US4365025A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Flexible polyurethane foams from polymethylene polyphenyl isocyanate containing prepolymers
Assignee: WR Grace and Co
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Filing: 1981-12-08
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Granted: 1982-12-21
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Expires: 2001-12-08
Abstract
Abstract Flexible polyurethane foams are made from isocyanate containing prepolymers where the isocyanate is a mixture of diphenylmethane diisocyanate (MDI) and polymeric forms of MDI. The isocyanate mixture has a functionality greater than 2.0. The prepolymer is an isocyanate capped polyol or mixture of polyols where the polyols are diols or triols having at least 50% by weight oxyethylene groups. The foams are made by reacting water with the prepolymer and fire retardant materials can be added to the reaction mixture to produce fire retardant foams. The foams have improved physical properties and flammability resistance.
Inventors
- 👤 Robert M. Murch
- 👤 Louis L. Wood
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 18:04
CPC Classifications
C; C08; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/48; C08G18/4833; C08G18/70; C08G18/72; C08G18/74; C08G18/76; C08G18/7657; C08G18/7664; C08G2110/00; C08G2110/0008; C08G2110/0016; C08G2110/0025; C08G2110/0083; Y; Y10; Y10S; Y10S521/00; Y10S521/905; Y10S521/914
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
101 words
A flexible foam having low compression set values of about 25% or less and good hydrolytic stability made by mixing together and reacting an aqueous phase and a resin phase comprising a prepolymer derived from (a) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of diphenylmethane diisocyanate and polymethylene polyphenyl isocyanate, and (b) a polyol having at least about 50% by weight of oxyethylene groups and having nominally two to three hydroxyl equivalents per mole, the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 1.5:1 to 5:1.
Claim 2
Dependent Claim
101 words
A flexible foam having low compression set values of about 25% or less and good hydrolytic stability made by mixing together and reacting an aqueous phase and a resin phase comprising a prepolymer derived from (a) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of diphenylmethane diisocyanate and polymethylene polyphenyl isocyanate, and (b) a polyol having at least about 50% by weight of oxyethylene groups and having nominally two to three hydroxyl equivalents per mole, the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 1.5:1 to 5:1.
Claim 3
Dependent Claim
23 words
A flexible foam according to claim 1, wherein the polyol is a diol having a molecular weight of from about 200 to 6,000.
Claim 4
Dependent Claim
20 words
A flexible foam according to claim 2, wherein the diol has a molecular weight of from about 400 to 4,500.
Claim 5
Dependent Claim
29 words
A flexible foam according to claim 1, wherein the polyol comprises a mixture of at least two diols each having a molecular weight of from about 200 to 6,000.
Claim 6
Dependent Claim
22 words
A flexible foam according to claim 1, wherein the polyol is a triol with a molecular weight of about 1,000 to 6,000.
Claim 7
Dependent Claim
23 words
A flexible foam according to claim 1, wherein the polyol is a mixture containing at least one diol and at least one triol.
Claim 8
Dependent Claim
17 words
A flexible foam according to claim 1, wherein the compression set value is about 20% or less.
Claim 9
Dependent Claim
19 words
A flexible foam according to claim 1, wherein the aqueous phase and/or resin phase further contains fire retardant materials.
Claim 10
Dependent Claim
17 words
A flexible foam according to claim 1, wherein the isocyanate product has a functionality of about 2.2.
Claim 11
Dependent Claim
93 words
A prepolymer capable of reacting with water to form a flexible foam having low compression set values and good hydrolytic stability, said prepolymer made by reacting together (a) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of diphenylmethane diisocyanate and polymethylene polyphenyl isocyanate, and (b) a polyol having at least about 50% by weight of oxyethylene groups and having nominally two to three hydroxyl equivalents per mole, the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 1.5:1 to 5:1.
