Polymer polyol compositions, a process for preparing these novel polymer polyol compositions, flexible foams prepared from these novel polymer polyols and a process for the preparation of these flexible foams

1. A polymer polyol composition having a solids content of from 10 to 72% by weight, and comprising

(A) a polymer polyol having a solids content of from 44 to 75% by weight, a viscosity at 25° C. of less than 50,000 mPa·s, and which comprises the reaction product of;

(1) at least one base polyol having a functionality of from 2 to 8 and a hydroxyl number of from 20 to 400;

(2) one or more ethylenically unsaturated monomers;

(3) a preformed stabilizer which comprises the reaction product of:

(a) a macromer that contains reactive unsaturation and comprises the reaction product of;

(i) a starter compound having a functionality of 2 to 8 and a hydroxyl number of from 20 to 50;

(ii) 0.1 to 3% by weight, based on 100% by weight, of the sum of components (i), (ii) and (iii), of a hydroxyl-reactive compound that contains reactive unsaturation;

and

(iii) 0.05 to 3% by weight, based on 100% by weight of the sum of components (i), (ii) and (ill), of diisocyanate;

with

(b) one or more ethylenically unsaturated monomer,

and

(c) at least one free radical intiator;

in the presence of

(d) a polymer control agent;

and, optionally,

(e) a liquid diluent;

in the presence of

(4) at least one free radical initiator;

and, optionally,

(5) a chain transfer agent:

and

(B) at, least one polyol component having a nationality of from 1 to 8 and a hydroxyl number of from 20 to 400;

wherein component (B) is present in an amount sufficient to reduce the total solids content in said polymer polyol (A) by at least 5% by weight.

2. The polymer polyol composition of claim 1 , wherein (A)(3)(a) said macromer comprises the reaction product of (i) a starter compound having a functionality of 3 to 6 and a hydroxyl number of from 25 to 40 (ii) 0.1 to 3% by weight, based on 100% by weight of the sum of components (i), (ii) and (iii): of a hydroxyl-reactive compound that contains reactive unsaturation that is selected from the group consisting of isopropenyl dimethyl benzyl isocyanate, methyl methacrylate, maleic anhydride, adducts of isophorone diisocyanate and 2-hydroxyethyl methacrylate and mixtures thereof; (iii) 0.1 to 3% by we based on 100% by weight of the sum of components (i), (ii) and (iii); of one or more isomers of diphenylmethane diisocyanate.

3. The polymer polyol composition of claim 1 , wherein (A)(3)(a)(i) said starter contains from 1 to 40% by weight, based on 100% by weight of (A)(3)(a)(i), of ethylene oxide which is added either as a co-feed or as a cap.

4. The polymer polyol composition of claim 1 , wherein (A)(3)(b) said one or more ethylenically unsaturated monomers comprises a mixture of styrene and acrylonitrile.

5. The polymer polyol composition of claim 1 , wherein (A)(3)(b) said mixtures of styrene and acrylonitrile is present in a weight ratio of from 20:80 to 80:20.

6. The polymer polyol composition of claim 1 , wherein (A)(3)(c) said free radical initiator is selected from the group consisting of azo compounds and peroxide compounds.

7. The polymer polyol composition of claim 1 , wherein (A)(2) said ethylenically unsaturated monomers comprises styrene and acrylonitrile in a weight ratio of 80:20 to 20:80.

8. The polymer polyol composition of claim 1 , wherein (A)(1) said base polyol has a functionality of from 3 to 6 and a hydroxyl number of from 25 to 200.

9. The polymer polyol composition of claim 1 , wherein (A)(4) said free radical initiator is selected from the group consisting of azo compounds, peroxide compounds and mixtures thereof.

10. The polymer polyol composition of claim 1 , wherein (B) said polyol has a functionality of from 2 to 3 and an OH number of from 25 to 200.

11. The polymer polyol composition of claim 1 , wherein component (B) is present in an amount sufficient to reduce the total solids content in said polymer polyol (A) by at least 33% by weight.

12. The polymer polyol composition of claim 1 , wherein component (B) is present in an amount sufficient to reduce the total solids content in said polymer polyol (A) by at least 61% by weight.

