Hybrid PHD/PMPO polyols for polyurethane foam applications

1. A stable, low-viscosity hybrid polymer polyol comprising the free-radical polymerization product of:

(A) a base polyol component comprising:

(1) from 1 to 100% by weight of a polymer modified polyol selected from the group consisting of:

(a) one or more dispersions of a polyurea and/or polyhydrazodicarbonamide in a hydroxyl group containing compound,

and

(b) one or more polyisocyanate polyaddition polyols;

and

(2) from 0 to 99% by weight of a polyol having a functionality of from 2 to 6, and an OH number of from 20 to 500;

with the proviso that said base polyol is not prepared from a natural oil, and wherein the sum of the %'s by weight of (A)(1) and (A)(2) totals 100% by weight of component (A);

(B) optionally, a preformed stabilizer;

and

(C) one or more ethylenically unsaturated monomers;

in the presence of:

(D) a free-radical polymerization initiator;

and

(E) optionally, a polymer control agent;

wherein the solids content of the hybrid polymer polyol ranges from 20 to 70% by weight, and comprises (i) from 1% to 60% by weight of polyureas and/or polyhydrazodicarbonamides or polyisocyanate polyaddition products, and (ii) from 40% to 99% by weight of graft copolymers comprising the ethylenically unsaturated monomers, with the sum of the %'s by weight of (i) and (ii) totaling 100% by weight of the solids in the hybrid polymer polyol.

2. The stable, low-viscosity hybrid polymer polyol of claim 1 , wherein (A) said base polyol component comprises:

(1) from 2 to 80% by weight of a polymer modified polyol selected from the group consisting of:

(a) one or more dispersions of a polyurea and/or polyhydrazodicarbonamide in a hydroxyl group containing compound, and

(b) one or more polyisocyanate polyaddition polyols;

and

(2) from 20 to 98% by weight of a polyol having a functionality of from 2 to 4 and an OH number of from 25 to 300;

with the proviso that said base polyol is not prepared from a natural oil, and wherein the sum of the %'s by weight of (A)(1) and (A)(2) totals 100% by weight of component (A).

3. The stable, low-viscosity hybrid polymer polyol of claim 1 , wherein (A)(1)(a) said one or more dispersions of a polyurea and/or polyhydrazodicarbonamide is the reaction product of (i) at least one organic polyisocyanate, with (ii) one or more amine functional compounds selected from the group consisting of primary and/or secondary amino-group containing di- and/or polyamines, hydrazines, hydrazides and mixtures thereof, in (iii) a hydroxyl group containing compound.

4. The stable, low-viscosity hybrid polymer polyol of claim 3 , in which (i) said organic polyisocyanate is toluene diisocyanate, (ii) said amine functional compound is hydrazine hydrate, and (iii) said hydroxyl group containing compound is a polyether polyol having a functionality of about 3 and an OH number of about 35, wherein the resultant polyhydrazodicarbonamide polyol has a functionality of about 3 and an OH number of about 28.

5. The stable, low-viscosity hybrid polymer polyol of claim 1 , wherein (C) said one or more ethylenically unsaturated monomers comprise styrene, acrylonitrile or mixtures thereof.

6. The stable, low-viscosity hybrid polymer polyol of claim 5 , wherein C) said ethylenically unsaturated monomers comprise a mixture of styrene and acrylonitrile in a weight ratio of about 80:20 to 20:80.

7. The stable, low-viscosity hybrid polymer polyol of claim 1 , wherein the solids content of the hybrid polymer polyol ranges from 25 to 65% by weight, and comprises (i) from 3 to 55% by weight of polyureas and/or polyhydrazodicarbonamides or polyisocyanate polyaddition products, and (ii) from 45% to 97% by weight of graft copolymers comprising the ethylenically unsaturated monomers, with the sum of the %'s by weight of (i) and (ii) totaling 100% by weight of the solids in the hybrid polymer polyol.

8. The stable, low-viscosity hybrid polymer polyol of claim 1 , which additionally comprises a chain transfer agent.

9. A process for the preparation of a stable, low-viscosity hybrid polymer polyol comprising

(I) free-radically polymerizing:

(A) a base polyol component comprising:

(1) from 1 to 100% by weight of a polymer modified polyol selected from the group consisting of:

(a) one or more dispersions of a polyurea and/or polyhydrazodicarbonamide in a hydroxyl group containing compound

and

(b) one or more polyisocyanate polyaddition polyols;

and

(2) from 0 to 99% by weight of a polyol having a functionality of from 2 to 6, and an OH number of from 20 to 500;

with the proviso that said base polyol is not prepared from a natural oil, and wherein the sum of the %'s by weight of (A)(1) and (A)(2) totals 100% by weight of component (A);

(B) optionally, a preformed stabilizer;

and

(C) one or more ethylenically unsaturated monomers;

in the presence of:

(D) a free-radical polymerization initiator;

and

(E) optionally, a polymer control agent;

wherein the resultant hybrid polymer polyol has a solids content of from 20 to 70% by weight, which comprises (i) from 1% to 60% by weight of polyureas and/or polyhydrazodicarbonamides or polyisocyanate polyaddition products, and (ii) from 40% to 99% by weight of graft copolymers comprising the ethylenically unsaturated monomers, with the sum of the %'s by weight of (i) and (ii) totaling 100% by weight of the solids in the hybrid polymer polyol.

