Stabilizers for polymer/polyols

Claim 2

A process for producing a stabilizer comprising reacting (a) a polyol having a theoretical functionality greater than four; (b) a reactive unsaturated compound capable of forming an adduct with the polyol; and (c) optionally, an ethylene oxide in the presence of a strong base at a reaction temperature wherein at least 60% of the unsaturation being added is retained with the proviso that if the polyol is not terminally reacted with ethylene oxide, then the adduct subsequently formed is reacted with ethylene oxide, the resulting product is thereafter further reacted or, alternatively, coupled with a chemically reactive compound to obtain a final product having a viscosity greater than 2000 cSt.

Claim 3

The process of claim 1 wherein the polyol is a polyoxyalkylene polyol.

Claim 4

The process of claim 1 or 2 wherein the polyol has a number average molecular weight greater than 4000.

Claim 5

The process of any of claims 1 to 3 wherein the reactive unsaturated compound is an anhydride.

Claim 6

The process of claim 4 wherein the anhydride is maleic anhydride.

Claim 7

The process of claim 4 wherein the adduct formed between the anhydride and the polyol has an acid number below 3.0.

Claim 8

The process of claim 6 wherein the acid number is below 1.0.

Claim 9

The process of any of claims 1 to 7 wherein the ratio of moles of the reactive unsaturated compound to moles of the polyol is in the range of 0.5:1 to 1.5:1.

Claim 10

The process of any of claims 1 to 8 wherein the polyol is started with sorbitol.

Claim 11

The process of any of claims 1 to 9 wherein the unsaturation is ultimately of the fumarate type.

Claim 12

The process of any of claims 1 to 10 wherein there is added from 10 to 200 ppm of a strong base.

Claim 13

The process of claim 11 wherein the strong base is selected from alkali and alkaline earth metal hydroxides, weak acid salts of alkali and alkaline earth metals and organic bases, and preferably potassium hydroxide.

Claim 14

The process of any one of claims 1 to 12 wherein the reaction temperature is from 100 to 125°C.

Claim 15

The process of any one of claims 1 to 13 wherein the chemically reactive compound is an organic polyisocyanate, such as MDI.

Claim 16

The stabilizer obtainable in accordance with the process of any one of claims 1 to 14.

Claim 17

In a process for preparing a stable polymer/polymer comprising polymerizing one or more ethylenically unsaturated monomers in a first polyol in the presence of a free radical catalyst to obtain a polymer/polyol having a solids content greater than 25 percent by weight, based on the total weight of the polymer/polyol wherein the improvement comprises the addition of 1 to 30 weight percent, based on the total weight of the polyol, of the stabilizer prepared by reacting: (a) a second polyol having a theoretical functionality greater than four; (b) a reactive unsaturated compound capable of forming an adduct with the polyol; and (c) optionally, an ethylene oxide in the presence of a strong base at a reaction temperature wherein at least 60% of the unsaturation being added is retained with the proviso that if the second polyol is not terminally reacted with ethylene oxide, then the adduct subsequently formed is reacted with ethylene oxide, the resulting stabilizer is thereafter further reacted or, alternatively, coupled with a chemically reactive compound to obtain a final stabilizer having a viscosity greater than 2000 cSt.

Claim 18

In a process for preparing a stable polymer/polymer comprising polymerizing one or more ethylenically unsaturated monomers in a first polyol in the presence of a free radical catalyst to obtain a polymer/polyol having a solids content greater than 25 percent by weight, based on the total weight of the polymer/polyol wherein the improvement comprises the addition of 1 to 30 weight percent, based on the total weight of the polyol, of the stabilizer prepared by reacting: (a) a second polyol having a theoretical functionality greater than four; (b) a reactive unsaturated compound capable of forming an adduct with the polyol; and (c) optionally, an ethylene oxide in the presence of a strong base at a reaction temperature wherein at least 60% of the unsaturation being added is retained with the proviso that if the second polyol is not terminally reacted with ethylene oxide, then the adduct subsequently formed is reacted with ethylene oxide, the resulting stabilizer is thereafter further reacted or, alternatively, coupled with a chemically reactive compound to obtain a final stabilizer having a viscosity greater than 2000 cSt.

Claim 19

The process of claim 16 wherein both polyols are polyoxyalkylene polyols.

Claim 20

The process of claim 16 or 17 wherein the ethylenically unsaturated monomers is one or more of styrene, acrylonitrile and vinylidene chloride.

Claim 21

The process of any one of claims 16 to 18 wherein the reactive unsaturated compound is an anhydride such as maleic anhydride.

Claim 22

The process of any one of claims 16 to 19 wherein the adduct formed between the anhydride and the second polyol has an acid number below 3.0, preferably below 1.0.

Claim 23

The process of any one of claims 16 to 21 wherein the strong base is potassium hydroxide.

Claim 24

The process of any one of claims 16 to 21 wherein the polyol is started with sorbitol.

Claim 25

The process of any one of claims 16 to 22 wherein the unsaturation is ultimately of the fumarate type.

Claim 26

The process of any one of claims 16 to 23 wherein the chemically reactive compound is an organic polyisocyanate, such as MDI.

Claim 27

The polymer/polyol obtainable in accordance with the process of any one of claims 16 to 24.

Claim 28

A polyurethane prepared from the polymer/polyol of claim 25.

Claim 29

The polyurethane of claim 26 wherein the polyurethane is a foam.