Claim 12
Dependent Claim
93 words
A prepolymer capable of reacting with water to form a flexible foam having low compression set values and good hydrolytic stability, said prepolymer made by reacting together (a) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of diphenylmethane diisocyanate and polymethylene polyphenyl isocyanate, and (b) a polyol having at least about 50% by weight of oxyethylene groups and having nominally two to three hydroxyl equivalents per mole, the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 1.5:1 to 5:1.
Claim 13
Dependent Claim
24 words
A prepolymer according to claim 10, wherein the polyol is at least one diol having a molecular weight of from about 200 to 6,000.
Claim 14
Dependent Claim
19 words
A prepolymer according to claim 11, wherein the diol has a molecular weight of from about 400 to 4,500.
Claim 15
Dependent Claim
28 words
A prepolymer according to claim 10, wherein the polyol comprises a mixture of at least two diols each having a molecular weight of from about 200 to 6,000.
Claim 16
Dependent Claim
21 words
A prepolymer according to claim 10, wherein the polyol is a triol with a molecular weight of about 1,000 to 6,000.
Claim 17
Dependent Claim
22 words
A prepolymer according to claim 10, wherein the polyol is a mixture containing at least one diol and at least one triol.
Claim 18
Dependent Claim
16 words
A prepolymer according to claim 10, wherein the isocyanate product has a functionality of about 2.2.
Claim 19
Independent Claim
104 words
A method of making a flexible foam having low compression set values of about 25% or less and good hydrolytic stability comprising mixing together and reacting an aqueous phase and a resin phase comprising a prepolymer derived from (a) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of diphenylmethane diisocyanate and polymethylene polyphenyl isocyanate, and (b) a polyol having at least about 50% by weight of oxyethylene groups and having nominally two to three hydroxyl equivalents per mole, the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 1.5:1 to 5:1.
Claim 20
Independent Claim
104 words
A method of making a flexible foam having low compression set values of about 25% or less and good hydrolytic stability comprising mixing together and reacting an aqueous phase and a resin phase comprising a prepolymer derived from (a) a diphenylmethane diisocyanate-containing isocyanate product with a functionality of greater than 2.0 comprising a mixture of diphenylmethane diisocyanate and polymethylene polyphenyl isocyanate, and (b) a polyol having at least about 50% by weight of oxyethylene groups and having nominally two to three hydroxyl equivalents per mole, the ratio of the isocyanate equivalents to the total hydroxyl equivalents being in the range of 1.5:1 to 5:1.
Claim 21
Dependent Claim
27 words
A method of making a flexible foam according to claim 17, wherein the polyol is a diol having a molecular weight of from about 200 to 6,000.
Claim 22
Dependent Claim
24 words
A method of making a flexible foam according to claim 18, wherein the diol has a molecular weight of from about 400 to 4,500.
Claim 23
Dependent Claim
33 words
A method of making a flexible foam according to claim 17, wherein the polyol comprises a mixture of at least two diols each having a molecular weight of from about 200 to 6,000.
Claim 24
Dependent Claim
26 words
A method of making a flexible foam according to claim 17, wherein the polyol is a triol with a molecular weight of about 1,000 to 6,000.
Claim 25
Dependent Claim
27 words
A method of making a flexible foam according to claim 17, wherein the polyol is a mixture containing at least one diol and at least one triol.
Claim 26
Dependent Claim
21 words
A method of making a flexible foam according to claim 17, wherein the isocyanate product has a functionality of about 2.2.
Claim 27
Dependent Claim
21 words
A method of making a flexible foam according to claim 17, wherein the compression set value is about 20% or less.
Claim 28
Dependent Claim
20 words
A method of making a flexible foam according to claim 17, wherein the aqueous phase further contains fire retardant materials.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1985-12-20 | 1986-06-21 | 1986-12-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1989-12-20 | 1990-06-21 | 1990-12-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1993-12-20 | 1994-06-21 | 1994-12-21 | $7700.00 | Window Closed / Lapsed |