10. The process of claim 9 , wherein (A) said base polyol component comprises:

(1) from 2 to 80% by weight of a polymer modified polyol selected from the group consisting of:

(a) one or more dispersions of a polyurea and/or polyhydrazodicarbonamide in a hydroxyl group containing compound, and

(b) one or more polyisocyanate polyaddition polyols;

and

(2) from 20 to 98% by weight of a polyol having a functionality of from 2 to 4 and an OH number of from 25 to 300;

with the proviso that said base polyol is not prepared from a natural oil, and wherein the sum of the %'s by weight of (A)(1) and (A)(2) totals 100% by weight of component (A).

11. The process of claim 9 , wherein (A)(1)(a) said one or more dispersions of a polyurea and/or polyhydrazodicarbonamide is the reaction product of (i) at least one organic polyisocyanate, with (ii) one or more amine functional compounds selected from the group consisting of primary and/or secondary amino-group containing di- and/or polyamines, hydrazines, hydrazides and mixtures thereof, in (iii) a hydroxyl group containing compound.

12. The process of claim 11 , in which (i) said organic polyisocyanate is toluene diisocyanate, (ii) said amine functional compound is hydrazine hydrate, and (iii) said hydroxyl group containing compound is a polyether polyol having a functionality of about 3 and an OH number of about 35, wherein the resultant polyhydrazodicarbonamide polyol has a functionality of about 3 and an OH number of about 28.

13. The process of claim 9 , wherein (C) said one or more ethylenically unsaturated monomers comprise styrene, acrylonitrile or mixtures thereof.

14. The process of claim 13 , wherein (C) said ethylenically unsaturated monomers comprise a mixture of styrene and acrylonitrile in a weight ratio of about 80:20 to 20:80.

15. The process of claim 9 , wherein the solids content of the hybrid polymer polyol ranges from 25 to 65% by weight, and comprises (i) from 3 to 55% by weight of polyureas and/or polyhydrazodicarbonamides or polyisocyanate polyaddition products, and (ii) from 45% to 97% by weight of graft copolymers comprising the ethylenically unsaturated monomers, with the sum of the %'s by weight of (i) and (ii) totaling 100% by weight of the solids in the hybrid polymer polyol.

16. The process of claim 9 , which additionally comprises a chain transfer agent.

17. A process for the preparation of a polyurethane foam, comprising reacting:

(I) a polyisocyanate component,

with

(II) an isocyanate-reactive component comprising the stable, low viscosity hybrid polymer polyol of claim 1 :

in the presence of

(III) a blowing agent,

and

(IV) at least one catalyst.

18. The process of claim 17 , wherein (II) said isocyanate-reactive component comprises (1) from 5 to 100% by weight of the hybrid polymer polyol, and (2) from 0 to 95% by weight of one or more isocyanate-reactive components selected from the group consisting of polyether polyols, polyester polyols, polyoxyalkylene polyols, crosslinking agents, chain extenders and mixtures thereof, with the sum of the %'s by weight of (1) and (2) totaling 100% by weight of component (II).

19. The process of claim 18 , wherein (II) said isocyanate-reactive component comprises (1) from 10 to 75% by weight of the hybrid polymer polyol, and (2) from 25 to 75% by weight of one or more isocyanate-reactive components selected from the group consisting of polyether polyols, polyester polyols, polyoxyalkylene polyols, crosslinking agents, chain extenders and mixtures thereof, with the sum of the %'s by weight of (1) and (2) totaling 100% by weight of component (II).

20. The process of claim 17 , wherein said process additionally comprises reacting

(V) at least one silicon surfactant.

21. A polyurethane foam comprising the reaction product of:

(I) a polyisocyanate component,

with

(II) an isocyanate-reactive component comprising the stable, low viscosity hybrid polymer polyol of claim 1 :

in the presence of

(III) a blowing agent,

and

(IV) at least one catalyst.

22. The foam of claim 21 , wherein (II) said isocyanate-reactive component comprises (1) from 5 to 100% by weight of the hybrid polymer polyol, and (2) from 0 to 95% by weight of one or more isocyanate-reactive components selected from the group consisting of polyether polyols, polyester polyols, polyoxyalkylene polyols, crosslinking agents, chain extenders and mixtures thereof, with the sum of the %'s by weight of (1) and (2) totaling 100% by weight of component (II).

23. The foam of claim 22 , wherein (II) said isocyanate-reactive component comprises (1) from 10 to 75% by weight of the hybrid polymer polyol, and (2) from 25 to 75% by weight of one or more isocyanate-reactive components selected from the group consisting of polyether polyols, polyester polyols, polyoxyalkylene polyols, crosslinking agents, chain extenders and mixtures thereof, with the sum of the %'s by weight of (1) and (2) totaling 100% by weight of component (II).

24. The foam of claim 21 , which additionally comprises

(V) at least one silicon surfactant.