Foamed isocyanate-based polymer having improved hardness properties and process for production thereof

Abstract

The invention relates to the surprising and unexpected discovery that a sub-group of phenolic resins (i.e., those which are substantially completely free of ether moieties) is particularly advantageous to confer load building properties to an isocyanate-based foam (e.g., a polyurethane foam). Indeed, its possible to utilize the sub-group of phenolic resins to partially or fully displace copolymer polyols conventionally used to confer load building characteristics to isocyanate-based polymer foams. Further, the invention relates to the surprising and unexpected discovery that a sub-group of phenolic resins (i.e., those which are substantially completely free of ether moieties) is particularly advantageous to confer energy absorption properties in an isocyanate-based foam.

1 . A foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a phenolic resin and a blowing agent; wherein the phenolic resin is substantially completely free of ether moieties.  
     
     
         2 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the active hydrogen-containing compound is selected from the group comprising polyols, polyamines, polyamides, polyimines and polyolamines.  
     
     
         3 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the active hydrogen-containing compound comprises a polyol.  
     
     
         4 . (Cancelled)  
     
     
         5 . (Cancelled)  
     
     
         6 . (Cancelled)  
     
     
         7 . The foamed isocyanate-based polymer defined in  claim 3 , wherein the polyol is a polyether polyol.  
     
     
         8 . The foamed isocyanate-based polymer defined in  claim 7 , wherein the polyether polyol has a molecular weight in the range of from about 200 to about 10,000.  
     
     
         9 . The foamed isocyanate-based polymer defined in  claim 7 , wherein the polyether polyol has a molecular weight in the range of from about 2000 to about 7,000.  
     
     
         10 . The foamed isocyanate-based polymer defined in  claim 7 , wherein the polyether polyol has a molecular weight in the range of from about 2,000 to about 6,000.  
     
     
         11 . (Cancelled)  
     
     
         12 . (Cancelled)  
     
     
         13 . (Cancelled)  
     
     
         14 . (Cancelled)  
     
     
         15 . (Cancelled)  
     
     
         16 . (Cancelled)  
     
     
         17 . (Cancelled)  
     
     
         18 . (Cancelled)  
     
     
         19 . (Cancelled)  
     
     
         20 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the isocyanate is selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.  
     
     
         21 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the isocyanate is selected from the group consisting essentially of (i) 2,4-diphenylmethane diisocyanate, 4,4 -diphenylmethane diisocyanate and mixtures thereof; and (ii) mixtures of (i) with an isocyanate selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.  
     
     
         22 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the blowing agent comprises water.  
     
     
         23 . (Cancelled)  
     
     
         24 . (Cancelled)  
     
     
         25 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the reaction mixture comprises phenolic resin in an amount of up to about 20 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         26 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the reaction mixture comprises phenolic resin in an amount in the range of from about 1.0 to about 15 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         27 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the reaction mixture comprises phenolic resin in an amount in the range of from about 1.0 to about 10 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         28 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the reaction mixture comprises phenolic resin in an amount in the range of from about 2.0 to about 20 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         29 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the phenolic resin comprises a molecular weight in the range of from about 200 to about 3000.  
     
     
         30 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the phenolic resin comprises a melting point in the range of from about 50° C. to about 150° C.  
     
     
         31 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the phenolic resin comprises a melting point in the range of from about 75° C. to about 100° C.  
     
     
         32 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the phenolic resin comprises a functionality in the range of from about 2 to about 8.  
     
     
         33 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the phenolic resin comprises less than about 0.05% by weight phenol.  
     
     
         34 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the phenolic resin comprises less than about 0.05% by weight formaldehyde.  
     
     
         35 . The foamed isocyanate-based polymer defined in  claim 1 , wherein the phenolic resin comprises less than about 0.05% by weight phenol and formaldehyde.  
     
     
         36 . A molded foam comprising the foamed isocyanate-based polymer defined in  claim 1 .  
     
     
         37 . A slab foam comprising the foamed isocyanate-based polymer defined in  claim 1 .  
     
     
         38 . A process for producing a foamed isocyanate-based polymer comprising the steps of: 
 contacting an isocyanate, an active hydrogen-containing compound, a phenolic resin and a blowing agent to form a reaction mixture; and    expanding the reaction mixture to produce the foamed isocyanate-based polymer;    wherein the phenolic resin is substantially completely free of ether moieties.    
     
     
         39 . The process defined in  claim 38 , wherein the active hydrogen-containing compound is selected from the group comprising polyols, polyamines, polyamides, polyimines and polyolamines.  
     
     
         40 . The process defined in  claim 38 , wherein the active hydrogen-containing compound comprises a polyol.  
     
