CA2246634A1 - Preparation of hydroxyphosphonates and their use for flameproofing plastics - Google Patents

Abstract

Dialkyl hydroxyalkanephosphonates are prepared by a process in which a phosphonate is reacted with an aldehyde in the presence of a basic catalyst.
Polyurethanes, in particular polyurethane foams, are prepared using dialkyl hydroxyalkanephosphonates.

Description

r.~,.~ of h~ ' ,' and their use for '' , ~ plastics The present invention relates to a process for the preparation of dialkyl L~llu~y " ,' .' , in which a ~' .' is reacted with an aldehyde in the presence of a basic catalyst. The present invention 20 fUlLh~lUUlC: relates to the use of dialkyl hydroxy?l' .' .' in the preparation of polyuuc~ , in particular in the preparation of polyul~lllculc foams. The present invention ' (h.~.IIIUI~ relates to pol,yuu~ . foams containing dialkyl hy~Lu~j.'- .' .' 25 PUI.~U-CIL.~ are materials which are suitable for a large number of different ,.I.~.li,-l;~...~ in the industrial and in the private sector. However, their use presents problems whenever the fire behavior of the POIYUI~:LIICUI~S
used plays a role in the prevention of danger, for example when they are used in areas where there is a fire risk or in private hr~--CPh~ C In order 30 to modify the fire behavior of pol~u., ' A . UUrl..~, agents with the aid of which the fire behavior can be influenced are usually added to these materials.

In the case of the pol~, ' foams, these problems occur to a particular extent following the prohibition of the use of chlululluulu.,~ul,ull~ (CFCs) as blowing agents in the production of pl)l~ tlldll~ foams for ecological reasons in many countries. In the search for substitutes, flammable blowing agents are therefore hl~ . 'y being used in the production of 5 polyul~ , foam. However, the use of flammable blowing agents leads to greater n Lullrl.ll ity of the pU~ t. foams and therefore sets high Itl~Uill,l..~lli.~ with respect to the flame retardancy (lldlll~ luurll.~,), making it necessary to adapt the '' I u, ' ,, systems to the changed conditions.

o For CFC-expanded pulyull ' foams, the use of tris(chlulu;.u~lul.yl) phospate (TCPP) as '' , uurlllg agent is disclosed in DE-A 16 94 430, while DE-A 19 56 406 reports the use of ammonium pulyl' .' (APP) and especially the use of . ' of APP and tris(haloalkyl) phosphate as fl~ luurlllg agents.

EP-A 0 645 418 describes a pumpable ll,.~ uurlht, mixture which comprises APP and TCPP, is stable to settlmg out and, in an n-pentane-blown form ' ' leads to CFC-free, flame-retardant polyuu~Lllane foam. This polyulcLll~me foam complies with flre class B2. Here, APP and zo TCPP act as a synergistic system since neither the use of APP alone nor of TCPP alone leads to foams l,oll~ )ùllllh.b to the ~I,u.. ' fire class.

However, the use of TCPP or other halogen-containing compounds gives ~5 rise to the danger of the formation of highly toxic polyh~l ~g ~m"..""l;l,i; or 'm...~ in the event of a fire. Of course, corrosive gases, such as HCI or HBr, are also formed and may cause dangerous concealed fire damage and may ful~l~,.l-lul~ give rise to ~u.~id~ bl~, danger to people.

For these reasons, poly.,~ , foams are hl~,lt~..Jy treated with a halogen-free ndl..~"uu' _ agent.

In addition to the stated halogen rnmrolln~lc, phosphorus compounds are 5 highly effective lld",~,l"u, ~ _ agents for IJulyul~lL~l~ foams. Owing to their high phosphorus content and good stability to hydrolysis, for example, l' .' substituted by short alkyl chains are preferred. Although dimethyl ' ,' .' has the highest phosphorus content, its use presents problems owing to the toxic effect of this compound and is there-o fore greatly restricted. Higher homologs of this class of cnmroun~c~ forexample diethyl: ' . ' , ' , must however be used in larger amounts owing to the lower phosphorus content, the plasticizing effect of these compounds which are unreactive with respect to isocyanate groups being poor.

It is known that these disadvantages can be avoided by using reactive phosphorus . ' Thus, US-A 5,173,515 describes a reactive, phosphorus-containing diol and proposes its use as llo~ luurll.~ agent.
However, the diethyl N,N-bis(2~ lluA~ l,yl) ' .~ .~ used 20 has an undesirably high reactivity which greatly restricts the possible amount used in polyul~;Llldll., foam r~ ' F.~ ""~u~, this compound has only a relatively low phosphorus content, which increases the amount required for adequate n ~ UUrlllg in cnmp~ricnn with compounds having a higher phosphorus content. For these reasons, the use of the described ~5 compound as a lla...~ .uurlllg agent is generally not advisable.

