GB2099440A - Rigid polymeric foams - Google Patents
Rigid polymeric foams Download PDFInfo
- Publication number
- GB2099440A GB2099440A GB8211759A GB8211759A GB2099440A GB 2099440 A GB2099440 A GB 2099440A GB 8211759 A GB8211759 A GB 8211759A GB 8211759 A GB8211759 A GB 8211759A GB 2099440 A GB2099440 A GB 2099440A
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- United Kingdom
- Prior art keywords
- component
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/48—Polyethers
- C08G18/4829—Polyethers containing at least three hydroxy groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/14—Manufacture of cellular products
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/48—Polyethers
- C08G18/4833—Polyethers containing oxyethylene units
- C08G18/4837—Polyethers containing oxyethylene units and other oxyalkylene units
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/48—Polyethers
- C08G18/4833—Polyethers containing oxyethylene units
- C08G18/4837—Polyethers containing oxyethylene units and other oxyalkylene units
- C08G18/4841—Polyethers containing oxyethylene units and other oxyalkylene units containing oxyethylene end groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
- C08G18/72—Polyisocyanates or polyisothiocyanates
- C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
- C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
- C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
- C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0025—Foam properties rigid
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0041—Foam properties having specified density
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0083—Foam properties prepared using water as the sole blowing agent
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Polyurethanes Or Polyureas (AREA)
Abstract
A method of making these foams comprises mixing together and allowing to react (a) a diphenylmethane diisocyanate composition comprising diphenylmethane diisocyanates and polymethylene polyphenyl polyisocyanates; (b) a polyoxyalkylene polyol having a molecular weight of not less than 3000, and containing oxypropylene and optionally oxyethylene residues, the latter in an amount of from 0 to 90% of the total alkylene oxide residues present; (c) water, a part of which is optionally replaced by a monomeric difunctional isocyanate-reactive compound having a molecular weight of from 62 to 300; (d) a catalyst for foam formation; and optionally (e) minor amounts of other conventional polyurethane foam ingredients; the amount of component (b) used being not less than 3 parts by weight for each part by weight of component (c) used and the Isocyanate Index of components (a), (b) and (c) taken together being from 70 to 120. Any conventional catalyst may be used, producing less brittle, less flammable water blown polyurea foams. Foam density is increased by increasing the proportion of the isocyanate-reactive compound to water in component (c).
Description
SPECIFICATION
Rigid polymeric foams
This invention relates to rigid polymeric foams and more particularly to polyisocyanate-based foams which are essentially water blown.
The production of polyisocyanate-based water blown foams is known. These foams are commonly called polyurea foams and are made by a process in which a polyisocyanate is reacted with water and a specific catalyst for foam formation, the water normally being used in large excess over that needed for complete reaction with the polyisocyanate.
One such process is described in UK Patent
Specification No. 1 548370 in which an imidazole compound is used as the catalyst. It has not been possible hitherto to employ any catalyst conventionally used for polyurethane foams in the production of polyurea foams because the foams tend to collapse. Polyurea foams also suffer from the disadvantages of brittleness and easy flammability.
By the present invention, less brittle, less flammable polyurea foams may be obtained using any conventional polyurethane foam catalyst.
According to the invention, we provide a method of making a rigid polymeric foam which comprises mixing together and allowing to react (a) a diphenylmethane diisocyanate composition comprising diphenylmethane diisocyanates and polymethylene polyphenyl polyisocyanates; (b) a polyoxyalkylene polyol having a molecular weight of not less than 3000, preferably of from 4500 to 7000, and containing oxypropylene and optionally oxyethylene residues, the latter in an amount of from 0 to 90% of the total alkylene oxide residues present; (c) water, a part of which is optionally replaced by a monomeric difunctional isocyanate-reactive compound having a molecular weight of from 62 to 300; (d) a catalyst for foam formation; and optionally (e) minor amounts of other conventional polyurethane foam ingredients; the amount of component (b) used being not less than 3 parts, preferably not less than 4 parts, by weight for each part by weight of component (c) used and the Isocyanate Index of components (a), (b) and (c) taken together being from 70 to 120, preferably from 95 to 1 05. The invention also includes the foam so obtained.