13. A polymer polyol composition having a solids content of from 10 to 72% by weight, and comprising

(A) a polymer polyol having a solids content of from 44 to 75% by weight, a viscosity at 25° C. of less than 50,000 mPa·s, and which comprises the reaction product of

(1) at least one base polyol having a functionality of from 2 to 8 and a hydroxyl number of from 20 to 400;

(2) one or more ethylenically unsaturated monomers;

(3) a preformed stabilizer which comprises the reaction product of:

(a) a macromer that contains reactive unsaturation and comprises the reaction product of:

(i) a starter compound having a functionality of 2 to 8 and a hydroxyl number of from 20 to 50;

(ii) 0.1 to 3% by weight, based on 100% by weight of the sum of components (i), (ii) and (iii), of a hydroxyl-reactive compound that contains reactive unsaturation;

and

(iii) 0.05 to 3% by weight, based on 100% by weight of the sum of components (i), (ii) and (iii), of diisocyanate comprising one or more isomers of diphenylmethane diisocyanate or an isomeric mixture of diphenylmethane diisocyanate:

with

(b) one or more ethylenically unsaturated monomers;

and

(c) at least one free radical initiator;

in the presence of

(d) a polymer control agent;

and, optionally,

(e) a liquid diluent;

in the presence of

(4) at least one free radical initiator;

and, optionally,

(5) a chain transfer agent;

and

(B) at least one polyol component having a functionality of from 1 to 8 and a hydroxyl number of from 20 to 400;

wherein component (B) is present in an amount sufficient to reduce the total solids content in said polymer polyol (A) by at least 5% by weight.

14. A process for preparing a novel polymer polyol composition comprising:

(I) blending:

(A) a polymer polyol having a solids content of from 44 to 75% by weight, a viscosity at 25° C. of less than 50,000 mPa·s, and which comprises the reaction product of:

(1) at least one base polyol having a functionality of from 2 to 8 and a hydroxyl number of from 20 to 400;

(2) one or more ethylenically unsaturated monomers;

(3) a preformed stabilizer which comprises the reaction product of:

(a) a macromer that contains reactive unsaturation and comprises the reaction product of:

(i) a starter compound having a functionality of 2 to 8 and a hydroxyl number of from 20 to 50;

(ii) 0.1 to 3% by weight, based on 100% by weight of the sum of components (I), (ii) and (iii), of a hydroxyl-reactive compound that contains reactive unsaturation;

and

(iii) 0.05 to by weight, based on 100% by weight of the sum of components (i), (ii) and (iii), of diisocyanate;

with

(b) one or more ethylenically unsaturated monomers;

and

(c) at leas, one free radical initiator;

in the presence of

(d) a polymer control agent;

and, optionally,

(e) a liquid diluent;

in the presence of

(4) at least one free radical initiator;

and, optionally,

(5) a chain transfer agent;

and

(B) at least one polyol component having a functionality of from 1 to 8 and a hydroxyl number of from 20 to 400;

wherein component (B) is present in an amount sufficient to reduce the total solids content in said polymer polyol (A) by at least 5% by weight.

15. A flexible polyurethane foam comprising the reaction product of;

(I) one or more diisocyanates, polyisocyanates or mixtures thereof;

with

(II) an isocyanate reactive component comprising the polymer polyol composition of claim 1 ;

in the presence of

(III) one or more catalysts;

(IV) one or more blowing agents;

and, optionally,

(V) one or more surfactants.

16. A process for the production of a flexible polyurethane foam comprising reacting:

(I) one or more diisocyanates, polyisocyanates or mixtures thereof;

with

(II) an isocyanate-reactive component comprising the polymer polyol composition of claim 1 ;

in the presence of

(III) one or more catalysts;

(IV) one or more blowing agents;

and, optionally,

one or more surfactants.

17. The flexible polyurethane foam of claim 15 , which is characterized by an increased solids efficiency at X % IFD as measured in accordance with ASTM D3574, wherein X % IFD equals 25% IFD, 50% IFD or 65% IFD.

18. The process for the production of a flexible polyurethane form of claim 16 , wherein the resultant flexible foam is characterized by an increased solids efficiency at X % IFD as measured in accordance with ASTM 03674, wherein X % IFD equals 25% IFD, 50% IFD or 65% IFD.