US-A 4,808,744 relates to t.~wt~.,ir",.ltiu,l products of diethyl LydluAy ' .' ,' with diethyl phosphite and their use as n . uurll.g agents. The use of diethyl h1~uAy ' . ' . ' itself 30 as lldlll~!luu~ _ agent is not proposed in the ~

Generally recognized theories assume that ~ '( 'y polyhydric alcohols (polyols) having a strong branching effect and fi~nr~in~qliri,~c of two or more have to be used for the preparation of isocyanate-based pUI~UUvlll~llC foams (Becker/Braun, K~ .,rll ~ . l" Volume 7, Pol~u~vlll.mv Carl Hanser 5 Verlag, Munich, Vienna, 1993, page 268). ~ r '' I alcohols (monools) on the other hand lead to chain termination in the reaction with the isocyanates or reduce the network density of the resulting polymer. This results in poor foam properties and inadequate processing behavior.
;ly~ f~ iUl~l 1' ,' have not been used to date as o Iku~ luurlll6 agens in r ~ ~ for isocyanate-based rigid foams.

There was therefore a need for highly effective llrlll~,~luurl~l6 agents which can be prepared from readily available starting materials in high yield.
There is also a need for pul~uu~:lllall~. foams which can be prepared using 15 highly effective nd~u~ luufi..D agents preparable from readily available starting materials in high yield, without sacrificing the mechanical foam properties and the processing behavior.

It is an object of the present invention to provide a process for the 20 preparation of highly effective r~ v agents which leads to high yields while ~ubaL~ idlly avoiding side reactions. It is a further object of the invention to provide Ikul,~ uvf~,d isocyanate-based pol~, vtll.lllv foams where the .li~-d~lllL6.,~ of the prior art are sub~ lly avoided and the l physical and processing properties are not adversely affected, 25 without the flre behavior d~tv~iul~i D.

We have fûund that these objects are achieved by the novel process for the preparation of dialkyl LylLu~.~ " .' ,' of the formula I and by pol~ul.,~ .ll.,s containing such dialkyl hydroxy~ ' and 30 processes for their preparation.

CA 02246634 l998-l0-07 The present invention relates to a process for the preparation of dialkyl hydroxyal' .' .' of the formula I

lR2 o 0--~P~CH,R3 (1) where Rl and R2, '. ' '!/ of one another, are each a linear or o branched, , ' ' or halogen- or hydroxyl s~ c~ Cl-C1O-alkyl radical or C6-CI3-aryl or C7-CI4-benzyl radical and R3 is hydrogen or a linear or branched Cl-C1O-alkyl radical or a C6-C13-aryl, C7-CI4-benzyl or furfuryl radical, in which a reaction mixture containing 15 a) a 1' .' of the formula 11 IR2 o O--P~H (Il) ~o R1--o where Rl and R2, i ~ of one another, are each a linear or branched, "-- ~ l - i or halogen- or hydroxyl S--~C~ P~ Cl-ClO-~5 radical or C6-C13-aryl or C7-CI4-benzyl radical, as component A, and (b) an aldehyde of the formula 111 R3--C\ all) where R3 is hydrogen or a linear or branched Cl-C10-alkyl radical or a C6-Cl3-aryl, C7-CI4-benzyl or furfuryl radical, as component B, is reacted together with o (c) a basic catalyst, as component C, wherein a mixture of the .~ A and B and C is brought to a UIC of from about 20 to about 60~C, or a mixture of the A and B or a mixture of the rr~mpt~ n~ A and C is brought 15 to a t~ ul~ of from about 20 to about 60~C, the missing component B or C in each case being added after the L~ atul~ of from about 20 to about 60~C has been reached, and the i . ~Lul~ of the reaction mixture is then brought to a value of from about 61 to about 300~C for from about I to about 30 minutes.

In the context of the present text, r~ .~ are understood as meaning diesters of phosphonic acid. Here, phosphonic acid is a tautomeric form of pllua~Jlluluu~ acid, the diesters of the 1' .' u~.~ acid and the esters of phosphonic acid being identical. Frequently, I' .' are also referred 25 to as phosphites, the secondary phosphites accordingly being used in the context of the present invention.

Examples of the 1' .' which may be used in the context of the present invention are dimethyl 1' .' , diethyl 1' .' , diisopropyl 30 1' .' ' . dibutyl 1' .' , dihexyl 1' .' , dioctyl 1' .' bis(2-1.yJluA~ ~llYl) I . . ~I;IIY~IIUAY~JIU~UYI I . ~ ~.,LI.~I
r~ .~ diallyl i' ,' , dibenzyl 1' .' , ethyl methyl IS ,~ , methyl benzyl 1' ,' and diphenyl 1~' and mixtures of two or more thereof.

