Foamed isocyanate-based polymer, a mix and process for production thereof

1. A foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a blowing agent and a highly branched polysaccharide of randomly bonded glucopyranose units, having an average number of 10-100 glucose residues wherein said polysaccharide is derivatized with at least two esters of different length and the derivatized polysaccharide has an active hydrogen functionality of 3 to 12, wherein one of said esters is a short chain ester of C2-C4, and wherein one of said esters is a long chain ester of C8-C12.

2. The isocyanate-based polymer of claim 1 , wherein said short chain ester is C2-C3.

3. The isocyanate-based polymer of claim 1 , wherein said short chain ester is C2.

4. The isocyanate-based polymer of claim 1 , wherein said long chain ester is C9-C11.

5. The isocyanate-based polymer of claim 1 , wherein said long chain ester is C10.

6. The isocyanate-based polymer of claim 1 , wherein the hydroxyl substitution of said derivatized polysaccharide is more than 70%.

7. The isocyanate-based polymer of claim 1 , wherein the hydroxyl substitution of said derivatized polysaccharide is at least 75%.

8. The isocyanate-based polymer of claim 1 , wherein the hydroxyl substitution of said derivatized polysaccharide is at least 80%.

9. The isocyanate-based polymer of claim 1 , wherein the ratio of hydroxyl substitution of said long and short chain esters is 0.2 to 4.

10. The isocyanate-based polymer of claim 1 , wherein the ratio of hydroxyl substitution of said long and short chain esters is 0.3 to 3.

11. The isocyanate-based polymer of claim 1 , wherein the ratio of hydroxyl substitution of said long and short chain esters is 0.3 to 1.

12. The isocyanate-based polymer of claim 1 , wherein said ratio of said long and short chain esters in 80% hydroxyl substitution is 60:20, 40:40, 30:50 or 20:60.

13. The isocyanate-based polymer of claim 1 , wherein said ratio of said long and short chain esters in 90% hydroxyl substitution is 50:40, 35:55 or 20:70.

14. The isocyanate-based polymer of claim 4 , wherein said derivatized highly branched polysaccharide has an active hydrogen functionality of 4 to 10.

15. The isocyanate-based polymer of claim 4 , wherein said derivatized highly branched polysaccharide has an active hydrogen functionality of 5 to 8.

16. The isocyanate-based polymer of claim 1 , wherein said derivatized highly branched polysaccharide has a solubility parameter below 16.

17. The isocyanate-based polymer of claim 1 , wherein said derivatized highly branched polysaccharide has a solubility parameter below 12.

18. The isocyanate-based polymer of claim 1 , wherein the active hydrogen-containing compound is selected from the group comprising polyols, polyamines, polyamides, polyimines and polyolamines.

19. The isocyanate-based polymer of claim 18 , wherein the active hydrogen-containing compound comprises a polyol.

20. The isocyanate-based polymer of claim 19 , wherein the polyol is a polyether polyol.

21. The isocyanate-based polymer of claim 1 , wherein said foamed isocyanate-based polymer is flexible polyurethane foam.

22. The isocyanate-based polymer of claim 19 , wherein the ratio of isocyanate groups of said isocyanate and hydroxyl groups of said polyol is from about 1.2:1 to 1:1.2.

23. The isocyanate-based polymer of claim 22 , wherein the ratio of isocyanate groups of said isocyanate and hydroxyl groups of said polyol is from about 1.1:1 to 1:1.1.

24. The isocyanate-based polymer of claim 1 , wherein said blowing agent is selected from water, non-water blowing agents, liquid carbon dioxide and combinations thereof.

25. The isocyanate-based polymer of claim 24 , wherein said non-water blowing agents are low-boiling organic liquids.

26. The isocyanate-based polymer of claim 1 , wherein said blowing agent comprises water.

27. The isocyanate-based polymer of claim 1 , wherein said reaction mixture further comprises at least one catalyst and at least one surfactant.

28. The isocyanate-based polymer of claim 27 wherein said catalyst is selected from the group consisting of tertiary amines and metallic salts or mixtures thereof.

29. The isocyanate-based polymer of claim 27 wherein said surfactant is selected from the group consisting of silicone surfactants.

30. The isocyanate-based polymer of claim 1 wherein said reaction mixture further comprises crosslinking agents and additives.

31. The isocyanate-based polymer of claim 1 , wherein said highly branched polysaccharide which is derivatized is added in an amount sufficient to confer load building to said foamed isocyanate-based polymer.

32. The isocyanate-based polymer of claim 1 , wherein said foamed isocyanate-based polymer has an Indentation Force Deflection loss when measured pursuant to ASTM D3574 which is less than that of a reference foam produced by substituting a copolymer polyol for the derivatized highly branched polysaccharide in the reaction mixture, the foamed isocyanate-based polymer and the reference foam having substantially the same density and Compressive Force Deflection when measured pursuant to ASTM D3574.

