CA1322816C - Rigid foams - Google Patents

Rigid foams

Info

Publication number
CA1322816C
CA1322816C CA000567719A CA567719A CA1322816C CA 1322816 C CA1322816 C CA 1322816C CA 000567719 A CA000567719 A CA 000567719A CA 567719 A CA567719 A CA 567719A CA 1322816 C CA1322816 C CA 1322816C
Authority
CA
Canada
Prior art keywords
weight
polyisocyanate composition
polyisocyanate
diisocyanates
polyisocyanates
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000567719A
Other languages
French (fr)
Inventor
Otto Dueber
Berend Eling
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Huntsman International LLC
Original Assignee
Imperial Chemical Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Imperial Chemical Industries Ltd filed Critical Imperial Chemical Industries Ltd
Application granted granted Critical
Publication of CA1322816C publication Critical patent/CA1322816C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72Polyisocyanates or polyisothiocyanates
    • C08G18/77Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
    • C08G18/78Nitrogen
    • C08G18/79Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08Processes
    • C08G18/16Catalysts
    • C08G18/22Catalysts containing metal compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72Polyisocyanates or polyisothiocyanates
    • C08G18/74Polyisocyanates or polyisothiocyanates cyclic
    • C08G18/76Polyisocyanates or polyisothiocyanates cyclic aromatic
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent

Landscapes

  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
  • Superconductors And Manufacturing Methods Therefor (AREA)

Abstract

Abstract "Rigid Foams"

A method for the preparation of rigid foams comprising reacting a polymethylene polyphenyl polyisocyanate composition with a polyfunctional active hydrogen compound under foam-forming conditions, the polyisocyanate composition containing not more than 20% by weight of diisocyanates and not more than 20% by weight of polyisocyanates containing more than 5 isocyanate groups per molecule. The foams produced have improved fire properties and enhanced surface properties.

Description

1322~6 This invention relates to rigid foams and especially to rigid pol~meric foams derived from certain polymethylene polyphenyl polyisocyanate compositions.

Polyme~hylene polyphenyl polyisocyanate compositions are manu~actured industrially by phosgen~ating mixtures o~
polyamines obtained by tho acid condensation o~ aniline and formaldehyde. The polyisocyanate mixtures that have achieved greatest commercial importance have contained from about 30 ~ to about 70 ~ by weight of diphenylmethane 10 diisocyanate together with various amounts o~ related methylene-bridged polyphenylene tri- to penta- and higher polyisocyanates, the actual compositions being largely dependent upon the initial aniline/~ormaldehyde ratio~
' .

15 Such compositions have been used in isocyanate-basad ~ormulations of many types and especially in the pxoduction o~ polyure~hane and polyisocyanurate rigid ~oams as descri~ed, ~or example, in Uni~ed Kingdom Patent speci~ica~ions 848671, 874430, 1146661, }184893 and 1223415.

20 It has now been found that superior rigid foams can be made ~rom polymethylene polyphenyl polyisocyanate mixtures having reduced contents of diisocyanates and higher molecular weigh~ polyisocyanates and correspondingly increased , ~.

,, - ~
-: - ~
' ': . - . .: :. ,. ; ~
- : . ~ - . : . . ~ .
, 1322~
contents of tri- to penta-isocyanates. In particular, it has been found that polyisocyanurate foams haviny improved ~ire properties, as measured by the oxygen index, and polyuxethane foams having enhanced surface properties, especially low~r surface Priability, may be prepared from said mixtures.

Accordingly, the invention provides a method ~or the preparation of rigid faams comprising reacting a polymethylene polyphenyl polyisocyanate composition with a 1~ poly~unctional active hydrogen compound under foam-forming conditions, the polyisocyanate composition con~aining not more than 20 % hy weight of diisocyanates and not more than 20 % by weight of polyisocyanàtes ~ontaining more than 5 isocyanate groups per molecule.
:
Typical polyisocyanate compositions for use in the method of the invention contain :
0 - 20 % diphenylmethane diisocyanates 40 - 80 % dimethylene triphenylene triisocyanates 5 - 25 % polymethyl~ne polyphenylene ~-zotetra- and pentaisocyanates and 0 - 20 ~ higher polymethylene polyphenylene polyisocyanates on a weight basis.
::

- . - .

.

. .
-.
. .

13~2~1 ~
Pre~erred polyisocyanate compositions Eor use in the method o~ the invention have a NCO-va].ue ranging from 32-33.3 per cetlt by weight, which constitute novel compositions which are also the specific subject matter of this invention.

It is prQ~erred that the diisocyanate content of the polyisocyanate composition is less than 15 % by weight. It is also preferred that the content o~ polyisocyanates having 6 or more NCO~groups is less than 10 % by weight~ Suitable composi~ions preferably have viscosities of less than 1000 centipoises at 25 Deg~ C.
.
PolyisocyanatP mixtures which may be used in accordance with the invention and methods for their preparation have been described in the prior ark, for example in DE-OS 3245678 and EP 133538. In general, the mixtures are prepared by solvent extraction processes performed upon the original polymethyl~ne polyphenyl polyamine mixtures b~fore phosgenation or upon the corresponding polymethylene polyphenyl polyisocyanates. Any excess diisocyanate can then be removed by distillation.

