Flexible cellular material, composition and process for its preparation

Abstract

A flexible cellular material can be made by extruding a composition containing a polyurethane prepolymer, where the prepolymer has end groups selected from the group consisting of isocyanate end groups and trialkoxysilyl end groups, and the prepolymer is self-crosslinkable with moisture. The flexible cellular material has an expanded or foamed polymer matrix.

1 . A flexible cellular material prepared by a method, comprising: 
 extruding a composition comprising a macromolecular constituent to form said flexible cellular material;    wherein the macromolecular constituent is a polyurethane prepolymer comprising end groups selected from the group consisting of isocyanate end groups and trialkoxysilyl end groups,    said prepolymer is self-crosslinkable with moisture, and    said flexible cellular material does not include a noncrosslinked elastomer component.    
     
     
         2 . The flexible cellular material of  claim 1 , wherein said flexible cellular material has a density of less than or equal to 260 kg/m 3 .  
     
     
         3 . The flexible cellular material of  claim 1 , wherein said flexible cellular material exhibits a compression set of less than 25%.  
     
     
         4 . The flexible cellular material of  claim 1 , wherein said flexible cellular material exhibits a cellular structure in which the cells have a dimension of less than 0.3 mm.  
     
     
         5 . The flexible cellular material of  claim 1 , wherein said flexible cellular material exhibits a cellular structure in which the cells have a dimension of 0.03 to 0.2 mm.  
     
     
         6 . The flexible cellular material of  claim 1 , wherein said prepolymer is essentially single-phase.  
     
     
         7 . The flexible cellular material of  claim 1 , wherein said prepolymer is selected from the group consisting of a random copolymer; a homopolymer; and a block or grafted copolymer in which the various blocks are miscible with one another.  
     
     
         8 . The flexible cellular material of  claim 1 , wherein said prepolymer is a non-crosslinked oligomer prepared by a reaction comprising: 
 reacting 
 (i) at least one component selected from polyols and polyamines with a functionality of at least 2, said at least one component having a backbone selected from the group consisting of polyester, polycaprolactone, polyether, polyolefin, polybutadiene, polyisoprene and polydimethylsiloxane backbones; and  
 (ii) at least one polyisocyanate selected from the group consisting of paraphenylene diisocyanate, trans-1,4-cyclohexane diisocyanate, 3-isocyanatomethyl-3,3,5-trimethylcyclohexyl isocyanate, 1,5-naphthalene diisocyanate, 4,4′-methylenebis(phenyl isocyanate), crude 4,4′-methylenebis(phenyl isocyanate), 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, crude toluene diisocyanate, and oligomers comprising isocyanate end groups;  
   wherein said at least one polyisocyanate has a functionality of at least 2.    
     
     
         9 . The flexible cellular material of  claim 8 , wherein said (i) at least one component has a molecular mass of at most 10,000 g/mol.  
     
     
         10 . The flexible cellular material of  claim 8 , wherein said (i) at least one component has a molecular mass of 500 to 4000 g/mol.  
     
     
         11 . The flexible cellular material of  claim 1 , wherein said prepolymer is a non-crosslinked oligomer prepared by a reaction comprising: 
 reacting 
 (i) a first component selected from polyols and polyamines with a functionality of at least 2, said first component having a backbone selected from the group consisting of polyester, polycaprolactone, polyether, polyolefin, polybutadiene, polyisoprene and polydimethylsiloxane backbones; and  
 (ii) at least one polyisocyanate selected from the group consisting of paraphenylene diisocyanate, trans-1,4-cyclohexane diisocyanate, 3-isocyanatomethyl-3,3,5-trimethylcyclohexyl isocyanate, 1,5-naphthalene diisocyanate, 4,4′-methylenebis(phenyl isocyanate), crude 4,4′-methylenebis(phenyl isocyanate), 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, and crude toluene diisocyanate;  
   wherein said at least one polyisocyanate has a functionality of at least 2.    
     
     
         12 . The flexible cellular material of  claim 8 , wherein said (i) at least one component and said (ii) at least one polyisocyanate are reacted in a molar ration of NCO:(OH+NH 2 ) of the 2:1 to 3.5:1.  
     
