U.S. patent application number 11/155725 was filed with the patent office on 2006-01-19 for organometallic compositions and polyisocyanate compositions containing them.
This patent application is currently assigned to ACMA Limited. Invention is credited to Martin G. Partridge, Christopher J. Skinner.
Application Number | 20060012067 11/155725 |
Document ID | / |
Family ID | 10858377 |
Filed Date | 2006-01-19 |
United States Patent
Application |
20060012067 |
Kind Code |
A1 |
Skinner; Christopher J. ; et
al. |
January 19, 2006 |
Organometallic compositions and polyisocyanate compositions
containing them
Abstract
An organometallic composition, suitable for use in curing
polyisocyanate compositions, comprises a complex of at least one
metal selected from iron, cobalt and aluminium and at least one
.beta.-dicarbonyl compound wherein when the metal is iron (II) or
cobalt (II) the molar ration of .beta.-dicarbonyl compound to metal
is in the range from 2.1:1 to 10:1, and when the metal is aluminium
(III), iron (III) or cobalt (III) the molar ration of
.beta.-dicarbonyl compound to metal is in the range from 3.1:1 to
10:1. A polyisocyanate composition containing the claimed
organometallic composition and a process for binding
lignocellulosic material is also described and claimed.
Inventors: |
Skinner; Christopher J.;
(Brussels, BE) ; Partridge; Martin G.;
(Stockton-on-Tees, GB) |
Correspondence
Address: |
MAYER, BROWN, ROWE & MAW LLP
1909 K STREET, N.W.
WASHINGTON
DC
20006
US
|
Assignee: |
ACMA Limited
Cheshire
GB
|
Family ID: |
10858377 |
Appl. No.: |
11/155725 |
Filed: |
June 20, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10060341 |
Feb 1, 2002 |
6908875 |
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11155725 |
Jun 20, 2005 |
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PCT/GB00/02820 |
Jul 21, 2000 |
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10060341 |
Feb 1, 2002 |
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Current U.S.
Class: |
264/109 ;
528/44 |
Current CPC
Class: |
C08G 18/222 20130101;
C08L 75/04 20130101; B01J 31/2208 20130101; C07F 15/065 20130101;
C08L 97/02 20130101; C08L 97/02 20130101; C07F 15/025 20130101 |
Class at
Publication: |
264/109 ;
528/044 |
International
Class: |
B27N 3/00 20060101
B27N003/00; C08G 18/00 20060101 C08G018/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 3, 1999 |
GB |
9918117.4 |
Claims
1. A process for the formation of a polyurethane by the reaction of
a polyisocyanate with a polyol in the presence of a catalyst
composition comprising an organometallic composition, suitable for
use in curing polyisocyanate compositions, comprising a complex of
(i) at least one metal selected from the group consisting of iron,
aluminium and cobalt; (ii) a .beta.-dicarbonyl compound selected
from benzoyl acetone, dibenzoylmethane,
2,2,6,6-tetramethylheptanedione, 1,1,1 -trifluoro-2,4-pentanedione,
or a .beta.-ketoester; and (iii) optionally, a second
.beta.-dicarbonyl compound; wherein, when the metal is iron (II) or
cobalt (II), the molar ratio of total .beta.-dicarbonyl compound to
metal is in the range from 2.1:1 to 10:1, and when the metal is
aluminium (III) iron (III) or cobalt (III), the molar ratio of
total .beta.-dicarbonyl compound to metal is in the range from
3.1:1 to 10:1.
2. The process according to claim 1, wherein the molar ratio of
total_.beta.-dicarbonyl compound to metal is in the range 3.5:1 to
8:1.
3. The process according to claim 1, wherein the .beta.-dicarbonyl
compound is a .beta.-diketonate or a .beta.-ketoester.
4. The process according to claim 3, wherein the .beta.-dicarbonyl
compound is selected from acetylacetone, benzoyl acetone,
dibenzoylmethane, 2,2,6,6-tetramethylheptanedione,
1,1,1-trifluoro-2,4-pentanedione, ethylacetoacetate,
methylacetoacetate, isopropylacetoacetate or
tertiarybutylacetoacetate.
5. The process according to claim 1, wherein the composition
comprises one .beta.-dicarbonyl compound.
6. The process according to claim 1, wherein the composition
comprises more than one .beta.-dicarbonyl compound.
7. The process according to claim 1, wherein the complex is
prepared by reacting an alkoxide or condensed alkoxide of aluminium
with one or more .beta.-dicarbonyl compound.
8. The process according to claim 1, wherein the complex is
prepared by reacting a halide, hydroxide or salt of iron, cobalt or
aluminium with one or more .beta.-dicarbonyl compound.
9. A polyisocyanate composition comprising an organometallic
composition, comprising a complex of: (i) at least one metal
selected from the group consisting of iron, aluminium and cobalt;
(ii) a .beta.-dicarbonyl compound selected from benzoyl acetone,
dibenzoylmethane, 2,2,6,6-tetramethylheptanedione,
1,1,1-trifluoro-2,4-pentanedione, or a .beta.-ketoester; and (iii)
optionally, a second .beta.-dicarbonyl compound; wherein, when the
metal is iron (II) or cobalt (II), the molar ratio of total
.beta.-dicarbonyl compound to metal is in the range from 2.1:1 to
10:1, and when the metal is aluminium (III) iron (III) or cobalt
(III), the molar ratio of total .beta.-dicarbonyl compound to metal
is in the range from 3.1:1 to 10:1.
10. The polyisocyanate composition according to claim 9, wherein
the amount of organometallic composition present is in the range
0.01 to 20 per cent by weight.
