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Process of preparing foams with internal mold-release agents    
United States Patent4201847   
Link to this pagehttp://www.wikipatents.com/4201847.html
Inventor(s)Kleimann; Helmut (Leverkusen, DE); von Bonin; Wulf (Leverkusen, DE); Schneider; Heinz-Georg (Gummersbach, DE)
AbstractA reaction product of a fatty acid ester and an organic polyisocyanate is included in a foamable reaction mixture containing an organic polyisocyanate to provide a molded product which can be removed from a mold whose surface has not been coated with conventional mold release agents.
   














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Inventor     Kleimann; Helmut (Leverkusen, DE); von Bonin; Wulf (Leverkusen, DE); Schneider; Heinz-Georg (Gummersbach, DE)
Owner/Assignee     Bayer Aktiengesellschaft (Leverkusen, DE)
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Publication Date     May 6, 1980
Application Number     05/924,260
PAIR File History     Application Data   Transaction History
Image File Wrapper   Patent Term   Fees
Litigation
Filing Date     July 13, 1978
US Classification     521/172 264/300 521/130 521/132 521/160 521/162 530/231
Int'l Classification     C08G 018/14 C08G 018/36
Examiner     Cockeram; H. S.
Assistant Examiner    
Attorney/Law Firm     Gene, Gil; Joseph C. Harsh; Olson; R. Brent ,
Address
Parent Case     This is a continuation, of application Ser. No. 438,071 filed Jan. 30, 1974, now abandoned.
Priority Data     Feb 16, 1973[DE]2307589
USPTO Field of Search     521/130 521/132 521/160 521/162 521/172 264/300
Patent Tags     preparing foams internal mold-release agents
   
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What is claimed is:

1. In a process for the production of molded articles of polyurethane foam by foaming a reaction mixture in a closed mold, said reaction mixture comprising a polyisocyanate, an organic compound containing at least two hydrogen atoms reactive with isocyanates, and a blowing agent, the improvement wherein said polyisocyanate consists of the reaction product of

(a) an organic polyisocyanate, and

(b) from 0.5 to 25% by weight based on the quantity of said organic polyisocyanate, of an active hydrogen-containing fatty acid ester prepared by reacting an alcohol with an aliphatic, saturated or unsaturated fatty acid, said ester being characterized in that at least one aliphatic acid which contains more than 8 carbon atoms is built into the molecule, said ester further characterized as having an acid number of 0 to 100 and a hydroxyl number of 0 to 150 with at least one of said numbers being greater than 0 and said ester having an average molecular weight of from 500 to 5000.

2. The process of claim 1, wherein said fatty acid is selected from the group consisting of octane carboxylic acids, dodecane acids, oleic acid, elaidic acid, stearic acid, palmitic acid, linoleic acid, linolenic acid, train oil fatty acids, fatty acids obtained from coconut oil, tallow fatty acids, fatty acids obtained by paraffin oxidation, tall oil fatty acids, and addition products of maleic acid with natural and synthetic oils.

3. The process of claim 2, wherein said fatty acid ester is prepared by reacting an alcohol with an aliphatic saturated or unsaturated fatty acid and a dicarboxylic acid.

4. The process of claim 3, wherein said dicarboxylic acid is selected from the group consisting of succinic acid, maleic acid, citric acid, azelaic acid and adipic acid.

5. The process of claim 1, wherein said reaction product is prepared by reacting said components (a) and (b) at a temperature of between 30.degree. C. and 200.degree. C.

6. The process of claim 1, wherein said organic polyisocyanate is the phosgenation product of aniline-formaldehyde condensates.

7. The process of claim 1, wherein the reaction mixture contains in addition to a fatty acid ester/polyisocyanate reaction product a mixture of mold release agents other than said reaction product.

8. The process of claim 7, wherein the mixture of mold release agent contains an oleic acid or tall oil fatty acid salt of the amide-containing amine which is the reaction product of N-dimethylaminopropylamine and oleic acid or tall oil fatty acid.

9. The process of claim 1, wherein said component (b) is present in amounts of from 2 to 18% by weight.

10. The process of claim 1, wherein the fatty acid ester is an ester of (a) oleic acid or tall oil fatty acid, (b) a dicarboxylic acid and (c) a polyhydric alcohol.

