The present invention relates to the synthesis of polymer polyols in unsaturated polyols as liquid phase, polymer polyols and their use.

Polymer polyols (“PMPOs”), processes for their production, and the use of such PMPOs, particularly in the production of flexible polyurethane foams. The PMPOs are produced using an ethylenically unsaturated composition that includes a crosslinker that results in crosslinks in the PMPO polymer particles that may decompose when exposed to flame temperatures. The PMPOs is capable of providing a flexible polyurethane foam that may exhibit combustibility resistance properties.

Polyether polyols are prepared by polymerizing unsaturated monomers in a continuous phase of a base polyol. A macromer or polymerization produce of such a macromer is present during the polymerization to stabilize the polymer particles as they form. The macromer is a polyether capped with certain unsaturated epoxide compounds.

Dispersions of silicate particles are formed in a polyol phase. The polyol, an alkoxysilane, water and catalyst are combined and reacted under specific temperature conditions to form the silicate particles in-situ in a liquid polyol phase. The dispersions are characterized in having excellent stability.

Processes for preparing a polymer polyol (PMPO) in which a base polyol is continuously produced in a continuous base polyol reactor, the base polyol is continuously discharged from the continuous base polyol reactor; the base polyol is continuously introduced to a continuous PMPO reactor, which is different from the continuous base polyol reactor, and PMPO is continuously removed from the PMPO reactor. Production plant configured to carry out such processes are also described.

Disclosed are polymer polyol compositions that include polymer particles produced from an ethylenically unsaturated compound resulting from the reaction of an amine-reactive ethylenically unsaturated compound with an amino diphenylamine, as well as to the use of such polymer polyol compositions in the production of flexible polyurethane foams. The polyurethane foam includes the reaction product of a reaction mixture that includes a polyisocyanate component and a polyol composition that includes the polymer polyol.

A reaction system for preparing polymer polyol and a method for preparing polymer polyol. The reaction system comprises a reactor, a first circulation unit, a second circulation unit, and a flow direction switching unit, wherein the reaction cavity of the reactor is divided into a first reaction chamber and a second reaction chamber by a partition plate, and the top of the partition plate is provided with an overflow port to communicate the first reaction chamber and the second reaction chamber with each other; the first circulation unit enables the material in the first reaction chamber to circulate between the discharge port of the first reaction chamber and the feed port of the first reaction chamber; the second circulation unit enables the material in the second reaction chamber to circulate between the discharge port of the second reaction chamber and the feed port of the second reaction chamber. The polymer polyol prepared by the reaction system has a low-viscosity effect, and by using the polymer polyol prepared by the method, a polyurethane foam having excellent mechanical properties and high hardness can be obtained.

The invention discloses one method of producing polyether polymer dispersant and polyether polymer, wherein the dispersant is a copolymer macromolecule prepared by the propylene oxide or ethylene oxide with an average molecular weight of 6000 to 20000, with containing at least one benzene ring group and one polymerizable carbon-carbon double or triple bond polymer. The preparation method of the dispersant is: synthesizing a basic polyether polyol, adding a cyclic dicarboxylic anhydride into the polyether polyol, then the polyether polyol is reacted with an epoxy compound with the polymerizable double bond, and capping with an epoxy compound to obtain the dispersant; preparing the polymer polyol by the basic polyol, an unsaturated vinyl monomer styrene and acrylonitrile, a polymerization initiator, the dispersant and an optional chain transfer agent; the basic polyether is a polyether polyol with a functionality of 3 to 8.

This invention relates to improved flexible foams prepared from polymer polyols and to a process for preparing these improved flexible foams.

The present invention is a composition comprising a) a stable aqueous dispersion of polymer particles having one or more structural units of i) a polyurea macromer; and ii) an acrylate, a methacrylate, a vinyl ester, or a styrene monomer, or a combination thereof; and/or b) an aqueous mixture of a i) polyurea macromer polymer particles; and b) acrylate, methacrylate, vinyl ester, or styrenic polymer particles, or a combination thereof, wherein the polyurea macromer is characterized by the following formula I: ##STR00001##
where A.sup.1, A.sup.2, R.sup.1, R.sup.2, and R.sup.3 are as defined herein. Compositions prepared using the compound of the present invention can be used to form coatings with excellent balance of low temperature film formation, hardness, and flexibility.