33. The isocyanate-based polymer of claim 1 , wherein said foamed isocyanate-based polymer has thickness loss when measured pursuant to ASTM D3574 which is less than that of a reference foam produced by substituting a copolymer polyol for the derivatized highly branched polysaccharide in the reaction mixture, the foamed isocyanate-based polymer and the reference foam having substantially the same density and Compressive Force Deflection when measured pursuant to ASTM D3574.

34. The isocyanate-based polymer of claim 1 , wherein said isocyanate is selected from 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and methylene diphenyldiisocyanate and combinations thereof, the active hydrogen-containing compound is a polypropylene oxide containing polyether polyol, the blowing agent is water and said derivatized polysaccharide is a polydextrose having an active hydrogen functionality of less than 15, derivatized with C2 and C10 esters to a hydroxyl substitution of 80%.

35. A process for producing a foamed isocyanate-based polymer comprising the steps of: contacting an isocyanate, an active hydrogen-containing compound, a blowing agent and a highly branched polysaccharide of randomly bonded glucopyranose units, having an average number of 10-100 glucose residues and an active hydrogen functionality of 3 to 12 to form a reaction mixture; and expanding the reaction mixture to produce the foamed isocyanate-based polymer; wherein said polysaccharide is derivatized with at least two esters of different length, wherein one of said esters is a short chain ester of C2-C4, and wherein one of said esters is a long chain ester of C8-C12.

36. The process of claim 35 , wherein said process comprises adding 1 to 50% by weight of said derivatized polysaccharide.

37. The process of claim 35 , wherein said process comprises adding 2 to 20% by weight of said derivatized polysaccharide.

38. The process of claim 35 , wherein said process comprises adding 2 to 10% by weight of said derivatized polysaccharide.

39. The process of claim 35 , wherein said short chain ester is C2-C3.

40. The process of claim 35 , wherein said short chain ester is C2.

41. The process of claim 35 , wherein said long chain ester is C9-C11.

42. The process of claim 35 , wherein said long chain ester is C10.

43. The process of claim 35 , wherein the hydroxyl substitution of said polysaccharide is more than 70%.

44. The process of claim 35 , wherein the hydroxyl substitution of said polysaccharide is at least 75%.

45. The process of claim 35 , wherein the hydroxyl substitution of said polysaccharide is at least 80%.

46. The process of claim 35 , wherein the ratio of hydroxyl substitution of said long and short chain esters is 0.2 to 4.

47. The process of claim 35 , wherein said derivatized highly branched polysaccharide has a solubility parameter below 16.

48. The process of claim 35 , wherein said mix further comprises at least one blowing agent selected from a group consisting of water, non-water blowing agents, liquid carbon dioxide and combinations thereof.

49. The process of claim 35 , wherein said mix further comprises at least one catalyst and at least one surfactant.

50. The process of claim 35 , wherein said reaction mixture further comprises crosslinking agents and additives.

51. A cushion material for household furnishings and automobiles comprising a foamed isocyanate-based polymer of claim 1 wherein said polymer is derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a blowing agent and a highly branched polysaccharide of randomly bonded glucopyranose units, having an average number of 10-100 glucose residues and an active hydrogen functionality of 3 to 12 wherein said polysaccharide is derivatized with at least two esters of different length, wherein one of said esters is a short chain ester of C2-C4 and wherein one of said esters is a long chain ester of C8-C12.

52. A carpet underlay comprising a foamed isocyanate-based polymer of claim 1 wherein said polymer is derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a blowing agent and a highly branched polysaccharide of randomly bonded glucopyranose units, having an average number of 10-100 glucose residues and an active hydrogen functionality of 3 to 12 wherein said polysaccharide is derivatized with at least two esters of different length, wherein one of said esters is a short chain ester of C2-C4 and wherein one of said esters is a long chain ester of C8-C12.

53. A packaging application comprising a foamed isocyanate-based polymer of claim 1 wherein said polymer is derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a blowing agent and a highly branched polysaccharide of randomly bonded glucopyranose units, having an average number of 10-100 glucose residues and an active hydrogen functionality of 3 to 12 wherein said polysaccharide is derivatized with at least two esters of different length, wherein one of said esters is a short chain ester of C2-C4 and wherein one of said esters is a long chain ester of C8-C12.

54. A method for molding a foamed isocyanate-based polymer which utilizes the foamed isocyanate-based polymer of claim 1 wherein said polymer is derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a blowing agent and a highly branched polysaccharide of randomly bonded glucopyranose units, having an average number of 10-100 glucose residues and an active hydrogen functionality of 3 to 12 wherein said polysaccharide is derivatized with at least two esters of different length, wherein one of said esters is a short chain ester of C2-C4 and wherein one of said esters is a long chain ester of C8-C12.

55. A method for making alternatively crushed or cut slabs of a foamed isocyanate-based polymer which comprises utilizing the foamed isocyanate-based polymer of claim 1 wherein said polymer is derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a blowing agent and a highly branched polysaccharide of randomly bonded glucopyranose units, having an average number of 10-100 glucose residues and an active hydrogen functionality of 3 to 12 wherein said polysaccharide is derivatized with at least two esters of different length, wherein one of said esters is a short chain ester of C2-C4 and wherein one of said esters is a long chain ester of C8-C12.