AU2005201273B2 - Composition and method for preparing polyurethanes and polyurethane foams - Google Patents

Description

S&FRef: 594982D1

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address of Applicant: Actual Inventor(s): Address for Service: Invention Title: Polythane Systems, Inc., of 2400 Spring Stuebner Road, Spring, Texas, 77389, United States of America Scott A. Brown Spruson Ferguson St Martins Tower Level 31 Market Street Sydney NSW 2000 (CCN 3710000177) Composition and method for preparing polyurethanes and polyurethane foams The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5845c Composition and Method of Preparing Polyurethanes and Polyurethane Foams This invention relates to a composition for preparing polyurethane foams with improved dimensional stability. This invention further relates to a composition for preparing a polyurethane in a wet environment. This invention further relates to a method for strengthening and sealing voids and geological formations which are moist or contain water. This invention further relatesto a method for repair, restoration and rehabilitation of earth supported concrete slabs and other structures by the subsurface formation of polyurethane forms.

to Due to the mandated elimination of fluorocarbons and hydrochlorofluorocarbons, the polyurethane foam industry is seeking alternate blowing agents. The non-reactive chemicals under consideration as replacements are hydrofluorocarbons, pentane, and other products currently under development. Water is currently used as a blowing agent for polyurethane foams, either as the sole blowing agent or as a co-blowing agent in the presence of another blowing agent. The isocyanate (-NCO) reacts with the water (H-O-H) to create a urea with carbon dioxide (C0 2 as a byproduct of the reaction. The CO 2 gas, when trapped in the reacting mass of polyurethane, expands the polyurethane to lower the density and form the foam structure.

Water is useful in the production of open cell flexible foams and rigid polyurethane foams. When water is used as the sole blowing agent in rigid, closed cell foams having a density of less than about 41bs/ft 3 (64kg/m 3 the foams are not dimensionally stable due to loss of gas pressure after the foam has set. Dimensional stability is a measure of the amount of volumetric change a foam undergoes on standing. Dimensional stability may be measured using specific ASTM standard methods such as D2126-87. The loss of gas pressure is due to the escape of the COz from the cell, and the resultant negative pressure within the cell results in shrinkage. This shrinkage may be significant. For example, a 2lbs/ft' (32kg/m 3 all water blown foam sample cut in a 2" cube may shrink to approximately half its original volume and have a prune-like appearance. One currently accepted method to increase dimensional stability is to increase the density of the polyurethane foam until the foam is stable, does not shrink significantly from loss of carbon dioxide.

N The polyisocyanate component of polyurethane foam forming compositions is reactive with water. Reaction of the polyisocyanate with water converts some of the polyisocyanate into the corresponding amine. The amine can react with the polyisocyanate to form a polyurea with properties that may be undesirable and inferior to the polyurethane foam formed in the absence of the amine. Excluding water during a polyurethane foam forming reaction is not always practical. For example, injection of polyurethane foam forming components into the ground to alleviate subsidence can be affected by moisture in the ground. Although some methods are known which attempt to reduce the problems caused by undesired reactions of excess water with polyisocyanates, these methods have '1 0 disadvantages.

Formation of a polyurethane in the presence of water has been accomplished in U.S.

Patent No. 4,761,099 by substantially removing the water by first injecting a polyisocyanate which is followed by a subsequent injection of a mixture of polyol and polyisocyanate. The first injection of polyisocyanate is believed to form, upon reaction with water, a polyurea.

The polyurea reacts further with the polyisocyanate and polyol and is incorporated into the polyurethane. This two step process will give poor results if the first injection of polyisocyanate is insufficient to react with all of the water present. Further, the incorporation of the polyurea may result in inferior properties in the subsequently formed polyurethane.

Other methods to strengthen geological formations, described in U.S. Patent No.

4,792,262, use polyols that are fat derivatives such as castor oil. These systems have poor compatibility with the polyisocyanate, have long curing times, react with water present in the formation, and are relatively expensive.

Water-blown polyurethane foam forming systems may be dimensionally unstable and very sensitive to water in excess of the amount needed to form the carbon dioxide blowing agent. Since isocyanate groups react with water, the process of reacting polyisocyanates in the presence of excess water is generally prohibitive. When a polyurethane forming mixture contacts water, the polyisocyanate reacts first, faster, with water, creating an amine that may react further with the remaining polyisocyanate to form a urea. The isocyanate thus reacted is not available to react with the polyol to form the urethane linkage. One way to compensate for the water reaction is to pre-polymerize the polyisocyanate, thereby reducing the available NCO groups. This process has the disadvantage of increasing the viscosity of the mixture prior to the final polyurethane foam forming reaction.