By the term "Isocyanate Index" we mean one hundred times the ratio of free isocyanate groups to isocyanate-reactive groups which are present before reaction takes place.
Component (a) is any one of the compositions obtained in known manner by the phosgenation of crude diaminodiphenylmethane. Such compositions are commonly referred to as crude MDI and sometimes as polymeric MDI. They comprise diphenylmethane diisocyanates, mainly the 4,4'-and 2,4'isomers, and polymethylene polyphenyl polyisocyanates of functionality greater than two.
The amount of diisocyanates present is from 30% to 95%, usually 40% to 80% by weight of the composition. Compositions whose isocyanate functionality is about 2.7 produce good quality foams but better still are foams produced from compositions whose functionality is about 2.9. Thus there is a preference for compositions containing more polymeric species. Small amounts of other polyisocyanates, such as tolylene diisocyanates, may be included in the diphenylmethane diisocyanate composition or the composition modified by reaction with, for example, small amounts of monomeric polyols.
Component (b) is traditionally a flexible foam polyol. It may be a polyoxypropylene polyol or a poly(oxypropylene-oxyethylene) polyol or a mixture thereof. Such polyols and methods for their preparation have been fully described in the relevant literature, many of the polyols being commercially available. The poly(oxypropylene-oxyethylene) polyols include ethylene oxide-tipped polyoxypropylene polyols and other random or block copolymers obtained by reacting ethylene and proplyene oxides with active hydrogen-containing initiators. Normally they will be triols having a nominal hydroxyl equivalent weight of not less than 1 000 and a hydroxyl number of 56 or less.Triols which we have found to be particularly useful are those, especially ethylene oxide tipped oxypropylated glycerols, having a nominal hydroxy equivalent weight of from 1 500 to 2300 and a hydroxyl number of from 37 to 24.
If water alone is used as component (c), low density rigid foams are obtained; i.e. foams having densities in a range of from 1 3 to 20 kg/m3. Denser foams, i.e. foams having densities greater than 20 kg/m3, are obtained if part of the water is replaced by a monomeric difunctional isocyanate-reactive compound, for example a diol, having a molecular weight of from 62 to 300. Depending on the particular compound or mixture of compounds chosen, an increase in density may be obtained at the expense of a loss in stiffness. Of suitable aliphatic diols, ethylene glycol is possibly the least detrimental in this respect.
If part of the water is replaced by a monomeric isocyanate-reactive compound of the type described, it is desirable to use a polyoxyalkylene polyol of higher ethylene oxide content as component (b) to preserve the quality of the foam. Generally, the greater the amount of the monomeric compound used, the higher should be the ethylene oxide content of the polyoxyalkylene polyol. As a guide, if water and a monomeric isocyanate-reactive compound are used in chemically equivalent amounts, the amount of ethylene oxide residues present in the polyoxyalkylene polyol is ideally in the range of from 50 to 80%, typically 75%, by weight of the total alkylene oxide residues present. If more monomeric compound is used, up to 90% by weight of the total alkylene oxide residues present may be ethylene oxide residues.If water alone is used a component (c) the amount of ethylene oxide residues present in the polyoxyalkylene polyol is ideally in the range of from 0 to 50%, preferably 10 to 30%, by weight of the total alkylene oxide residues present.
The amount of component (b) used should not be less than 3 parts by weight for each part by weight of component (c) used. If water alone is used as component (c) we have found that particularly good foams are obtained when 25 parts by weight of component (b) are used for every 6 parts by weight of component (c). If part of the water is replaced by a monomeric difunctional isocyanate-reactive compound, the amount of the polyoxyalkylene polyol is increased to keep the weight ratio of components (b) and (c) constant. For example, if a foam is made from 4 parts of a polyoxyalkylene polyol of molecular weight 5000 and 1 part of water a denser, but in other respects equivalent, foam can be made from 8 parts of a polyol of the same molecular weight but higher ethylene oxide content, 0.5 parts of water and 1.5 parts of ethylene glycol.Generally, the more polyoxyalkylene polyol used, the less stiff is the foam produced. The maximum amount of component (b) which should be used is therefore dependent on the stiffness of the foam required.