In particular, DE 3245678 describes a method to ohtain a polyisocyanate compvsitiGn by phosgenating a polyamine fraction which comprises at least 94 ~ by weight of - , ~ ., , . - .

. ~ .

. ~ ~. ' '' ' :

132~816 triamines. The polyamine fraction is obtained upon fractional distillation of a mixture containing di- and polyphenylene polymethylene polyamines - which results from acid condensation o~ aniline and formaldehyde.

Polyfunctional active hydrogen compounds which may be used in the method of the invention include polyols, polyamines and water which, reæpectively, react with polyisocyanates forming polyurethane and polyurea products. The polyisocyanate may be reacted with the active hydrogen compounds in approximately stoichiometric quantities (NC0 index 100) or, alternatively, higher NC0 indices, for example 500 or 1000 or even higher, may be employed together with trimerisation catalysts so as to form polyisocyanurate modified products.

Use~ul polyols and polyamines include the conventional materials used or proposed to be used in the manufacture of polyurethane, polyurea and polyisocyanurate rigid foams~
.
- Suitable polyols generally have two or more hydroxyl groups and moleculax weights of ~rom 62 to 1500, the functionality and molecular weight appropriate to either polyurethane or polyisocyanurate foams being selected in known manner.
Examples of such polyols include ethylene glycol, glycsrol, ~ .

~3228~

trimethylolpropane, triethanolamine and their lower molecular weight oxyalkylation products. Alkanolamines such as monoethanol amine might also be usad. Other useful polyols include the lower molecular weight oxyalkylation products o~ ~sorbitol, sucrose and aromatic polyamines such as tolylene diamine and pol~methylene polyphenyl polyamines as well as bis-phenol~ and polyether and polyester polyols.
J

Suitable polyamines generally have two or more primary or secondary amino groups and molecular weights o~ from 60 to 10 1500~

Nixtures of polyols and/or polyamines~and/or water may;be used.

The polyisocyanate composition and the polyfunctional active hydrogen compound may be reacted under conventional ~oam-forming conditions. In general, this involves preparing a reaction mixture containing a blowing agent in addition to the polyisocyanate and active hydrogen compound.

Such reaction mixtures may also contain other conventional ingredients, for example cakalysts, surfactants, flame re~ardants and trimerisation catalysts.
:' .

-. - - .
~ .
'; ' ' ',' ~. ~:

.
: . ., : .. . :
.

~228~
-6- .
Suitable blowing agents i.nclude inert volatile liquids, especially halogenated alkanes such as trichlorofluoro-methane arld dichlorodi~luoromethane. In some cases, water can be e~ployed as a blowing agent in addition to, or instead of, the inert liqu.id.

Surfactants useful in ~oam preparation include siloxane-oxyalkylene copol~ners and conventional non~ionic surfactants. Catalysts useful in the preparation o~
polyurethane and polyurea foams include the usual tertiary amines and tin compounds whilst trimerisation catalysts required for polyisocyanuratQ foams include alkali metal and alkaline ~arth metal hydroxides, alXoxides and alkanoates.
Particularly useful catalysts for the production of polyisocyanurat~ foams include mixtures of a salt of the formula :
.

, Rl - C - COO- M+

~3 and a salt of the formula :
, ...... ...... . . ~ . .
.
.:

g ~ ~

/ ~2 ` ~ , I
; Rl - C - COO ~ Q~

\ R3 / ~
wherein M represents an alkali metal or tetraalkylammonium, Q represents a group IIA metal or zinc and R1, R2 and R3, which may be the same or different, represent hydrogen, lower alkyl, cycloalkyl, phenyl or alkylphenyl.

Such caitalysts are in particular preferred when the isocyanate index is higher than 500.
The foamR may be prepared using any of the conventional mixing and ~abrication techniquies. Thus, spraying techniques or moulding or lamination proce~ses may be used as desired. The reduced surface friability of the polyuxethane ~oams is particularly valuable in laimination processes inasmuch as the adhesion between the foam and the facing materials is significantly improved.

The invention is illustrated but not limited by the ~ollowing examples in which all parts are by weight.

' .
'' '~ ' .
. .. ~ , .
- . , , ~322~

x~am le 1 Two polyurethane ~oams were made ~rom the following formulations :

Oxypropylated glycerol (OH~540) 38~1 36.8 Silicone ~luid DC-193 (DOW Chemical) 0.5 0.5 N,N-Dimethylcyclohexylamine 1.0 1.0 Dibutyltin dilaurate 0.015 0.015 Trichlorofluoromethane 13`.0 13.0 Polyisocyanate 1 47.4 lO Polyisocyanate 2 ~ 48.7 .
Polyisocyanate 1 was a polymethylene polyphellyl polyisocyanate composition having an NCO value of 33.0 and containing 16 % hy weight of diisocyanate and 6 % by weight of polyisocyanates having a molecular weight high~r than 650.
Polyisocyanate 2 was a conventional polymethylene polyphenyl polyisocyana~e composition having an NCO value of 3006 and containing 50 % by weight of diisocyanate.
It was shown by tactile examination that the surface ~riability of foam 1 was less than that o~ foam 2.