Another method to compensate for the reaction of the polyisocyanate with wate increase the reactivity of the polyisocyanate or the polyol. This is done to form the urc linkages before the water interferes with the polyurethane foam forming reaction. Th the disadvantage of decreasing the amount of time before the polyurethane viscosity inc to a point at which it will no longer flow as a liquid. This reduces the amount of ti which the polyurethane forming composition must be completely injected into a void filled or into a substrate to reduce or eliminate earth subsidence, water seepage or j substrate to stabilize and/or compact the substrate.

A need exists for a polyurethane foam forming composition for forming a low do water-blown polyurethane foam with good dimensional stability. Also, a need exists polyurethane foam forming composition for forming a low density water-blown polyure foam with good dimensional stability in the presence of water in excess of the amot water needed to form carbon dioxide as the blowing agent.

A need exists for a polyurethane foam forming composition for forming a nonv blown polyurethane foam with good dimensional stability in the presence of water.

A need exists for an improved polyurethane foam forming composition suitabi subsurface injection to stabilize or reduce earth subsidence beneath a concrete slab or structure.

A need exists for a diluent or additive for use with a polyurethane foam for composition for forming a polyurethane foam that retards reaction of a polyisocyanate water in the environment.

A need exists for a method of reducing or stabilizing earth subsidence of con slabs or other structures by subsurface injection of an improved polyurethane foam fon composition for forming water-blown polyurethane foam with good dimensional stabili the presence of excess water beyond that needed to generate the carbon dioxide blo' agent.

A need exists for an improved method for forming water-blown polyurethane

I

with good dimensional stability in the presence of water in excess of the amount of v needed to form carbon dioxide as the blowing agent.

A need exists for a method for forming a nonwater-blown polyurethane foam good dimensional stability in the presence of water.

4-AUG2008 12:57 SPRUSON FERGUSON 92615486 NO. 4042 P. 4 00 0 0 Polyisocyanates and polyols may react together in the presence of water to form a J) polyurethane. The water reacts with some of the polyisocyanate to generate an amine and Scarbon dioxide. As the amine and polyol react with the polyol react with the polyisocyanate, the mixture begins to gel and the carbon dioxide causes the reactive mixture to form a foam.

Generally, water is more reactive with a polyisocyanate than is a polyol and an excess amount of water causes the formation of an excess of the desired carbon dioxide and amine which

C

c leads to an inferior, undesirable polymeric material. The present invention provides an Cl improved polyurethane foam forming composition and a method of using the improved Spolyurethane foam forming composition which permits the formation of a polyurethane by 0 to the reaction of a polyisocyanate and polyol, even in the presence of an amount of water in 0 excess of the amount needed to generate carbon dioxide as a blowing agent.

c One embodiment according to the present invention is a composition for preparing a polyurethane foam, the composition comprising: a polyisocyanate; 1i a polyol; a blowing agent; and a substantially non-reactive ester diluent.

One embodiment according to the present invention is a method of stabilizing or reducing earth subsidence beneath a structure on a substrate with a water blown polyurethane foam made in the presence of excess water comprising; mixing a polyisocyanate, a polyol having a quantity of water for generating carbon dioxide by reaction with a portion of the polyisocyanate, and a substantially water insoluble and substantially non-reactive diluent to form a polyurethane reaction mixture; and injecting the polyurethane reaction mixture into the substrate.

One embodiment of the according to the present invention is a closed-cell polyurethane foam, said foam being a reaction product of a composition comprising: a polyisocyanate; a polyol; a blowing agent; and a substantially non-reactive ester diluent One embodiment according to the present invention is a method of preparing a closed-cell polyurethane foam, the method comprising: mixing components of a reaction mixture comprising: a polyisocyanate; (9368T_1):KZA COMS ID No: ARCS-200756 Received by IP Australia: Time 13:00 Date 2008-08-04 a polyol; a blowing agent; and a substantially non-reactive ester diluent; and allowing the reaction mixture to react and form the closed-cell polyurethane foam.

One embodiment according to the present invention is a polyurethane foam forming composition comprising a polyisocyanate, a polyol, a blowing agent and a substantially water insoluble ester diluent that is substantially unreactive with the polyisocyanate.

One embodiment according to the present invention is a polyurethane foam forming composition for forming a low density polyurethane foam, having good dimensional stability, comprising a polyisocyanate, a polyol and a substantially water insoluble ester diluent that is substantially unreactive with the polyisocyanate.

One method of preparing the polyurethane foam according to the present invention includes mixing the polyisocyanate or the polyol or both in a substantially water insoluble diluent prior to or simultaneously with the mixing of the polyisocyanate and polyol to form polyurethane foam.

One embodiment of the present invention is a polyurethane elastomer forming composition having a substantially water insoluble and substantially non-reacting diluent which permits the formation of the elastomer in the presence of water.

One embodiment according to the present invention is a method of stabilizing, correcting or reducing ground subsidence by introducing a polyurethane foam forming composition having a substantially non-reactive and substantially water insoluble diluent into the area of subsidence.