The .~Lu.~ iullcJ 1' .' may be used in industrial form, i.e. with a 1' ,' content of at least about 90, preferably at least about 95 or about 98, % by weight.

o However, the 1' )~' are preferably used in essentially pure form The r . used in the novel process may, if required, therefore be subjected to ~ irlu~Liull in a stage preceding the novel process, pnrjfir~tjr,n of the r . by distillation being preferred. In a particularly preferred e, L ' t, the ,uulirlc~Liull of the 1' .' by distillation is carried out 15 under reduced pressure, preferably at up to about 120~C and at from about 0.01 to about 100, preferably from about 0.1 to about 10, mbar.

In the context of the present invention, an aldehyde of the formula 111 is used as component B. Examples of aldehydes which may be used in the 20 novel process are rw '' 'yJe, p~v,.r..".. ~1rhyJe, acetaldehyde, glyoxal, ,u~u,uiwlaldeh~Jc, L ~ ' ' ' yJe, ~ ~JIald~,hyJc~ benzaldehyde, cyclo-L~,Ayl~,~buA~ldehyde~ furfural, isov-l " ' ~Je, di.,ll~' ' ' ' yJc, 2-CLhYILA~ I and '' ' yJu and mixtures of two or more of stated aldehydes. r. ~ yJe, p~fnrn~lAIhyde, ac.,L~ldl,h~J~" IJIU,U' ~'' hyJe, 25 L ~ lJ~.L~Jc, L ' ' ' yJc and furfural and a mixture of two or more thereof are preferred.

In the context of the present invention, the term aldehyde includes compounds which produce an aldehyde cul,c,~!u..Ji ,, to the formula 111 only 30 in the reaction mixture. An example of such a compound is p~fnrr~ Phyde At least one basic catalyst is used as component C in the reaction mixture in the context of the present invention. Basic catalysts preferably used in 5 the novel process are catalysts based on organic ~ T-- ', in particular based on organic nitrogen Tertiary amino : , ', in particular 11 " yldlllh.~,s or cycloalkyldialkylamines, are particularly suitable for use as component C in o the novel process. Examples of said amino compounds are t~ /lalllhlc, ~ JIUIJ~LllllillC, N-clllylu;;.ulJIulJ.yLl~llillc and N,N-di~ ,lull.,Ayh,llyl~lllille.
T~i~"Lylamill~, and N,N-dilll.~ ,lol.GAylalllillc and mixtures thereof are preferably used as component C in the context of the present invention.

15 In the context of the present invention, it is preferred if the component C
is contained in the reaction mixture in an amount of from about 0.1 to about 5% by weight.

The novel process is carried out in a manner which depends on the chosen 20 procedure with regard to the addition of the ----r ' A, B and C.

If the ---r ' A, B and C are to be added right at the beginning of the novel process, the - r ' A, B and C are first mixed, preferably in the reaction vessel.

However, it is preferred in the context of the present invention if the -- 1, A and B or A and C are initially taken and are mixed. It is particularly preferred if the ~ A and B are initially taken and are mixed.

The ~ T ' A and B are preferably used in a roughly equimolar amount. However, a slight excess of component B may, if required, also be present.
.

5 The -----r ' A and B or A and C are ~,lv _ '~, initially taken and mixed in a vessel which is suitable for carrying out the reaction after the mixing. However, it is also possible initially to take and to mix the two ~.. 1,.. ,. ~ A and B or A and C in a vessel spatially separated from the apparatus for carrying out the process and, thereafter or after storage, o to transfer the mixture to a vessel suitable for carrying out the novel process.

The c~ present in the reaction mixture can be mixed by means of Cu~ du~ l mixing apparatuses known to a person skilled in the art. The 15 agitation of the reaction mixture is adv _ '~, maintained at least until conversion to the end product has begun.

The agitation is a.lv ~ continued during the entire novel process.

20 Particularly if one of the two ~ , A or B is solid and the other is liquid, it should be ensured that the mixture containing the r ' A
and B is c '~, stirred in order to avoid settling out and an associated ' ,, reaction.

25 If the mixture of the: . A and B has too high a viscosity or if both r ' A and B are solids, a suitable solvent can be added to the reaction mixture. The solvents used are in particular inert, dry solvents, for example ~ , n-heptane, toluene or N-.l..,~

30 As long as only the r ' A and B are present in the reaction mixture, component C, i.e. the basic catalyst, may now be added.

After the mixing process, the mixture containing the c~ A, B and, if required, C is heated to about 20-60~C, preferably about 30-45~C. Such s heating should extend over a period of from about 5 to about 50 minutes.