,, , ~ , 13~2~

g E ample 2 Polyisocyanurate foams were prapared ~rom the following formulations :

A B C
Polypropylene glycol 425 18.9 12.7 7.90 Silicone ~luid DC-193 0~35 0.35 0.35 (DOW Chemical) Potassium acetate (50 ~
ethylene glycol solution) 0.45 0.30 0,30 N,N-dimeth~lcyclohexylamine 1.00 0.30 0.30 ~richloro~luoromethane 10.00 10.00 10.00 Polyisocyanate 1 69.9 77.5 88.1 Three corresponding ~`oams were then prepared from the same formulations except that Polyisocyanate 1 was replaced by Polyisocyanate 2 (as in Example l)o The six rigid polyisocyanurate foams so obtained were subjected to the Oxygen Index test (ASTM 2863) giving the follo~ing results :

A B C
Polyisocyanate 1 2~.4 25.0 27.0 Polyisocyanate 2 23.8 25.7 28.0 (as in Example 1~

.. . . . . . . . . .. .... .. . . . . .
, ., ,~

., .

,

Claims (10)

1. A method for the preparation of rigid foams comprising reacting a polymethylene polyphenyl polyisocyanate composition with a polyfunctional active hydrogen compound under foam-forming conditions, the poly-isocyanate composition containing not more than 20 % by weight of diisocyanates and not more than 20 % by weight of polyisocyanates containing more than 5 isocyanate groups per molecule.
2. A method according to claim 1 wherein the polyisocyanate composition contains 0-20 %
diphenylmethane diisocyanates, 40-80 % dimethylene triphenylene triisocyanates, 5-25 % polymethylene polyphenylene tetra- and penta-isocyanates and 0-20 %
higher polymethylene polyphenylene polyisocyanates on a weight basis.
3. A method according to claim 1 or 2 wherein the NCO
content of the polyisocyanate composition is from 32 %
to 33.3 % by weight.
4. A method according to claim 1 or 2 wherein the polyisocyanate composition contains less than 15 % by weight of diisocyanates.
5. A method according to claim 1 or 2 wherein the polyisocyanate composition contains less than 10 % by weight of polyisocyanates containing more than 5 isocyanate groups per molecule.
6. A method according to claim 1 or 2 wherein the polyisocyanate composition has a viscosity of less than 1000 centipoises at 25 Deg. C.
7. A method according to claim 1 or 2 wherein the polyfunctional active hydrogen compound is a polyol, a polyamine, water or mixtures of one or more of these.
8. A method according to claim 1 or 2 wherein the polyisocyanate composition is used in a greater than stoichiometric amount together with a trimerisation catalyst.
9. A method according to claim 8 wherein the catalyst comprises a mixture of a salt of the formula :

and a salt of the formula :

wherein M represents an alkali metal or tetraalkylammonium, Q represents a group IIA metal or zinc and R1, R2 and R3, which may be the same or different, represent hydrogen, lower alkyl, cycloalkyl, phenyl or alkylphenyl.
10. A method according to claim 9 wherein the NCO index is higher than 500.
CA000567719A 1987-05-26 1988-05-26 Rigid foams Expired - Fee Related CA1322816C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB878712364A GB8712364D0 (en) 1987-05-26 1987-05-26 Rigid foams
GB8712364 1987-05-26

Publications (1)

Publication Number Publication Date
CA1322816C true CA1322816C (en) 1993-10-05

Family

ID=10617928

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000567719A Expired - Fee Related CA1322816C (en) 1987-05-26 1988-05-26 Rigid foams

Country Status (10)

Country Link
KR (1) KR970002520B1 (en)
AT (1) ATE94182T1 (en)
CA (1) CA1322816C (en)
DK (1) DK289088A (en)
FI (1) FI882485A (en)
GB (1) GB8712364D0 (en)
HK (1) HK1001692A1 (en)
NO (1) NO882283L (en)
NZ (1) NZ224659A (en)
PT (1) PT87571B (en)

Also Published As

Publication number Publication date
PT87571B (en) 1992-12-31
NO882283D0 (en) 1988-05-25
GB8712364D0 (en) 1987-07-01
KR970002520B1 (en) 1997-03-05
DK289088A (en) 1988-11-27
DK289088D0 (en) 1988-05-26
HK1001692A1 (en) 1998-07-03
PT87571A (en) 1989-05-31
FI882485A0 (en) 1988-05-26
KR880014023A (en) 1988-12-22
FI882485A (en) 1988-11-27
ATE94182T1 (en) 1993-09-15
NO882283L (en) 1988-11-28
NZ224659A (en) 1990-08-28

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