(936867I) KZA CI One embodiment according to the present invention is a method of stabilizing, correcting or reducing ground subsidence by introducing a polyurethane foam forming composition, into the area of subsidence, having a substantially non-reactive and substantially Cl water insoluble diluent, a polyisocyanate, a polyol-and a blowing-agent.

For a further understanding of the nature, objects and advantages of the present invention, reference should be made to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals indicate like elements and c- wherein: O 5 Fig. I shows a side sectional view of injection of the polyurethane forming NI composition being used to fill a geological void or area of subsidence to raise a surface subsidence.

The use of a substantially non-water soluble diluent for a polyisocyanate and/or a polyol component of a polyurethane unexpectedly provides a composition that permits the formation of a water-blown, low-density polyurethane. Unexpectedly, the use of a substantially non-water soluble diluent for a polyisocyanate and/or a polyol component of a polyurethane forming composition provides a composition that permits the formation of a polyurethane in the presence of excess water. The use of a substantially non-water soluble diluent for a polyisocyanate and/or a polyol component of a polyurethane unexpectedly provides a composition that permits the formation of a water-blown, low-density polyurethane in the presence of excess water. The low density foams typically have a density less than about 5 lbs/ft 3 Retarding the reactivity of water with a polyisocyanate has unexpectedly been achieved by mixing the polyisocyanate (A-side) or polyol (B-side) or both in a substantially water insoluble diluent which is substantially non-reactive with the polyisocyanate.

Alternatively, the separate diluent, A-side, and B-side components may be simultaneously coinjected and mixed to form a polyurethane product. Diluents which are useful include, but are not limited to, esters. Diesters are more preferred and are exemplified by, but not limited to, 2 2 4 -trimethyl-1,3-pentanediol diisobutyrate (sold by Eastman Chemical Company under the trademark TXIB). The diluent may be present in a range of from about 2 weight to about 70 weight of the total polyurethane polymer. The diluent more preferably is present in the range of from about 5 weight to about 60 weight The term polyisocyanate as used herein refers to any isocyanate having an average functionality greater than or equal to about 2.0. The polyisocyanate component (A-side) used 0 6 Sin the compositions and methods according to the present invention is preferably based on diphenylmethane diisocyanates such as those obtainable by aniline/formaldehyde Scondensation followed by phosgenation ("polymeric MDI") or derivatives of these polyisocyanates which may contain carbodiimide, biuret, urethane, isocyanurate, allophanate groups, and mixtures of compounds having these groups, and are liquid at room temperature.

Useful polyisocyanates and mixtures include, but are not limited to, those that are liquid at room temperature and have been obtained by the phosgenation of aniline/formaldehyde N- condensates ("polymeric MDI") and their liquid, isocyanate-containing reaction products 0 with sub-equivalent quantities (NCO/OH molar ratio=1:0.005 to 1:0.3) of polyfunctional C 10 alcohols, prepolymers. Preferred polyols have a molecular weight range of about 62 to about 3,000, and more preferred polyols have a molecular weight range of about 106 to about 3,000. Polyols containing ether and/or ester groups are useful. Mixtures of and 4,4'diisocyanatodiphenyl methane which are liquid at room temperature are also suitable for use as polyisocyanate (A-side). Other organic polyisocyanates including, but not limited to, other aromatic polyisocyanates, aliphatic polyisocyanates, prepolymers formed from aromatic or aliphatic polyisocyanates and mixtures thereof may also be used according to the present invention. Alternatively, solid polyisocyanates may also be used if they are soluble in the diluent. Preferred polyisocyanates for preparation of polyurethane foams are exemplified by, but not limited to, polymeric MDI sold by Bayer under the trademark MONDUR MR, by BASF under the trademark LUPRANATE M20S, by The Dow Chemical Company under the trademark PAPI 27 or by Huntsman Chemical under the trademark RUBINATE M. A preferred polyisocyanate for the preparation of a polyurethane elastomer is exemplified by, but not limited to, a 143 equivalent weight modified 4 4 '-diphenylmethane diisocyanate having an average functionality of about 2.1 such as MM 103 sold by BASF, MONDUR CD sold by Bayer, ISONATE 143L sold by The Dow Chemical Company or LF 1680 sold by Huntsman Chemical. Polyisocyanates and isocyanates having average isocyanate functionality greater than or equal to about 2.0 may also be used as the polyisocyanate component of the polyurethane forming reaction mixture.

In the reaction mixtures used in the methods according to the present invention, the individual components are present in such quantities that they correspond to an isocyanate index of from about 0.9 to about 5.0, preferably about 1.05 to about 4.0. By "isocyanate index" is meant the quotient of the number of isocyanate equivalents in the reaction mixture divided by the number of hydroxyl equivalents present in the reaction mixture, counting as a difunctional compound.

