Abstract: The present invention provides a process for preparing a stable graft polyol dispersion. The graft polyol dispersion has low viscosity and a high solids content. An ethylenically unsaturated monomer is polymerized in a polyol mixture including a macromer polyol and a carrier polyol. A free radical initiator and a reaction moderator are also present during polymerization. The reaction moderator is of the formula: wherein R is a phenyl group, R1 is selected from the group of an aliphatic hydrocarbon radical having 1 to 18 carbon atoms, and R2 is selected from the group of a phenyl group, a nitrile group, a methoxycarbonyl group, a carbamoyl group, and combinations thereof.

Abstract: Disclosed is a process for preparation of final graft polyols via a continuous process. In, addition, a final graft polyol formed by the process is disclosed. The process includes the steps of reacting a plurality of ethylenically unsaturated monomers and a reaction moderator with a macromer having induced unsaturation in the presence of a carrier polyol, a free radical polymerization initiator, and a first graft polyol. The process provides for the preparation of a final graft polyol having a solids level of from 30 to 70% in a continuous process. The final graft polyol produced by the process has a lower viscosity over a range of solids levels, a reduced amount of very large irregularly shaped particles, a reduced viscosity change in response to a change in reaction temperature compared to a typical graft polyol, a reduced tendency to foul the continuous reactor, and a broader particle size distribution compared to an identical graft polyol prepared by a semi-batch process.

Abstract: Polyols initiated with a first initiator having a relatively high functionality averaging greater than eight and comprising a range of species of different functionality, and optionally a second initiator, having low functionality, i.e. a two to eight nominal functionality initiator molecule. Another aspect of the invention is a process for making the polyol. The invention is also directed to a process for producing polyurethane foam by reacting the polyol of the invention with isocyanates, and the foam produced thereby.

Abstract: Polyols initiated with a first initiator having a relatively high functionality averaging greater than eight and comprising a range of species of different functionality, and optionally a second initiator, having low functionality, i.e. a two to eight nominal functionality initiator molecule. Another aspect of the invention is a process for making the polyol. The invention is also directed to a process for producing polyurethane foam by reacting the polyol of the invention with isocyanates, and the foam produced thereby.

Abstract: Disclosed is a process for preparation of final graft polyols via a continuous process. In addition, a final graft polyol formed by the process is disclosed. The process includes the steps of reacting a plurality of ethylenically unsaturated monomers and a reaction moderator with a macromer having induced unsaturation in the presence of a carrier polyol, a free radical polymerization initiator, and a first graft polyol. The process provides for the preparation of a final graft polyol having a solids level of from 30 to 70% in a continuous process. The final graft polyol produced by the process has a lower viscosity over a range of solids levels, a reduced amount of very large irregularly shaped particles, a reduced viscosity change in response to a change in reaction temperature compared to a typical graft polyol, a reduced tendency to foul the continuous reactor, and a broader particle size distribution compared to an identical graft polyol prepared by a semi-batch process.

Abstract: Thus, there is provided according to the present invention polyol compositions comprising (A) a polytetramethylene ether glycol, and (B) a trifunctional active hydrogen compound-initiated polyoxyalkylene polyether polyol having a degree of unsaturation of not greater than 0.04 milliequivalents per gram of said polyether polyol.

Abstract: The present invention relates to graft polyols employing a t-amyl peroxy compound as free radical initiator. The novel graft polyols are made by polymerizing at least one monomer in a polyol composition in the presence of a free radical initiator and preferably a chain transfer agent. The resulting graft polyols are in turn useful in reactions with polyisocyanates to make polyurethane products.

Abstract: Thus, there is provided according to the present invention polyol compositions comprising(A) a polytetramethylene ether glycol, and(B) a trifunctional active hydrogen compound-initiated polyoxyalkylene polyether polyol having a degree of unsaturation of not greater than 0.04 milliequivalents per gram of said polyether polyol.

Abstract: There is a provided a stable low viscosity graft polymer dispersion comprising from 25 to 60 weight percent based on the total weight of the polymer dispersion of at least three ethylenically unsaturated monomers polymerized in the presence of a reaction moderator and a free radical initiator in a polyol mixture initially containing less than 0.1 moles of induced unsaturation per mole of said polyol mixture. One of the monomers in the mixture of ethylenically unsaturated monomers is a hydroxylfunctional or aminofunctional C.sub.2 -C.sub.6 alkyl methacrylate.

Abstract: There is a provided a stable low viscosity graft polymer dispersion comprising from 25 to 60 weight percent based on the total weight of the polymer dispersion of at least three ethylenically unsaturated monomers polymerized in the presence of a reaction moderator and a free radical initiator in a polyol mixture initially containing less than 0.1 moles of induced unsaturation per mole of said polyol mixture. One of the monomers in the mixture of ethylenically unsaturated monomers is a hydroxylfunctional or aminofunctional C.sub.2 -C.sub.6 alkyl methacrylate.