     
         41 . (Cancelled)  
     
     
         42 . (Cancelled)  
     
     
         43 . (Cancelled)  
     
     
         44 . The process defined in  claim 40 , wherein the polyol is a polyether polyol.  
     
     
         45 . The process defined in  claim 44 , wherein the polyether polyol has a molecular weight in the range of from about 200 to about 10,000.  
     
     
         46 . The process defined in  claim 44 , wherein the polyether polyol has a molecular weight in the range of from about 2000 to about 7,000.  
     
     
         47 . The process defined in  claim 44 , wherein the polyether polyol has a molecular weight in the range of from about 2,000 to about 6,000.  
     
     
         48 . (Cancelled)  
     
     
         49 . (Cancelled)  
     
     
         50 . (Cancelled)  
     
     
         51 . (Cancelled)  
     
     
         52 . (Cancelled)  
     
     
         53 . (Cancelled)  
     
     
         54 . (Cancelled)  
     
     
         55 . (Cancelled)  
     
     
         56 . (Cancelled)  
     
     
         57 . The process defined in  claim 38 , wherein the isocyanate is selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.  
     
     
         58 . The process defined in  claim 38 , wherein the isocyanate is selected from the group consisting essentially of (i) 2,4-diphenylmethane diisocyanate, 4,4 -diphenylmethane diisocyanate and mixtures thereof; and (ii) mixtures of (i) with an isocyanate selected from the group comprising 2,4-toluene diisocyanate, 2,6-toluene diisocyanate and mixtures thereof.  
     
     
         59 . The process defined in  claim 38 , wherein the blowing agent comprises water.  
     
     
         60 . (Cancelled)  
     
     
         61 . (Cancelled)  
     
     
         62 . The process defined in  claim 38 , wherein the reaction mixture comprises phenolic resin in an amount of up to about 20 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         63 . The process defined in  claim 38 , wherein the reaction mixture comprises phenolic resin in an amount in the range of from about 1.0 to about 15 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         64 . The process defined in  claim 38 , wherein the reaction mixture comprises phenolic resin in an amount in the range of from about 1.0 to about 10 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         65 . The process defined in  claim 38 , wherein the reaction mixture comprises phenolic resin in an amount in the range of from about 2.0 to about 20 parts by weight per 100 parts by weight of active hydrogen-containing compound used in the reaction mixture.  
     
     
         66 . The process defined in  claim 38 , wherein the phenolic resin comprises a molecular weight in the range of from about 200 to about 3000.  
     
     
         67 . The process defined in  claim 38 , wherein the phenolic resin comprises a melting point in the range of from about 50° C. to about 150° C.  
     
     
         68 . The process defined in  claim 38 , wherein the phenolic resin comprises a melting point in the range of from about 75° C. to about 100° C.  
     
     
         69 . The process defined in  claim 38 , wherein the phenolic resin comprises a functionality in the range of from about 2 to about 8.  
     
     
         70 . The process defined in  claim 38 , wherein the phenolic resin comprises less than about  0 . 05 % by weight phenol.  
     
     
         71 . The process defined in  claim 38 , wherein the phenolic resin comprises less than about 0.05% by weight formaldehyde.  
     
     
         72 . The process defined in  claim 38 , wherein the phenolic resin comprises less than about 0.05% by weight phenol and formaldehyde.  
     
     
         73 . A foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a phenolic resin substantially completely free of ether moieties and a blowing agent; the foamed isocyanate-based polymer having an Indentation Force Deflection loss when measured pursuant to ASTM D3574 which is less than that of a reference foam produced by substituting a copolymer polyol for the phenolic resin in the reaction mixture, the foamed isocyanate-based polymer and the reference foam having substantially the same density and Indentation Force Deflection when measured pursuant to ASTM D3574 (50 in 2  indentor; 15″×15″×4″ sample size; 25° C., 50% relative humidity).  
     
     
         74 . A foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a phenolic resin substantially completely free of ether moieties and a blowing agent; the foamed isocyanate-based polymer having thickness loss when measured pursuant to ASTM D3574 which is less than that of a reference foam produced by substituting a copolymer polyol for the phenolic resin in the reaction mixture, the foamed isocyanate-based polymer and the reference foam having substantially the same density and Indentation Force Deflection when measured pursuant to ASTM D3574.  
     
     
         75 . A liquid mixture comprising an active hydrogen-containing compound and a phenolic resin substantially completely free of ether moieties.  
     
     
         76 . A method of conferring a load bearing property to an isocyanate-based polymer foam comprising the step of incorporating a phenolic resin substantially completely free of ether moieties in a formulation used to produce the foam.  
     
     
         77 . A method of conferring an energy absorbing property to an isocyanate-based polymer foam comprising the step of incorporating a phenolic resin substantially completely free of ether moieties in a formulation used to produce the foam.