Polyol (also referred to as "B-side" and as "resin blend") is typically bas mixtures of organic polyhydroxyl compounds having an OH number of about 10 to 6233, preferably from about 50 to about 1800. The polyols may have a nominal mol weight average ranging from about 18 to about 10,000, preferably from about 18 to 6000 and most preferably from about 90 to about 6000. The polyols have a hyc functionality of from about 2 to about 8, preferably from about 2 to about 6.

polyhydroxyl compounds are preferably polyether polyols or mixtures of such poll polyols known from polyurethane chemistry.

The polyhydroxyl compounds are generally mixtures of several components alt pure polyhydroxyl compounds, i.e. individual compounds, may in principle be used.

single polyhydroxyl components are used, the conditions given above concernin: molecular weight and hydroxyl functionality apply to these individual compounds.

mixtures of various polyhydroxyl compounds are used, the particulars given concerning the hydroxyl number apply to the average volume of the mixture as a whole.

means that individual components of a mixture may have hydroxyl numbers outside the range.

The polyols may have primary hydroxyl groups, secondary hydroxyl groups mixture of primary and secondary hydroxyl groups. Further, the polyols may be partia completely capped with ethylene oxide or propylene oxide to alter the reactivity o polyols or to increase the molecular weight of the polyols.

Suitable polyether polyols include, but are not limited to, the ethoxylation a propoxylation products of 2- to 8-functional starter molecules such as, for example, v ethylene glycol, 1,2-dihydroxy propane, trimethylol propane, diethylene glycol, trieth, glycol, dipropylene glycol, pentaerythritol, glycerol, sorbitol, sucrose, ethylene diar polytetramethylene glycol and butylene oxide based polyols. Suitable mixtures of this may be obtained, for example, by subjecting mixtures of starter molecules of the mentioned above as examples to an ethoxylation and/or propoxylation reac Alternatively, polyhydroxyl polyethers which have been prepared separately subsequently be mixed together to form the polyol component according to the prn invention.

8 cN Alternatively, polyester polyols or mixtures of polyester polyols known from a polyurethane chemistry may be used. The polyol components may also contain other polyhydroxyl compounds known from polyurethane chemistry such as castor oil or polyester CI polyols which may be obtained by the reaction ofpolyhydric alcohols of the type exemplified above with polybasic carboxylic acids such as adipic acids, dimethyl terephthalate, phthalic acid and/or phthalic acid anhydride. These polyester polyols preferably have a molecular weight average of 400 to about 4000. The polyol components may also contain small Ci quantities of water up to about 2% by weight).

The following are examples of suitable auxiliary agents and additives which may cN 10 optionally be used.

Water, which may be added in a quantity of up to about 5 by weight, preferably up to about 4 by weight, and most preferably up to about 2% by weight based on the weight of polyisocyanate.

Adding a conventional catalyst or combination of conventional catalysts alters the rate of the polyurethane foam formation. Catalysts for the isocyanate addition reaction include, but are not limited to, organic tin compounds such as tin (II) octoate, dibutyl tin dilaurate, UL-22 (sold by Witco Chemical Organics Division under the trademark WITCO FOMREZ UL-22) or lead naphthenate (PbN); or tertiary amines such as N,N-dimethyl cyclohexylamine (DMCHA) sold as PolyCat 8 by Air Products Chemicals, 1, 4 -diazabicyclo[2.2.2]octane (TEDA) sold under the tradename DABCO by Air Products Chemicals, and 70 bis(dimethylaminoethyl)ether in DPG (sold as BL-11 by Air Products Chemicals); or amine polyol catalysts such as 33% TEDA in glycol or dimethylethanolamine

(DMEA);

amine catalysts such as pentamethyldiethylenetriamine (PMDETA). These catalysts are generally used in a quantity of up to about 4% by weight, preferably from about 0.3 to about 1% by weight, based on the total quantity of the polyurethane forming composition. Other conventional amine and organometallic catalysts known for use in polyurethane forming reactions may be used. The type and amount of catalyst can be readily determined, by routine testing, by one of ordinary skill to provide the desired reaction time for a particular application.

Organic blowing agents include, but are not limited to, non-ozone depleting hydrofluorocarbons, non-ozone depleting hydrochlorofluorocarbons and aliphatic hydrocarbons. Conventional blowing agents known for preparing water-blown and nonwater blown polyurethanes may be used. The blowing agents may be used singly or in mixtures. The use of individual blowing agents or mixtures of blowing agents is deten by the desired properties of the polyurethane. A person of ordinary skill in the preparing polyurethanes can make the selection of the proper blowing agent or combir of blowing agents for a particular application by routine testing.

Conventional foam regulators or surfactants such as the polyether polysilo: known to be useful in polyurethane foam forming reactions may be used. Non-sil surfactants may also be used. The non-silicone surfactants include, but are not limitt LK443 (sold by Air Products). Suitable surfactants may be obtained from Goldscl Chemical, Air Products Chemicals, Inc., Witco or others. One example of a useful sil surfactant is B8423 sold by Goldschmidt Chemical under the trademark TEGOSTAB B8 Other auxiliary agents and additives which may be used include, but are not lii to, conventional flame retarders phosphoric acid derivatives and brominate chlorinated compounds), and organic or inorganic fillers urea, calcium carbonate, or talcum).