11. The polyisocyanate composition according to claim 9, wherein
the polyisocyanate is diphenylmethane diisocyanate or a mixture of
methylene bridged polyphenyl polyisocyanates.
12. The polyisocyanate composition according to claim 9, wherein
the composition contains a release agent in an amount in the range
0.2 to 10 per cent by weight.
13. The polyisocyanate composition according to claim 12, wherein
the release agent is a polysiloxane, a fatty acid, a fatty acid
amide, a fatty acid ester or a polyolefin wax.
14. The polyisocyanate composition according to claim 9, wherein
the composition contains a diluent.
15. A process for binding lignocellulosic material comprising the
steps of: a) bringing said lignocellulosic material in contact with
a polyisocyanate composition according to claim 9, and b)
subsequently allowing said material to bind.
16. The process according to claim 15, wherein the polyisocyanate
composition is brought into contact with the lignocellulosic
material and the combination thereby formed is hot-pressed at a
temperature in the range 150.degree. C. to 250.degree. C. and 2 to
6 MPa specific pressure.
17. The process according to claim 15, wherein the polyisocyanate
composition is applied in an amount to give a weight ratio of
polyisocyanate to lignocellulosic material in the range 0.1:99.9 to
20:80.
18. The process according to claim 15, wherein a release agent is
applied to the surface of the polyisocyanate treated
lignocellulosic material or to the press metal surface prior to hot
pressing the combination.
Description
[0001] This invention relates to novel organometallic compositions
and polyisocyanate compositions containing them and, in particular,
to organometallic compositions based on iron or aluminium and which
are useful in polyisocyanate compositions for binding
lignocellulosic material.
[0002] The use of organic polyisocyanates as binders for
lignocellulosic material in the manufacture of sheets or moulded
bodies such as waferboard, chipboard, fibreboard and plywood is
well known. In a typical process the organic polyisocyanate,
optionally in the form of a solution, dispersion or aqueous
emulsion, is applied to the lignocellulosic material which is then
subjected to heat and pressure.
[0003] Suitable polyisocyanate compositions are disclosed in PCT
Application WO 97/17388 and our co-pending UK Application GB
9815029.5. These compositions comprise a Group IVB metal compound,
preferably a titanium chelate, optionally in combination with a
compatibilising compound and/or conventional release agents.
Although these compositions perform well as binders for
lignocellulosic material and provide good release performance, it
is desirable to develop alternative compositions which provide at
least as good stability on storage before use, together with good
curing properties and excellent bonding strength when applied to
the lignocellulosic material.
[0004] GB-A-951949 describes the use of metal chelates, including
chromium, vanadyl and ferric acetylacetonate as catalysts for the
preparation of non-cellular polyurethanes for use as rocket
propellants. There is however no description of the storage
stability of isocyanate compositions containing these materials or
of any of the compositions now found to be beneficial in the
preparation of polyisocyanate compositions.
[0005] The use of various metal acetylacetonates as catalysts for
the isocyanate-hydroxyl group reaction to form a urethane group has
been discussed by J. W. Britain, (I & EC Product Research and
Development, vol 1, no 4, (December 1962) at page 261 - 264). There
is, however, no indication that compositions of the present
invention may be beneficial in such applications.
[0006] It has now been surprisingly found that certain compositions
prepared from .beta.-dicarbonyl compounds can be used to prepare
polyisocyanate compositions which are very stable on prolonged
storage and economical when used for binding lignocellulosic
material.
[0007] According to one aspect of the invention an organometallic
composition, suitable for use in curing polyisocyanate
compositions, comprises a complex of at least one metal selected
from the group consisting of iron, aluminium and cobalt and at
least one .beta.-dicarbonyl compound wherein, when the metal is
iron (II) or cobalt (II), the molar ratio of .beta.-dicarbonyl
compound to metal is in the range from 2.1:1 to 10:1, and when the
metal is aluminium (III) iron (III) or cobalt (III), the molar
ratio of .beta.-dicarbonyl compound to metal is in the range from
3.1:1 to 10:1.
[0008] Also according to the invention, a polyisocyanate
composition comprises an organometallic composition, said
organometallic composition being a complex of at least one metal
selected from the group consisting of iron, aluminium and cobalt
and a .beta.-dicarbonyl compound wherein, when the metal is iron
(II) or cobalt (II), the molar ratio of .beta.-dicarbonyl compound
to metal is in the range from 2.1:1 to 10:1, and when the metal is
aluminium (III), iron (III) or cobalt (III) the molar ratio of
.beta.-dicarbonyl compound to metal is in the range from 3.1:1 to
10:1.
[0009] The iron, aluminium or cobalt composition of the invention,
suitable for use in a polyisocyanate composition, is described
herein as a "complex". It is a feature of this invention that some
of the .beta.-dicarbonyl compound will be chemically bound to the
metal (Fe, Al or Co) but that some can be described as "free". The
exact proportions which are bound and free will depend partly upon
the exact molar ratios present in the complex, which metal is used
and in which oxidation state the metal is in, but it has been shown
that the "free" ester does influence the properties, particularly
the stability on storage, of a polyisocyanate composition as a
binder for lignocellulosic materials. The use of the word "complex"
does not imply that said complex is necessarily separately prepared
before addition to a polyisocyanate to form the polyisocyanate
compositions of the invention. The complex can be formed in the
course of preparing the inventive polyisocyanate composition using
alternative methods as described hereinafter.
[0010] The .beta.-dicarbonyl compound used to prepare the complexes
of the invention can be any suitable .beta.-dicarbonyl compound.
