Abstract: Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

Abstract: This invention relates to novel macromers prepared from amine based polyols, preformed stabilizers prepared from these macromers, and to polymer polyols prepared from the preformed stabilizers. The present invention also relates to processes for preparing these compositions.

Abstract: The present invention provides a polyurethane coating composition comprising a fluorosurfactant, a silane adhesion promoter, and a silane modified polyisocyanate, wherein the composition has excellent substrate wet-out and adhesion under direct wet-on-hot and cold spray applications. The coating composition is particularly well suited to use with polyurethane pultrusion composites.

Abstract: Disclosed are powder coating compositions that include a polymeric aromatic product of an aromatic isocyanate manufacturing process.

Abstract: Methods of manufacturing wall structures having high racking strength are described in this specification. The methods include spray applying a foam-forming composition into a cavity of a wall structure, wherein the wall structure is disposed in a climate-controlled spray application station and allowing the foam-forming material to expand within at least a portion of the cavity to form a foam layer deposited in the cavity. In the methods, the foam layer is formed in-situ during the manufacturing method, and the density of the foam layer is selected and the relative humidity and dew point of the air in the climate-controlled spray application station throughout the spray applying is selected so that the wall structure has a racking strength of at least 500 pounds per linear foot.

Abstract: Disclosed are powder coating compositions that include a polymeric aromatic product of an aromatic isocyanate manufacturing process.

Abstract: Disclosed are coated particles. The coated particles include substrate particles and a coating disposed over at least a portion of the substrate particles. The coating includes a condensation reaction product of a reaction mixture that includes a liquid isocyanate-functional component and an isocyanate-reactive composition. Also disclosed are methods for making such particles and methods for using such particles as proppants in hydraulic fracturing.

Abstract: A foam wall structure includes a frame, at least one primary support member, a slab of polyiso board and a foam layer. The frame can include: a first member, a second member spaced apart from the first member; and two side members extending between the first and second members. The frame defining a front frame surface and an opposite rear frame surface. The at least one primary support member can be positioned between the two side members and extend between the first and second member. The primary support member defines a front support surface and an opposite rear support surface. The slab of polyiso board may be attached to the front frame surface. The foam layer can be received within at least a portion of the frame and overlies the front surface of the primary support member. A method of making a foam wall structure and a pre-fabricated wall is also disclosed.

Abstract: This invention relates to an improved continuous process for the production of low molecular weight polyoxyalkylene polyether polyols. These polyoxyalkylene polyether polyols have a hydroxyl content of from about 3.4 to about 12.1% by weight, and may also be characterized as having an OH number of from about 112 to about 400. The process comprises establishing oxyalkylation conditions in a continuous reactor in the presence of a DMC catalyst; continuously introducing alkylene oxide and a low molecular weight starter into the continuous reactor; recovering a partially oxyalkylated polyether polyol from the reactor; and allowing the recovered partially oxyalkylated polyether polyol to further reactor until the unreacted alkylene oxide content of the mixture is reduced to 0.001% or less by weight.

Abstract: Polyols are produced by an alkoxylation process in which a vegetable oil containing hydroxyl functional groups is combined with a DMC catalyst to form a mixture, the DMC catalyst is then activated by adding ethylene oxide and/or propylene oxide to the vegetable oil/catalyst mixture, and ethylene oxide and propylene oxide are added to the mixture containing activated DMC catalyst in amounts such that the total of percentage of ethylene oxide in the polyol plus percentage of primary hydroxyl groups in the polyol produced is from 50 to 77% and the percentage of primary hydroxyl groups is at least 30% but less than 50%. These polyols are useful for the production of molded polyurethane foams, particularly, hot-cure molded polyurethane foams.

Abstract: Thermoplastic compositions are disclosed comprising a thermoplastic resin, a first impact modifier characterized by core-shell morphology and comprising a functional shell polymer, and a second impact modifier comprising a component capable of reaction with a functional shell polymer. In addition, thermoplastic compositions are also disclosed that comprise a thermoplastic resin and a loose agglomerations of particles that have open spaces, at least 50% of the loose agglomerations comprise open spaces that measure 31 to 60% by area of the loose agglomeration, and particles that are characterized by core-shell morphology. The inventive compositions demonstrate low gloss, high impact strength, good weatherability, and good flow properties.

Abstract: Disclosed are continuous compression molding processes for producing a flexible polyurethane foam laminate and laminates produced thereby, which may be suitable for use, for example, as a carpet underlayment.

Abstract: Disclosed are processes and systems for producing polyether polyols and for the recovery of heat generated during such polyether polyol production.

Abstract: This invention relates to polymer polyols comprising the free-radical polymerization product of a base polyol, at least one ethylenically unsaturated monomer, and, optionally, a preformed stabilizer, in the presence of at least one free-radical polymerization initiator and at least one chain transfer agent, in which the base polyol is a natural oil. A process for preparing these polymer polyols is also described. The present invention also relates to a polyurethane foam prepared from these polymer polyols and to a process for the preparation of these polyurethane foams.

Abstract: Methods of manufacturing pre-fabricated insulated wall structures are described in this specification. The methods include (a) attaching a foam panel to a front frame surface of a substantially horizontally positioned frame; (b) placing the frame having the foam panel attached thereto on a track conveyor configured to convey the frame having the foam panel attached thereto in a substantially upright position; (c) conveying the frame having the foam panel attached thereto on the track conveyer in a substantially upright position to a spray foam application station; and (d) spray applying a spray foam composition into a cavity of the frame to form a substantially upright positioned wall structure having a foam layer deposited in the cavity in which the foam layer adheres to the foam panel. Also disclosed are track conveyors suitable for use in such methods.

Abstract: In one or more embodiments, the present invention provides a novel approach to the addition of plasticizers for softening TPUs, i.e., lowering the durometer and the melt viscosity. This approach involves incorporating bonded sulfonate groups with quaternary ammonium counterions into the TPU. In one or more embodiments of the present invention, the softening of TPU is achieved by incorporating an ionic diol, such as N,N-bis (2-hydoxyethyl)-2-aminoethane-sulfonic acid (BES), coupled with various bulky alkyl ammonium cations, during the chain extension step of the TPU synthesis. It is believed that that steric hindrance of the bulky quaternary ammonium groups weakens the dipole-dipole interactions of the sulfonate groups and/or lowers the crystallinity of the hard block, thereby creating additional free volume that softens the polymer and lowers the melt viscosity.

Abstract: Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

Abstract: Wall structures and methods of manufacturing wall structures are described in this specification. The wall structures include a frame, a first foam panel attached to the frame, a second foam panel disposed in a cavity defined by the frame, and a foam layer.