Auxiliary agents and additives used are generally mixed with polyol (B-side) bef polyurethane forming process is carried out. The polyurethane forming reaction mixtt typically prepared from a two component mixture. The polyurethane foam forming rea mixture is prepared by vigorously mixing polyisocyanate with polyol or with the mixtu polyol and auxiliary agents and additives. The diluent may be pre-mixed with eithe polyisocyanate or the polyol or, alternatively, may be added as a separate compo: Mixing apparatus known in the art may be used for this purpose.

To prepare the reaction mixtures, the polyisocyanates and polyhydroxyl compo are mixed together in the proportions required to provide about 0.9 to 5.0, preferably a 1.05 to 4.0 isocyanate groups for each isocyanate reactive group (in particular hydr groups). The components are mixed in by conventional methods using conventi equipment.

Additionally, flame-retardants may be added to the polyurethane reaction mix Typically, the flame-retardants are added to the polyol (B-side), but non-reactive flz retardants could be added to the polyisocyanate (A-side). Typical flame retardants incl but are not limited to, reactive bromine based compounds known to be used in polyuretl chemistry and chlorinated phosphate esters, including but not limited trichloropropylphosphate

(TCPP).

The low-density water blown polyurethane foams of the present invention may be prepared by mixing either the polyisocyanate (A-side), the polyol (B-side) or both in the N, diluent. Alternatively, the diluent may be co-injected as a separate component into conventional equipment that will mix the diluent and the other components of the Cc, 5 polyurethane forming reaction mixture. The mixture of the diluent and the other N polyurethane foam components typically has a lower viscosity than the polyisocyanate or Spolyol component. Water is added to the polyol (B-side) in an amount calculated to provide the desired amount of carbon dioxide to act as a blowing agent. Polyols are hygroscopic, so the amount of water present in the polyol is typically measured and taken into account in calculating the amount of water to be added such that the total amount of water needed will be the sum of the water present in the polyol and the water added to the B-side. The polyisocyanate, polyol and water may be mixed by conventional methods including, but not limited to, static mixers. The polyurethane reaction mixture will form a polyurethane with the carbon dioxide acting as a blowing agent to cause the polyurethane to form a foam structure.

Water blown closed-cell, low-density rigid polyurethane foams made using conventional formulations generally have poor dimensional stability. Conventionally prepared water blown, closed-cell, low density polyurethane foams generally shrink and/or collapse over a period of time ranging from hours to months. The water blown closed cell, low density polyurethane foams use carbon dioxide, formed by the in situ reaction between water and a portion of the polyisocyanate present, to cause the reacting polymer mixture to foam. After the polyurethane foam is fully formed, the carbon dioxide may diffuse out of the closed cells faster than air can diffuse into the cells, creating a vacuum. The resulting pressure differential causes the foam to shrink and/or collapse.

Surprisingly, the use of a diluent in the polyurethane forming reaction mixture permits the formation of water blown, closed-cell rigid foams with improved dimensional stability.

Typically, the foams have a closed-cell content greater than about 50%, preferably greater than about 70% and more preferably greater than about The formulation in Example 1 below, including TXIB as a diluent, when mixed with a polymeric MDI, such as MONDUR MR sold by Bayer or RUBINATE M sold by Huntsman Chemical, at a weight ratio of isocyanate to resin blend of 55.6 to 44.4 using conventional polyurethane foam equipment provides a resultant polyurethane foam with a density of about 3.01bs/ft 3 (48kg/m 3 A second foam prepared from the second batch of the formulation in Example 1 I 4 11 provided a resultant polyurethane foam having a density of about 3.01bs/ft 3 (48kg/m 3 and a closed cell content, according to ASTM D-2856, of about 94.6%. This demonstrated that the inclusion of TXIB in a formulation for water blown closed cell polyurethane foam had little or no adverse affect on the properties of the polyurethane foam based on the high closed-cell content.

The effect of a diluent, such as TXIB, on a polyurethane forming reaction mixture for a water blown low density polyurethane foam was subjected to an extreme test by exposure to excess water. The formulation of Example 1 was tested by injection directly into a 55 gallon drum filled with water. The reaction mixture initially sank to the bottom of the drum but floated to the surface of the water as the reaction mixture produced carbon dioxide which caused foaming and a reduction. in density of the reaction material. The resultant polymer was a polyurea/polyurethane composition that had a density range of from about 0.97 (15.5kg/m 3 to about 1.331bs/ft 3 (21.3kg/m 3 The same formulation sprayed directly on the ground, without exposure to a large amount of water, exposure only to ambient moisture, had a density of about 2.741bs/ft 3 (43.9kg/m3). Although the material of Example 1, having TXIB present in the formulation when injected into the water, resulted in a polymer of mixed polyurea/polyurethane composition, this mixed polyurea/polyurethane composition was much superior compared to a similar test of a commercially available water blown foam forming composition which formed a water saturated mass of polyurea with very low structural integrity, the material crumbled when touched, which was unsuitable for testing.