Preferred .beta.-dicarbonyl compounds include diketones, for
example acetylacetone (2,4-pentanedione), benzoyl acetone,
dibenzoylmethane, 2,2,6,6-tetramethylheptanedione and
1,1,1-trifluoro- 2,4-pentanedione and esters of acetoacetic acid
such as ethylacetoacetate, methylacetoacetate,
isopropylacetoacetate and tertiarybutylacetoacetate. A complex may
be based on one .beta.-dicarbonyl compound but particularly useful
complexes have been prepared from a mixture of .beta.-dicarbonyl
compounds, such as a mixture of acetylacetone and
ethylacetoacetate.
[0011] The molar ratio of .beta.-dicarbonyl compound to metal in
the complex is from greater than the oxidation state of the metal
up to 10. Preferably, the molar ratio is preferably in the range
3.5:1 to 8:1 and more preferably in the range 5:1 to 8:1. In
agreement with conventional theories about the co-ordination
chemistry of iron (II) and cobalt (II) complexes, two molecules of
the .beta.-dicarbonyl compound will be chemically bound to the
metal atom and any remaining will be "free", and for aluminium
(III), iron (III), and cobalt (III) complexes, three molecules of
the .beta.-dicarbonyl compound will be chemically bound to the
metal atom and any remaining will be "free".
[0012] Typically, the complexes of iron, cobalt or aluminium may be
prepared from the alkoxide, condensed alkoxide, hydroxide, halide
or other compounds by methods known to those skilled in the art.
For example, aluminium complexes may be prepared directly from the
metal, the metal tri-alkyl, or more preferably from the alkoxide or
halide by reaction with .beta.-dicarbonyl compound. Iron complexes
may also be derived from alkoxides. Typical alkoxides have the
general formula M(OR).sub.X in which M is Al or Fe, x is the
oxidation state of the metal, i.e. 2 or 3, and R is a substituted
or unsubstituted, cyclic or linear, alkyl, alkenyl, aryl or
alkyl-aryl group or mixtures thereof. Preferably, R contains up to
8 carbon atoms and, more preferably, up to 6 carbon atoms.
Generally, all OR groups are identical but alkoxides derived from a
mixture of alcohols can be used and mixtures of alkoxides can be
employed when more than one metal is present in the complex.
Suitable alkoxides include trimethoxyaluminium, trimethoxyiron,
triethoxyaluminium, triethoxyiron, tri-isopropoxyaluminium,
tri-isopropoxyiron, tri-n-propoxyaluminium, tri-n-propoxyiron,
tritertiarybutoxy-aluminium, tritertiarybutoxyiron,
tri-sec-butoxyaluminium and tri-sec-butoxyiron. Iron and cobalt
complexes are preferably prepared for example from the halide by
direct reaction of the metal compound with the .beta.-dicarbonyl
compound in the presence of a base or from the hydroxide.
Metathesis reactions whereby the complex is prepared from an iron,
cobalt or aluminium compound, usually but not always a halide, and
a salt, usually but not always the sodium, potassium, lithium or
magnesium salt of the .beta.-dicarbonyl compound, are also suitable
for preparing complexes of the present invention.
[0013] The aluminium complex can be readily prepared by mixing, for
example, an alkoxide or condensed alkoxide with an appropriate
amount of .beta.-dicarbonyl compound. Alcohol from the alkoxide
will be displaced by the .beta.-dicarbonyl compound and,
preferably, the displaced alcohol is removed by, for example,
distillation. In a preferred method, 3 moles of .beta.-dicarbonyl
compound (e.g. acetylacetone) per atom of Al are added to an
alkoxide or condensed alkoxide and the displaced alcohol is removed
by distillation. Additional .beta.-dicarbonyl compound is then
added to the stripped product. This method is advantageous because
it provides a consistent product of known stoichiometry. The iron
or cobalt complexes can readily be prepared by generating a
reactive hydroxide by treatment of the metal chloride in water with
ammonia and reacting this with .beta.-dicarbonyl compound.
[0014] In one method of preparing the polyisocyanate compositions
of the invention, a product containing 2 or 3 moles of
.beta.-dicarbonyl compound per Co, Fe or Al atom can be mixed with
additional .beta.-dicarbonyl compound to produce the complex of the
invention and this complex can be added to a polyisocyanate
composition. For aluminium complexes, a product containing 1 mole
of .beta.-dicarbonyl compound per Al atom is a suitable starting
material for this method. Alternatively, the product containing 2
or 3 moles of .beta.-dicarbonyl compound per Co, Fe or Al atom can
be prepared and any additional .beta.-dicarbonyl compound required
to produce the polyisocyanate composition of the invention can be
added to the polyisocyanate before or after the iron or aluminium
compound has been added. Other methods of preparing the composition
of the invention will be apparent to a person skilled in this
art.
[0015] A further metal complex may be present in the organometallic
composition, for example a complex of titanium, zirconium or
hafnium may be present in addition to the Co, Fe or Al complex.
Such a complex may, for example, comprise a complex of at least one
of titanium, zirconium or hafnium and at least one of an
acetoacetate ester or alkoxide. As an example, a complex of the
general formula Ti(OR).sub.2(EAA).sub.2 may be present, where R is
a substituted or unsubstituted, cyclic or linear, alkyl, alkenyl,
aryl or alkyl-aryl group or mixtures thereof and EAA is
ethylacetoacetate.
[0016] The amount of iron, aluminium or cobalt complex present in
the polyisocyanate composition of the invention is usually in the
range 0.01 to 20% by weight, based on the polyisocyanate and,
preferably, the amount is in the range 0.1 to 10%. More preferably,
the amount of complex present is in the range 0.2 to 7% by weight
with respect to polyisocyanate and, frequently, acceptable curing
can be achieved if the amount of complex present is in the range
0.2 to 2% by weight with respect to polyisocyanate.
