U.S. patent application number 09/938490 was filed with the patent office on 2002-02-28 for amine catalyst for producing rigid polyurethane foam.
This patent application is currently assigned to Tosoh Corporation. Invention is credited to Okuzono, Shuichi, Tamano, Yutaka, Tokumoto, Katsumi.
Application Number | 20020026078 09/938490 |
Document ID | / |
Family ID | 26334693 |
Filed Date | 2002-02-28 |
United States Patent
Application |
20020026078 |
Kind Code |
A1 |
Tokumoto, Katsumi ; et
al. |
February 28, 2002 |
Amine catalyst for producing rigid polyurethane foam
Abstract
An amine catalyst for production of a polyurethane and a
polyisocyanurate is provided which comprises a quaternary ammonium
compound represented by General Formula (1): 1 where R.sub.1 to
R.sub.6 are independently a linear or branched saturated
hydrocarbon group of 1 to 4 carbon atoms; R.sub.7 and R.sub.8 are
independently a linear or branched, saturated or unsaturated
hydrocarbon group of 2 to 12 carbon atoms; n is a number of 0 to 3,
provided that at n=o any one of R.sub.1, R.sub.2 and R.sub.3, and
R.sub.5 and/or R.sub.6 may be linked together to form a
heterocycle, or at n=1, 2, or 3, R.sub.5 or R.sub.6 and R.sub.4 may
be linked together to form a heterocycle; A is a carbonate group or
an organic acid group; and X is number of 1 to 2. The catalyst has
high activity in formation of polyurethane foams and
polyisocyanurate foams, having less odor, and producing foams of
high fire retardance, having high curability, high retarding
effect, and low corrosiveness.
Inventors: |
Tokumoto, Katsumi;
(Kudamatsu-shi, JP) ; Tamano, Yutaka;
(Tokuyama-shi, JP) ; Okuzono, Shuichi;
(Kudamatsu-shi, JP) |
Correspondence
Address: |
NIXON & VANDERHYE P.C.
1100 North Glebe Road, 8th Floor
Arlington
VA
22201-4714
US
|
Assignee: |
Tosoh Corporation
|
Family ID: |
26334693 |
Appl. No.: |
09/938490 |
Filed: |
August 27, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09938490 |
Aug 27, 2001 |
|
|
|
09172016 |
Oct 14, 1998 |
|
|
|
6307102 |
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Current U.S.
Class: |
564/291 ;
521/95 |
Current CPC
Class: |
C08G 2110/0025 20210101;
C08G 2110/005 20210101; C08G 18/1875 20130101; C08G 2115/02
20210101; C08G 2110/0008 20210101 |
Class at
Publication: |
564/291 ;
521/95 |
International
Class: |
C08K 005/19 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 15, 1997 |
JP |
HEI 9-281841 |
Jan 7, 1998 |
JP |
HEI 10-1476 |
Claims
What is claimed is:
1. An amine catalyst for production of a polyurethane and a
polyisocyanurate, comprising a quaternary ammonium compound
represented by General Formula (1): 4where R.sub.1 to R.sub.6 are
independently a linear or branched saturated hydrocarbon group of 1
to 4 carbon atoms; R.sub.7 and R.sub.8 are independently a linear
or branched, saturated or unsaturated hydrocarbon group of 2 to 12
carbon atoms; n is a number of 0 to 3, provided that at n=o any one
of R.sub.1, R.sub.2 and R.sub.3, and R.sub.5 and/or R.sub.6 may be
linked together to form a heterocycle, or at n=1, 2, or 3, R.sub.5
or R.sub.6 and R.sub.4 may be linked together to form a
heterocycle; A is a carbonate group or an organic acid group; and X
is number of 1 or 2.
2. The amine catalyst for production of a polyurethane and a
polyisocyanurate according to claim 1, wherein the group A of the
quaternary ammonium salt compound represented by General Formula
(1) is a carbonate group.
3. The amine catalyst for production of a polyurethane and a
polyisocyanurate according to claim 1, wherein the group A of the
quaternary ammonium salt compound represented by General Formula
(1) is a 2-ethylhexanoate group.
4. A catalyst for producing a flexible polyurethane foam, wherein
the compound represented by General Formula (1) is a quaternary
ammonium carbonate represented by General Formula (2): 5where
R.sub.1 to R.sub.8 are independently a linear or branched,
saturated or unsaturated hydrocarbon group of 1 to 12 carbon atoms;
n is a number of 0 to 3, provided that at n=o any one of R.sub.1,
R.sub.2 and R.sub.3, and R.sub.5 and/or R.sub.6 may be linked
together to form a heterocycle, or at n=1, 2, or 3, R.sub.5 or
R.sub.6, and R.sub.4 may be linked together to form a
heterocycle.
5. A process for producing a flexible polyurethane foam by reaction
of a polyol and a polyisocyanate in the presence of a catalyst and
a blowing agent, wherein one or more of the quaternary ammonium
carbonate set forth in claim 4 is used as a catalyst.
6. A process for producing a flexible polyurethane foam by reaction
of a polyol and a polyisocyanate in the presence of a catalyst and
a blowing agent, wherein the quaternary ammonium carbonate set
forth in claim 4 and triethylenediamine are used combinedly as the
catalyst.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an amine catalyst for
producing a polyurethane or a polyisocyanurate, and a process for
producing a flexible polyurethane foam employing the amine
catalyst. More specifically, the present invention relates to a
novel catalyst for producing a flexible polyurethane which has high
activity for forming polyurethane or polyisocyanurate, giving less
odor, giving high fire retardance, and having excellent curability,
and also relates to a process for producing a flexible polyurethane
foam by use, as a catalyst, of a quaternary ammonium carbonate
which has high activity for polyurethane formation, having less
odor, and being less corrosive.
[0003] 2. Description of the Related Art
[0004] Polyurethane products and polyisocynurate products are
widely used for furniture, automobile interior materials,
insulating materials, and so forth. In recent years, the production
of these products are required to be improved in productivity,
moldability, physical properties, and so forth, and not to cause
environmental pollution. Therefore, the catalyst is sought for to
achieve high catalytic activity and high functionality.
[0005] For example, for improvement of productivity and
moldability, a catalyst is demanded which is capable of curing at a
high curing rate. For improvement of physical properties, a
catalyst is demanded which is effective in improvement of fire
retardance of an insulating material as a building material. For
environmental protection, an amine catalyst or a blowing agent is
demanded which has less odor, and the catalyst should be suitable
for the formulation for flon consumption reduction.
[0006] A catalyst for formation of polyisocyanurate (trimerization)
is exemplified by metal type catalysts such as alkali metal
carboxylates, metal alcoholates, metal phenolates, metal
hydroxides; tertiary amines; tertiary phosphines; and phosphorus
onium salts. Alkali metal carboxylate salts such as potassium
acetate, and potassium 2-ethylhexanoate are used owing to high
activity of promoting isocyanurate reaction (isocyanurate activity)
and effectiveness of improving fire retardance of a rigid foam as a
building material. Quaternary ammonium salts of tetraalkylmonoamine
type such as quaternary hydroxyalkyltrimethylammonium
2-ethylhexanoate (disclosed in JP-A-52-17484) are used owing to
high isocyanurate activity. Furthermore, a method of employing a
quaternary ammonium organic acid salt is disclosed in
JP-A-9-124760.
[0007] Flexible polyurethane foams are widely used for furniture,
automobile interior materials, bedding materials, cushion
materials, and so forth. In recent years, the production of these
polyurethane products are required to be improved in productivity,
moldability, physical properties, and so forth, and not to cause
environmental pollution. Therefore, the catalyst is sought to
achieve high catalytic activity and high functionality.
[0008] For example, for improvement of productivity and
moldability, a catalyst is demanded which is capable of delaying.
For improvement of physical properties, a catalyst is demanded
which is effective in improvement of air permeability. For
environmental protection, an amine catalyst or a blowing agent is
demanded which has less odor, and the catalyst should be suitable
for the formulation for flon consumption reduction.
[0009] In production of polyurethane foams, the organic
carboxylates of a tertiary amine disclosed in JP-A-60-58418 are
known to be useful as delayed action catalysts. The delayed action
catalyst, which has a low initial activity, is capable of delaying
the time of initiation of the foaming reaction after mixing of the
source materials, the polyol and the organic isocyanate. Therefore,
the handling of the liquid mixture and the flowability of the
mixture, and other properties are improved. For example, the source
material liquid can be filled sufficiently to the corner of a large
mold. This type of catalyst exhibits the catalyst activity by
thermally dissociating the tertiary amine compound when the foaming
reaction has proceeded to cause rise of the reaction temperature.
Consequently, the catalyst activity is greatly increased to allow
the produced foam to distribute throughout a complicated mold
without defect formation, and thereby the curing is accelerated to
shorten the mold-release time of the produced foam and improves the
productivity.
[0010] However, conventional catalysts for rigid isocyanurate foam
production have various disadvantages. For example, conventionally
used alkali metal carboxylates and tetraalkylmonoamine type
quaternary ammonium salts, although they have relatively high
isocyanuration activity, delay the initial reaction remarkably but
accelerate the isocyanuration at the later stage of foaming to
result in rapid rise of the foaming profile, impair the flowability
and broaden the density distribution disadvantageously. Further,
the conventional tetraalkylmonoamine type quaternary ammonium salts
evolve low-volatile amine by decomposition of the quaternary
ammonium salt during the foam formation to aggravate working
environment. Further more, when a tertiary amine is combinedly used
for accelerating the initial reaction and improving the foam
flowability, although it improves the flowability, the tertiary
amine generates strong odor, renders the foam more friable, and
lowers fire retardance because the isocyanuration is retarded,
disadvantageously.
[0011] On the other hand, the for polyurethane production catalyst
having been employed because of their delayed action has various
disadvantages. For example, organic carboxylic acid salts of a
tertiary amine are strongly corrosive because of its lower pH, and
tend to corrode materials such as a urethane foaming machine to
lower the productivity, disadvantageously. This disadvantage can be
overcome by decreasing the amount of the organic carboxylic acid to
raise the pH, but this offsets the desired delaying effect. In one
method, a suitable tertiary amine is mixed to the tertiary amine
carboxylate to solve the problem, but the corrosion cannot be
completely prevented because of the essential use of an organic
carboxylic acid.
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to provide a novel
amine catalyst for polyurethane and polyisocyanurate production
having a high catalyst activity, giving less odor, enabling high
fire retardance and giving high curability.
[0013] Another object of the present invention is to provide a
process for producing a flexible polyurethane foam by use of a
catalyst which has sufficiently high delaying effect and is
practically non-corrosive.
[0014] The amine catalyst of the present invention for production
of a polyurethane and a polyisocyanurate comprises a quaternary
ammonium compound represented by General Formula (1): 2
[0015] where R.sub.1 to R.sub.6 are independently a linear or
branched saturated hydrocarbon group of 1 to 4 carbon atoms;
R.sub.7 and R.sub.8 are independently a linear or branched,
saturated or unsaturated hydrocarbon group of 2 to 12 carbon atoms;
n is a number of 0 to 3, provided that at n=o any one of R.sub.1,
R.sub.2 and R.sub.3, and R.sub.5 and/or R.sub.6 may be linked
together to form a heterocycle, or at n=1, 2, or 3, R.sub.5 or
R.sub.6 and R.sub.4 may be linked together to form a heterocycle; A
is a carbonate group or an organic acid group; and X is number of 1
to 2.
[0016] The process of the present invention for producing a
flexible polyurethane foam by reaction of a polyol and a
polyisocyanate in the presence of a catalyst and a blowing agent
comprises use of one or more quaternary ammonium carbonate
represented by General Formula (2): 3
[0017] where R.sub.1 to R.sub.8 are independently a linear or
branched, saturated or unsaturated hydrocarbon group of 1 to 12
carbon atoms; n is a number of 0 to 3, provided that at n=o any one
of R.sub.1, R.sub.2 and R.sub.3, and R.sub.5 and/or R.sub.6 may be
linked together to form a heterocycle, or at n=1, 2, or 3, R.sub.5
or R.sub.6, and R.sub.4 may be linked-together to form a
heterocycle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] After comprehensive investigation to solve the problems
involved in known catalyst, it was found by the inventor of the
present invention that a quaternary ammonium salt type of catalyst
having a special structure is useful for production of polyurethane
and polyisocyanurate, and has extremely high catalyst activity,
particularly in polyisocyanurate production, being effective in
improvement of flowability and in unifomization of density
distribution by accelerating the initial stage of foaming reaction,
being effective in improving fire retardance, having a low
volatility to give less odor. Further it was also found that among
the quaternary ammonium salt type catalyst having a specified
structure has significantly high delaying effect in flexible
polyurethane foam, and significantly less corrosive. The present
invention has accomplished on the basis of the above findings.
[0019] In the present invention, among the catalysts represented by
General Formula (1), the quaternary ammonium carbonate can be
prepared, for example, by reaction of a corresponding tertiary
amine with a carbonate diester (e.g., dimethyl carbonate). The
organic acid salt of a quaternary ammonium salt can be prepared by
anion exchange reaction of a corresponding quaternary ammonium
carbonate with an organic acid by removal of carbon dioxide and the
alcohol as the byproducts. The producing reaction can be conducted
at a temperature ranging from 50 to 150.degree. C. in an autoclave
for a time ranging from 1 to 20 hours, preferably in the presence
of a reaction solvent to complete the reaction rapidly at a high
yield. The reaction solvent is not specially limited, and includes
methanol, and ethanol, and the amount thereof is not limited.
[0020] The tertiary amine employed for production of the quaternary
ammonium carbonate in the present invention include
[0021] N,N,N',N'-tetramethylethylenediamine,
[0022] N,N,N',N'-tetramethylpropylenediamine,
[0023] N,N,N',N'-tetramethylbutanediamine,
[0024] N,N,N",N"-pentamethyldiethylenetriamine,
[0025]
N,N,N',N",N"-pentamethyl-(3-aminopropyl)-ethylenediamine,
[0026] N,N,N',N",N"-pentamethyldipropylenetriamine,
[0027] N,N,N',N'-tetramethylguanidine,
[0028] 1,3,5-tris(N,N-dimethylaminopropyl)hexahydro-s-triazine,
[0029] 1,8-diazabicyclo[5.4.0]undecene-7, triethylenediamine,
[0030] N,N,N',N'-tetramethylhexamethylenediamine,
[0031] N-methyl-N'-(2-dimethylaminoethyl)piperazine,
[0032] N,N'-dimethylpiperazine, N-methylmorpholine,
[0033] N-ethylmorpholine, bis(2-dimethylaminoethyl) ether,
[0034] 1-methylimidazole, 1,2-dimethylimidazole,
[0035] 1-isobutyl-2-methylimidazole, and
[0036] 1-dimethylaminopropylimidazole. Of these, specially
preferred are N,N,N',N'-tetramethylethylenediamine,
[0037] N,N,N',N",N"-pentamethyldiethylenetriamine,
triethylenediamine, and
[0038] N,N,N',N'-tetramethylhexamethylenediamine.
[0039] The carbonate diester is not specially limited, and includes
specifically diethyl carbonate, dimethyl carbonate, and dibutyl
carbonate.
[0040] The organic acid used for producing an organic acid salt of
a quaternary ammonium for the catalyst of the present invention may
be any known organic acid, and is not specially limited, including
specifically aliphatic and aromatic monocarboxylic acids such as
formic acid, acetic acid, 2-ethylhexanoic acid, octanoic acid, and
benzoic acid; aliphatic and aromatic dicarboxylic acids such as
malonic acid, and terephthalic acid; phenolic compounds, sulfonic
acid compounds, and phosphate compounds.
[0041] The catalyst comprising the quaternary ammonium salt
represented by General Formula (1) of the present invention is
useful as the amine catalyst for production of polyurethane and
polyisocyanurate. For example, reaction of a polyol and an
isocyanate in the presence of a catalyst of the present invention,
and optionally a blowing agent and other additive, produces a
polyurethane product or a polyisocyanurate product such as a
flexible foam, a semirigid foam, a rigid foam, and elastomer.
[0042] The polyol employed in the above production may be any known
polyetherpolyols, polyesterpolyols, polymer polyols, and the like,
and is not specially limited.
[0043] Examples of the polyether polyol are alkylene oxide adducts
of an active hydrogen compound. The active hydrogen compound
includes polyhydric alcohols such as ethyleneglycol,
propyleneglycol, 1,4-butanediol, 1,6-hexanediol, diethyleneglycol,
triethyleneglycol, dipropyleneglycol, neopentylglycol, glycerin,
trimethylolpropane, pentaerythritol, methylglycoside, sorbitol, and
sucrose; polyhydric phenols such as pyrogallol, and hydroquinone;
bisphenols such as bisphenol A, bisphenol S, bisphenol F, and low
condensate of phenol and formaldehyde; aliphatic diamines such as
propylenediamine, hexamethylenediamine, ethylenediamine,
diethylenetriamine, triethylenetetramine, pentamethylenehexamine,
ethanolamine, diethanolamine, triethanolamine, and
aminoethylethanolamine; aromatic amines, such as aniline,
phenylenediamine, xylylenediamine, methylenedianiline, and diphenyl
ether diamine; alicyclic amines such as isophoronediamine, and
cyclohexylenediamine; heteroalicyclic amines such as
aminoethypiperazine; the aforementioned polyhydric phenols, and
Mannich polyols (compounds prepared by reaction of the
aforementioned aliphatic amine and formalin). Such an active
hydrogen compound may be a mixture of two or more thereof. The
alkylene oxide to be added to the active hydrogen compound includes
ethylene oxide, propylene oxide, and butylene oxide, and
combination of two or more thereof. Of these, ethylene oxide,
propylene oxide, and combination thereof are preferred.
[0044] The polyesterpolyol includes condensation polyesters
prepared by reaction of a polybasic acid such as succinic acid,
adipic acid, sebacic acid, maleic acid, dimer acids, and
trimellitic acid with a polyhydric alcohol; and polylactone polyol
prepared by ring-opening polymerization of .epsilon.-caprolactone,
or the like.
[0045] The polymer polyol includes, for example, those obtained by
reaction of the aforementioned polyetherpolyol with an ethylenic
unsaturated monomer such as butadiene, acrylonitrile, and styrene
in the presence of a radical polymerization catalyst.
[0046] Among the aforementioned polyols, for production of flexible
polyurethane foam, preferred are polyetherpolyols and polymer
polyols, and mixtures thereof. Especially preferred are the ones
prepared from glycerin as a source material and having a molecular
weight ranging from about 3000 to about 12000. Preferred polymer
polyols have a molecular weight ranging from 5000 to 12000. The
polyetherpolyol and a polymer polyol are preferably mixed in a
ratio ranging from 50:50 to 90:10.
[0047] The isocyanate may be any known isocyanate without
limitation, including aromatic polyisocyanates; aliphatic
polyisocyanates such as isophorone diisocyanate, 1,6-hexamethylene
diisocyanate, and 4,4-dicyclohexylmethane diisocyanate; aromatic
polyisocyanates such as xylylene diisocyanate, tetramethylxylylene
diisocyanate; modifications thereof (carbodiimide-modification,
allophanate-modification, urea-modification, biuret-modification,
isocyanurate-modification, oxazolidone-modification, etc.); and
isocyanate-terminated prepolymers.
[0048] The aromatic polyisocyanate includes specifically 2,4- or
2,6-toluene diisocyanate (TDI), crude TDI, diphenylmethane 2,4'- or
4,4'-diisocyanate (MDI), and polymethylene polyphenyl
polyisocyanate (crude MDI).
[0049] The aliphatic polyisocyanate includes specifically
isophorone diisocyanate, 1,6-hexamethylene diisocyanate, and
4,4-dicyclohexylmethane diisocyanate.
[0050] A polyol-isocyanate index [(equivalent number of isocyanate
group in isocyanate component per equivalent number of active
hydrogen in polyol component).times.1000] is in the range from
about 60 to about 130 in polyurethane product production, and in
the range from about 150 to 400 in polyisocyanurate ring-containing
product production.
[0051] Out of the above isocyanates, mixtures of TDI and MDI are
particularly preferred in the production of flexible polyurethane
foam. The isocyante index therefor ranges from 70 to 130, but is
not limited thereto.
[0052] The catalyst of the present invention increases the foam
curing rate after the reaction, serving to shorten the mold release
time of the foam to improve remarkably the productivity. The
catalyst is used usually in an amount ranging from 0.02 to 5 parts,
preferably from 0.05 to 3 parts, to 100 parts of the used
polyol.
[0053] The catalyst of the present invention has high catalytic
activity in production of polyisocyanurate products also, and is
effective in improving the flowability by promotion of the initial
reaction of the foam, narrowing the density distribution, and
causes less odor owing to its low volatility. In this case, the
catalyst is used usually in an amount ranging from 0.1 to 8%,
preferably from 0.5 to 5%, by weight on the basis of the weight of
the polyol. With the catalyst of less than 0.1% by weight, the
resulting rigid polyisocyanurate foam has insufficient mechanical
strength, whereas with the catalyst of more than 8% by weight, the
flowability is less in the production of the rigid polyisocyanurate
foam.
[0054] The catalyst of the present invention, particularly the one
represented by General Formula (2), in production of flexible
polyurethane foams, is advantageous in its high delaying effect,
low corrosiveness, and low odor. The amount of the catalyst ranges
usually from 0.01 to 10 parts, preferably from 0.05 to 5 parts, to
100 parts of the used polyol.
[0055] The catalyst of the present invention may be used in
combination with another catalyst within the range where the
catalyst function is not impaired. The combinable catalyst includes
known tertiary amines and organic acid salts thereof, quaternary
ammonium salts, organometallic compounds, and alkali metal salts or
alkaline earth metal salts of known carboxylic acids.
[0056] The known tertiary amines include tertiary amines such as
triethylenediamine, N,N,N',N'-tetramethylethylenediamine,
[0057] N,N,N',N",N"-pentamethyldiethylenetriamine,
[0058] 1,3,5-tris(N,N-dimethylaminopropyl)hexahydro-s-triazine,
[0059] N,N,N',N'-tetramethylhexamethylenediamine, and
[0060] 1,2-dimethylimidazole;
[0061] alkanolamines such as N,N-dimethylaminoethanol, and
[0062] N,N,N'-trimethylaminoethylethanol; and
[0063] amine compounds having primary and secondary amino groups
such as dimethylaminopropylamine, and
[0064] bisdimethylaminopropylamine. These amines are preferred
because of high catalytic activity, desirable foaming profile, and
improved flowability. However, the tertiary amine are not limited
thereto.
[0065] The quaternary ammonium salts include known
tetraalkylammonium halides such as tetramethylammonium chloride;
tetraalkylammonium hydroxides such as tetramethylammonium
hydroxide; organic acid salts of tetraalkylammonium such as
tetramethyammonium 2-ethylhexanoate,
2-hydroxypropyltrimethylammonium formate, and
2-hydroxypropyltrimethylamm- noium 2-ethylhexanoate, but is not
limited thereto. of these, organic acid salts of tetraalkylammonium
are particularly preferred because of the high catalytic activity
and the high isocyanurate activity.
[0066] The known organic metal compounds are not limited specially,
and include organic tin compounds and organic lead compounds such
as dibutyltin dilaurate, lead octanoate, and lead
2-ethylhexanoate.
[0067] The known alkali metal or alkaline earth metal carboxylates
include sodium salts and potassium salts of aromatic monocarboxylic
acids and aromatic dicarboxylic acids. Of these, alkali metal
carboxylates are preferred because of the high catalytic activity
and the high nurate activity. More preferable are potassium
acetate, potassium octanoate, and potassium 2-ethylhexanoate.
[0068] In the production of flexible polyurethane foams,
triethylenediamine is particularly preferred as the tertiary amine
for the catalyst among the aforementioned catalysts. The
triethylenediamine is used in an amount preferably ranging from 0.1
to 2.0 parts by weight to 1.0 part by weight of the quaternary
ammonium carbonate. With triethylenediamine of less than 0.1 part
by weight, the foam is not formed completely, being liable to cause
shrinkage or depression, whereas with triethylenediamine of more
than 2.0 parts by weight, the expected delaying effect may not be
achieved. The organic metal compound is preferably an organic tin
compound, more preferably stannous dioctanoate, and dibutyltin
dilaurate. The organic metal compound is used in an amount ranging
usually from 0.01 to 5.0 parts, preferably from 0.05 to 3.0 parts
by weight to 100 parts by weight of the polyol. With the amount of
the organic metal compound of less than 0.05 parts by weight, the
produced foam tends to cause cracking, whereas with the amount
thereof more than 3.0 parts by weight, the produced foam tends to
shrink.
[0069] As a blowing agent, a hydrogen atom-containing halogenated
hydrocarbon, a low-boiling hydrocarbon and/or water is used as a
bowing agent in the production of a polyurethane foam or a
polycyanurate foam with the catalyst of the present invention. The
hydrogen atom-containing halogenated hydrocarbon as the blowing
agent include specifically HCFC type ones such as HCFC-123,
HCFC-141b, HCFC-22, and HCFC-142b; HFC type ones such as HFC-134a,
HFC-245fa, HFC-245ca, and HFC-236ea; and mixtures of two or more
thereof. Of these, preferred are HCFC-141b, HFC-134a, HFC-245fa,
and mixtures of two or more thereof. The low-boiling hydrocarbon
means usually a hydrocarbon having a boiling point ranging from 0
to 50.degree. C., specifically including propane, butane, pentane,
cyclopentane, and mixtures thereof.
[0070] The hydrogen atom-containing halogenated hydrocarbon as the
blowing agent is used in an amount ranging usually from 5 to 100
parts, preferably from 10 to 80 parts by weight, to 100 parts by
weight of the polyol. The low-boiling hydrocarbon as the blowing
agent is used in an amount ranging usually from 1 to 40 parts,
preferably from 1 to 30 parts by weight, to 100 parts by weight of
the polyol. The water as the sole blowing agent is used in an
amount ranging usually from 0.5 to 10 parts, preferably from 1 to 8
parts by weight, to 100 parts by weight of the polyol. In the
combined use of a hydrogen atom-containing halogenated hydrocarbons
and water as the blowing agent, the hydrogen atom-containing
halogenated hydrocarbon is used in an amount ranging usually from 1
to 100 parts, preferably from 10 to 80 parts by weight, and water
is used in an amount ranging usually from 0.1 to 10 parts,
preferably from 0.5 to 8 parts by weight, to 100 parts by weight of
the polyol. In the combined use of a low-boiling hydrocarbons and
water as the blowing agent, the low-boiling hydrocarbon is used in
an amount ranging usually from 1 to 40 parts, preferably from 1 to
30 parts by weight, and water is used in an amount ranging usually
from 0.1 to 10 parts, preferably from 0.1 to 5 parts by weight, to
100 parts by weight of the polyol.
[0071] In the production of flexible polyurethane foam, water is
especially suitable among the aforementioned blowing agents. The
amount of water to be used depends on the density of the intended
foam product, and is usually not less than 2 parts by weight,
preferably in the range from 3.0 to 8.0 parts by weight to 100
parts by weight of the polyol.
[0072] The specific application fields of the catalyst of the
present invention include furniture cushions, automobile seats,
automobile steering wheels made of an integral skin foam, and heat
insulating material for refrigerators and building materials.
[0073] The quaternary ammonium salt catalyst of the present
invention is used in a smaller amount owing to the high catalytic
activity, which is effective in reduction of production cost of
polyurethanes and polyisocyanurates. This catalyst accelerates the
initial reaction, improving the foaming profile and flowability,
resulting in narrow density distribution of the produced foam, and
high moldability of the foam, advantageously.
[0074] The quaternary ammonium salt catalyst of the present
invention shortens the foam curing time after the reaction of
polyurethane production to shorten the mold release time, which is
effective in improvement of productivity.
[0075] The isocyanurate foam produced by use of the quaternary
ammonium catalyst of the present invention exudes only little odor,
which improves remarkably the working environment in the foam
production and decreases the residual odor in the foam products.
Furthermore, the product has higher fire retardance, less
friability of the foam surface, and lower thermal conductivity,
advantageously.
[0076] The catalyst of the present invention has further advantages
in flexible polyurethane foam production as follows. The quaternary
ammonium carbonate represented by General Formula (2) is used in a
small amount owing to its high activity, and is effective in
reduction of polyurethane production cost. The catalyst has a low
initial activity, so that the time of initiation of foam formation
reaction can be delayed after the mixing of the polyol and the
organic isocyanate as the source materials, improving handleability
and flowability of the source liquid mixture to allow it to flow to
corners of a large mold.
[0077] The quaternary ammonium carbonate represented by General
Formula (2) develops the catalytic activity when the foam formation
reaction has proceeded to result in temperature rise. Consequently,
the catalyst activity is greatly increased to allow the foam formed
by the foaming reaction to flow into a complicated mold entirely,
and the curing is accelerated to shorten the foam release time to
improve remarkably the productivity.
[0078] The foam products produced according to the present
invention has a lower density and has excellent air
permeability.
[0079] Further, the quaternary ammonium carbonate represented by
General Formula (2) exudes only little odor, which improves
remarkably the working environment in the foam production and
exuding little residual odor in the foam products.
[0080] Furthermore, the quaternary ammonium carbonate represented
by General Formula (2) is extremely less corrosive to metal
materials, causing no corrosion of polyurethane production
equipment such as a catalyst storage tank, and a foam formation
apparatus, thus improving the productivity.
[0081] The present invention is described more specifically by
reference to example and comparative examples without limiting to
the invention thereto in any way.
[0082] [Catalyst Production]
PRODUCTION EXAMPLE 1
[0083] Into an autoclave equipped with a stirrer, were placed
N,N,N',N",N"-pentamethyldiethylenetriamine (1 mol), dimethyl
carbonate (1.5 mol), and methanol as a solvent (2.0 mol). The
mixture was allowed to react at a reaction temperature of
110.degree. C. for 12 hours to obtain a solution of the product in
methanol. The unreacted dimethyl carbonate and the methanol were
distilled off to obtain the intended product. The product was a
viscous liquid, and was found to be mainly composed of
bis(N-(3,6-trimethyl-3,6-diazaheptyl)-N,N,N-trimethylammonium- )
carbonate by .sup.13C-NMR and .sup.1H-NMR. This product is
hereinafter referred to as Catalyst A.
PRODUCTION EXAMPLE 2
[0084] A product mainly composed of
bis(N-(2-dimethylaminoethyl)-N,N,N-(tr- imethylammonium) carbonate
was prepared in the same manner as in Production Example 1 except
that N,N,N',N'-tetramethylethylenediamine (1 mol) was used in place
of N,N,N',N",N"-pentamethyldiethylenetriamine (1 mol). This product
is hereinafter referred to as Catalyst B.
PRODUCTION EXAMPLE 3
[0085] A product mainly composed of
bis(1-methyl-1-azonia-8-azabicyclo[2.2- .2]octane) carbonate was
prepared in the same manner as in Production Example 1 except that
triethylenediamine (1 mol) was used in place of
N,N,N',N",N"-pentamethyldiethylenetriamine (1 mol). This product is
hereinafter referred to as Catalyst C.
PRODUCTION EXAMPLE 4
[0086] Into an autoclave equipped with a stirrer, were placed
N,N,N',N'-tetramethylethylenediamine (1 mol), dimethyl carbonate
(1.5 mol), and methanol (2.0 mol) as a solvent. The mixture was
allowed to react at a reaction temperature of 110.degree. C. for 12
hours to obtain a solution of the product in methanol. Thereto,
2-ethyl hexanoate (1 mol) was added. Then by-product carbon dioxide
and the methanol were removed to obtain the intended product, which
was mainly composed of
bis(N-(2-dimethylaminoethyl)-N,N,N-(trimethylammonium)
2-ethylhexanoate. This product is hereinafter referred to as
Catalyst D.
PRODUCTION EXAMPLE 5
[0087] A product mainly composed of
bis(N,N-dimethylaminohexamethylene-N'-- trimethylammonium)
carbonate was prepared in the same manner as in Production Example
1 except that N,N,N',N'-tetramethylhexamethylenediamin- e (1 mol)
was used in place of N,N,N',N",N"-pentamethyldiethylenetriamine (1
mol). This product is hereinafter referred to as Catalyst E.
[0088] [Production of Polyisocyanurate Product]
EXAMPLES 1-4
[0089] Rigid isocyanurate foams were prepared with formulations of
the polyol and the polyisocyanate shown in Table 1 (isocyanate
index: 200) by using respectively Catalysts A, B, C, and D produced
in Production Examples 1-4, and a blowing agent and a foam
stabilizer as shown in Table 1. The products were tested and
evaluated for the reactivity (cream time, gel time, and rise time)
of the rigid isocyanurate foam, the flowability (density,
moldability, and density distribution) of the molded foam product,
the fire retardance (oxygen index, and smoking), the friability,
the thermal conductivity, and the residual catalyst odor. Table 1
shows the evaluation results.
[0090] Table 1 shows that the quaternary ammonium salt catalyst of
the present invention has high catalytic activity, accelerates
initial reaction (cream time), and gives a smooth foaming profile.
Further, the catalyst exudes less odor, thereby improving the
working environment in foam production, and leaving no residual
odor in the final foam products. The obtained foam has excellent
moldability, narrow density distribution, high flowability, high
oxygen index, less smoking property, and high fire retardance. The
surface of the obtained foam has a low friability and a low thermal
conductivity.
COMPARATIVE EXAMPLES 1-3
[0091] Foams were prepared in the same manner as in Example 1
except that conventional isocyanurate catalysts were used as shown
in formulations in Table 1. Table 1 also shows the evaluation
results.
[0092] In Comparative Example 1, the used conventional quaternary
ammonium salt catalyst had low catalytic activity, and should be
used in a larger amount. The produced foam exuded strong residual
odor.
[0093] In Comparative Example 2, the used conventional quaternary
ammonium salt catalyst gave a short cream time, and a smooth
foaming profile, but the catalytic activity was low and the
catalyst should be used in a larger amount. The produced foam
exuded strong remaining odor.
[0094] In Comparative Example 3, the used conventional quaternary
ammonium salt catalyst had low catalytic activity, and should be
used in a larger amount, requiring a longer cream time and giving a
rapid foaming profile. The resulting foam had a broad density
distribution, and poor moldability. In the fire retardance test,
the resulting foam had a relatively high oxygen index, but smoke
generation is significant with unsatisfactory balance of the fire
retardance. The surface of the obtained foam has a high friability
and a high thermal conductivity.
[0095] [Production of Flexible Polyurethane Foam Product]
EXAMPLES 5-8
[0096] Flexible isocyanurate foams were prepared with formulations
of the polyol and the polyisocyanate shown in Table 2 (isocyanate
index: 105) by using respectively Catalysts A, B, C, and E produced
in Production Examples 1-3, and 5, and a blowing agent and a foam
stabilizer as shown in Table 2. The products were tested and
evaluated for the reactivity (cream time, gel time, and rise time)
of the flexible isocyanurate foam, the delaying effect (elongation
in seconds of cream time of the respective catalyst in comparison
with Catalyst L33 as the reference), and the properties (density,
and air permeability) of the foam products. Table 2 shows the
evaluation results.
[0097] Table 2 shows that the quaternary ammonium salt catalysts of
the present invention enable delaying of the initial reaction
(cream time). The catalysts corrode only little the metallic
materials, and give a foam product having a low density and a high
air-permeability. Further, the catalyst exudes less odor, thereby
improving the working environment in foam production, and leaving
no residual odor in the final foam products.
COMPARATIVE EXAMPLES 4-5
[0098] Foams were prepared in the same manner as in Example 5
except that conventional catalysts were used as shown in
formulations in Table 2. Table 2 also shows the evaluation
results.
[0099] In Comparative Example 4, the used conventional tertiary
amine catalyst did not delay the cream time for the same gel
time.
[0100] In Comparative Example 5, the used conventional catalyst of
the organic acid salt of tertiary amine delayed the cream time for
the same gel time, but the catalytic activity was low and the
catalyst should be used in a larger amount. The organic carboxylic
acid contained in the catalyst caused remarkable corrosion of metal
materials.
1 TABLE 1 Example Comparative Example 1 2 3 4 1 2 3 Formulation
(parts by weight) Polyol A *1 70 70 70 70 70 70 70 Polyol B *2 20
20 20 20 20 20 20 Polyol C *3 10 10 10 10 10 10 10 Crude MDI *4 295
295 295 295 295 295 295 Catalyst A *5 3.50 -- -- -- -- -- --
Catalyst B *6 -- 4.40 -- -- -- -- -- Catalyst C *7 -- -- 5.30 -- --
-- -- Catalyst D *8 -- -- -- 7.00 -- -- -- Tetraalkylammonium salt
*9 -- -- -- -- 5.70 -- -- Hydroxyalkylammonium salt *10 -- -- -- --