Example 6 shows the improved properties of one embodiment according to the present invention in which the polyisocyanate is Mondur MR. The ratio of polyisocyanate to resin blend is 55.4:44.6 by weight. The isocyanate index is about 1.05. The density of a sample from Example 6, tested according to ASTM D-1622, was about 2.711bs/ft 3 (43.4kg/m 3 The sample from Example 6, tested according to ASTM D-1621, had a perpendicular compressive strength of about 20.69 (142.7kPa) and a parallel compressive strength of about 27.83 psi (191.9kPa). The sample from Example 6, tested according to ASTM D-2856, gave a closed-cell content of 81.2%.

The dimensional stability of samples from Example 6 was determined according to ASTM D-2126. Samples were tested under differing combinations of temperature and relative humidity. The test conditions were 70 0 C at 95% relative humidity, 100 0 C at ambient relative humidity and minus 30 0 C at ambient relative humidity. The volumes of the T.r7 7crl 12 samples were checked at 1 day, 7 days, 14 days and 28 days. Volume changes of less than 1% are small and may be difficult to measure accurately.

A foam according to one embodiment of the present invention has a volumetric "1 change of less than about 15% after storing the foam for 28 days at 70 °C and 95% relative humidity, preferably less than 10% after storing the foam for 28 days at 70 °C and relative humidity, and most preferably less than 5% after storing the foam for 28 days at °C and 95% relative humidity.

The sample tested at 70 C at 95% relative humidity showed a maximum volume increase of 0.4% on day 1. The sample subsequently began to shrink showing only 0.1% 1 0 increase by day 7 and by day 14 showed 0.3% volume decrease. By day 28, the sample showed a total volume change of about 0.4%.

The sample tested at 100 OC at ambient relative humidity showed a volume increase of 1.6 at day 1 which increased to 2.1 at day 7. The sample subsequently shrank showing only a 0.2% increase at day 14. By day 28, the sample showed a total volume change of about 1.70%.

The sample tested at minus 30 °C at ambient relative humidity showed a 0.4% volume increase at day 1 which remained unchanged at day 7. Subsequently, the sample shrank by day 14 having a 0.8 volume decrease. By day 28, the sample showed a total volume change of about 0.30%.

Unexpectedly, the use of a diluent in the polyurethane foam forming composition of the present invention even permits the formation of a dimensionally stable, low density, water blown polyurethane foam when at least the polyisocyanate is mixed in the diluent prior to injecting the mixture of polyisocyanate (A-side) and polyol/water (B-side). Without the diluent present, the otherwise same polyurethane foam forming mixture would form a significant amount of polyurea, an inferior foam which typically is brittle.

Additionally, it has been discovered that the inclusion of a diluent, such as TXIB, in a formulation for the preparation of open-cell foams show unexpected improvement in physical properties such as having a more uniform foam, the cells are of more uniform size relative to a similar foam prepared without the TXIB.

The polyisocyanates discussed above may be reacted with polyamines to form polyurea compounds. The polyamines include amines with functionality of from about 2 to about 3. The average molecular weight of the amines ranges from about 60 to about 5000; preferably from about 200 to about 5000; and most preferably from about 400 to about 5000.

13 i The additives described for use in the polyurethanes may also be used in the preparation ofpolyureas. Preferred amines are exemplified by, but not limited to, the JEFFAMINE T Ki and JEFFAMINE D series sold by Huntsman Corporation.

Unexpectedly, the incorporation of a substantially non-reactive, water insoluble diluent into the reaction mixture used to form a polyurea achieves a polyurea without any substantial deterioration of properties as compared to a polyurea formed in the absence of the diluent. Suitable diluents include, but are not limited to, esters. More preferred diluents include diesters and a most preferred diluent is TXIB. Further, the inclusion of a Sdiluent such as TXIB in a polyurea forming reaction mixture reduces the adverse effects of excess water.

Unexpectedly, as shown by Examples 2-5, it was discovered that polyurethane elastomers may be formed in the presence of excess water with reduced degradation of the polyurethane elastomer relative to preparing the same polyurethane elastomer in a wet environment when the polyurethane elastomer forming composition includes a diluent. As is shown in Example 2, a polyurethane elastomer was prepared, by conventional methods, from the formulation using an ethylene oxide capped, 6000 molecular weight triol; 1,4butanediol; a 143 equivalent weight 4,4'-diphenylmethane diisocyanate having an average functionality of about 2.1; and dibutyltindilaurate. The resultant polyurethane polymer was a firm elastomer with a density of about 621bs/ft 3 (993kg/m 3 By contrast, the same formulation listed in Example 3, when mixed and poured into water forms a lower density (about 291bs/ft 3 (464kg/m3)) polymer, that floats on the water, having a mixed composition as evidenced by the presence of both soft and hard portions. Comparison of Examples 2 and 3 demonstrates that the presence of water interferes with the polyurethane forming reaction of a conventional formulation for preparing a polyurethane elastomer.