In a preferred e_ L ' of the invention, the component C is added once the desired i, ~ has been reached. The reaction mixture thus obtainable, containing , A, B and C, is then heated to a o t~ ,ldL..~i of from about 61 to about 300~C.

The heating process may take from about 5 to about 90 minutes. However, the heating is preferably carried out rapidly, i.e. within from about 5 to about 30 minutes.

Once the desired t~ .dLu.~ has been reached, the reaction mixture is kept at this t~ .,.dLul~i for about from I to about 30, preferably from about 1.5 to about 15, particularly preferably from about 2 to about 10, minutes. A
suitable desired t.,..llJ.,.dLul~ for the reaction is, for example, from about 80 20 to about 180~C, in particular from about 90 to about 140~C.

After the reaction at elevated t~,l.ll,.,l..'a..~, an dfL.,.LI. may be carried out at from about 20 to about 60~C. Here, the reaction mixture is stirred for from about 20 to about 120, preferably from about 30 to about 90, 25 minutes at the desired i, c~. The desired t~ .dLul~ may be, for example, 20, 30, 40, 50 or 60~C.

The reaction mixture is, if required, then treated by means of a suitable lUI irl~ iull method in order to isolate the reaction product. Suitable ~c ~, . irl~ m methods are known to a person skilled in the art. If the reaction product is a compound in the solid state, it may be ~ld~ ~ , for example, first to remove any distillable impurities still present in the reaction mixture by applying reduced pressure and/or increasing the t~ Ll..c of the reaction mixture. If the reaction was carried out in the 5 presence of a solvent, it is also advisable to remove this solvent by reducing the pressure of the reaction vessel. After the treatment of the reaction mixture under reduced pressure and at elevated tcl-l~J.,IaLulca, solid reaction products can as a rule be subjected to cu... _lltiUII.II ~ irlU~lLiUIl processes for solids. For example, recrystallization has proven a suitable ~o ~. ir.l"lLio. method for the solid reaction products obtained when the novel process is carried out. Suitable solvents and processes for recrystallization are known to a person skilled in the art from relevant standard works.

If the reaction products of the novel process are in a liquid state, the 15 product can be worked up by distillation. Under 4u.lu~L"I i~, pressure, separation of the rcaction product from any impurities present can be achieved only by increasing the temperature, but a cull~ ~Liull of an increase in the t.,lll~ LL,.~i and a reduction of the pressure in the reaction apparatus is preferably used for the purification by distillation.

However, a 1~ ;.... is not necessary in the case of all reactions. As a rule, the novel process leads to products whose purity is sufficient for further use in many ~

25 The present invention fu.Lh~llllulc relates to A I uu6,d, i containing POI~UIC~II~ foams expanded, for example, without the use of clllu.,'' u~,~ubu..~ (CFCs).

Such pol~ cLllllllc foams are used ~., ' 'y as insulating materials for 30 cold and heat insulation, for example in .~r,:~, . in the building _ industry, in hot water tanks, natural gas tanks and district heating pipes.
With the Ic,uld(,~ v.lt of CFCs by alternative blowing agents, such as HCFCs, HFCs, CO2 and hydlu,~ubu..., the cost of achieving constantly good fire protection behavior increases. This manifests itself as a rule in 5 larger amounts of n.. ,l,l u~ ' v agents which must be added to the rUI IllUIdLiU~

As mentioned above, r ' ~ alcohols (monools) lead to chain termination in the preparation of polyl.luLh ._s from polyrul..,Liull~l alcoholso and pulyi~u~ ' or reduce the network density of any crosslinked polymer. For llolyulcLLII~ foams, this results in poor foam properties and inadequate processing behavior. ~JilOrul.u~iul~ll r~ .~ have therefore not been used to date as ll~..._~lul~ ~ agents in ' ' for i~uv;. based rigid foams.

Surprisingly, the adverse processing end product properties of the novel poly,,.cLh~._ foams which are feared as a result of the novel use of the ..vulull~u~.y-functional lldul~ luuGI.g agents can be avoided if suitable r~.. " ~ and in particular, according to the invention, a nd.ll~".uurlllg 20 agent of the formula I are used for the preparation of the novel polylllcLllduc foams.

The present invention therefore relates to a POIYIIICtII~U~ which contains a dialkyl hydroxy~ . ' . ' of the formula 1. In the context of the ~5 present invention, such polyule~ are also referred to as treated with . uu v agent.

In the context of the present text, treated with ll~l~ uuGIlv agent is understood as meaning that the A . UUrlUg agent is contained in the 30 pOlyulcLlldllc either in free form, i.e. as a molecule of the formula 1, or as a derivative, in particular as part of an ester or urethane group. The last two IJOaailJ'iLiv5 include in particular the fact that the fl~ uu' v agent of the formula I is covalently bonded at the end of the polymer chain via an appropriate ester or urethane group. It is particularly preferred if tbe 5 r~ ~ UUfillg agent is attached terminally to the polymer backbone via a urethane group.

