Polyisocyanate compositions containing in-situ formed pyrophosphate mold release agent and process of making

Claim 2

A process for preparing a liquid, storage-stable, polyisocyanate composition containing a mold release agent formed in situ which process comprises heating at a temperature in the range of about 60° C. to about 190° C. a mixture of an organic polyisocyanate and from about 1 to about 20 parts, per 100 parts by weight of said polyisocyanate, of an acid phosphate selected from the class consisting of acid phosphates having the formulae ##STR4## and mixtures of two or more of said acid phosphates wherein, in the above formulae, each R is independently selected from the class consisting of alkyl having at least 3 carbon atoms, alkenyl having at least 3 carbon atoms, aryl, aryl substituted by at least one alkyl group, alkyl substituted by at least one acyloxy group wherein the acyl group is the residue of an aliphatic monocarboxylic acid having at least 2 carbon atoms and ##STR5## wherein R 1 is selected from the group consisting of alkyl, aryl and aryl substituted by at least one alkyl, one of A and B represents hydrogen and the other is selected from the class consisting of hydrogen, methyl, chloromethyl and 2,2,2-trichloroethyl; X is a chalogen selected from the class consisting of oxygen and sulfur; and m is a number having an average value of 1 to 25; the said heating of said mixture being carried out for a time such that no phase separation occurs upon cooling the reaction mixture to ambient temperature.

Claim 3

A process according to claim 1 wherein the organic polyisocyanate is a mixture of polymethylene polyphenyl polyisocyanates containing from about 25 to about 90 percent by weight of methylenebis(phenyl isocyanate), the remainder of said mixture being oligomeric polymethylene polyphenyl polyisocyanates of functionality greater than 2.

Claim 4

A process according to claim 1 wherein the acid phosphate is a mixture of mono- and di-alkyl acid phosphates wherein alkyl contains at least 3 carbon atoms.

Claim 5

A process according to claim 1 wherein the acid phosphate is a mixture of mono- and di-alkenyl acid phosphates wherein alkenyl contains at least 3 carbon atoms.

Claim 6

A process according to claim 1 wherein the acid phosphate is a mixture of mono- and di-alkylpolyoxyalkylene acid phosphates wherein alkylene is selected from the class consisting of ethylene and propylene.

Claim 7

A process according to claim 1 wherein the acid phosphate is a mixture of mono- and di-arylpolyoxyalkylene acid phosphates wherein alkylene is selected from the class consisting of ethylene and propylene and said aryl group is unsubstituted or substituted by at least one alkyl group.

Claim 8

A process for preparing a liquid, storage-stable, polyisocyanate composition containing a mold release agent formed in situ which process comprises heating, at a temperature in the range of about 60° C. to about 190° C., a mixture of (a) a mixture of polymethylene polyphenyl polyisocyanates containing from about 25 to about 90 percent by weight of methylenebis(phenyl isocyanate), the remainder of said mixture being oligomeric polymethylene polyphenyl polyisocyanates of functionality greater than 2; and (b) from about 1 to about 20 parts, per 100 parts by weight of polyisocyanate, of an acid phosphate selected from the class consisting of acid phosphates having the formulae ##STR6## and mixtures of two or more of said acid phosphates; wherein, in the above formulae, each R is independently selected from the class consisting of alkyl having at least 3 carbon atoms, alkenyl having at least 3 carbon atoms, aryl, aryl substituted by at least one alkyl group, alkyl substituted by at least one acyloxy group wherein the acyl group is the residue of an aliphatic monocarboxylic acid having at least 2 carbon atoms and ##STR7## wherein R 1 is selected from the group consisting of alkyl, aryl and aryl substituted by at least one alkyl, one of A and B represents hydrogen and the other is selected from the class consisting of hydrogen, methyl, chloromethyl and 2,2,2-trichloroethyl; X is a chalcogen selected from the class consisting of oxygen and sulfur; and m is a number having an average value of 1 to 25; the said heating of said mixture being carried out for a time such that no phase separation occurs upon cooling the reaction mixture to ambient temperature.

Claim 9

A process for preparing a liquid, storage-stable, polyisocyanate composition containing a mold release agent formed in situ which process comprises heating, at a temperature in the range of about 60° C. to about 190° C., a mixture of (a) a mixture of polymethylene polyphenyl polyisocyanates containing from about 25 to about 90 percent by weight of methylenebis(phenyl isocyanate), the remainder of said mixture being oligomeric polymethylene polyphenyl polyisocyanates of functionality greater than 2; and (b) from about 1 to about 20 parts, per 100 parts by weight of polyisocyanate, of an acid phosphate selected from the class consisting of acid phosphates having the formulae ##STR6## and mixtures of two or more of said acid phosphates; wherein, in the above formulae, each R is independently selected from the class consisting of alkyl having at least 3 carbon atoms, alkenyl having at least 3 carbon atoms, aryl, aryl substituted by at least one alkyl group, alkyl substituted by at least one acyloxy group wherein the acyl group is the residue of an aliphatic monocarboxylic acid having at least 2 carbon atoms and ##STR7## wherein R 1 is selected from the group consisting of alkyl, aryl and aryl substituted by at least one alkyl, one of A and B represents hydrogen and the other is selected from the class consisting of hydrogen, methyl, chloromethyl and 2,2,2-trichloroethyl; X is a chalcogen selected from the class consisting of oxygen and sulfur; and m is a number having an average value of 1 to 25; the said heating of said mixture being carried out for a time such that no phase separation occurs upon cooling the reaction mixture to ambient temperature.

Claim 10

A process according to claim 7 in which the polyisocyanate is preheated to a temperature within the stated range and the acid phosphate is admixed with the said preheated polyisocyanate.

Claim 11

A process according to claim 7 or 8 in which the acid phosphate is a mixture of mono- and di-alkyl acid phosphates wherein alkyl contains at least 3 carbon atoms.

Claim 12

A process according to claim 9 wherein said mixture of mono- and di-alkyl acid phosphates is a mixture of lauryl monoacid phosphate and dilauryl acid phosphate.

Claim 13

A process according to claim 7 or 8 in which the acid phosphate is a mixture of mono- and di-alkenyl acid phosphates wherein alkenyl contains at least 3 carbon atoms.

Claim 14

A process according to claim 7 or 8 in which the acid phosphate is a mixture of mono- and di-alkylpolyoxyalkylene acid phosphates wherein alkylene is selected from the class consisting of ethylene and propylene.

Claim 15

A process according to claim 7 or 8 in which the acid phosphate is a mixture of mono- and di-aryl polyoxyalkylene acid phosphates wherein alkylene is selected from the class consisting of ethylene and propylene and said aryl group is unsubstituted or substituted by at least one alkyl group.

Claim 16

A liquid, storage-stable, polyisocyanate composition prepared in accordance with claim 1.

Claim 17

A liquid, storage-stable, polyisocyanate composition prepared in accordance with claim 7.