11. The process of claim 1, wherein the fatty acid ester is an ester of (a) oleic acid, (b) adipic acid and (c) pentaerythritol, said ester having an acid number of about 3 to about 30 and a hydroxyl number of about 30 to about 70 and an average molecular weight of about 900 to about 2500.

12. The process of claim 1, wherein the fatty acid ester is a ricinoleic acid polyester having a molecular weight of between 800 and 2500.
 Description Submit all comments and votes
 


This invention relates to a process for making molded foam resins having improved properties which facilitate release of the foam from a mold.

Foam resins based on organic polyisocyanates, e.g. polyurethane foams which have a dense outer skin and a cellular core as obtained by the method of foaming in the mold (German Auslegeschrift No. 1,196,864 and French Pat. Specification No. 1,559,325) are eminently suitable for the series production of lightweight constructions, e.g. for the manufacture of furniture, vehicles and buildings.

To produce the molded polyurethane products, a foamable reaction mixture containing an organic polyisocyanate, compounds which contain at least two hydrogen atoms capable of reacting with isocyanates and additives is introduced into closed, heatable molds in which the mixture foams up and then solidifies in a very compressed state. The resin completely fills the mold and accurately reproduces the internal surfaces of the mold.

The molds are preferably made of a material with a high thermal capacity and high thermal conductivity, the material used being preferably metal although other materials such as synthetic resins, glass, wood, etc. may also be used.

The mold is usually covered with a mold release agent so that parts of the foam resin will not adhere to the surface when the foam resin product is released from the mold. Waxes, soaps or oils, for example, are among the various mold release agents in use. These mold release agents form a thin film between the surface of the mold and the foam resin product. This film does not adhere either to the mold or to the synthetic resinous product and therefore facilitates release of the product from the mold.

This prior art method has various disadvantages for the production of a series of molded products. The mold release agent must be applied repeatedly at regular intervals and, during this time, the mold is unavailable for production. Fine engravings in the mold, for example to imitate the structure of wood or grain of leather, become covered with residues of mold release agent in the course of time. Removal of these firmly adhering residues from the molds which frequently have a very complex internal surface requires considerable effort. The molded products also become coated with a thin film of the release agent, to which lacquer systems will not adhere. The surfaces of the molded product must therefore be ground or cleaned with solvents before they are lacquered in order that the lacquer will adhere sufficiently firmly to the synthetic resin.

In U.S. Pat. No. 3,726,952, it has been disclosed that the application of a mold release agent to the mold can be obviated by mixing the foamable reaction mixture with certain additives which modify the properties of the finished synthetic resin product so that it can easily be released from metal molds without any damage to its surface. Among the additives which have been proposed for this purpose are salts of aliphatic carboxylic acids containing at least 25 carbon atoms with amines, perferably primary amines, or amines which contain amide or ester groups.

In German Offenlegungsschrift No. 2,121,670 there is disclosed a process for the production of foam resins by foaming a reaction mixture of organic polyisocyanates, compounds which contain reactive hydrogen atoms, water and/or organic blowing agents and additives in a closed mold, the additives used being, e.g. a mixture of (a) salts of aliphatic carboxylic acids containing at least 20 aliphatic carbon atoms with amines which may contain amide and/or ester groups and (b) natural and/or synthetic oils, fats, or waxes.

Since these additives have an internal lubricating effect on the synthetic resin mixture they also impart excellent flow properties to the synthetic resin in the mold and reduce the formation of bubbles on the surface of the synthetic resin. In addition, these internal mold release agents have an antistatic effect and they impart excellent mold release properties even in metal molds which have a very complicated surface. Although excellent mold release effects can be obtained by these disclosed methods, it has been found in practice that the esters of higher fatty acids or their mixed esters frequently used as synthetic oils or waxes are insufficiently compatible with the isocyanate or polyol components used as starting materials for the foams, i.e. mixtures of these starting components with the fatty acid esters used as mold release agents are frequently unstable in storage and separate into their individual phases. Although this process of separation can be prevented by stirring the contents in the storage containers, this is not a satisfactory commercial solution to the problem because the storage containers are in most cases not equipped with stirrers. Moreover, the separation process may have already occurred during the transport of the material.

The problem of finding internal mold release agents which will form a stable mixture with at least one of the starting components of the foam so that the mixture will have no tendency to undergo phase separation has existed.

It is therefore an object of this invention to provide an improved process for molding foamable reaction mixtures containing an organic polyisocyanate. Another object of this invention is to provide a process for molding foamable mixtures containing an organic polyisocyanate and an internal mold release agent which is devoid of the foregoing disadvantages. Still another object of this invention is to provide a foamable reaction mixture containing an organic polyisocyanate and an effective internal release agent which is miscible with the other components of the mixture. A further object of the invention is to provide a foamable reaction mixture containing an organic polyisocyanate adapted for molding a series of products one after the other without interruption for the application of a mold release to the surface of the mold.

The foregoing objects and others are accomplished in accordance with this invention, generally speaking, by providing a process for molding a foamable reaction mixture containing an organic polyisocyanate and a reaction product of an organic polyisocyanate with an ester or mixed ester of a higher fatty acid which contains active hydrogen atoms as a mold release agent. It has now surprisingly been found that reaction products of organic polyisocyanates with esters or mixed esters of higher fatty acids which contain active hydrogen atoms (hereinafter referred to as "fatty acid esters") used either alone or in combination with other mold release agents or systems of mold release agents provide excellent mold release properties in the molding of a foamable reaction mixture containing an organic polyisocyanate and, that, moreover, these fatty acid esters will dissolve in the foamable mixture and will not undergo phase separation.

A process in which foams are produced by foaming a reaction mixture containing an organic polyisocyanate, an organic compound containing hydrogen atoms reactive with a polyisocyanate and having a molecular weight of at least 62, preferably 62 to about 10,000, water and/or organic blowing agents and optionally other additives together with a reaction product of a fatty acid ester and a polyisocyanate in a closed mold is preferred.

The mold release effect can be measured by the force in kp/cm.sup.2 which is required to open the mold when removing the molded product. It can also be assessed subjectively by opening a suitable mold by hand and removing the foam panel (20.times.20.times.1 cm) which has partly foamed. The mold release forces required for foams which have been treated with the mold release reaction products provided by the invention are considerably lower than those required for comparable foams which have been produced by foaming reaction mixtures without these additives.

For the purpose of this invention, foam resins based on organic polyisocyanates are understood to mean both foams which are produced from an organic polyisocyanate alone and those which can be obtained by addition of an organic polyisocyanate with an organic compound which contains at least two Zerewitinow active hydrogen atoms, e.g. polycarbodiimide foam, polyisocyanurate foam, polyurea foam, polybiuret foam, polyamide foam, polyallophanate foam or polyurethane foam, or foams containing a mixture of urethane, urea, allophanate, biuret, amide, carbodiimide and/or isocyanurate groups and any other foam based on a polyisocyanate. The process described here is particularly suitable for the production of foams which contain urethane groups prepared from a foamable reaction mixture containing an organic polyisocyanate.

Any suitable organic polyisocyanate may be used such as, for example, an aliphatic, cycloaliphatic, araliphatic, aromatic or heterocyclic polyisocyanate including those described by W. Siefgen in Justus Liebigs Annalen der Chemie, 562, pages 75 to 136. Examples of suitable polyisocyanates are ethylene diisocyanate, tetramethylene-1,4-diisocyanate, hexamethylene-1,6-diisocyanate, dodecane-1,12-diisocyanate, cyclobutane-1,3-diisocyanate, cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate and any mixtures of these isomer, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane (German Auslegeschrift No. 1,202,785), hexahydrotolylene-2,4-diisocyanate and hexahydrotolylene-2,6-diisocyanate and any mixtures of these isomers, hexahydrophenylene-1,3-diisocyanate, hexahydrophenylene-1,4-diisocyanate, perhydrodiphenylmethane-1,4'-diisocyanate, perhydrodiphenylmethane-4,4'-diisocyanate, phenylene-1,3-diisocyanate, phenylene-1,4-diisocyanate, tolylene-2,4-diisocyanate, tolylene-2,6-diisocyanate and any mixtures of these isomers, diphenylmethane-2,4'-diisocyanate, diphenylmethane-4,4'-diisocyanate, naphthylene-1,5-diisocyanate, triphenylmethane-4,4',4"-triisocyanate, polyphenyl-polymethylene polyisocyanates which may be obtained by aniline-formaldehyde condensation followed by phosgenation and which have been described, e.g. in British Pat. No. 874,430 and 848,671; perchlorinated aryl polyisocyanates as described e.g. in German Auslegeschrift No. 1,157,601; polyisocyanates which contain carbodiimide groups as described in German Patent Specification No. 1,092,007; the diisocyanates described in U.S. Pat. Specification No. 3,492,330; polyisocyanates which contain allophanate groups as described e.g. in British Patent Specification No. 994,890; Belgian Pat. Specification No. 761,626 and published Dutch Patent Application No. 7,102,524, polyisocyanates which contain isocyanurate groups as described e.g. in German Pat. Specifications No. 1,022,789; 1,222,067 and 1,027,394 and in German Offenlegungsschriften No. 1,929,034 and 2,004,048; polyisocyanates which contain urethane groups as described e.g. in Belgian Patent Specification No. 752,261 or in U.S. Pat. Specification No. 3,394,164; polyisocyanates which contain acylated urea groups as described in German Patent Specification No. 1,230,778, polyisocyanates which contain biuret groups as described e.g. in German Pat. Specification No. 1,101,394; in British Pat. Specification No. 889,050 and in French Pat. Specification No. 7,017,514; polyisocyanates prepared by telomerisation reactions as described e.g. in Belgian Pat. Specification No. 723,640; polyisocyanates which contain ester groups as described e.g. in British Pat. Specification Nos. 965,474 and 1,072,956; in U.S. Pat. Specification No. 3,567,763 and in German Patent Specification No. 1,231,688 and reaction products of the above mentioned isocyanates with acetals according to German Pat. Specification No. 1,072,385.

The distillation residues obtained from the commercial production of isocyanates, which still contain isocyanate groups, may also be used, if desired in the form of solutions in one or more of the above mentioned polyisocyanates. Any mixtures of the above mentioned polyisocyanates may also be used.

It is generally preferred to use commercially readily available polyisocyanates, e.g. tolylene-2,4-diisocyanate and tolylene-2,6-diisocyanate and any mixtures of these isomers ("TDI") polyphenyl-polymethylene-polyisocyanates obtained by aniline-formaldehyde condensation followed by phosgenation ("crude MDI") and polyisocyanates which contain carbodiimide groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret groups ("modified polyisocyanates").

Organic compounds with a molecular weight generally between 62 and 10,000 which contain at least two hydrogen atoms capable of reacting with isocyanates may also be used as one of the starting components of the foamable reaction mixture. These may be compounds which contain amino groups, thiol groups or carboxyl groups but are preferably organic polyhydroxyl compounds, in particular polyhydric alcohols containing 2 to 8 hydroxyl groups and especially those having a molecular weight of 800 to 10,000, preferably 1000 to 6000, e.g. the polyesters, polyethers, polythioethers, polyacetals, polycarbonates and polyester amides containing at least two, generally 2 to 8, but preferably 2 to 4 hydroxyl groups which are known per se for the production of homogeneous and cellular polyurethanes.

Any suitable polyester containing hydroxyl groups may be used, e.g. the reaction products of polyhydric alcohols, preferably dihydric alcohols to which trihydric alcohols may be added, with polybasic carboxylic acids, preferably dibasic carboxylic acids. Instead of using free polycarboxylic acids, the corresponding polycarboxylic acid anhydrides or polycarboxylic acid esters of lower alcohols or mixtures thereof may be used for producing the polyesters. The polycarboxylic acids may be aliphatic, cycloaliphatic, aromatic and/or heterocyclic and may be substituted, e.g. by halogen atoms, and/or unsaturated. The following are mentioned as examples: succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, trimellitic acid, phthalic acid anhydride, tetrahydrophthalic acid anhydride, hexahydrophthalic acid anhydride, tetrachlorophthalic acid anhydride, endomethylene tetrahydrophthalic acid anhydride, glutaric acid anhydride, maleic acid, maleic acid anhydride, fumaric acid, dimeric and trimeric fatty acids such as oleic acid optionally mixed with monomeric fatty acids, dimethyl terephthalate and bis-glycol terephthalate. The following are examples of suitable polyhydric alcohols: ethylene glycol, propylene-1,2-glycol propylene-1,3-glycol, butylene-1,4-glycol, butylene-2,3-glycol, hexane-1,6-diol, octane-1,8-diol, neopentyl glycol, cyclohexane dimethanol (1,4-bis-hydroxy-methylcyclohexane), 2-methyl-propane-1,3-diol, glycerol, trimethylolpropane, hexane-1,2,6-triol, butane-1,2,4-triol, trimethylolethane, pentaerythritol, quinitol, mannitol, sorbitol, methyl glycoside, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycols, dipropylene glycol, polypropylene glycols, dibutylene glycol and polybutylene glycols. The polyesters may also contain terminal carboxyl groups. Polyesters of lactones such as .epsilon.-caprolactone or of hydrocarboxylic acids such as .omega.-hydroxycaproic acid may also be used. The low molecular weight polyhydric alcohols mentioned above may also be used as such.

Polyethers used according to the invention which contain at least 2 and generally 2 to 8, preferably 2 or 3 hydroxyl groups are also known per se and may be prepared, e.g. by the polymerisation of epoxides such as ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide or epichlorohydrin, each with itself, e.g. in the presence of BF.sub.3, or by the addition of these epoxides, either alone, as mixtures or successively, to starting components which contain reactive hydrogen atoms such as alcohols or amines, e.g. water, ethylene glycol, propylene-1,3-glycol, propylene-1,2-glycol, trimethylolpropane, 4,4'-dihydroxydiphenylpropane, aniline, ammonia, ethanolamine or ethylene diamine. Sucrose polyethers such as those described, e.g. in German Auslegeschrfit No. 1,176,358 and 1,064,938 may also be used according to the invention. It is frequently preferred to use polyethers which contain predominantly primary hydroxyl groups (up to 90% by weight, based on all the hydroxyl groups present in the polyether). Polyethers which have been modified by vinyl polymers are also suitable, e.g. the polyethers obtained by the polymerisation of styrene or acrylonitrile in the presence of polyethers (U.S. Pat. Specification Nos. 3,383,351; 3,304,273; 3,523,093 and 3,110,695 and German Patent Specification No. 1,152,536). Polybutadienes which contain hydroxyl groups may also be used.

Among the polythioethers there should be particularly mentioned the condensation products of thiodiglycol with itself and/or with other glycols, dicarboxylic acids, formaldehyde, aminocarboxylic acids or aminoalcohols. These products are either polythio mixed ethers, polythio ether esters or polythio ether ester amides, depending on the cocomponents.

The polyacetals used may be, for example, compounds prepared from glycols such as diethylene glycol, triethylene glycol, 4,4'-dioxethoxy-diphenyldimethylmethane, hexanediol and formaldehyde. Polyacetals suitable for the invention may also be prepared by polymerising cyclic acetals.

The polycarbonates with hydroxyl groups may be those known per se which can be prepared, for example, by reacting diols such as propane-1,3-diol, butane-1,4-diol and/or hexane-1,6-diol, diethylene glycol, triethylene glycol or tetraethylene glycol with diarylcarbonates such as diphenyl carbonate or phosgene.

Suitable polyester amides and polyamides include, for example, the predominantly linear condensates obtained from polybasic saturated and unsaturated carboxylic acids or their anhydrides and polyvalent saturated and unsaturated amino alcohols, diamines, polyamines and their mixtures.

Polyhydroxyl compounds which already contain urethane or urea groups and modified or unmodified natural polyols such as castor oil, carbohydrates or starch may also be used. Addition products of alkylene oxides with phenol formaldehyde resins or with urea formaldehyde resins may also be used for the process of the invention.

Representatives of these compounds are described, for example, in High Polymers, Volume XVI, "Polyurethanes, Chemistry and Technology", by Saunders and Frisch, published by Interscience Publishers, New York, London, Volume I, 1962, pages 32-34 and pages 44-54 and Volume II, 1964, pages 5-6 and 198-199 and in Kunststoff-Handbuch, Volume VII, Vieweg-Hochtlen, Carl-Hanser-Verlag, Munich, 1966, e.g. on pages 45 to 71.

Water and/or readily volatile organic substances may be used as blowing agents according to the invention. Suitable organic blowing agents are e.g. acetone, ethyl acetate, halogenated alkanes, such as methylene chloride, chloroform, ethylidene chloride, vinylidene chloride, monofluorotrichloromethane, chlorodifluoromethane, dichlorodifluoromethane and trichloro trifluoroethane, as well as butane, hexane, heptane or diethylether. A blowing effect can also be obtained by adding compounds which decompose at temperatures above room temperature to liberate gases such as nitrogen, e.g. azo compounds such as azo isobutyric acid nitrile. Other examples of blowing agents and details of their methods of use have been described in Kunststoff-Handbuch, Volume VII, published by Vieweg and Hochtlen, Carl-Hanser-Verlag, Munich 1966, e.g. on pages 108 to 109, 453 to 455 and 507 to 510.

Catalysts are frequently used in the process according to the invention. The catalysts used may be known per se, e.g. tertiary amines such as triethylamine, tributylamine, N-methyl-morpholine, N-ethyl-morpholine, N-cocomorpholine, N,N,N',N'-tetramethyl-ethylenediamine, 1,4-diaza-bicyclo-(2,2,2)-octane, N-methyl-N'-dimethylaminoethyl-piperazine, N,N-dimethylbenzylamine-bis-(N-diethylaminoethyl)-adipate, N,N-diethylbenzylamine, pentamethyldiethylenetriamine, N,N-dimethyl-cyclohexylamine, N,N,N',N'-tetramethyl-1,3-butanediamine, N,N-dimethyl-.beta.-phenylethylamine, 1,2-dimethylimidazole, 2-methylimidazole and tetramethylguanidine.

Triethanolamine, triisopropanolamine, N-methyl-diethanolamine, N-ethyl-diethanolamine, N,N-dimethyl-ethanolamine and their reaction products with alkylene oxides such as propylene oxide and/or ethylene oxide are examples of suitable tertiary amines which contain hydrogen atoms which are reactive with isocyanate groups.

Silaamines which contain carbon-silicon bonds may also be used as catalysts, e.g. the compounds described in German Pat. Specification No. 1,229,290 such as 2,2,4-trimethyl-2-silamorpholine and 1,3-diethylaminomethyl-tetramethyldisiloxane.

Bases which contain nitrogen, such as tetralkylammonium hydroxides, and alkali metal hydroxides such as sodium hydroxide, alkali metal phenolates such as sodium phenolate and alkali metal alcoholates such as sodium methylate are also suitable catalysts. Hexahydrotriazines may also be used as catalysts.

Organic metal compounds may also be used as catalysts, especially organic tin compounds.

The organic tin compounds used are preferably tin(II) salts (stannous salts) of carboxylic acids such as tin(II) acetate, tin(II) octoate, tin(II) ethyl hexoate and tin(II) laurate and the dialkyl tin salts of carboxylic acids such as dibutyl tin diacetate, dibutyl tin dilaurate, dibutyl tin maleate or dioctyl tin diacetate.

Other examples of catalysts which may be used according to the invention and details of their mode of action are described in Kunststoff-Handbuch, Volume VII, published by Vieweg and Hochtlen, Carl-Hanser-Verlag, Munich, 1966, e.g. on pages 96 to 102.

Any catalytic amount of the catalyst may be used. The catalysts are generally used in quantities of between about 0.001% and 10% by weight, based on the weight of the organic compound having at least two hydrogen atoms capable of reacting with isocyanates and, preferably, a molecular weight of 62 to about 10,000.

Any suitable surface active additive may also be used in the process according to the invention (emulsifiers and foam stabilizers). Suitable emulsifiers are e.g. the sodium salts of ricinoleic sulphonates or the sodium salts of fatty acids or salts of fatty acids with amines such as oleic acid diethylamine or stearic acid diethanolamine. Alkali metal salts or ammonium salts of sulphonic acids such as dodecylbenzene sulphonic acid or dinaphthylmethane disulphonic acid or alkali metal or ammonium salts of fatty acids such as ricinoleic acid or of polymeric fatty acids may also be used as surface active additives.

The main foam stabilizers used are water-soluble polyether siloxanes. The structure of these compounds is generally such that a copolymer of ethylene oxide and propylene oxide is linked to a polydimethylsiloxane group. Foam stabilizers of this type have been described e.g. in U.S. Pat. Specification No. 3,201,272, Column 3, line 60 to Column 4, line 3.

Reaction retarders may also be used according to the invention, e.g. substances which are acid in reaction such as hydrochloric acid, sulphuric acid, phosphoric acid or organic acid halides, as well as cell regulators of known type such as paraffins or fatty alcohols or dimethylpolysiloxanes; in addition there may be used pigments or dyes and flame-retarding agents known per se, e.g. tris-chloroethyl phosphate or ammonium phosphate and polyphosphate, age resisters and stabilizers to protect against weathering, plasticizers, fungistatic and bacteriostatic substances, fillers such as barium sulphate, kieselguhr, carbon black or whiting.

Other examples of surface active additives, foam stabilizers and cell regulators, reaction retarders, stabilizers, flame retarding substances, plasticizers, dyes, fillers and fungistatic and bacteriostatic substances and details of their mode of action and methods of using these additives have been described in Kunststoff-Handbuch Volume VI, published by Vieweg and Hochtlen, Carl-Hanser-Verlag, Munich, 1966, e.g. on pages 103 to 113.

The foaming process is preferably carried out in molds. Foaming in the mold is carried out by introducing the reaction mixture into a mold suitably made of a metal such as aluminium or a synthetic resin, e.g. epoxy resin. The foamable reaction mixture reacts and expands inside the closed mold to form the molded product. Foaming may either be carried out so that the molded product has a cellular structure on its surface or it may be carried out to produce a molded product with a compact skin and cellular core. According to the invention the foamable reaction mixture may be introduced into the mold in such an amount that the resulting foam only just fills the closed mold. Alternatively, a larger quantity of reaction mixture than would be required for filling the interior of the closed mold with solidified cellular product may be introduced. This second method is known as over-charging. It has been disclosed, e.g. in U.S. Pat. Specification Nos. 3,178,490 and 3,182,104.

When foaming is carried out in molds, mold release agents already know per se may be used in addition.

The process according to the invention may also be used for producing cold setting foams (see British Pat. Specification No. 1,162,517 and German Offenlegungeschrift No. 2,153,086).

According to the invention, reaction products of fatty acid esters and organic polyisocyanates are added.

Suitable fatty acid esters are in particular those in which at least one aliphatic acid which contains more than 8 carbon atoms is built into the molecule and which have acid numbers of between 0 and 100, preferably between 0 and 40 and hydroxyl numbers between 0 and 150, preferably between 0 and 75, at least one of those two values being greater than 0.

The fatty acid esters used may also have the character of polyesters or mixed esters which may be prepared both from monofunctional and from polyfunctional carboxylic acids and/or alcohols. The fatty acid esters may be prepared from several different types of fatty acids or carboxylic acids and/or alcohols so that complicated fatty acid esters with an average molecular weight generally between 500 and 5000 and preferably between 800 and 3000 are obtained by a process of mixed condensation.

Amines or amino alcohols may also be used in the preparation of the fatty acid esters to produce fatty acid mixed esters which contain basic or amide groups. These mixed esters are suitable for the process according to the invention. Such mixed esters can be obtained, for example, by adding ammonia, monoalkylamines or dialkylamines or their alkoxylation products, for example with ethylene oxide, propylene oxide or higher epoxides or by using acid amides which contain carboxyl groups or alcohol groups. These acid amides may be obtained, for example, by the amidation of carboxylic acids with monoalkanolamines or dialkanolamines such as ethanolamine, diethanolamine, propanolamine, or dipropanolamine or the like.

The fatty acid esters used for the reaction with the polyisocyanates are preferably those which can be prepared by esterifying carboxylic acids with alcohols or which can be obtained from natural substrates. The following are examples of suitable carboxylic acids and alcohols: butanol, hexanol, octanol-isomers, dodecanol, oleyl alcohol, other fatty alcohols, natural or synthetic steroid alcohols, ricinoleic acid, ethylene gly