It is l~uLi~,ul~uly preferred if the novel pol~,..cLl.dlle contains, as a ll~.,~lu~ ' V agent, a compound or a mixture of two or more compounds o selected from the group consisting of dimethyl 1-L~UAY ' ,' .' dimethyl l-hY~UAY~ ' .' .' dimethyl I-ll,~JluAy~
dimethyl l LY~UAYb~ .' . ' , diethyl I-L~d~UAY ' .' . ' and diethyl l-hY~UA~ h; .' .' In addition to the novel n ~ UUrll.~ agent, further lldn~ /luurlllg agents differing from the dialkyl hydroxyalhy'j' .' used according to the invention may be present in the novel ~!ulyulv~Lcul~,. In a further preferred of the invention, at least one further liquid or solid lldl~ luurlllg agent or a mixture of two or more thereof is therefore also 20 present in the novel pul~.,,, ' Liquid lld~ luurll.~ agents which may be present in the novel l~ulyul~LII~ulv are, for example, dimethyl, ' .' .' , diethyl rll 1' ~1' .
triethyl phosphate, tributyl phosphate, Llibu~vAy~iLyl phosphate, triphenyl 25 phosphate dissolved in triethyl phosphate, diphenyl dicresyl phosphate, resorcinol l,;~b . ' ~1 phosphate, tris(2-LydluAyl,lul,yl) phosphate, tris-(5-hydroxy-3-oxapentyl) phosphate, tris(5-hydroxy-2,5-dimethyl-3-oxapentyl) phosphate, tris(2-L~LvAy~,lu~,,l) phosphite, tris(5-hydroxy-3-oxapentyl) phosphite, tris(5-hydroxy-2~5-dimethyl-3-oxapentyl) phosphite, pentakis-30 (d;~/lULJyl~ glycol) ~'i,' .' , heptakis(~ .lul.ylv.~ glycol) Ll.' pentakis(diyluyyh~ glycol) I'ipt .' , heptakis(d;y.uy~l.,ll~. glycol) tri-phosphate, tris(2-chloroethyl) phosphite, N,N-bis(2-hydlu,~. hyl) diethyl phosphite, N,N-bis(2-hyLu~yyluy~ diethyl phosphite, alkoxylation products of phosphoric acid, yUIy~ acid and 5 r~ .~ u..~ acid, ethylelle oxide and/or propylene oxide and/or butylene oxide preferably being used as alkoxylating agents, tris(2-chlvluyluyyl) phosphate, tris(2,3-dichloropropyl) phosphate, tetrakis(2-chloroethyl) ethylene ~i' .' , dissolved dibl.. ~ ylglycol and its reaction products, dissolved ~ 1 alcohol and its reaction products, dissolved o ~lil.l~ bu ' ' and its reaction products, dissolved 2,3-dL~ r Uyall(l and its reaction products, dissolved t~ .' ' li('. anhydride and its reaction products, dissolved t~tl~blullluvi~yll~lOl A and its reaction products,dissolved tlivlUlllU~/h~llvl and its reaction products, bromine-containing phosphoric esters and h~l v ' hydluu~bu..~, N,N',N''-hexa(2-15 Lydlw~y~llyl)mpl~minp~ N,N',N''-hexa(2-Lydlw-yyluyyl) ~ , N,N',N"-hexa(S-hydroxy-3-oxapentyl)melamine and hexa(u.~,LIIu,.ylll~.~lyl)m~ l~minP

Solid ~ luurll.~ agents which may be present in the novel polyul~
are, for example, ammonium phosphate, ammonium yulyl ' . ' 20 :'- ' hydrogen phosphate, ammonium dihydrogen phosphate, phospham, melamine, melamine cyanurate, melamine phosphate, melamine y~,' ,' , melamine borate, melamine barbiturate, tris(Ly~Lu,.~
cyanurate, aluminum trihydrate, magnesium hydroxide, graphite, expanded graphite, calcium borate, barium borate, zinc borate, zinc hydlu~.y: , ~5 natural and modifled starches, cellulose, lignin, zeolites, bentonite, guanidine carbonate, guanidine barbiturate, v ' carbonate, LyJIulll~ ";t~. and huntite.

The processing and product properties of the novel polyuu, ' are as a rule dependent on the ~lu~ index. With regard to processing and .

product properties of the novel pUIyull'' , it is preferred if all com-pounds used for the preparation of the polyul~ ' and having hydrogen atoms reactive toward isocyanates have a c, u~ ..b index Ic of at least 3.