[0017] Polyisocyanates for use in the polyisocyanate composition of
the present invention may be any organic polyisocyanate compound or
mixture of organic polyisocyanate compounds, provided said
compounds have at least 2 isocyanate groups. Organic
polyisocyanates include diisocyanates, particularly aromatic
diisocyanates, and isocyanates of higher functionality.
[0018] Examples of organic polyisocyanates which may be used in the
composition of the present invention include aliphatic isocyanates
such as hexamethylene diisocyanate; and aromatic isocyanates such
as m- and .beta.-phenylene diisocyanate, tolylene-2,4- and
tolylene-2,6-diisocyanate, diphenyl- methane-4,4'-diisocyanate,
chlorophenylene-2,4-diisocyanate, naphthylene-1,5-diisocyanate,
diphenylene-4,4'-diisocyanate, 4,4'-diisocyanate
3,3'-dimethyl-diphenyl, 3-methyldiphenylmethane-4,4'-diisocyanate
and diphenyl ether diisocyanate; and cycloaliphatic diisocyanates
such as cyclohexane-2,4- and cyclohexane-2,3-diisocyanate,
1-methylcyclohexyl-2,4- and 1-methyl-cyclohexyl-2,6-diisocyanate
and mixtures thereof and bis-(isocyanato-cyclohexyl)methane and
triisocyanates such as 2,4,6-triisocyanatotoluene and
2,4,4-triisocyanatodiphenylether.
[0019] Modified polyisocyanates containing isocyanurate,
carbodiimide or uretonimine groups may be employed as well.
Further, blocked polyisocyanates, like the reaction product of a
phenol or an oxime and a polyisocyanate, may be used, having a
deblocking temperature below the temperature applied when using the
polyisocyanate composition.
[0020] The organic polyisocyanate may also be an isocyanate-ended
prepolymer made by reacting an excess of a diisocyanate or higher
functionality polyisocyanate with a polyol. Water-emulsifiable
organic polyisocyanates like those described in UK patent no. 1 444
933, in European patent publication no. 516 361 and in PCT patent
publication no. 91/03082 can also be used.
[0021] Mixtures of isocyanates may be used, for example a mixture
of tolulene diisocyanate isomers such as the commercially available
mixtures of 2,4- and 2,6-isomers and also the mixture of di- and
higher poly-isocyanates. Polyisocyanate mixtures may optionally
contain monofunctional isocyanates such as .beta.-ethyl
phenylisocyanate. Such mixtures are well-known in the art and
include the crude phosgenation products containing methylene
bridged polyphenyl polyisocyanates, including diisocyanate,
triisocyanate and higher polyisocyanates together with any
phosgenation by-products.
[0022] Preferred isocyanates to be used in the present invention
are those wherein the isocyanate is an aromatic diisocyanate or
polyisocyanate of higher functionality such as a pure
diphenylmethane diisocyanate or a mixture of methylene bridged
polyphenyl polyisocyanates containing diisocyanates, triisocyanates
and higher functionality polyisocyanates.
[0023] Methylene bridged polyphenyl polyisocyanates are well known
in the art. They may be prepared by phosgenation of corresponding
mixtures of polyamines. For convenience, polymeric mixtures of
methylene bridged polyphenyl polyisocyanates containing
diisocyanate, triisocyanate and higher functionality
polyisocyanates are referred to hereinafter as polymeric MDI.
Suitable polyisocyanates include SUPRASEC.TM. DNR, SUPRASEC.TM.
2185, RUBINATE.TM. M and RUBINATE.TM.1840, all available from
Huntsman Polyurethanes.
[0024] Preferably the polyisocyanate is liquid at room
temperature.
[0025] Conventional release agents can be added to or used in
combination with the polyisocyanate composition of the present
invention containing an iron or aluminium complex of a
.beta.-dicarbonyl compound.
[0026] The conventional release agent is present in an amount
varying between 0.2 and 10%, preferably between 0.5 and 6% and most
preferably between 1 and 3% by weight based on the polyisocyanate
whereas the iron or aluminium complex of a -dicarbonyl compound is
preferably present in an amount varying between 0.2 and 4%, most
preferably between 0.2 and 2% by weight based on the
polyisocyanate.
[0027] Examples of conventional release agents include
polysiloxanes, saturated or unsaturated fatty acids (such as oleic
acid) or fatty acid amides or fatty acid esters and polyolefin
waxes.
[0028] Preferred conventional release agents to be used according
to the present invention are polyolefin waxes or mixtures of
polyolefin waxes, especially functionalised polyolefin waxes, which
are dispersible in an aqueous medium to form an aqueous emulsion.
More preferably, the polyolefin waxes are selected from oxidised
polyethylene waxes and oxidised polypropylene waxes.
[0029] A preferred method for using the release agent is to apply
the emulsion to the surface of the polyisocyanate treated
lignocellulosic material or to the press metal surface prior to hot
pressing the combination.
[0030] When used, the aqueous emulsion of the polyolefin wax should
normally contain a sufficient amount of the polyolefin wax to
provide a coverage of about 0.01 to about 1, and preferably about
0.02 to about 0.5 mg of the polyolefin wax per cm.sup.2 of
lignocellulosic material or press metal surface. Generally, lower
levels of polyolefin wax are preferred as they are more cost
effective. When taking the emulsifiers into account, the aqueous
emulsions will usually contain about 0.2 to about 10%, preferably
about 0.3 to about 5% by weight of total solids. The emulsions are
usually prepared at 30 to 40% total solids, transported to the
point of use and then diluted with water to the desired
concentration.