     
         13 . The flexible cellular material of  claim 8 , wherein said prepolymer is prepared by a reaction further comprising modifying an oligomer obtained by the react between (i) and (ii) by reaction with a trialkoxysilylating agent.  
     
     
         14 . The flexible cellular material of  claim 1 , wherein said composition further comprises a particulate or pulverulent filler.  
     
     
         15 . The flexible cellular material of  claim 1 , wherein said flexible cellular material is in the form of a strip, panel, strand or pipe.  
     
     
         16 . The flexible cellular material of  claim 1 , wherein said method further comprises, prior to said extrusion, mixing said composition with a pressurized gas.  
     
     
         17 . The flexible cellular material of  claim 1 , wherein said method further comprises crosslinking the extruded composition in a moist atmosphere.  
     
     
         18 . A method of making a flexible cellular material, comprising: 
 extruding a composition comprising a macromolecular constituent to form said flexible cellular material;    wherein the macromolecular constituent is a polyurethane prepolymer comprising end groups selected from the group consisting of isocyanate end groups and trialkoxysilyl end groups,    said prepolymer is self-crosslinkable with moisture and    said flexible cellular material does not include a noncrosslinked elastomer component.    
     
     
         19 . The method of  claim 18 , wherein said prepolymer is essentially single-phase.  
     
     
         20 . The method of  claim 18 , wherein said prepolymer is selected from the group consisting of a random copolymer; a homopolymer; and a block or grafted copolymer in which the various blocks are miscible with one another.  
     
     
         21 . The method of  claim 18 , wherein said prepolymer is a non-crosslinked oligomer prepared by a reaction comprising: 
 reacting 
 (i) at least one component selected from polyols and polyamines with a functionality of at least 2, said at least one component having a backbone selected from the group consisting of polyester, polycaprolactone, polyether, polyolefin, polybutadiene, polyisoprene and polydimethylsiloxane backbones; and  
 (ii) at least one polyisocyanate selected from the group consisting of paraphenylene diisocyanate, trans-1,4-cyclohexane diisocyanate, 3-isocyanatomethyl-3,3,5-trimethylcyclohexyl isocyanate, 1,5-naphthalene diisocyanate, 4,4′-methylenebis(phenyl isocyanate), crude 4,4′-methylenebis(phenyl isocyanate), 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, crude toluene diisocyanate, and oligomers comprising isocyanate end groups;  
   wherein said at least one polyisocyanate has a functionality of at least 2.    
     
     
         22 . The method of  claim 21 , wherein said (i) at least one component has a molecular mass of at most 10,000 g/mol.  
     
     
         23 . The method of  claim 21 , wherein said (i) at least one component has a molecular mass of 500 to 4000 g/mol.  
     
     
         24 . The method of  claim 18 , wherein said prepolymer is a non-crosslinked oligomer prepared by a reaction comprising: 
 reacting 
 (i) a first component selected from polyols and polyamines with a functionality of at least 2, said first component having a backbone selected from the group consisting of polyester, polycaprolactone, polyether, polyolefin, polybutadiene, polyisoprene and polydimethylsiloxane backbones; and  
 (ii) at least one polyisocyanate selected from the group consisting of paraphenylene diisocyanate, trans-1,4-cyclohexane diisocyanate, 3-isocyanatomethyl-3,3,5-trimethylcyclohexyl isocyanate, 1,5-naphthalene diisocyanate, 4,4′-methylenebis(phenyl isocyanate), crude 4,4′-methylenebis(phenyl isocyanate), 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, and crude toluene diisocyanate;  
   wherein said at least one polyisocyanate has a functionality of at least 2.    
     
     
         25 . The method of  claim 21 , wherein said (i) at least one component and said (ii) at least one polyisocyanate are reacted in a molar ration of NCO:(OH+NH 2 ) of the 2:1 to 3.5:1.  
     
     
         26 . The method of  claim 21 , wherein said prepolymer is prepared by a reaction further comprising modifying an oligomer obtained by the react between (i) and (ii) by reaction with a trialkoxysilylating agent.  
     
     
         27 . The method of  claim 18 , wherein said composition further comprises a particulate or pulverulent filler.  
     