The novel polyu~ ,., in particular the novel polyu., ' foams, are obtainable by reacting at least d) one organic l~uly;~u~"~ ' as component D with o e) a higher molecular weight compound having at least two functional groups which are reactive toward isocyanates and carry hydrogen atoms, as component E, and f) a hydroxyl-carrying fl~ uurl~ agent of tbe formula I as component F and g) if required, a chain extender or a w, " '' _ agent or mixtures thereof and h) if required, a blowing agent and i) if required, a catalyst and j) additives and assistants or if required, mixtures thereof.
~o The present invention therefore also relates to a polyu.c;ll.~,e obtainable by reacting at least three r ' D, E and F, d) an organic pol~i~ùu;. being used as component D and ~s e) a higher molecular weight compound having at least two functional groups which are reactive toward isocyanates and carry hydrogen atoms being used as component E and f) a dialkyl h~uJ.~ ' ~' .' of the formula I being used as component F.

Suitable organic poly;~u~,j. (component D) are the aliphatic, cy~l~r~liph~rir, araliphatic and preferably aromatic polyruucliull~l isocyanateSknown per se.

s Specific examples are: alkylene d;;-UCY having 4 to 12 carbon atoms in the alkylene radical, such as dodecane I,12-diiau~,~. , 2-cLl ylil"l~u-~ ylcuc 1,4-(li;.o,y , 2-hl~Lhy~ Lalll~Lllylclie l,S-~ ucy ' yl~,l~ 1,4-dii,u.,; and preferably 1- ' yl~,l~ 1,6-di;~ul,y cycloaliphatic diiau~ , such as .,yl' ' 1,3- and 1,4-dii~ocy_ o and any desired mixtures of these isomers, I-isocyanato-3,3,5-trimethyl-5-iso.,y~.u~tulll~,Lllyl.,y,'~'~ (isophorone diisucy~luoLc, IPDI), hc~lly~uL~Ilu~ , 2,4- and 2,6-.lii,u,,~. and the cullc~l~ullJu.~ isomer mixtures, and preferably aromatic di- and polyi~uu~ , e.g. toluylene 2,4- and 2,6-dii~u~,y and the .,ul~ isomer mixtures, mixtures ~s of ~ hl.~ ..e 4,4'-, 2,4'- and 2,2'-dii~ucy and polyphenyl pùly ' yl~.ne polyi,u.,~ (crude MDI) and mixtures of crude MDI and toluylene dii~u~,~ The organic di- and polyi,o.,y may be used iudiv ' "~, or in the form of their mixtures.

~o Modified poly' ' i,u~"~ i.e. products which are obtained by chemical reaction of organic di- and/or polyi,u.,y , are frequently also used. Examples are di- and/or polyi,u.,y containing ester, urea, biuret, lllbOlliilllil~e, i~Ul~J ', uretdione and/or urethane groups.
Specific examples are: organic, preferably aromatic, polyi,u.,~
~s containing urethane groups and having NCO contents of from 33.6 to 15, preferably from 31 to 21, % by weight, based on the total weight, as can be obtained from the reaction of pulyi~u~.; molecules, for example with low molecular weight diols, triols, dialkylene glycols, trialkylene glycols or polyu..y " ylcl~c glycols having molecular weights of up to 6000, in 30 particular having molecular weights of up to 1500, modified di~l..,l.,lhl",h~,.l"

4,4'-J;i~uc~ , modified ~ L~ ha, 4,4'- and 2~4~-diiauu~_ mixtures or modified crude MDI or toluylene 2,4- or 2~6-di;~u~.y , it being possible, for example, to use di- or polyoxyalkylene glycols h~diviJu~lly or as mixtures for the '~
s Suitable di- or polyuAydlkylcnc glycols are, for example, diethylene glycol, ~ UIU~J1ICII~ glycol, polyuA~,thylcu~" I)UIYUAY~JIUUYI~ C and POIYUAY~UIUIJYICIIC
POIYUA~-YI~ glycols, triols and/or tetrols. Also suitable are NCO-containing ~JIc~ulyl~ having NCO contents of from 25 to 3.5, preferably o from 21 to 14, % by weight, based on the total weight, prepared from tbe polyester polyols or preferably polyether polyols described below or mixtures thereof and ~i Y 4,4'-dii~ucy_ . mixtures of ~'i' ~' ' 2,4'- and 4,4'-dii~ucy , toluylene 2,4- and/or 2,6-dii~uc~ or crude MDI. Liquid polyi,u.,.y_ containing .,~uI,o.li;...ide groups and/or s isu~ rings and having NCO contents of from 33.6 to 15, preferably from 31 to 21, % by weight, based on the total weight, for example based on di~ llc 4,4'-, 2,4'- and/or 2,2'-di;~ucj. and/or toluylene 2,4'- and/or 2,6'-dii~uc~ . have also proven useful.

