Patents by Inventor John E. Hayes
John E. Hayes has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 8877863Abstract: The present invention provides a process for preparing a polymer polyol (PMPO) by alkoxylating a starter compound(s) having active hydrogen atoms in the presence of a double metal cyanide (DMC) catalyst, radical initiator(s) and optionally PMPO stabilizers and simultaneously polymerizing unsaturated monomer(s) with radical initiator(s). The polymer polyols (PMPOs) made by the inventive process may find use in the preparation of polyurethane foams and elastomers.Type: GrantFiled: May 23, 2013Date of Patent: November 4, 2014Assignee: Bayer MaterialScience LLCInventors: Jose F. Pazos, John E. Hayes
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Publication number: 20130261207Abstract: The present invention provides a process for preparing a polymer polyol (PMPO) by alkoxylating a starter compound(s) having active hydrogen atoms in the presence of a double metal cyanide (DMC) catalyst, radical initiator(s) and optionally PMPO stabilizers and simultaneously polymerizing unsaturated monomer(s) with radical initiator(s).Type: ApplicationFiled: May 23, 2013Publication date: October 3, 2013Applicant: Bayer MaterialScience LLCInventors: Jose F. Pazos, John E. Hayes
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Patent number: 8470927Abstract: The present invention provides a process for preparing a polymer polyol (PMPO) by alkoxylating a starter compound(s) having active hydrogen atoms in the presence of a double metal cyanide (DMC) catalyst, radical initiator(s) and optionally PMPO stabilizers and simultaneously polymerizing unsaturated monomer(s) with radical initiator(s). The polymer polyols (PMPOs) made by the inventive process may find use in the preparation of polyurethane foams and elastomers.Type: GrantFiled: February 26, 2004Date of Patent: June 25, 2013Assignee: Bayer MaterialScience LLCInventors: Jose F. Pazos, John E. Hayes
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Patent number: 8134022Abstract: The present invention relates to a polyether carbonate polyol made by copolymerizing a starter molecule with carbon dioxide, at a pressure ranging from about 10 psia to about 2,000 psia, and an alkylene oxide, at a temperature ranging from about 50° C. to about 190° C. and in the presence of from about 0.001 wt. % to about 0.2 wt. % of a substantially non-crystalline double metal cyanide (DMC) catalyst, wherein the polyol has an incorporated carbon dioxide content of from about 1 wt. % to about 40 wt. %, wherein the ratio of cyclic carbonate by-product to total carbonate is less than about 0.3 and wherein the weight percentages are based on the weight of the polyol. The inventive polyether carbonate polyols may find use in producing polyurethane foams, elastomers, coatings, sealants and adhesives with improved properties.Type: GrantFiled: September 13, 2010Date of Patent: March 13, 2012Assignee: Bayer MaterialScience LLCInventors: Karl W. Haider, Kenneth G. McDaniel, Sr., John E. Hayes, Jianzhong Shen
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Patent number: 7977501Abstract: The present invention relates to a polyether carbonate polyol made by copolymerizing a starter molecule with carbon dioxide, at a pressure ranging from about 10 psia to about 2,000 psia, and an alkylene oxide, at a temperature ranging from about 50° C. to about 190° C. and in the presence of from about 0.001 wt. % to about 0.2 wt. % of a substantially non-crystalline double metal cyanide (DMC) catalyst, wherein the polyol has an incorporated carbon dioxide content of from about 1 wt. % to about 40 wt. %, wherein the ratio of cyclic carbonate by-product to total carbonate is less than about 0.3 and wherein the weight percentages are based on the weight of the polyol. The inventive polyether carbonate polyols may find use in producing polyurethane foams, elastomers, coatings, sealants and adhesives with improved properties.Type: GrantFiled: July 24, 2006Date of Patent: July 12, 2011Assignee: Bayer MaterialScience LLCInventors: Karl W. Haider, Kenneth G. McDaniel, John E. Hayes, Jianzhong Shen
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Publication number: 20100331517Abstract: The present invention relates to a polyether carbonate polyol made by copolymerizing a starter molecule with carbon dioxide, at a pressure ranging from about 10 psia to about 2,000 psia, and an alkylene oxide, at a temperature ranging from about 50° C. to about 190° C. and in the presence of from about 0.001 Wt. % to about 0.2 wt. % of a substantially non-crystalline double metal cyanide (DMC) catalyst, wherein the polyol has an incorporated carbon dioxide content of from about 1 wt. % to about 40 wt. %, wherein the ratio of cyclic carbonate by-product to total carbonate is less than about 0.3 and wherein the weight percentages are based on the weight of the polyol. The inventive polyether carbonate polyols may find use in producing polyurethane foams, elastomers, coatings, sealants and adhesives with improved properties.Type: ApplicationFiled: September 13, 2010Publication date: December 30, 2010Applicant: Bayer MaterialScience LLCInventors: Karl W. Haider, Kenneth G. McDaniel, John E. Hayes, Jianzhong Shen
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Publication number: 20080090921Abstract: The present invention provides a reaction system for the preparation of a fiber reinforced composite according to the pultrusion process made from continuous fiber reinforcing material and a polyurethane formulation containing a polyisocyanate component including at least one polyisocyanate and an isocyanate-reactive component containing at least one double metal cyanide (“DMC”)-catalyzed polyol. The inventive polyurethane formulations and improved pultrusion processes offer better processing and may yield better reinforced composites.Type: ApplicationFiled: October 12, 2006Publication date: April 17, 2008Inventors: John E. Hayes, Albert Magnotta, Nigel Barksby