[0031] It has been found that the polyolefin wax emulsion, when
used in combination with polyisocyanate compositions of the present
invention, may be usefully applied to the lignocellulosic material
or press metal surface in an amount equivalent to 8 to 14 mg per
cm.sup.2 A particularly preferred polyethylene wax emulsion which
can be used in a process in combination with a polyisocyanate
composition of the present invention is Rubilon.TM. 603 or
Rubilon.TM. 605, both available from Huntsman Polyurethanes. A
particularly preferred polypropylene wax emulsion which can be used
in the present process is ME 42040 available from Michelman Inc. of
Cincinnati, Ohio.
[0032] In order to further improve the storage stability of the
polyisocyanate composition of the present invention a diluent may
be added to the composition. Suitable diluents include plasticizers
of the type mentioned in "Taschenbuch der Kunststoff-Additive", Ed.
by R. Gachter and H. Muller, Carl Hanser Verlag Munchen, third
edition, 1989. Preferred diluents are phthalates, aliphatic
carboxylates, fatty acid esters, linseed oil and soybean oil. A
particularly preferred diluent is Priolube 1403 available from
Unichema being methyl oleate. These diluents are added in amounts
of from 1 to 40 parts by weight per 100 parts by weight of
polyisocyanate and preferably in amounts of from 1 to 15 parts by
weight per 100 parts by weight of polyisocyanate.
[0033] The composition further may comprise conventional additives
like flame retardants, lignocellulosic preserving agents,
fungicides, waxes, sizing agents, fillers, surfactants, thixotropic
agents and other binders like formaldehyde condensate adhesive
resins and lignin (optionally in combination with a lignin solvent
such as described in PCT Patent Application No. EP96/00924).
[0034] A particularly preferred additive to be used in the
polyisocyanate composition of the present invention is a coupling
agent such as an organofunctional silane (for example, Dynasylan
AMEO, available from Huels). Adding such a coupling agent to the
polyisocyanate composition leads to improved board properties. The
organofunctional silane coupling agents are used in amounts ranging
from 0.01 to 3%, preferably from 0.1 to 2% by weight based on the
polyisocyanate.
[0035] The polyisocyanate composition of the present invention can
be made by simply mixing the ingredients at room temperature.
[0036] The present invention is also concerned with a process for
preparing lignocellulosic bodies by bringing lignocellulosic parts
into contact with the present polyisocyanate composition and by
pressing this combination.
[0037] Therefore the present invention also provides a process for
binding lignocellulosic material comprising the steps of [0038] a)
bringing said lignocellulosic material in contact with the
polyisocyanate composition according to one embodiment of this
invention and [0039] b) subsequently allowing said material to
bind.
[0040] The lignocellulosic bodies are prepared by bringing the
lignocellulosic parts into contact with the polyisocyanate
composition by means such as mixing, spraying and/or spreading the
composition with/onto the lignocellulosic parts and by pressing the
combination of the polyisocyanate composition and the
lignocellulosic parts, preferably by hot-pressing, typically at
150.degree. C. to 250.degree. C. and 2 to 6 MPa specific pressure.
Such binding processes are commonly known in the art.
[0041] In waferboard manufacture the lignocellulosic material and
the polyisocyanate composition may be conveniently mixed by
spraying the present polyisocyanate composition on the
lignocellulosic material while it is being agitated.
[0042] As described hereinbefore, in a preferred process according
to the invention, a release agent, which is preferably an aqueous
emulsion of a polyolefin wax, is applied to the surface of the
polyisocyanate treated lignocellulosic material or to the press
metal surface prior to hot pressing the combination.
[0043] The lignocellulosic material after treatment with the
polyisocyanate composition is placed on plates made of aluminium or
steel which serve to carry the furnish into the press where it is
compressed to the desired extent usually at a temperature between
150.degree. C. and 250.degree. C.
[0044] While the process is particularly suitable for the
manufacture-of waferboard known also as oriented strand board and
will be largely used for-such manufacture, the process may not be
regarded as limited in this respect and can also be used in the
manufacture of medium density fiberboard, particle board (also
known as chipboard) and plywood. Thus the lignocellulosic material
used can include wood strands, woodchips, wood fibres, shavings,
veneers, wood wool, cork, bark, sawdust and like waste products of
the wood working industry as well as other materials having a
lignocellulosic basis such as paper, bagasse, straw, flax, sisal,
hemp, rushes, reeds, rice hulls, husks, grass, nutshells and the
like. Additionally, there may be mixed with the lignocellulosic
materials other particulate or fibrous materials such as ground
foam waste (for example, ground polyurethane foam waste), mineral
fillers, glass fibre, mica, rubber, textile waste such as plastic
fibres and fabrics.
[0045] When the polyisocyanate composition is applied to the
lignocellulosic material, the weight ratio of
polyisocyanate/lignocellulosic material will vary depending on the
bulk density of the lignocellulosic material employed. Therefore,
the polyisocyanate compositions may be applied in such amounts to
give a weight ratio of polyisocyanate/lignocellulosic material in
the range of 0.1:99.9 to 20:80 and preferably in the range of
0.5:99.5 to 10:90.
[0046] If desired, other conventional binding agents, such as
formaldehyde condensate adhesive resins, may be used in conjunction
with the polyisocyanate composition.
[0047] More detailed descriptions of methods of manufacturing
waferboard and similar products based on lignocellulosic material
are available in the prior art. The techniques and equipment
conventionally used can be adapted for use with the polyisocyanate
compositions of the present invention.
[0048] The polyisocyanate compositions of the present invention are
extremely effective in minimising unwanted adhesion to caul plates,
press plates and other surfaces with which the treated
lignocellulosic material may come into contact. Their storage
stability and release performance is improved compared to
polyisocyanate compositions of the prior art, as well as the
obtained board properties. The sheets and moulded bodies produced
from the polyisocyanate compositions of the present invention have
excellent mechanical properties and they may be used in any of the
situations where such articles are customarily used.