As shown by Examples 4 and 5, the presence of a diluent may reduce the degradation in the quality of a polyurethane elastomer made in the presence of water. In Example 4, an elastomer was made using a formulation having an ethylene oxide capped, 6000 molecular weight triol; 1,4-butanediol; a 143 equivalent weight 4,4'diphenylmethane diiosocyanate having an average functionality of about 2.1 dibutyltindilaurate and TXIB. The resultant polymer was a firm elastomer having a density of about 671bs/ft 3 (1073kg/m3). Example 5 demonstrates that when the same formulation was subjected to an extreme test by being poured into water, the reaction mixture sank to the bottom of the water and remained there while continuing to react to S13a

O

c form an elastomer similar to one formed in the absence of water. The polyurethane elastomer having TXIB, when formed in water, had a density of about 691bs/ft 3 N (1105kg/m 3 SThe Examples 2-5 demonstrate that formulations, for the preparation of polyurethane elastomers, which incorporate diluents, such as TXIB, substantially reduce water induced degradation in the formation of a polyurethane elastomer even in the presence of large 1 amounts of water. The use of TXIB in polyurethane elastomer formulations is applicable to low and high-density elastomers.

SUse of the polyurethane foam forming composition described above provides a method to stabilize geological formations and to reduce or eliminate subsidence problems I associated with surface structures such as highways. Other uses include injection of the polyurethane foam forming composition into a substrate to reduce or eliminate water flow or 10 water leakage or to stabilize and/or compact the substrate. A known method of reducing subsidence is disclosed in U.S. Patent No. 4,567,708 which is fully incorporated by reference.

Referring to Figure 1, the method according to the present invention includes the steps of mixing a polyisocyanate, a polyol, a blowing agent and a substantially water insoluble and non-reactive diluent, and injecting the polyurethane foam forming mixture 1 into the void 2 or substrate 3 beneath the structure 4. Arrows 5 indicate movement of the structure 4 as the mixture 1 expands in the void 2 shown in Fig. 1.

Optionally, additives such as catalysts or surfactants as previously described may be added to the mixture prior to injection. Preferred diluents include, but are not limited to, esters. Dibasic esters, such as TXIB, are more preferred.

This method may also use a modified polyisocyanate as the polyisocyanate component of the foam forming mixture. The modified polyisocyanate includes, but is not limited to, isocyanate prepolymers and isocyanate homopolymers. Also, a polyurea foam may be used by replacing all or at least a substantial amount of the polyol with a polyamine, as described above.

According to the present invention, the use of a substantially non-reactive, water insoluble diluent permits the preparation of low density water blown polyurethane foams with good dimensional stability. The use of a diluent also permits the formation of polyurethane foams and elastomers in the presence of quantities of water that would impair the quality of the foams or elastomers made in the absence of the diluent.

The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the details of the illustrated apparatus and construction and method of operation may be made without departing from the spirit of the invention.

m EXAMPLE 1 Ingredient Parts By Weight R-470-X 40-770 36 TXIB 47.4 0.3 DMEA 1.9 UL-2 0.025 BL-11 0.2 B8423 1.8 Water 2.4 Total 100.025 The above resin blend was reacted with polymeric MDI (MONDUR MR or RUBINATE M) in a weight ratio of 44.6 to 55.4. R-470-X is sold by The Dow Chemical Company under the trademark VORANOL R-470-X. PC-5 is PMDETA. B8423 is a silicon surfactant sold by Goldschmidt Chemical Company under the trademark TEGOSTAB® B8423. 40-770 is a tetrol, with a hydroxyl number average of 770, sold by Arch PerformanceUrethanes and Organics.

ELASTOMER Examples 2 and 3 Ingredient Parts by Weight Example 2 Example 3 Density (Ibs/ft 3 Density (lbs/ft 3 M3901 85.0 BDO Crosslinker 15.0 T-12 0.01 Water present No Yes Total 100.1 62 (993kg/m) 29 (464kg/m 3 The resin blends above were reacted with ISONATE 143L at an index of about 1.1 Q ELASTOMER Examples 4 and ELASTOMER Examples 4 and The resin blends above were reacted with 1SONATE 143L at an index of about 1.1 Example 6 Ingredient Parts by Weight 470X 12.00 40-770 33.25 UTXB 48.00 0.25 DMEA 1.70 UL-22 0.025 BL-I 0.20 :8423 1.80 Water 2.80 Total 100.025 The above resin blend was reacted with polymeric MDI (MONDUR MR or RUBINATE M)in a weight ratio of 44.6 resin blend to 55.4 to isocyanate. The isocyanate index is 1.05.

