HIGH FUNCTIONALITY ISOCYANATES AS POLYMER POLYOL STABILIZERS AND THE POLYMER POLYOLS PREPARED FROM THESE STABILIZERS
A high functionality macromer that is the reaction product of (1) a polyisocyanate having an NCO group content of about from about 10% to about 33% having a functionality greater than 2, (2) at least one alcohol with reactive unsaturation, and (3) a hydroxyl group-containing polyether having an OH number of from 9 to 60 and a functionality of from 1 to 6 is used to produce a pre-formed stabilizer that is used to produce a high solids content polymer polyol.
1 . A high functionality macromer which comprises the reaction product of:
(a) a polyisocyanate having an NCO group content of about from about 10% to about 33% having a functionality greater than 2,
(b) at least one alcohol with reactive unsaturation,
and
(c) a hydroxyl group-containing polyether having an OH number of from 9 to 60 and a functionality of from 1 to 6,
optionally, in the presence of
(d) a catalyst.
2 . The macromer of claim 1 in which (a) is selected from the group consisting of aliphatic isocyanates, aromatic isocyanates, and mixtures thereof.
3 . The macromer of claim 1 in which (b) is selected from the group consisting of hydroxyalkyl acrylates, hydroxyalkyl methacrylates, hydroxyaryl acrylates, hydroxyaryl methacrylates, aromatic-substituted ethylenically unsaturated monols, isopropenylphenyl monols, hydroxyl nitriles, and mixtures thereof.
4 . The macromer of claim 1 in which (b) comprises 2-hydroxyethyl methacrylate.
5 . The macromer of claim 1 in which (a) and (b) are reacted before being reacted with (c).
6 . A process for the preparation of a high functionality macromer, comprising:
(I) reacting
(a) a polyisocyanate having an NCO group content of about 10 to about 33% having a functionality greater than 2,
(b) at least one alcohol with reactive unsaturation and
(c) a hydroxyl group-containing polyether having an OH number of from 9 to 60 and a functionality of from 1 to 6,
optionally, in the presence of
(d) a catalyst.
7 . The process of claim 6 in comprising reacting (a) and (b) to form a modified polyisocyanate that is subsequently reacted with (c).
8 . A preformed stabilizer comprising the free-radical polymerization product of:
(A) macromer of claim 1 ,
with
(B) at least one ethylenically unsaturated monomer,
formed in the presence of
(C) at least one free-radical polymerization initiator,
and, optionally,
(D) a liquid diluent,
and, optionally,
(E) a chain transfer agent.
9 . The preformed stabilizer of claim 8 in which (A) comprises the reaction product of:
(a) a polyisocyanate having an NCO group content of from about 10 to about 33%
with
(b) an alcohol selected from the group consisting of hydroxyalkyl acrylates, hydroxyalkyl methacrylates, hydroxyaryl acrylates, hydroxyaryl methacrylates, aromatic-substituted ethylenically unsaturated monols, isopropenyiphenyl monols, hydroxyl nitriles and mixtures thereof;
and
(c) a hydroxyl group-containing polyether having a functionality of from about 1 to about 6, an OH number of from about 9 to about 60 and a molecular weight of from about 2,000 to about 12,000.
10 . A process for the preparation of a preformed stabilizer comprising:
(I) free-radically polymerizing:
(A) ethylenically unsaturated macromer of claim 1 ,
with
(B) at least one ethylenically unsaturated monomer,
in the presence of
(C) at least one free-radical polymerization initiator,
and, optionally,
(D) a liquid diluent,
and, optionally,
(E) a chain transfer agent.
11 . A polymer polyol comprising the reaction product of:
(I) a base polyol having a hydroxyl number of from about 20 to about 500, a functionality of about 2 to about 6, and an equivalent weight of from about 100 to about 3,000,
(II) the preformed stabilizer of claim 9 ,
and
(III) at least one ethylenically unsaturated monomer,
in the presence of
(IV) at least one free-radical polymerization initiator,
and, optionally,
(V) a chain transfer agent.
12 . The polymer polyol of claim 11 in which (IV) is selected from the group consisting of acyl peroxides, alkyl peroxides, azo compounds and mixtures thereof.
13 . A process for the production of a polymer polyol comprising.
(1) free-radically polymerizing:
(I) a base polyol having a hydroxyl number of from about 20 to about 500, a functionality of from about 2 to about 6,
(II) the preformed stabilizer of claim 9 ,
and
(III) at least one ethylenically unsaturated monomer,
in the presence of
(IV) at least one free-radical polymerization initiator,
and, optionally,
(V) a chain transfer agent.
14 . The process of claim 13 in which (IV) is selected from the group consisting of acyl peroxides, alkyl peroxides, azo compounds and mixtures thereof.
15 . A polymer polyol comprising the reaction product of:
(I) a base polyol having a hydroxyl number of from about 20 to about 500, a functionality of from about 2 to about 6,
(II) the macromer of claim 1 ,
and
(III) at least one ethylenically unsaturated monomer,
in the presence of:
(IV) at least one free-radical polymerization initiator,
and, optionally,
(V) a chain transfer agent.
16 . A process for the production of a polymer polyol comprising:
(1) free-radically polymerizing:
(I) a base polyol having a hydroxyl number of from about 20 to about 500, a functionality of from about 2 to about 6,
(II) the macromer of claim 1 ,
and
(III) at least one ethylenically unsaturated monomer,
in the presence of:
(IV) at least one free-radical polymerization initiator,
and, optionally,
(V) a chain transfer agent.
17 . A process of for the production of a polyurethane comprising reacting (1) a polyisocyanate with (2) an isocyanate-reactive component comprising the polymer polyol of claim 15 .
18 . A process for the production of a polyurethane comprising reacting (1) a polyisocyanate with (2) an isocyanate-reactive component comprising the polymer polyol of claim 11 .