The method of the present invention is characterised by the use of water, or mixtures of water and the monomeric difunctional isocyanate-reactive compound, component (c), in amounts chemically equivalent, or thereabouts, to the diphenylmethane diisocyanate composition and in this respect differs from known methods for the production of the socalled polyurea foams. The number of isocyanate-reactive groups provided by the polyoxyalkylene polyol, component (b), will be small compared to the number provided by component (c). Thus it is a requirement of the present invention that the Isocyanate Index of components (a), (b) and (c) taken together is in the range of from 70 to 120, preferably from 95 to 105.
It is an advantage of the present invention that, whereas specific catalysts have hitherto been necessary for the production of so-called polyurea foams, any of the catalysts suitable for polyurethane foams may be used as component (d). Such catalysts have been fully described in the relevant literature and include tertiary amines and organic metal compounds, particularly tin compounds. Examples of suitable tertiary amines include N,N-dimethylcylohexylamine, N,N-dimethylbenzylamine, N,Ndimethylethanolamine and 1 ,4-diazabicy- clo[2.2.2]octane. Organic metal compounds which may be used as catalysts include stannous octoate and dibutyltin dilaurate. A mixture of catalysts, for example a mixture of amines or an amine and a tin compound, may also be used.
Other conventional polyurethane foam ingredients which may optionally be used as component (e) include surfactants, for example siloxane-oxyalkylene copolymers, fillers, fire-retardants, pigments and dyes.
The foams of the invention are essentially water blown foams and it should not normally be necessary to include a blowing agent in addition to the water of component (c). However, if it is desired to lower the foam density a low boiling solvent, for example trichlorofluoromethane, may be added.
The components of the foam-forming reaction mixture may be mixed together in any convenient manner, for example by using an" of the mixing equipment described in the relevant literature for the purpose. If desired, mutually inert individual components may be pre-blended so as to reduce the number of component streams requiring to be brought together in a final mixing step. It is often convenient to have a two-stream system whereby one stream comprises the polyisocyanate and the second comprises all the other components of the reaction mixture.
If desired, the density of the foamed product can be further modified by overpacking, that is to say foaming the reaction mixture in a closed mould having a volume less than that which would be occupied by the resultant foam if the reaction mixture were allowed to rise freely.
The rigid polymeric foams of the present invention tend to be less brittle, less flammable and have a higher closed-cell content than the so-called polyurea foams produced hither to. They also show advantages with respect to reduced shrinkage. The higher density foams of the invention tend to be less brittle than other conventional rigid foams.
Claims (9)
1. A method of making a rigid polymeric foam which comprises mixing together and allowing to react (a) a diphenylmethane diisocyanate composition comprising diphenylmethane diisocyanates and polymethylene polyphenyl polyisocyanates; (b) a polyoxyalkylene polyol having a molecular weight of not less than 3000 and containing oxypropylene and optionally oxyethylene residues, the latter in an amount of from 0 to 90% of the total alkylene oxide residues present; (c) water, a part of which is optionally replaced by a monomeric difunctional isocyan ate-reactive compound having a molecular weight of from 62 to 300; (d) a catalyst for foam formation; and optionally (e) minor amounts of other conventional polyurethane foam ingredients; the amount of component (b) used being not less than 3 parts by weight for each by weight of component (c) used and the Isocyanate
Index of components (a), (b) and (c) taken together being from 70 to 1 20.
2. A method according to claim 1 in which the polyoxyalkylene polyol (b) has a molecular weight of from 4500 to 7000.
3. A method according to claim 1 or 2 in which the amount of component (b) used is not less than 4 parts by weight for each part by weight of component (c) used.
4. A method according to any one of the preceding claims in which the Isocyanate Index of components (a), (b) and (c) taken together is from 95 to 105.
5. A method according to any one of the preceding claims in which the polyoxyalkylene component (b) is a polyoxypropylene polyol or a poly(oxypropylene-oxyethylene) polyol or a mixture thereof and is a triol having a nominal hydroxyl equivalent weight of not less than 1000 and a hydroxyl number of 56 or less.
6. A method according to claim 5 in which component (b) is an ethylene oxide tipped oxypropylated glycerol having a nominal hydroxyl equivalent weight of from 1 500 to 2300 and a hydroxyl number of from 37 to 24.