-- 7.00 -- Potassium 2-ethylhexanoate *11 -- -- -- -- -- -- 7.00
water 2 2 2 2 2 2 2 141b *12 40 40 40 40 40 40 40 Foam stabilizer
*13 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Index *14 200 200 200 200 200 200
200 Reactivity (seconds) Cream time 22 22 23 21 20 24 25 Gel time
44 45 45 45 46 46 45 Rise time 75 68 74 74 66 76 61 Foam properties
Core density (Kg/m.sup.3) 29.5 31.5 30.2 30.5 31.7 30.7 29.2
Density distribution (Kg/m.sup.3) *15 2.1 2.1 2.1 2.2 3.0 2.4 5.8
Oxygen index (%) 22.8 22.8 22.8 22.8 23.2 22.8 23.2 Smoke emission
(Dmax/g) *16 20.5 20.4 20.4 20.6 20.9 20.5 23.0 Friability Good
Good Good Good Fair Fair Poor Thermal conductivity 16.9 16.9 16.9
16.9 17.0 17.0 21.0 (mW/mK) Odor Slight Slight Slight Slight Slight
Medium Slight Notes to Table 1 *1 Aromatic polyesterpolyol (OH
value: 327 mgKOH/g) *2 Aromatic amine type polyetherpolyol (OH
value: 472 mgKOH/g) *3 Sugar type polyetherpolyol (OH value: 456
mgKOH/g) *4 MR-200 (produced by Nippon Polyurethane Industry Co.,
isocyanate content: 31%) *5 Quaternary ammonium carbonate prepared
by reaction of N,N,N',N",N"-pentamethyldiethylenetriamine and
dimethyl carbonate (mole ratio: 1/1.5) *6 Quaternary ammonium
carbonate prepared by reaction of
N,N,N',N'-tetramethylethylene-diamine and dimethyl carbonate (mole
ratio: 1/1.5) *7 Quaternary ammonium carbonate prepared by reaction
of triethylenediamine and dimethyl carbonate (mole ratio: 1/1.5) *8
Quaternary ammonium salt prepared by reaction of
N,N,N',N'-tetramethylethylenediamine and dimethyl carbonate (mole
ratio: 1/1.5) and subsequent anion exchange with 2-ethylhexanoic
acid *9 Methyltriethylammonium octanoate *10
N,N,N-trimethyl-2-hydroxypropyl quaternary ammonium
2-ethylhexanoate solution (70% in ethylene glycol) *11 Potassium
2-ethylhexanoate solution (70% in ethylene glycol) *12 HCFC-141b
*13 Silicone type surfactant *14 [(Isocyanate group)/(OH
group)](mole ratio) .times. 100 *15 Difference between the maximum
and the minimum of the densities measured by cutting a panel mold
foam at intervals of 5 cm from the bottom to the top *16 Smoking
measured according to NBS, ASTM (E662) Standard (per gram
sample)
[0101]
2 TABLE 2 Comparative Example Example 5 6 7 8 4 5 Formulation
(parts by weight) Polyol A *1 60 60 60 60 60 60 Polyol B *2 40 40
40 40 40 40 Diethanolamine *3 1.0 1.0 1.0 1.0 1.0 1.0
Triethanolamine *4 2.0 2.0 2.0 2.0 2.0 2.0 TM80 *5 46.9 46.9 46.9
46.9 46.9 46.9 L33 *6 0.30 0.30 0.30 0.30 0.80 -- Catalyst A *7
0.45 -- -- -- -- -- Catalyst B *8 -- 0.45 -- -- -- -- Catalyst C *9
-- -- 0.58 -- -- -- Catalyst E *10 -- -- -- 0.40 -- -- TOYOCAT-TF
*11 -- -- -- -- -- 1.20 water 3.20 3.20 3.20 3.20 3.20 3.20 Foam
stabilizer A *12 1.0 1.0 1.0 1.0 1.0 1.0 Foam stabilizer B *13 1.0
1.0 1.0 1.0 1.0 1.0 Index *14 105 105 105 105 105 105 Reactivity
(seconds) Cream time 13.6 13.6 14.0 13.6 11.0 13.6 Gel time 60 60
60 60 61 61 Rise time 78 78 78 80 78 78 Delaying effect (seconds)
*15 2.6 2.6 3.0 2.6 -- 2.6 Foam properties Core density
(Kg/m.sup.3) 38.2 37.2 38.5 38.5 36.7 36.9 Air permeability *16
Good Good Good Good Good Fair Metal corrosiveness of catalyst *17
Non Non Non Non Non Severe Notes to Table 2 *1 Polyetherhpolyol (OH
value: 30 mgKOH/g, produced by Sanyo Chemical Co.) *2 Polymer
polyol (OH value: 27.5 mgKOH/g, produced by Sanyo Chemical Co.) *3
Crosslinking agent *4 Crosslinking agent *5 Mixture of T-80
(produced by Nippon Polyurethane Industry Co.) and MR200 (produced
by Nippon polyurethane Industry Co., Isocyanate content: 31%) at
mixing ratio of 80:20 *6 Triethylenediamine solution (33% in
dipropylene glycol) *7 Quaternary ammonium carbonate prepared by
reaction of N,N,N',N",N"-pentamethyldiethylenetriamine and dimethyl
carbonate (mole ratio: 1/1.5) *8 Quaternary ammonium carbonate
prepared by reaction of N,N,N',N'-tetramethylethylenediamine and
dimethyl carbonate (mole ratio: 1/1.5) *9 Quaternary ammonium
carbonate prepared by reaction of triethylenediamine and
dimethylcarbonate (mole ratio: 1/1.5) *10 Quaternary ammonium
carbonate prepared by reaction of
N,N,N',N'-tetramethylhexamethylenediamine and dimethyl carbonate
(mole ratio: 1/1.5) *11 Triethylenediamine formate (produced by
Tosoh Corp.) *12 Silicone type surfactant (produced by Toray
Silicone Co.) *13 Silicone type surfactant (produced by Nippon
Unicar Co.) *14 [(Isocyanate group)/(OH group)] (mole ratio)
.times. 100 *15 Time (seconds) of delay of cream time by use of the
respective catalyst relative to sole use of L33 *16 Measured by
means of Dow Air Flow Apparatus *17 Catalyst and a test piece are
enclosed in a stainless pressure container at a prescribed
temperature for a prescribed days, and the surface state is
observed. Test piece: Soft steel (SS-41) 15 .times. 25 .times. 3 mm
Test temperature: 50.degree. C. Test period: 30 days Evaluation
standard: Non: No corrosion observed Fair: Colored dots scattered
on the surface Severe: Entire surface turned black
* * * * *