[0049] The invention is illustrated but not limited by the
following examples.
EXAMPLE 1
Preparation of Aluminium tris(acetylacetonate)
[0050] To a flask containing 50 g of a mixture of heptane isomers
was added 30.8 g (0.125 mol) of Al tris(sec-butoxide). To this was
added with stirring 37.55 g (0.375 mol) of acetylacetone. After
stirring, a white precipitate of aluminium tris(acetylacetonate)
was collected and washed on a filter paper. Yield=36.6 g (91%).
Preparation of Iron tris(acetylacetonate)
[0051] 20.3 g of anhydrous iron (III) chloride (0.124 mol) was
dissolved in 30 g of demineralised water with gentle warming. To
this was added 45 ml of ammonia solution (SG. 0.880). The mixture
was then heated on a steam bath for 30 minutes. The precipitate of
iron(III) hydroxide was filtered and washed free of chloride. The
moist iron (III) hydroxide and 60 g of acetylacetone (0.6 mol) were
mixed together and heated for 30 minutes. Crystals of
Fe(acac).sub.3 were deposited and were recrystallised from ethanol.
TABLE-US-00001 TABLE 1A Moles EAA Sample Metal added* 1A (comp) Fe
0 1B Fe 0.5 1C Fe 2.0 1D Fe 4.0 1E (comp) Al 0 1F Al 0.5 1G Al 2.0
1H Al 4.0
[0052] TABLE-US-00002 TABLE 1B Moles acac Sample Metal added* 1J -
(comp) Fe 0 1K Fe 0.5 1L Fe 2.0 1M Fe 4.0 1N - (comp) Al 0 1O Al
0.5 1P Al 2.0 1Q Al 4.0 *per mole metal tris(acetylacetonate)
[0053] Complexes were prepared by mixing the metal acetylacetonates
prepared as above with ethylacetoacetate (EAA) or acetyl acetone
(acac) in various molar ratios, as shown in Tables 1A and 1B.
Control samples having no added .beta.-dicarbonyl compound were
included.
[0054] The samples were evaluated by preparing, at 25.degree. C.,
duplicate compositions comprising 100 parts by weight of
polyisocyanate (polymeric MDI, Suprasec DNR, available from
Huntsman Polyurethanes) and between 0.23 and 0.6 Darts of the
samples designated 1A to 1Q wherein in every case the quantity of
metal (iron or aluminium) added was 0.706 mmol. The compositions
were then stored at 45.degree. C. and the viscosity tested, at
25.degree. C., by means of a Brookfield viscometer at various
intervals. The average results are given in Tables 2A and 2B below
[all viscosities are in Pa s]. TABLE-US-00003 TABLE 2A Time Sample
(Days) 1A 1B 1C 1D 1E 1F 1G 1H 0 202 202 202 202 202 202 202 202 10
474 250 250 262 344 224 216 220 21 1030 376 300 334 425 251 256 242
70 3602 978 542 509 615 536 266 258 94 6448 1736 704 732 880 406
352 308
[0055] TABLE-US-00004 TABLE 2B Time Sample (Days) 1J 1K 1L 1M 1N 1O
1P 1Q 0 244 244 244 244 244 244 244 244 18 345 296 312 320 932 536
362 392 44 392 330 372 396 1763 868 536 574 60 490 380 418 448 3138
1288 994 984
[0056] Generally, the most relevant period for storage stability at
room temperature is the period 14 to 46 days after production of
the polyisocyanate composition. From Tables 2A and 2B it can be
seen that iron and aluminium complexes of the invention used in
polyisocyanate compositions of provide an economical means of
stabilising the compositions over the un-complexed
tris(acetylacetonate) compounds.
EXAMPLE 2
Preparation and Testing of Aluminium tris(ethylacetoacetate)
Complexes
[0057] To a flask containing 50.02 g of a mixture of heptane
isomers was added 31.0 g (0.125 mol) of aluminium
tris(sec-butoxide). To this was added, with stirring, 48.87 g
(0.376 mol) of ethylacetoacetate. After stirring the liquor was
transferred to a rotary evaporator flask and the volatile
sec-butanol and heptanes (78.66 g) were removed under vacuum
leaving aluminium tris(ethylacetoacetate) (51.23 g, 0.124 mol).
[0058] Samples of aluminium tris(ethylacetoacetate) prepared as
above was mixed with additional ethylacetoacetate as indicated in
Table 3 below. TABLE-US-00005 TABLE 3 Sample Moles EAA added* 2A -
(comp) 0 2B 0.5 2C 4.0 *per mole of Al(EAA).sub.3
[0059] The samples were evaluated by preparing, at 25.degree. C.,
duplicate compositions comprising 100 parts by weight of
polyisocyanate (polymeric MDI, Suprasec DNR, available from
Huntsman Polyurethanes) and between 0.29 and 0.66 parts of the
samples designated 2A-2C wherein in every case the quantity of
metal (aluminium) added was 0.706 mmol. The compositions were then
stored at 45.degree. C. and the viscosity tested, at 25.degree. C.,
by means of a Brookfield viscometer at various intervals. The
average results are given in Table 4 below [all viscosities are in
Pa s]. The results show that EAA complexes with Al(EAA).sub.3 to
provide improved storage stability in isocyanate compositions
TABLE-US-00006 TABLE 4 Time Sample (days) 2A 2B 2C 0 224 224 224 10
272 236 234 20 310 258 252 49 324 256 274 73 510 290 418
EXAMPLE 3
[0060] Preparation and testing of Iron
tris(acetylacetonate)/ethylacetoacetate complex A sample of an
organometallic complex was prepared by mixing 1 mole of iron
tris(acetylacetonate), as prepared in Example 1, with 2.5 moles
ethylacetoacetate. The sample was evaluated by preparing, at
25.degree. C., a composition comprising 100 parts by weight of
polyisocyanate (polymeric MDI, Rubinate 1840, available from
Huntsman Polyurethanes) and 0.48 parts of the sample. The
composition was then stored at 45.degree. C. and the viscosity
tested, at 25.degree. C., by means of a Brookfield viscometer at
various intervals. Results are given in Table 5 below [all
viscosities are in Pa s]. TABLE-US-00007 TABLE 5 Time (days) 0 20
40 65 100 Viscosity (Pa s) 220 290 300 420 620
EXAMPLE 4
[0061] An organometallic complex was prepared by mixing 2.5 g of
iron tris(acetylacetonate), obtained from the Sigma-Aldrich Company
Limited, with 2.3 g ethylacetoacetate in a flask with stirring.
