Abstract: A composite body is provided that includes a rigid polyurethane foam shell and an elastomeric polyurethane layer disposed over the rigid polyurethane foam shell. The rigid polyurethane foam shell defines a cavity within the composite body. The rigid polyurethane foam shell has a closed cell content of at least 70% and comprises the reaction product of a first isocyanate component and a first isocyanate-reactive component in the presence of a blowing agent. The elastomeric polyurethane layer is disposed over the polyurethane foam shell. The elastomeric polyurethane layer comprises the reaction product of a second isocyanate component and a second isocyanate-reactive component. A method of forming the composite body includes the step of molding the rigid polyurethane foam shell, demolding the rigid polyurethane foam shell from the mold, and applying an elastomeric polyurethane composition upon the rigid polyurethane foam shell after demolding to form the elastomeric polyurethane layer.

Abstract: A composite article comprises a first layer resulting from the reaction of at least one ethylenically unsaturated monomer and a second layer different than the first layer and resulting from the reaction of an isocyanate-reactive resin and a polyisocyanate. Adhesion promoter is dispersed in at least one of the first layer and the second layer. The adhesion promoter comprises a first reactive end group selected from the group of an ethylenically unsaturated monomer, an ethylenically unsaturated acrylate monomer, an ethylenically unsaturated methacrylate monomer, or a combination thereof and a second reactive end group that reacts with isocyanate. The adhesion promoter reacts into the first and second layers through differentially reactive groups such that the adhesion promoter is compatible with the first and second layers to improve adhesion therebetween. A method of forming the composite article is also disclosed.

Abstract: A composite article comprises a first layer resulting from the reaction of at least one ethylenically unsaturated monomer and a second layer different than the first layer and resulting from the reaction of an isocyanate-reactive resin and a polyisocyanate. Adhesion promoter is dispersed in at least one of the first layer and the second layer. The adhesion promoter comprises a first reactive end group selected from the group of an ethylenically unsaturated monomer, an ethylenically unsaturated acrylate monomer, an ethylenically unsaturated methacrylate monomer, or a combination thereof and a second reactive end group that reacts with isocyanate. The adhesion promoter reacts into the first and second layers through differentially reactive groups such that the adhesion promoter is compatible with the first and second layers to improve adhesion therebetween. A method of forming the composite article is also disclosed.

Abstract: A process is disclosed for formation of a preformed stabilizer for use in formation of graft polyols. The preformed stabilizer has a reduced level of transesterification products and results in less reactor fouling. The preformed stabilizer is prepared in the presence of phosphorous compounds, which reduces the unwanted transesterification products.

Abstract: The subject invention provides polyurethane foam and a method of purifying polyether polyols of non-volatile impurities for use in forming the polyurethane foam. The method includes the step of providing a crude polyether polyol having a non-volatile impurity present therein. The crude polyether polyol is contacted with an adsorbent selected from at least one of activated carbon, diatomaceous earth, charcoal, attapulgite, and clay to remove the impurity and filtered to form a purified polyether polyol. The filtering of the crude polyether polyol is carried out through a filter media that is used both in a pre-filtering step prior to adding the adsorbent and the filtering step to remove the adsorbent to reduce losses of the purified polyether polyol because of its high viscosity. The purified polyether polyol is then used to form a polyurethane foam having improved stability.

Abstract: A process is disclosed for formation of a preformed stabilizer for use in formation of graft polyols. The preformed stabilizer has a reduced level of transesterification products and results in less reactor fouling. The preformed stabilizer is prepared in the presence of phosphorous compounds, which reduces the unwanted transesterification products.

Abstract: A method for preparing compression molded or pressed lignocellulosic articles is disclosed. The method involves forming a binder resin by combining a polyisocyanate component with a parting agent and preferably a synergist. The parting agent is the reaction product of an isocyanate compound and an isocyanate-reactive compound of the general structure R—(ao)n—Y where: R is a hydrophobic group containing alkyl, alkaryl, polyaryl, or siloxane moieties; (ao) is an alkylene oxide or mixture of alkylene oxides; n is from 1 to 25; and Y represents a monofunctional isocyanate-reactive group. A resinated lignocellulosic mixture is formed by combining the binder resin with lignocellulosic particles. Then a compression molded or pressed lignocellulosic article is formed by compressing the resinated lignocellulosic mixture at an elevated temperature and under pressure.

Abstract: A method for preparing compression molded or pressed lignocellulosic articles is disclosed. The method involves forming a binder resin by combining a polyisocyanate component with a parting agent and preferably a synergist. The parting agent is the reaction product of an isocyanate compound and an isocyanate-reactive compound of the general structure R—(ao)n—Y where: R is a hydrophobic group containing alkyl, alkaryl, polyaryl, or siloxane moieties; (ao) is an alkylene oxide or mixture of alkylene oxides; n is from 1 to 25; and Y represents a monofunctional isocyanate-reactive group. A resinated lignocellulosic mixture is formed by combining the binder resin with lignocellulosic particles. Then a compression molded or pressed lignocellulosic article is formed by compressing the resinated lignocellulosic mixture at an elevated temperature and under pressure.

Abstract: The present invention provides a liquid methylene bis(phenylisocyanate) composition including a high concentration of methylene bis(phenylisocyanate) which has an improved storage stability. The invention further provides a method of making the liquid methylene bis(phenylisocyanate) compositions of the present invention.

Abstract: A method for preparing compression molded or pressed lignocellulosic articles is disclosed. The method involves forming a binder resin by combining a polyisocyanate component with a parting agent and preferably a synergist. The parting agent is the reaction product of an isocyanate compound and an isocyanate-reactive compound of the general structure R—(ao)n—Y where: R is a hydrophobic group containing alkyl, alkaryl, polyaryl, or siloxane moieties; (ao) is an alkylene oxide or mixture of alkylene oxides; n is from 1 to 25; and Y represents a monofunctional isocyanate-reactive group. A resinated lignocellulosic mixture is formed by combining the binder resin with lignocellulosic particles. Then a compression molded or pressed lignocellulosic article is formed by compressing the resinated lignocellulosic mixture at an elevated temperature and under pressure.

Abstract: There is disclosed a parting agent comprising the reaction product of an isocyanate compound and an isocyanate-reactive compound of the general structure R-(ao)n-Y wherein: R is a hydrophobic group containing alkyl, alkaryl, polyaryl, or siloxane moieties; (ao) is an alkylene oxide or mixture of alkylene oxides such as ethylene oxide, propylene oxide, butylene oxide, and mixtures thereof; n is about 1 to about 25; and Y represents a monofunctional isocyanate-reactive group. There is also disclosed the processes that may be utilized to produce the parting agent.

Abstract: There is disclosed a parting agent comprising the reaction product of an isocyanate compound and an isocyanate-reactive compound of the general structure

Abstract: A method for preparing compression molded or pressed lignocellulosic articles is disclosed. The method involves forming a binder resin by combining a polyisocyanate component with a parting agent and preferably a synergist. The parting agent is the reaction product of an isocyanate compound and an isocyanate-reactive compound of the general structure R—(ao)n—Y where: R is a hydrophobic group containing alkyl, alkaryl, polyaryl, or siloxane moieties; (ao) is an alkylene oxide or mixture of alkylene oxides; n is from 1 to 25; and Y represents a monofunctional isocyanate-reactive group. A resinated lignocellulosic mixture is formed by combining the binder resin with lignocellulosic particles. Then a compression molded or pressed lignocellulosic article is formed by compressing the resinated lignocellulosic mixture at an elevated temperature and under pressure.

Abstract: A polyester polyol composition comprising a phthalic anhydride-initiated polyester polyol, a C4-C6 hydrocarbon blowing agent, and an alkylene oxide modified silicone glycol compatibilizing agent having an HLB of from about 5 to about 8 is disclosed. The blowing agent is soluble in the polyol composition, thereby reducing the risks associated with such blowing agents in processes for making rigid polymer foam articles and providing rigid foams having good dimensional stability and improved insulation properties. An alkylene oxide and isocyanate modified silicone glycol compatibilizing agent is also disclosed.

Abstract: A polyester polyol composition comprising a phthalic anhydride-initiated polyester polyol, a C4-C6 hydrocarbon blowing agent, and an alkylene oxide modified silicone glycol compatibilizing agent having an HLB of from about 5 to about 8 is disclosed. The blowing agent is soluble in the polyol composition, thereby reducing the risks associated with such blowing agents in processes for making rigid polymer foam articles and providing rigid foams having good dimensional stability and improved insulation properties. An alkylene oxide and isocyanate modified silicone glycol compatibilizing agent is also disclosed.

Abstract: The present invention provides a liquid methylene bis(phenylisocyanate) composition including a high concentration of methylene bis(phenylisocyanate) which has an improved storage stability. The invention further provides a method of making the liquid methylene bis(phenylisocyanate) compositions of the present invention.