Polyurethane foam from high functionality polyisocyanate
A formulation system contains: (a) a pre-polymer reaction product of a polymeric isocyanate and a polyether polyol, where: (i) the polymeric isocyanate contains five weight-percent or more methylene diphenyl diisocyanate; (ii) the polymeric isocyanate has a functionality of 3.0 or less; (iii) the polyether polyol is present in the pre-polymer at a concentration of one to 25 weight-percent; (iv) the polyol has an equivalent weight of 50 to 500 grams per equivalent; (v) the —NCO concentration of the pre-polymer is 15 to 31 weight-percent; (vi) the pre-polymer is free of isocyanate trimers; (b) a polyester polyol component containing 10 to 25 weight-percent of free glycol; and (c) a blowing agent that contains less than five weight-percent water; where the ratio of pre-polymer and polyester result in foam having a trimer content of 12 to 22 weight-percent, and an —NCO index of more than 300 and less than 700.
1. A formulation system comprising:
(a) a pre-polymer that is a reaction product of a polymeric isocyanate and a polyether polyol, where:
(i) the polymeric isocyanate contains five weight-percent or more methylene diphenyl diisocyanate based on total polymeric isocyanate weight;
(ii) the polymeric isocyanate has a functionality of 3.0 or less;
(iii) the polyether polyol is present in the pre-polymer at a concentration of one weight-percent or more and 25 weight-percent or less based on total pre-polymer weight;
(iv) the polyether polyol has an equivalent weight of 50 or more and 500 or less grams per equivalent;
(v) the —NCO concentration of the pre-polymer is 15 weight-percent or more and 31 weight-percent or less based on total pre-polymer weight as determined according to ASTM D2572;
(vi) The pre-polymer is free of isocyanate trimers as determined by nuclear magnetic resonance spectroscopy; and
(b) a polyester polyol component comprising 10 weight-percent or more and 25 weight-percent or less of free glycol based on total polyester polyol component weight and the balance being polyester polyol; and
(c) a blowing agent that contains less than five weight-percent water based on total blowing agent weight;
where the ratio of pre-polymer and polyester polyol are such that, when mixed together they result in foam having a trimer content of 12 weight-percent or more and 22 weight-percent or less based on total polymer weight in the foam, and an —NCO index of more than 300 and less than 700.
2. The formulation system of claim 1 , where the blowing agent is selected from a group consisting of water, pentane isomers, 2,2-dimethylbutane and hydrofluoro-olefins.
3. The formulation system of claim 1 , where the polyester polyol is a reaction product of terephthalic acid and glycerol.
4. A method comprising mixing the pre-polymer, polyester polyol and blowing agent of claim 1 together to produce polymeric foam.
5. The method of claim 4 , where the concentration of blowing agent is sufficient to produce polymeric foam having a density of 24 kilograms per cubic meter or more and 48 kilograms per cubic meter or less as determined by ASTM D1622.
6. The method of claim 4 , where the blowing agent is selected from a group consisting of water and pentane isomers.