[0062] The organometallic complex (0.48 parts) was mixed with 100
parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR,
available from Huntsman Polyurethanes). This composition was used
to prepare single layer boards of aspen at 2.5% and 6% resin based
on dry wood.
[0063] Boards of 12.times.450.times.450 mm and density 650
kg/m.sup.3 were made using the above composition and also
containing a sizing wax emulsion (SPG 60 available from Condea
Chemie) at 1% loading (solid wax) based on dry wood. The
prepressing moisture content was 8%. For comparison, similar boards
were prepared using the polyisocyanate without the organometallic
complex (Comparison).
[0064] Composites were then prepared using the following pressing
conditions: TABLE-US-00008 Press Close (Contact position): 50 s
Cure Time: 10 s / mm Degas Time: 15 s Press Temperature:
200.degree. C.
[0065] The composites produced under conditions described above
were then tested using a range of industry standard tests to
measure physical properties (Modulus of elasticity and rupture
according to EN310; Swelling after 24 hrs of soaking in water
according to EN317). Results are given in Table 6 below.
[0066] The measured properties showed no significant performance
difference between composites prepared with SUPRASEC DNR alone and
when the product of Example 4 was present. This demonstrates the
utility of using polyisocyanate compositions containing
compositions of the invention to produce composites without
affecting physical performance of the resulting composite panels.
TABLE-US-00009 TABLE 6 2.5% Binder loading 6% Binder loading
Property Example 4 SD Comparison SD Example 3 SD Comparison SD
Modulus of Elasticity 4562 797 4993 431 5345 1129 5113 644 (%)
Modulus of Rupture 34.9 9.0 35.5 5.8 44.5 12.7 43.5 9.0 (%)
Thickness Swell (%) 16.5 1.6 17.0 3.3 10.6 1.0 7.8 1.0
EXAMPLE 5
[0067] Boards were made using a polyisocyanate comprising different
parts by weight of the organometallic complex of Example 4 and 100
parts by weight of standard polyisocyanate (SUPRASEC DNR--see Table
7). The release performance of the boards was tested. In order to
reproduce the failure mode all spray of release agent was stopped
from the 7th repeat onwards. It is considered that a release rating
(see below) of 3 will cause a catastrophic failure under
large-scale manufacturing conditions. The release trials were run
in parallel and for each composite the release from the top and
bottom platten was measured. The per cent wood failure (amount of
the platten covered by residual wood) was also recorded. Results
are summarised in Tables 8 and 9 below.
[0068] Composites were prepared using the following pressing
conditions: TABLE-US-00010 Press Close (Contact position): 20 s
Cure Time: 9.3 s / mm Degas Time: 20 s Press Temperature:
170.degree. C.
[0069] TABLE-US-00011 TABLE 7 Weight percent Release agent Sample
Example 4 product (g/m.sup.2) 5A 0 4 5B 0.48 2 5C 0.32 2 5D 0.32
1
[0070] The release rating is given a value from 1 to 5 having the
following significance: [0071] 1 complete sticking, board can not
be removed without destruction of the board [0072] 2 sticking with
wood failure higher than 50% [0073] 3 sticking with wood failure
less than 25% but higher than 5% [0074] 4 sticking with wood
failure less than 5%. Little force needed to remove board. [0075]
4.5 sticking without wood failure, hanging board. No effort needed
to remove board. [0076] 5 perfect release, the board releases
spontaneously.
[0077] The results shown in Tables 8 and 9 show that a composition
containing an organometallic complex of the invention improves the
performance of a system using an external release agent and allows
this performance to be maintained as the level of external release
agent is significantly reduced. TABLE-US-00012 TABLE 8 % Wood %
Wood No. Release Rating Failure Release Rating Failure of re- 5A 5A
5A 5A 5B 5B 5B 5B peats Top Bottom Top Bottom Top Bottom Top Bottom
1 4.5 5 0.5 5 5 5 0 0 2 5 4.5 0.5 7 5 5 0 0 3 5 4 2 10 5 5 0 0 4 5
4.5 3 10 5 5 0 0 5 5 5 3 10 5 5 0 0 6 5 4 1 12 5 5 0 0 7 5 4 2 15 5
5 0 0 8 4.5 5 5 5 9 4.5 5 5 5 10 4.5 5 2 15 4.5 5 0 0.5
[0078] TABLE-US-00013 TABLE 9 % Wood % Wood No. Release Rating
Failure Release Rating Failure of re- 5C 5C 5C 5C 5D 5D 5D 5D peats
Top Bottom Top Bottom Top Bottom Top Bottom 1 5 5 0 0 5 5 0 0 2 5 5
0 0 5 5 0 0 3 5 5 0 0 5 5 0 0.5 4 5 5 0 0 5 5 0 0 5 5 5 0 0 5 5 0 0
6 5 4.5 0 0 4.5 5 0 0 7 5 4.5 0 0 5 5 0 0 8 5 5 4.5 5 9 4.5 5 5 5
10 4 5 0.5 0 4.5 5 0 0
EXAMPLE 6
Testing Cobalt tris(acetylacetonate) (Co(acac).sub.3) Complexes
[0079] Samples of cobalt tris(acetylacetonate) obtained from the
Sigma-Aldrich Company Limited were mixed with ethylacetoacetate
(EAA) in molar ratios between 1:0.5 and 1:4 (cobalt
tris(acetylacetonate): .beta.-dicarbonyl compound). The samples
were evaluated by preparing, at 25.degree. C., duplicate
compositions comprising 100 parts by weight of polyisocyanate
(polymeric MDI, Suprasec DNR, available from Huntsman
Polyurethanes) and between 0.25 and 0.62 parts of the mixed samples
made up as shown in Table 10 wherein in every case the quantity of
metal (cobalt) added was 0.706 mmol. The compositions were then
stored at 45.degree. C. and the viscosity tested, at 25.degree. C.,
by means of a Brookfield viscometer at various intervals.