Abstract: There is a provided a stable low viscosity graft polymer dispersion comprising from 25 to 60 weight percent based on the total weight of the polymer dispersion of at least three ethylenically unsaturated monomers polymerized in the presence of a reaction moderator and a free radical initiator in a polyol mixture initially containing less than 0.1 moles of induced unsaturation per mole of said polyol mixture. One of the monomers in the mixture of ethylenically unsaturated monomers is a hydroxylfunctional or aminofunctional C.sub.2 -C.sub.6 alkyl methacrylate.

Abstract: There is a provided a stable low viscosity graft polymer dispersion comprising from 25 to 60 weight percent based on the total weight of the polymer dispersion of at least three ethylenically unsaturated monomers polymerized in the presence of a reaction moderator and a free radical initiator in a polyol mixture initially containing less than 0.1 moles of induced unsaturation per mole of said polyol mixture. One of the monomers in the mixture of ethylenically unsaturated monomers is a hydroxylfunctional or aminofunctional C.sub.2 -C.sub.6 alkyl methacrylate.

Abstract: A flexible open-cell polyurethane is described that is the reaction product of a mixture comprising(a) a polyisocyanate component comprising monomeric or polymeric MDI, and(b) a polyol component having at least 50% of its 0H functional groups as secondary OH groups.

Abstract: The flame retardancy of flexible polyurethane foams is increased by incorporation into the foam forming reactants of a low molecular weight, high primary hydroxyl trifunctional polyether polyol having a hydroxyl number between 300 and 500 and a primary hydroxyl content greater than 50 percent.

Abstract: Macromers for use in preparing stable, low viscosity graft polymer polyols of high solids content are disclosed. These macromers are easily made in high yield with short cycle times, and may be used to prepare graft dispersions containing amine based polyols.

Abstract: Graft polymer dispersions in polyoxyalkylene polyether polyols are employed together with flame retardant compounds to prepare flame retardant polyurethane foams. The polymer dispersions employ less than 0.1 mole of induced unsaturation per mole of polyol mixture. Processes for the preparation of these polymer dispersions employ fumarate derived polyetherester polyols or polyetherester polyols prepared by reacting a polyoxyalkylene polyether polyol with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and an alkylene oxide in the presence of salts and oxides of divalent metals. The polymer dispersions are prepared in the presence of a reaction moderator and employ 50 weight percent or more of acrylonitrile.

Abstract: White graft polymer dispersions in polyoxyalkylene polyether polyols are employed together with flame retardant compounds to prepare flame retardant polyurethane foams. The polymer dispersions employ less than 0.1 mole of induced unsaturation per mole of polyol mixture. Improved processes for the preparation of these polymer dispersions employ either maleate or fumarate derived polyetherester polyols or polyetherester polyols prepared by reacting a polyoxyalkylene polyether polyol in the presence of a chain transfer agent with a compound selected from the group consisting of maleic acid, maleic anhydride and fumaric acid and an alkyklene oxide in the presence of salts and oxides of divalent metals.

Abstract: Graft polymer dispersions in a polyol are prepared by a continuous process employing in situ free radical polymerization of an ethylenically unsaturated monomer in a polyol containing from about 0.001 to 0.09 mole of induced unsaturation per mole of polyol in the presence of an effective amount of a chain transfer agent. Products prepared by this process have uniform viscosity with resulting product uniformity. Polyurethane foams incorporating flame retardants prepared from these dispersions readily pass the California No. 117 Flame Test.

Abstract: A low viscosity, stable graft polymer dispersion is prepared by polymerizing in the presence of a free radical initiator, from about 25 to about 75 weight percent based on the total weight of the dispersion, an ethylenically unsaturated monomer or mixture of monomers, in a polyol mixture comprising (1) from about 25 to about 99 weight percent of a polyol containing from 2 to 8 hydroxyl groups and having an equivalent weight from 30 to about 200, (2) from about 1 to about 75 weight percent of a macromer containing induced unsaturation, said macromer comprising the reaction product of a polyether polyol having an equivalent weight from 100 to 10,000 with a compound having both ethylenic unsaturation and a group selected from the group consisting of a hydroxyl, carboxyl, anhydride, isocyanate and epoxy or mixtures thereof. These graft polymer dispersions are useful for preparing polyurethane products.

Abstract: White graft polymer dispersions in polyoxyalkylene polyether polyols are employed together with flame retardant compounds to prepare flame retardant polyurethane foams. The polymer dispersions employ less than 0.1 mole of induced unsaturation per mole of polyol mixture. Improved processes for the reparation of these polymer dispersions employ either isomerized maleate containing polyetherester polyols or polyetherester polyols prepared by reacting a polyoxyalkylene polyether polyol, a polycarboxylic acid anhydride and an alkylene oxide in the presence of salts and oxides of divalent metals.