2~ The modified poly;~uuj_ can, if required, be mixed with one another or with unmodified organic pulyi~uc;_ ' . e.g. 'i,' ~' ' 2,4'-dii~u~,~ . I'i ' .y' ' 4~4~-dii~uc.y , crude MDI, toluylene 2,4-dii~u~,.y and/or toluylene 2,6-dii~u~

25 D;,uh~ e dii~uc~. ' isomer mixtures and crude MDI having a ~'i' .~' ' dii,u,; isomer content of from 33 to 55% by weight and polyi,u~,~ mixtures containing urethane groups and based on 'i,' .~h ' dii~uc~. having an NCO content of from 15 to 33% by weight have proven particularly useful.

3~

AJv " ly used high molecular weight compounds having at least two reactive hydrogen atoms (component E) are those having a filnr~inn~ity of from 2 to 8, preferably from 2 to 6, and a molecular weight of from 300 to 8000, preferably from 300 to 3000. For example, ,uul~ uulyalllil~.
s and/or, preferably, polyols selected from the group consisting of the pOI,~ ,.,uùly~JlS, pOI~ ul,~JlS, polyLlliu~ Julyuls~ pOI,~
hydroxyl-containing polyacetals and hydroxyl-containing aliphatic pol~ or mixtures of at least two of the stated polyols have proven useful. Pol~ l,uolyul3 and/or polyether polyols are preferably used. The 10 hydroxyl number of the pulyhyJluAy compounds is as a rule from 150 to 850, preferably from 200 to 600, mg KOH/g.

Suitable pul~tul~olyul~ can be prepared, for example, from organic di~,~buAyli~: acids of 2 to 12 carbon atoms, preferably aliphatic diu~l)uAyli(, 15 acids of 4 to 6 carbon atoms, and polyhydric alcohols, preferably diols, of 2 to 12, preferably 2 to 6, carbon atoms. Examples of suitable Ji~,~buAyliu acids are: succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, ~L~ )UAYI;I; acid, maleic acid, fumaric acid, phthalic acid, isophthalic acid and tul,l' ' ' acid. Instead of the 20 Ji~llbUAylil.; acids, it is also possible to use the .:u.l. r " " Jiu~lJuAyli~:
acid derivatives, for example Ji~buAyli~; esters of alcohols of I to 4 carbon atoms or dil,~ uAyliu anhydrides. Dicarboxylic acid mixtures comprising succinic, glutaric and adipic acid in weight ratios of, for example, 20 to 35: 35 to 50: 20 to 32 are preferably used, adipic acid ~5 being particularly preferably used. Examples of dihydric and polyhydric alcohols, in particular diols, are: ethanediol, diethylene glycol, 1,2- and 1,3 ,ulu,u...._diol, diylu,uylull~, glycol, 1,4-butanediol, 1,5-p~ :-1...l;nl 1,6-hexanediol, 1,10-decanediol, glycerol and ~hll~,Jljlul,u~u,u _. F~h~
diethylene glycol, 1,4-butanediol, I,S-prnr~n~liol, 1,6 k_Adl~Jiol or mixtures 30 of at least two of the stated diols are preferably used, in particular mixtures of 1,4-butanediol, 1,5-pentanediol and 1,6 h_A~Ieviul. roly~,~t~ ulyv6 obtained from lactones, for example from e-v~ulul~vLullc~ or from hydluAy~ uAyliL acids, for example from LL~-hYdIUAYC~IUIU;V acid, may also be used.
s For tbe preparation of the poly.,.tv.~olyuls, the organic, for example aromatic and preferably aliphatic, polyucul,uAylic acids and/or polyv~l,vAyliu acid derivatives and polyhydric alcohols can be subjected to uuly, ' '-in the absence of a catalyst or preferably in the presence of an~o c~.uliri.,,l~iull catalyst, adv _ '~, in an atmosphere comprising inert gas, such as nitrogen, carbon monoxide, helium, argon, etc., in the melt at from 150 to 250CC, preferably from 180 to 220~C, if required under reduced pressure, to the desired acid number, which is ddv g '.y less than 10, preferably less than 2. In a preferred ~ l~o~ the ~ ~t i~ l;'- mixture 15 is subjected to poly. ' at the ~I,u... ' tClll~Uvl~ to an acid number of from 80 to 30, preferably from 40 to 30, under I' pressure and ~ c~ Iy under a pressure of less than 500, preferably from 50 to 150, mbar. Examples of suitable c.,~.ir~ io catalysts are iron, cadmium, cobalt, lead, zinc, antimony, m~vnl-~i..rn ~o titanium and zinc catalysts in the form of metals, metal oxides or metal salts. However, the luuly~ ' can also be carried out in tbe liquid phase in the presence of diluents and/or entraining agents, e.g. benzene, toluene, xylene or vLlu~ub~ v, for removing the (.~.\ 1 ..- -~;.,.. water by azeotropic distillation.