[0080] Average results are given in Table 10 below [all viscosities
are in Pa s]. TABLE-US-00014 TABLE 10 Days Moles EAA added* 0 19 43
60 0 (comp) 244 268 251 292 0.5 244 274 256 302 2.0 244 256 256 266
4.0 244 252 256 272 *per mole Co tris(acetylacetonate)
[0081] The results show that EM complexes with cobalt
tris(acetylacetonate) to provide improved storage stability in
isocyanate compositions
EXAMPLE 7
Preparation and Testing of Iron tris(tetramethylheptanedionate)
(Fe(TMHD).sub.3) Complexes
[0082] Iron tris(tetramethylheptanedionate) was mixed with
ethylacetoacetate (EAA) in molar ratios between 1:0.5 and 1:4
(Fe(TMHD).sub.3: .beta.-dicarbonyl compound). The samples were
evaluated by preparing, at 25.degree. C., duplicate compositions
comprising 100 parts by weight of polyisocyanate (polymeric MDI,
Suprasec DNR, available from Huntsman Polyurethanes) and between
0.43 and 0.79 parts of the mixed samples made up as shown in Table
11 wherein in every case the quantity of metal (iron) added was
0.706 mmol. The compositions were then stored at 45.degree. C. and
the viscosity tested, at 25.degree. C., by means of a Brookfield
viscometer at various intervals. Average results are given in Table
11 below [all viscosities are in Pa s]. TABLE-US-00015 TABLE 11
Days Moles EAA 0 31 55 Fe(TMHD).sub.3 0 (comp) 212 286 338
Fe(TMHD).sub.3 0.5 212 240 224 Fe(TMHD).sub.3 1.0 212 230 214
Fe(TMHD).sub.3 2.0 212 236 212 Fe(TMHD).sub.3 4.0 212 244 272
[0083] The results show that EM complexes with Fe(TMHD).sub.3 to
provide improved storage stability in isocyanate compositions
EXAMPLE 8
Preparation and Testing of Iron tris(benzoylacetone)
(Fe(BzAc).sub.3) Complexes
[0084] Iron tris(benzoylacetone) was mixed with ethylacetoacetate
(EAA) in molar ratios between 1:0.5 and 1:4 (Fe(BzAc).sub.3:
.beta.-dicarbonyl compound). The samples were evaluated by
preparing, at 25.degree. C., duplicate compositions comprising 100
parts by weight of polyisocyanate (polymeric MDI, Suprasec DNR,
available from Huntsman Polyurethanes) and between 0.38 and 0.75
parts of the mixed samples made up as shown in Table 12 wherein in
every case the quantity of metal (iron) added was 0.706 mmol. The
compositions were then stored at 45.degree. C. and the viscosity
tested, at 25.degree. C., by means of a Brookfield viscometer at
various intervals. Average results are given in Table 12 below [all
viscosities are in Pa s]. TABLE-US-00016 TABLE 12 Days Moles EAA 0
20 49 63 Fe(BzAc).sub.3 0 (comp) 240 270 290 320 Fe(BzAc).sub.3 0.5
240 266 279 330 Fe(BzAc).sub.3 1.0 240 270 263 302 Fe(BzAc).sub.3
2.0 240 290 286 348 Fe(BzAc).sub.3 4.0 240 314 354 386
[0085] The results show that Fe(BzAc).sub.3 itself provides a
storage-stable isocyanate composition and that .beta.-dicarbonyl
compound may be added to effect a change in stability.
EXAMPLE 9
Preparation and Testing of mixed Ti/Fe and Ti/Al Complexes
[0086] A mixture was prepared of iron tris(acetylacetonate), and
di(isopropoxy)titanium bis(ethylacetoacetate), having an equal
number of moles of iron and titanium and containing an additional
2.5 moles of EAA per mole of titanium plus iron. A similar mixture
was also prepared using di(isopropoxy)titanium
bis(ethylacetoacetate) and Al(acac).sub.3. Shelf life tests were
performed as before using 0.5 g of these mixtures per 100 g of
polyisocyanate The results are shown in Table 14
[0087] The results show that combining Ti and Fe or Al can provide
improved control over the storage stability of
catalyst-polyisocyanate compositions. TABLE-US-00017 TABLE 13
Ti(OiPr).sub.2 Al(acac).sub.3 Fe(acac).sub.3 (EAA).sub.2 EAA Days
(moles) (moles) (moles) (moles) 0 15 44 60 0.5 -- 0.5 2.5 244 354
476 542 -- 0.5 0.5 2.5 244 382 524 584 -- -- 1 (Com- 2.5 244 406
564 656 parison)
* * * * *