Inventors:
Andy I. McLaughlin - Meridian MS
Richard L. Donald - Meridian MS
Robert H. Blanpied - Meridian MS
Robert J. Butkus - Meridian MS
Assignee:
Atlas Roofing Corporation - Meridian MS
International Classification:
C08G 1818
C08G 1822
C08J 908
Abstract:
In a method of producing a thermosetting foam, a first of two foam forming blends ("A Blend") is prepared using polymeric polymethylene polyphenylisocyanate ("PMDI"). A second of two foam forming blends ("B Blend") is prepared by mixing together a polyol; water; a tertiary amine catalyst having at least one ethyl (--CH. sub. 2 --CH. sub. 2 --) linkage between two heteroatoms, the heteroatoms being chosen from the group consisting of Nitrogen and Oxygen; and, an alkali metal organo-salt catalyst. A first blowing agent is included with one of the two foam forming blends. When the first and second foam forming blends are mixed together, the tertiary amine catalyst quickly initiates a reaction predominately of the polymeric polymethylene polyphenylisocyanate with water (as opposed to a reaction with the polyol). The quick reaction of the PMDI with water causes, prior to a gel point of the foam, both (1) the production of a second blowing agent for forming cells in the blends and for causing expansion in the liquid blends; and (2) sufficient exothermic heat to initiate boiling of the first blowing agent. Relatively large amounts of alkali metal organo-salt catalyst induce rapid vaporizing of the first blowing agent due to a high level of exothermic heat, whereby expansion of the mixed blends is substantially completed prior to the effective conversion of the mixed liquid blends to a solid.