I.

Physical Properties of Example 6 Property Test.Method Result Result Density ASTM-1622 .2.71 lb1 3 2.711b/ft 3 Compressive strength ASTM-1 621 Perpendicular 20469 psi 20.69 psi Parallel .27.83 psi 27.83 psi Y% Closed cell ASTM D-2856 81.2 :81.2 Dimensional Stability IASTM3 D-2 126: Volumn e Change I Day 7 Day 14 Day 28, day 0 C/95%o RH 0.4 0.1 -0.3 0.40 100 0 C/ambient RH 1.6 .2.1 .0.2 1.70 *C/ambient RH 0.4 0.41 -0.8 0.30 Note: 2.71]b/ft 20.69 psi 27.83 psi.

43.4kg/n 3 142.6 kP~a 191.9 kPa

Claims (4)

1. A composition for preparing a polyurethane foam, the composition comprising: a polyisocyanate; a polyol; a blowing agent; and a substantially non-reactive ester diluent. The composition of claim 1, wherein the diluent is a substantially water NI insoluble ester. o0 3. The composition of claim 2, wherein the diluent is a diester. N 4. The composition of claim 3, wherein the diluent is a 2,2,4-trimethyl-l,3- pentanediol diisobutyrate. The composition of any one of claims 1 to 4, wherein the polyurethane foam has a closed-cell content greater than about 50% of the cells. Is 6. The composition of claim 5, wherein the blowing agent further comprises a non-reactive material.

7. The composition of any one of claims 1 to 6, wherein the foam has a volumetric change of less than about 15% after storing the foam for 28 days at 70 0 C and relative humidity.

8. The composition of claim 7, wherein the foam has a density of less than about

80.09 kg/m 3 (5 pounds per cubic foot). 9. The composition of any one of claims 1 to 8, wherein an isocyanate index ranges from about 0.9 to The composition of any one of claims 1 to 9, wherein the blowing agent is water. 11. The composition of claim 10, wherein the foam has a volumetric change of less than about 15% after storing the foam for 28 days at 70 0 C and 95% relative humidity. 12. The composition of claim 10, wherein the foam has a closed-cell content which is greater than 50% of the total cells. 13. The composition of claim 10, wherein the foam has a density of less and about 80.09 kg/m 3 (5 pounds per cubic foot). 14. The composition according to claim 1, substantially as hereinbefore described with reference to any one of the examples or accompanying drawings. 1226584 I 4-AUG2008 12:57 SPRUSON FERGUSON 92615436 NO. 4042 P. 6 00 19 O O 15. A method of stabilizing or reducing earth subsidence beneath a structure on a 0n substrate with a water blown polyurethane foam made in the presence of excess water Scomprising: mixing a polyisocyanate, a polyol having a quantity of water for generating 0 5 carbon dioxide by reaction with a portion of the polyisocyanate, and a substantially water insoluble and substantially non-reactive diluent to form a polyurethane reaction mixture; and injecting the polyurethane reaction mixture into the substrate. 0 16. The method of claim 15, wherein the diluent is 2,2,4-trimethyl-1,3- f) to pentanediol diisobutyrate. 0 17. A closed-cell polyurethane foam, said foam being a reaction product of a composition comprising: a polyisocyanate; a polyol; is a blowing agent; and a substantially non-reactive ester diluent. 18. The foam of claim 17, wherein the diluent is diester. 19. The foam of claim 17 or 18, wherein the diluent is 2,2,4-trimethyl-1,3- pentanediol diisobutyrate. 20. A method of preparing a closed-cell polyurethane foam, the method comprising: mixing components of a reaction mixture comprising: a polyisocyanate; a polyol; a blowing agent; and a substantially non-reactive ester diluent; and allowing the reaction mixture to react and form the closed-cell polyurethane foam. 21. The method of claim 20, wherein the diluent is a substantially water insoluble ester. 22. The method of claim 21, wherein the diluent is a diester. 23. The method of claim 22, wherein the diluent is 2,2,4-trimethyl-1,3- pentanadiol diisobutyrate. 24. A method of stabilizing or reducing earth subsidence beneath a structure or a substrate with a water blown polyurethane foam made in the presence of excess water 122658M4 COMS ID No: ARCS-200756 Received by IP Australia: Time 13:00 Date 2008-08-04 00 Lv 0 comprising the steps substantially as hereinbefore described with reference to any one of the examples or accompanying drawings. c 25. A method of preparing a closed-cell polyurethane foam comprising the steps substantially as hereinbefore described with reference to any one of the examples or O 5 accompanying drawings. Dated 6 May, 2008 Polythane Systems, Inc. N Patent Attorneys for the Applicant/Nominated Person C SPRUSON FERGUSON 1226584 I