     
         28 . The method of  claim 18 , further comprising, prior to said extrusion, mixing said composition with a pressurized gas.  
     
     
         29 . The method of  claim 18 , further comprising crosslinking the extruded composition in a moist atmosphere.  
     
     
         30 . A composition comprising a macromolecular constituent, wherein said macromolecular constituent is a polyurethane prepolymer comprising end groups selected from the group consisting of isocyanate end groups and trialkoxysilyl end groups, 
 said prepolymer is self-crosslinkable with moisture, and    said composition does not include a second elatomeric polymer.    
     
     
         31 . The composition of  claim 30 , wherein said prepolymer is essentially single-phase.  
     
     
         32 . The composition of  claim 30 , wherein said prepolymer is selected from the group consisting of a random copolymer; a homopolymer; and a block or grafted copolymer in which the various blocks are miscible with one another.  
     
     
         33 . The composition of  claim 30 , wherein said prepolymer is a non-crosslinked oligomer prepared by a reaction comprising: 
 reacting 
 (i) at least one component selected from polyols and polyamines with a functionality of at least 2, said at least one component having a backbone selected from the group consisting of polyester, polycaprolactone, polyether, polyolefin, polybutadiene, polyisoprene and polydimethylsiloxane backbones; and  
 (ii) at least one polyisocyanate selected from the group consisting of paraphenylene diisocyanate, trans-1,4-cyclohexane diisocyanate, 3-isocyanatomethyl-3,3,5-trimethylcyclohexyl isocyanate, 1,5-naphthalene diisocyanate, 4,4′-methylenebis(phenyl isocyanate), crude 4,4′-methylenebis(phenyl isocyanate), 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, crude toluene diisocyanate, and oligomers comprising isocyanate end groups;  
   wherein said at least one polyisocyanate has a functionality of at least 2.    
     
     
         34 . The composition of  claim 33 , wherein said (i) at least one component has a molecular mass of at most 10,000 g/mol.  
     
     
         35 . The composition of  claim 33 , wherein said (i) at least one component and said (ii) at least one polyisocyanate are reacted in a molar ration of NCO:(OH+NH 2 ) of the 2:1 to 3.5:1.  
     
     
         36 . The composition of  claim 33 , wherein said prepolymer is prepared by a reaction further comprising modifying an oligomer obtained by the react between (i) and (ii) by reaction with a trialkoxysilylating agent.  
     
     
         37 . The composition of  claim 30 , wherein said composition further comprises a particulate or pulverulent filler.  
     
     
         38 . An extrudable composition, comprising the composition of  claim 30  mixed with a pressurized gas.  
     
     
         39 . A method of making a composition, comprising: 
 reacting 
 (i) a first component selected from polyols and polyamines with a functionality of at least 2, said first component having a backbone selected from the group consisting of polyester, polycaprolactone, polyether, polyolefin, polybutadiene, polyisoprene and polydimethylsiloxane backbones; and  
 (ii) at least one polyisocyanate selected from the group consisting of paraphenylene diisocyanate, trans-1,4-cyclohexane diisocyanate, 3-isocyanatomethyl-3,3,5-trimethylcyclohexyl isocyanate, 1,5-naphthalene diisocyanate, 4,4′-methylenebis(phenyl isocyanate), crude 4,4′-methylenebis(phenyl isocyanate), 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4-toluene diisocyanate and 2,6-toluene diisocyanate, and crude toluene diisocyanate;  
   wherein said at least one polyisocyanate has a functionality of at least 2, and    said composition does not include a second elastomeric polymer.    
     
     
         40 . The method of  claim 39 , wherein said (i) at least one component and said (ii) at least one polyisocyanate are reacted in a molar ration of NCO:(OH+NH 2 ) of the 2:1 to 3.5:1.  
     
     
         41 . The method of  claim 39 , further comprising modifying an oligomer obtained by the react between (i) and (ii) by reaction with a trialkoxysilylating agent.  
     
     
         42 . The method of  claim 39 , further comprising adding a particulate or pulverulent filler.  
     
     
         43 . A method of making an extrudable composition, comprising: 
 mixing the composition of  claim 30  with a pressurized gas.