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Publication number: 20080087373Abstract: The present invention provides a reaction system for the preparation of a fiber reinforced composite according to the pultrusion process made from continuous fiber reinforcing material and a polyurethane formulation made from a polyisocyanate component containing at least one polyisocyanate and an isocyanate-reactive component containing at least one polymer polyol (“PMPO”). The inventive polyurethane formulations and improved pultrusion processes offer better processing and may yield better reinforced composites.Type: ApplicationFiled: October 12, 2006Publication date: April 17, 2008Inventors: John E. Hayes, Nigel Barksby, Albert Magnotta
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Publication number: 20080090966Abstract: The present invention provides a reaction system for the preparation of a fiber reinforced composite according to the pultrusion process made from continuous fiber reinforcing material and an immiscible polyurethane formulation containing a polyisocyanate component including at least one polyisocyanate and an isocyanate-reactive component including at least one isocyanate-reactive compound. The inventive polyurethane formulations and improved pultrusion processes offer better processing and may yield better reinforced composites.Type: ApplicationFiled: October 12, 2006Publication date: April 17, 2008Inventors: John E. Hayes, Albert Magnotta, Nigel Barksby
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Publication number: 20080021154Abstract: The present invention relates to a polyether carbonate polyol made by copolymerizing a starter molecule with carbon dioxide, at a pressure ranging from about 10 psia to about 2,000 psia, and an alkylene oxide, at a temperature ranging from about 50° C. to about 190° C. and in the presence of from about 0.001 wt. % to about 0.2 wt. % of a substantially non-crystalline double metal cyanide (DMC) catalyst, wherein the polyol has an incorporated carbon dioxide content of from about 1 wt. % to about 40 wt. %, wherein the ratio of cyclic carbonate by-product to total carbonate is less than about 0.3 and wherein the weight percentages are based on the weight of the polyol. The inventive polyether carbonate polyols may find use in producing polyurethane foams, elastomers, coatings, sealants and adhesives with improved properties.Type: ApplicationFiled: July 24, 2006Publication date: January 24, 2008Inventors: Karl W. Haider, Kenneth G. McDaniel, John E. Hayes, Jianzhong Shen
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Patent number: 7179882Abstract: The present invention relates to low viscosity polymer polyols and to a process for the preparation of these low viscosity polymer polyols. These polymer polyols comprise the free-radical polymerization product of (A) a base polyol, (B) a pre-formed stabilizer, and (C) at least one ethylenically unsaturated monomer, in the presence of (D) at least one free-radical polymerization initiator, and (E) at least one polymer control agent. The total amount of polymer control agent present in the polymer polyols of the present invention ranges from greater than about 5.0% up to about 20% by weight, based on 100% by weight of the polymer polyol.Type: GrantFiled: August 2, 2004Date of Patent: February 20, 2007Assignee: Bayer Materialscience LLCInventors: Rick L. Adkins, Scott A. Guelcher, James R. Charron, John E. Hayes
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Patent number: 6835801Abstract: The present invention is directed to an activated starter mixture which can be used to prepare polyoxyalkylene polyols. The present invention is also directed to a process for preparing an activated starter mixture, particularly, to a process for preparing an activated starter mixture which is composed of a low molecular weight starter compound. The present invention is also directed to a batch or semi-batch process for the polyaddition of an alkylene oxide on to an activated starter mixture, particularly, on to an activated starter mixture which is composed of a low molecular weight starter compound. The present invention provides an activated starter mixture, particularly, an activated starter mixture which is composed of a low molecular weight starter compound, which rapidly initiates polymerization. The present invention can eliminate the need to synthesize costly high molecular weight starter compounds by KOH catalysis in a separate, dedicated reactor.Type: GrantFiled: July 19, 2002Date of Patent: December 28, 2004Assignee: Bayer Antwerp, N.V.Inventor: John E. Hayes
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Publication number: 20040064001Abstract: The present invention is directed to a process for preparing ethylene oxide-capped polyols which involves combining a double-metal cyanide-catalyzed polyol with a basic catalyst. The present invention is also directed to a process for preparing ethylene oxide-capped polyols which involves combining a double-metal cyanide-catalyzed polyol with a base-catalyzed polyol. The present invention is also directed to a process for preparing ethylene oxide-capped polyols in which removal of catalyst residues or salts formed by the neutralization of the basic catalyst is not required. The polyols produced by the processes of the present invention have a relatively high content of primary hydroxyl groups.Type: ApplicationFiled: September 30, 2002Publication date: April 1, 2004Inventors: Stephan Ehlers, Jose F. Pazos, Christian Steinlein, Michael Schneider, Jorg Hofmann, Majid Keyvani, John E. Hayes
