Low Viscosity Systems for Fibre-Reinforced PU Composites

Title: 2K POLYURETHANE SYSTEMS WITH PHASE SEPARATION – AND-  2K POLYURETHANE SYSTEMS WITH A HIGH GLASS-TRANSITION TEMPERATURE

 Number/Link: WO2013/127732 and WO2013/127734

Applicant/Assignee: Henkel

Publication date: 6-09-2013

Gist”: Low-viscosity, high-potlife 2-component systems useful for the production of composites are prepared from a polyol and isocyanate component characterised only in that polyol and iso are immiscible (case 1) or that the di-iso contains an amount of uretonimine (case 2).

Why it is interesting: These are two rather strange cases.  The claims are very wide and the only ‘inventive step’ for the WO-32 case is that iso and polyol are chosen such that they are incompatible and phase separate after mixing as evidenced by the mixture becoming turbid.  The inventive step in the WO-34 case is that the isocyanate is based on 2,4′ and 4,4′ MDI of which 3-25% (of the NCO) has been converted to uretonimine. Advantages mentioned are low viscosity, long potlife (open time) and a high Tg after crosslinking.  In the examples a polyol/iso mixture is shown with an NCO index of 120, resp 150 without any catalyst or another additives. The ‘surprising effect’ in this invention is not immediatly clear to me and judging from the number of “X”-es in the search report the claims will most likely not get granted as such.

Carbon Fibre Composite

Carbon Fibre Composite

Reducing aldehyde emissions from flexible foams

Title: POLYURETHANE FOAMS WITH DECREASED ALDEHYDE EMISSIONS, A PROCESS FOR PREPARING THESE FOAMS AND A METHOD FOR DECREASING ALDEHYDE EMISSIONS IN POLYURETHANE FOAMS

 Number/Link: WO2013116092

Applicant/Assignee: Bayer

Publication date: 8-08-2013

Gist”: Use of small amounts of hexamethylenediisocyanate trimer or small amounts of “PHD” polyols result in reduced aldehyde emissions from flex foams.

Why it is interesting: Reduction of VOC emissions and especially emissions of formaldehyde and acetaldehyde are an important issue for the polyurethane flexible foam industry, especially for bedding and automotive applications. This invention teaches two “tricks” to help solve the problem.  To a (preferably) TDI-based flex foam formulation which comprises at least one SAN or PIPA filled polyol, 0.5-3 pbw of trimerized hexamethylene diisocyanate is added on 100 pbw of the isocyanate.  Alternatively 2-3 pbw of PHD polyol is added on 100 pbw of the iso-reactive component. In the art “PHD polyol” usually stands for a polyurea ‘filled’ polyol (polyharnstoff dispersion), but in this case it stands for polyhydrazodicarnbonamide filled polyols. These PHD polyols are prepared by reacting a hydrazine with an isocyanate (pref TDI80) in a base polyol, so they are actually a subset of ‘conventional’ PHD dispersions.  The patent application is a bit confusing in this respect.

Hydroazodicarbonamide

Hydrazodicarbonamide

Polymer Polyols with Phosphorous-Containing Particles

Title: PHOSPHOROUS BASED POLYADDITION/POLYURETHANE-UREA POLYOLS

 Patent Number & Link: WO2013101524

Applicant/Assignee: Dow

Publication date: 4-07-2013

Gist”: PHD and PIPA polyols are produced in the presence of phosphorous containing polyols

Why it is interesting: PDH or PIPA polymer polyols can be prepared by dissolving a low MW amine- or  hydroxyl containing co-reactant in a ‘base polyol’ and subsequently reacting with an isocyanate. When executed properly and with the correct ingredients this results in a stable dispersion of respectively urea or urethane particles in the base polyol. (see also previous posts in this blog). This invention states that by using phosphorous flame retardants containing amine or hydroxyl groups in addition to the co-reactant, PIPA or PHD (or hybrid) polymer polyols can be prepared with flame the retardant incorporated in the particles, resulting in a flame retardant polymer polyol.

Phosphorous polyol as used in the invention

Phosphorous polyol as used in the invention

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