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  Isocyanate-based foam having improved anti-yellowing properties and process for production thereofUSPTO Application #: 20070208097Title: Isocyanate-based foam having improved anti-yellowing properties and process for production thereof Abstract: There is described an isocyanate-based polymer foam having improved anti-yellowing properties. The foam produced from a formulation comprising an isocyanate, a blowing agent, a first active hydrogen-containing compound and a second active hydrogen-containing compound different than the first active hydrogen-containing compound. The second active hydrogen-containing compound comprises an active hydrogen-containing phosphite compound. A process for producing such a foam is also described. (end of abstract)
Agent: Patent Administrator Katten Muchin Rosenman LLP - Washington, DC, US Inventors: Wen Wei Zhao, Mladen Vidakovic, Eugene Smeianu USPTO Applicaton #: 20070208097 - Class: 521172000 (USPTO) Related Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Synthetic Resins Or Natural Rubbers, Ion-exchange Polymer Or Process Of Preparing, Cellular Product Derived From A -n=c=x Containing Reactant Wherein X Is A Chalcogen Atom, -xh Reactant Contains A C=x Group, E.g., Carboxylic Acid Ester, Etc. The Patent Description & Claims data below is from USPTO Patent Application 20070208097. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] The present application is a continuation of U.S. patent Application Ser. No. 10/783,023, filed Feb. 23, 2004, which claims the benefit under 35 U.S.C. .sctn.119(e) of provisional patent application Ser. No. 60/448,476, filed Feb. 21, 2003, the contents of which are hereby incorporated by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] In one of its aspects, the present invention relates to an isocyanate-based polymer foam and to a process for production thereof. More particularly, the present invention relates to an isocyanate-based polymer foam, inter alia, having improved anti-yellowing properties compared to prior art foams. In another of its aspects, the present invention relates to a process for producing such an isocyanate-based polymer foam. [0004] 2. Description of the Prior Art [0005] Isocyanate-based foams, such as polyurethane foams, are known in the art. Generally, those of skill in the art understand isocyanate-based polymers to be polyurethanes, polyureas, polyisocyanurates and mixtures thereof. [0006] It is also known in the art to produce foamed isocyanate-based polymers. Indeed, one of the advantages of isocyanate-based polymers compared to other polymer systems is that polymerization and foaming can occur in situ. This results in the ability to mould the polymer while it is forming and expanding. [0007] One of the conventional ways to produce a polyurethane foam is known as the "one-shot" technique. In this technique, the isocyanate, a suitable polyol, a catalyst, water (which acts as a reactive "blowing" agent and can optionally be supplemented with one or more physical blowing agents) and other additives are mixed together at once using, for example, impingement mixing (e.g., high pressure). Generally, if one were to produce a polyurea, the polyol would be replaced with a suitable polyamine. A polyisocyanurate may result from cyclotrimerization of the isocyanate component. Urethane modified polyureas or polyisocyanurates are known in the art. In either scenario, the reactants would be intimately mixed very quickly using a suitable mixing technique. [0008] Another technique for producing foamed isocyanate-based polymers is known as the "prepolymer" technique. In this technique, a prepolymer is produced by reacting polyol and isocyanate (in the case of a polyurethane) in an inert atmosphere to form a liquid polymer terminated with reactive groups (e.g., isocyanate moieties and active hydrogen moieties). To produce the foamed polymer, the prepolymer is thoroughly mixed with a lower molecular weight polyol (in the case of producing a polyurethane) or a polyamine (in the case of producing a modified polyurea) in the presence of a curing agent and other additives, as needed. [0009] Regardless of the technique used, one of the characteristics of isocyanate-based foams, particularly polyurethane foams produced from formulations containing aromatic isocyanates (e.g., TDI, MDI and mixtures thereof), is their tendency to change colour after production. Specifically, polyurethane foams are known to change colour from slightly off-white directly after production to mustard yellow within hours or days after production. [0010] The colour change usually occurs on the surface of the foam within a relatively thin layer as a result of exposure to light (fluorescent or non-fluorescent) and atmosphere. This type of environmental induced colour change is different from scorching discoloration resulting from thermal induced degradation and does not have any significant impact on the physical properties of the foam. Nevertheless, the colour is unwelcome by most customers. [0011] It is known in the prior art that isocyanate-based foams produced from formulations containing aliphatic and/or alicyclic-based isocyanates are less susceptible to environmentally induced discoloration when compared to isocyanate-based foams produced from formulations containing aromatic-based isocyanates. See for example any one of the following: Japanese patent application S52-52997/1977, Japanese patent application H02-255817/1990, Japanese patent application H04-318016/1992 and U.S. Pat. No. 4,542,166 for teachings of yellowing-resistant isocyanate-based foams produced from formulations containing aliphatic and/or alicyclic-based isocyanates. Unfortunately, isocyanate-based foams produced from formulations containing aliphatic and/or alicyclic-based isocyanates have been met with very limited commercial success as a result of relatively poor physical properties such as melting upon exposure to ultraviolet radiation, relatively low heat resistance, relatively high material costs (i.e., of the isocyanates) and the like. [0012] To date the prior art has not developed a technique for slowing down or avoiding the post-production colour change in isocyanate-based foams such as polyurethane foams produced from formulations containing aromatic-based isocyanates. [0013] Accordingly, there remains a need in the art an isocyanate-based polymer foam, particularly such foams produced from formulations containing aromatic-based isocyanates having improved anti-yellowing properties. Ideally, such a foam could be produced without the need to alter foam moulding equipment and other chemical components in the formulation used to produce the foam. Thus, it would be highly desirable to be able to produce such a foam by the addition to the formulation of a relatively low cost additive have no significant deleterious effect on the resultant foam SUMMARY OF THE INVENTION [0014] It is an object of the present invention to obviate or mitigate at least one of the above-mentioned disadvantages of the prior art. [0015] Accordingly, in one of its aspects, the present invention provides an isocyanate-based polymer foam produced from a formulation comprising an isocyanate, a blowing agent, a first active hydrogen-containing compound and a second active hydrogen-containing compound different than the first active hydrogen-containing compound, the second active hydrogen-containing compound comprising an active hydrogen-containing phosphite compound. [0016] A molded isocyanate-based polymer foam produced from a formulation comprising an isocyanate, a blowing agent, a first active hydrogen-containing compound and a second active hydrogen-containing compound different than the first active hydrogen-containing compound, the second active hydrogen-containing compound comprising an active hydrogen-containing phosphite compound. [0017] An isocyanate-based polymer foam produced from a formulation comprising an isocyanate, a blowing agent, a first active hydrogen-containing compound and a second active hydrogen-containing compound different than the first active hydrogen-containing compound, the second active hydrogen-containing compound comprising an active hydrogen-containing phosphite compound, with the proviso that the active hydrogen-containing phosphite compound is not present in any amount of 2 percent by weight of the foam. [0018] In another of its aspects, the present invention provides a process for producing a foamed isocyanate-based polymer comprising the steps of: [0019] contacting an isocyanate, a blowing agent, a first active hydrogen-containing compound and a second active hydrogen-containing compound different than the first active hydrogen-containing compound to form a reaction mixture; and [0020] expanding the reaction mixture to produce the foamed isocyanate-based polymer [0021] wherein the second active hydrogen-containing compound comprises an active hydrogen-containing phosphite compound. Continue reading... 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