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Publication number: 20040014908Abstract: The present invention is directed to an activated starter mixture which can be used to prepare polyoxyalkylene polyols. The present invention is also directed to a process for preparing an activated starter mixture, particularly, to a process for preparing an activated starter mixture which is composed of a low molecular weight starter compound. The present invention is also directed to a batch or semi-batch process for the polyaddition of an alkylene oxide on to an activated starter mixture, particularly, on to an activated starter mixture which is composed of a low molecular weight starter compound.Type: ApplicationFiled: July 19, 2002Publication date: January 22, 2004Inventor: John E. Hayes
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Patent number: 6077978Abstract: Acidification, neutralization, or removal of basic impurities from acid sensitive low molecular weight starter or acidification of a reactor heel prior to addition of acid sensitive low molecular weight starter allows direct oxyalkylation of continuously added acid sensitive low molecular weight starter to produce polyoxyalkylene acid sensitive low molecular weight starter-initiated or co-initiated polyols in the presence of a double metal cyanide catalyst. The preferred acid sensitive low molecular weight starter is glycerine.Type: GrantFiled: September 17, 1997Date of Patent: June 20, 2000Assignee: ARCO Chemical Technology L.P.Inventors: Kenneth G. McDaniel, Mark J. Perry, John E. Hayes
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Patent number: 5990232Abstract: Unique, well defined polyethers containing both hydroxyl-functionality and unsaturation-functionality are prepared by oxyalkylating an unsaturated monomer having at least two free carboxylic acid groups in the presence of an effective amount of a double metal cyanide complex catalyst, optionally, when necessary, in the presence of a free radical polymerization inhibitor. The resulting polyethers are eminently suitable for such uses as polymer polyol stabilizers or stabilizer precursors, and both in situ and ex situ impact modifiers for thermoplastics.Type: GrantFiled: August 25, 1997Date of Patent: November 23, 1999Assignee: ARCO Chemical Technology, L.P.Inventors: Jianzhong Shen, Kenneth G. McDaniel, John E. Hayes, Uli B. Holeschovsky, Harry R. Hinney
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Patent number: 5854386Abstract: Unique, well defined polyethers containing both hydroxyl-functionality and unsaturation-functionality are prepared by oxyalkylating an unsaturated monomer having at least one oxyalkylatable hydrogen in the presence of an effective amount of a double metal cyanide complex catalyst, optionally, when necessary, in the presence of a free radical polymerization inhibitor. The resulting polyethers are eminently suitable for such uses as polymer polyol stabilizers or stabilizer precursors, and both in situ and ex situ impact modifiers for thermoplastics.Type: GrantFiled: August 25, 1997Date of Patent: December 29, 1998Assignee: ARCO Chemical Technology, L.P.Inventors: Jianzhong Shen, Kenneth G. McDaniel, John E. Hayes, Uli B. Holeschovsky, Harry R. Hinney
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Patent number: 5844070Abstract: A process for activating double metal cyanide catalysts is disclosed. A polyol starter or starter/catalyst mixture is heated under vacuum under conditions effective to achieve improved stripping compared with that which can be achieved through conventional vacuum stripping. Coupling vacuum stripping with inert gas sparging or stripping in the presence of an organic solvent gives a starter/catalyst mixture that activates rapidly in an epoxide polymerization process. Rapid activation makes process start-ups reliable and reduces cycle time. The process gives polyols with lower viscosity, lower polydispersity, and lower unsaturation for better polyurethanes.Type: GrantFiled: May 16, 1997Date of Patent: December 1, 1998Assignee: Arco Chemical Technology, L.P.Inventors: John E. Hayes, Leah J. Langsdorf, Bruce H. Isaacs, Fred J. Armellini
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Patent number: 5488085Abstract: Polymer polyols prepared by a semi-batch process using a small amount of a seed polymer polyol are disclosed. The final polymer polyol has a broader particle size distribution as compared to an identically prepared polymer polyol prepared in the absence of the seed polymer polyol. The polymer polyols are suitable for use in producing polyurethanes, particularly polyurethane foams.Type: GrantFiled: August 18, 1994Date of Patent: January 30, 1996Assignee: ARCO Chemical Technology, L.P.Inventors: John E. Hayes, Donald W. Simroth, Xinhua Zhou
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Patent number: 5478638Abstract: A reinforced conveyor belt especially suited to transport sharp objects such as glass and scrap metal. The belt has a top and bottom layer of flexible, abrasion-resistant material, such as rubber. There is a middle layer of woven, multi-layered fabric, preferably made of cotton threads with reinforcing rods interwoven therein. The reinforcement rods run transversely and occupy sites in the intermediate layers of the fabric normally occupied by weft threads. Interweaving the layers of fabric and inserting the rod into one of the intermediate fabric layer provides the belt with tensile strength, puncture resistance, and a barrier against longitudinal tearing. Finally, the bottom surface of the belt is textured to provide additional durability and traction.Type: GrantFiled: July 15, 1994Date of Patent: December 26, 1995Inventors: Gary B. Springer, John E. Hayes, Jr.