7. A method according to any one of the preceding claims in which the diphenylmethane diisocyanate composition (a) is crude
MDI.
8. A method according to claim 1 substantially as herein described.
9. A rigid polymeric foam obtained by a method according to any one of the preceding claims.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB8211759A GB2099440A (en) | 1981-05-28 | 1982-04-23 | Rigid polymeric foams |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB8116382 | 1981-05-28 | ||
GB8211759A GB2099440A (en) | 1981-05-28 | 1982-04-23 | Rigid polymeric foams |
Publications (1)
Publication Number | Publication Date |
---|---|
GB2099440A true GB2099440A (en) | 1982-12-08 |
Family
ID=26279628
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB8211759A Withdrawn GB2099440A (en) | 1981-05-28 | 1982-04-23 | Rigid polymeric foams |
Country Status (1)
Country | Link |
---|---|
GB (1) | GB2099440A (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0389881A2 (en) * | 1989-03-29 | 1990-10-03 | Bayer Ag | Process for the preparation of closed-cell urethane-, urea- and isocyanurate groups containing rigid foams and their use |
EP0451559A2 (en) * | 1990-04-05 | 1991-10-16 | Basf Corporation | Integral skin polyurethane foam |
GB2249793A (en) * | 1990-11-16 | 1992-05-20 | Basf Corp | Integral-skin rigid urethane foam |
WO1998021259A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | Process for making rigid and flexible polyurethane foams |
WO1998021261A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | New flexible polyurethane foams |
WO1998021260A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | Process for preparing rigid and flexible polyurethane foams |
WO1998021258A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | Process for making flexible polyurethane foams |
-
1982
- 1982-04-23 GB GB8211759A patent/GB2099440A/en not_active Withdrawn
Cited By (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0389881A2 (en) * | 1989-03-29 | 1990-10-03 | Bayer Ag | Process for the preparation of closed-cell urethane-, urea- and isocyanurate groups containing rigid foams and their use |
EP0389881A3 (en) * | 1989-03-29 | 1991-03-20 | Bayer Ag | Process for the preparation of closed-cell urethane-, urea- and isocyanurate groups containing rigid foams and their use |
US5350780A (en) * | 1989-03-29 | 1994-09-27 | Bayer Aktiengesellschaft | Process for the preparation of substantially closed-cell rigid foams containing urethane, urea, biuret, and isocyanurate groups and a method of use thereof |
EP0451559A2 (en) * | 1990-04-05 | 1991-10-16 | Basf Corporation | Integral skin polyurethane foam |
EP0451559A3 (en) * | 1990-04-05 | 1992-11-25 | Basf Corporation (A Delaware Corp.) | Integral skin polyurethane foam |
GB2249793A (en) * | 1990-11-16 | 1992-05-20 | Basf Corp | Integral-skin rigid urethane foam |
WO1998021260A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | Process for preparing rigid and flexible polyurethane foams |
WO1998021261A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | New flexible polyurethane foams |
WO1998021259A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | Process for making rigid and flexible polyurethane foams |
WO1998021258A1 (en) * | 1996-11-08 | 1998-05-22 | Imperial Chemical Industries Plc | Process for making flexible polyurethane foams |
US6020390A (en) * | 1996-11-08 | 2000-02-01 | Imperial Chemical Industries Plc | Process for making flexible polyurethane foams |
US6020391A (en) * | 1996-11-08 | 2000-02-01 | Imperial Chemical Industries Plc | Flexible polyurethane foams |
US6043292A (en) * | 1996-11-08 | 2000-03-28 | Imperial Chemical Industries Plc | Process for making flexible polyurethane foams |
US6147134A (en) * | 1996-11-08 | 2000-11-14 | Imperial Chemical Industries Plc | Process for preparing rigid and flexible polyurethane foams |
US6187832B1 (en) | 1996-11-08 | 2001-02-13 | Imperial Chemical Industries Plc | Process for making flexible polyurethane foams |
US6288134B1 (en) * | 1996-11-08 | 2001-09-11 | Imperial Chemical Industries Plc | Flexible polyurethane foams |
US6346204B1 (en) | 1996-11-08 | 2002-02-12 | Huntsman International Llc | Process for preparing rigid and flexible polyurethane foams |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |