxyalkylene polymer of average molecular weight 3500-6000.  The foam premix may include a catalyst, e.g. a tertiary amine, retarders, a stabilizing or thickening agent such as ethoxylated cellulose, linear or branched lactone polyesters such as are described in Specification 859,642, silicone or paraffin oils, surfectants, clays or diatomaceous earths, and dyes.  A polycarboxylic acid may be used as a part-replacement for water in the foam-producing reaction.  According to an example, 1100 g. of unsubstituted epsilon-caprolactam, 56,8 g. ethylene glycol and 6,2 g. trimethylolpropane were heated to a temperature of 60 to 70 DEG  C. in the presence of 2,6 g. boron trifluoride ethyl etherate as catalyst and to the mixture 1100 g. ethylene oxide were added in the course of 5,25 hours.  The resulting mixture of oxyalkylene-carboxyalkylene copolymers was a yellow liquid having a carboxyl number of 1,6 and a hydroxyl number of 49,1.  75 g. of the oxyalkylene-carboxyalkylene copolymer were mixed in with 2,2 g. water, 1g. of a polyoxyethylated vegetable oil and 2g. N-methyl morpholine.  28g. of a mixture of 65% 2, 4- and 35% 2, 6-tolylene diisocyanates containing 0,5% of an ethoxylated cellulose having an average ethoxy content of 47,5 to 49%, were then added under intensive agitation.  As soon as the foaming reaction began, the mixture was transferred into an open mould to expand and to set for twenty-four hours at room temperature for complete curing.  The foamed polymer produced had a density of 0,042 g./cm.3, a tensile strength of 2,025 g./cm.2, and required loading at 84, 98 and 259 g./cm.2 for 25% deflection at temperatures of +20 DEG , 0 DEG  and -40 DEG C. respectively.ALSO:Foamed polymers of oxyalkylene-carboxyalkylenes (produced by reaction of a poly functional focal compound, a lactone and a 1, 2-epoxide as described and claimed in Specification 880,923 (see Group IV(a)) are prepared by reacting the oxyalkylene-carboxyalkylene polymers with water and a substantial molar excess, preferably 100-700% by weight, of polyisocyanate. A considerable number of isocyanates, including higher functional polyisocyanates, are specified.  The rigidity of the foam produced depends on the molecular weight of the oxyalkylene-carboxyalkylene polymer employed, viz, polymers of molecular weight 100-1600 for semi-rigid foams, for flexible, open-cell foams the polymer should be substantially linear and have a molecular weight of 1600-2800, and for flexible, closed-cell foams the polymer should be branched and have a molecular weight of 3500-6000.  A specified blend has 70 to 95% of a linear oxyalkylene-carboxy-alkylene polymer having an average molecular weight of 1600-2800 and 30 to 5% of a branched oxyalkylene-carboxyalkylene polymer of average molecular weight 3500-6000.  The foam premix may include a catalyst e.g. a tertiary amine, retarders, a stabilizing or thickening agent and such as ethoxylated cellulose, linear or branched lactone polyesters such as are described in Specification 859,642, silicone or paraffin oils, surfectants, clays or diatamaceous earths, and dyes.  A polycarboxylic acid may be used as a part-replacement for water in the foam-producing reaction.  According to an example, 75 g. of oxyalkylene-carboxyalkylene copolymer were mixed in with 2,2 g. water, 1g. of a polyoxyethylated vegetable oil and 2g. N-methylmorpholine.  28g. of a mixture of 65% 2, 4- and 35% 2, 6- tolylene diisocyanates containing 0,5% of an ethoxylated cellulose having an average ethoxy content of 47,5 to 49%, were then added under intensive agitation.  As soon as the foaming reaction began, the mixture was transferred into an open mould to expand and to set for twenty-four hours at resin temperature for complete curing.  The foamed polymer produced had a density of 0.042 g.l cm.3, a tensile strength of 2,025 g.l cm2, and required loading at 84, 98 and 259 g.l cm.2 for 25% deflection at temperatures of +20 DEG , 0 DEG , and -40 DEG C. respectively.