Method of preparing a urethane prepolymer and polymer

Claim 1

A method of forming a hydrophilic urethane prepolymer, said method comprising the steps of: (a) adding to a polyether or polyester compound under substantially anhydrous conditions a stoichiometric excess of compound containing at least two active isocyanate groups per molecule to form a reaction mixture and initiate an exothermic condensation reaction between said polyether or polyester compound and said isocyanate compound, the temperature of said reactants being such that the temperature of said reaction mixture after addition of isocyanate is greater than about 120° C.; (b) allowing said reaction to proceed in order to form a hydrophilic urethane prepolymer; (c) observing the temperature of said reaction mixture as said reaction proceeds; and (d) adding to said reaction mixture additional anhydrous polyether or polyester compound when said reaction mixture temperature exceeds a predetermined maximum value, whereby said reaction is quenched.

Claim 2

A method of forming a hydrophilic urethane prepolymer, said method comprising the steps of: (a) adding to a polyether or polyester compound under substantially anhydrous conditions a stoichiometric excess of compound containing at least two active isocyanate groups per molecule to form a reaction mixture and initiate an exothermic condensation reaction between said polyether or polyester compound and said isocyanate compound, the temperature of said reactants being such that the temperature of said reaction mixture after addition of isocyanate is greater than about 120° C.; (b) allowing said reaction to proceed in order to form a hydrophilic urethane prepolymer; (c) observing the temperature of said reaction mixture as said reaction proceeds; and (d) adding to said reaction mixture additional anhydrous polyether or polyester compound when said reaction mixture temperature exceeds a predetermined maximum value, whereby said reaction is quenched.

Claim 3

A method of forming a hydrophilic urethane prepolymer, said method comprising the steps of: (a) adding to a polyether or polyester compound under substantially anhydrous conditions a stoichiometric excess of a compound containing at least two active isocyanate groups per molecule to form a reaction mixture and initiate an exothermic condensation reaction between said polyether or polyester compound and said isocyanate compound, the temperature of said reactants being such that the temperature of said reaction mixture after addition of isocyanate is greater than about 120° C.; (b) allowing said reaction to proceed in order to form a hydrophilic urethane prepolymer; (c) observing the temperature of said reaction mixture; (d) adding to said reaction mixture additional anhydrous polyether or polyester compound when said reaction mixture temperature exceeds a predetermined maximum value, whereby said reaction is quenched; (e) allowing said reaction mixture temperature to fall below said predetermined maximum value after quenching; and (f) adding to said reaction mixture a quantity of said isocyanate compound sufficient to re-initiate said reaction.

Claim 4

A method of forming a hydrophilic urethane prepolymer, said method comprising the steps of: (a) adding to a polyether or polyester compound under substantially anhydrous conditions a stoichiometric excess of a compound containing at least two active isocyanate groups per molecule to form a reaction mixture and initiate an exothermic condensation reaction between said polyether or polyester compound and said isocyanate compound, the temperature of said reactants being such that the temperature of said reaction mixture after addition of isocyanate is greater than about 120° C.; (b) allowing said reaction to proceed in order to form a hydrophilic urethane prepolymer; (c) observing the temperature of said reaction mixture; (d) adding to said reaction mixture additional anhydrous polyether or polyester compound when said reaction mixture temperature exceeds a predetermined maximum value, whereby said reaction is quenched; (e) allowing said reaction mixture temperature to fall below said predetermined maximum value after quenching; and (f) adding to said reaction mixture a quantity of said isocyanate compound sufficient to re-initiate said reaction.

Claim 5

A method of forming a cellular urethane polymer, said method comprising the steps of: (a) adding to a polyether or polyester compound under substantially anhydrous conditions a stoichiometric excess of a compound containing at least two active isocyanate groups per molecule to initiate an exothermic condensation reaction between said polyether or polyester compound and said isocyanate compound, the temperature of said reactants being such that the temperature of said reactants after addition of isocyanate is greater than about 120° C.; (b) allowing said reaction to proceed in order to form a hydrophilic urethane prepolymer; and (c) reacting said prepolymer with water to form said cellular urethane polymer.

Claim 6

A method of forming a cellular urethane polymer, said method comprising the steps of: (a) adding to a polyether or polyester compound under substantially anhydrous conditions a stoichiometric excess of a compound containing at least two active isocyanate groups per molecule to initiate an exothermic condensation reaction between said polyether or polyester compound and said isocyanate compound, the temperature of said reactants being such that the temperature of said reactants after addition of isocyanate is greater than about 120° C.; (b) allowing said reaction to proceed in order to form a hydrophilic urethane prepolymer; and (c) reacting said prepolymer with water to form said cellular urethane polymer.