For the preparation of the uuly~ uls, the organic pvlyv~lJuAylic acids and/or pulyc~buAyli~: acid derivatives and polyhydric alcohols are .dv v '~/ subjected to poly~ ' in a molar ratio of from 1:1 to 1:1.8, preferably from 1:1.5 to 1:2.

The pol~ ,ol~uls obtained preferably have a functionality of from 2 to 4, in particular from 2 to 3, and a molecular weight of from 480 to 3000, preferably from 600 to 2000, in particular from 600 to 1500.

5 ~owever, p~ui ' Iy used polyols are ~lul~lL~ Jolyub which are prepared by known processes, for example by anionic pO~ i~tiu.~ with alkali metal hydroxides, e.g. sodium hydroxide or potassium hydroxide, or alkali metal :' ' ' , e.g. sodium methylate, sodium ethylate, potassium ethylate or potassium i~u~lu~J1' , as catalysts and with the addition of at least one 10 initiator molecule which contains 2 to 8, preferably 2 to 6, reactive hydrogen atoms in bound form, or by cationic pOIylll~,li~liull with Lewis acids, such as antimony p.,ll~lllul;J~, boron trifluoride etherate, etc., or bleaching earths as catalysts, from one or more alkylene radicals.

15 Suitable alkylene oxides are, for example, i ' yd~urul_u, 1,3-propylene oxide, 1,2- and 2,3-butylene oxide, styrene oxide and preferably ethylene oxide and 1,2-propylene oxide. The alkylene oxides may be used indivi-dually, alternately in succession or as mixtures. ~xamples of suitable initiator molecules are: water, organic d;~bu.~ylic acids, such as succinic 20 acid, adipic acid, phthalic acid and terephthalic acid, aliphatic and aromatic, L ~ ' d or N-monoalkyl ' i, N,N-dialkyl s l~c~ihl~ d or N,N'-dialkyl ' ' diamines having I to 4 carbon atoms in the alkyl radical, such as I '' or monoalkyl- or dialkyl ' ' e~
di~ ', tli~ ,t~,. , 1,3-~1u~Jyl~ I- ;., 1,3- and 25 1,4-1,u,yl.. ,~.l;- ;., 1,2-, 1,3-, 1,4-, 1,5- and 1,6-1 ~1. .\.. I;AI.. ;''-, I' v' ' ;, 2,3-, 2,4- and 2,6-tuh.yl I;AIII;I and 4,4'-, 2,4'- and 2,2 -, ~ l~lo.

Other suitable initiator molecules are: r~' ~ , e.g. rlll .. ,1~",; N-30 ~ and N-~h~ , .li"lk~' e.g.

1' ' ' , N-methyl- and N e.~.yl~ -, and i e g 1,; :1 -- .~ -; ~, and ammonia Polyhydric, in particular dihydric and/or trihydric, alcohols, such as ethanediol, 1,2- and 1,3-~nu~ul~,diul, diethylene glycol, di~)lu,uylcll., glycol, 1,4-butanediol, 1,6 ~ 1, glycerol, s Llhll~,LhylOl~lu,u~ c, pell~.,ly;lllitul, sorbitol and sucrose, are preferably used A polyether alcohol or a mixture of polyether alcohols, which are obtainable from the u~.y,~ yLlLiull of sorbitol or sucrose or a mixture thereof, is ~o preferably used in the context of the present invention as a higher molecularweight compound having at least two hydrogen atoms reactive toward isocyanates (component E) for the preparation of the novel puly~l-cLlldllc The l~oly~ oly-Jls, preferably ~olyu-.yl~ul~luu~ ulyuls and 15 POIYUAY~)IU~UYI~ OIYU~ IYI~ UIYUIS~ have a functionality of, preferably, from 2 to 6, in particular from 2 to 4, and molecular weights of from 3û0 to 3000, preferably from 300 to 2000, in particular from 400 to 2000.
Suitable IJulyu~.ytc.l.~ ,;llyl~.lc glycols have a molecular weight of up to about 3500 Other suitable poly"Lh...~.olyul~ are polymer-modified puly"Lh~ Olyul~, preferably graft pUl~ OlyuL~ in particular those based on styrene and/or .I~,lylu..itlilc, which are prepared by in situ POIYUI~ LiUII of ~clylulliLI;I~,, styrene, or preferably mixtures of styrene and ...,,y' '~, for example in 25 a weight ratio of from 90:10 to 10:90, preferably from 70:30 to 30:70, in, adv _ '~" the ahU.~ " ' PUI~LII~ OIYUIS~ similarly to German Patents 11,394, 1,222,669 (US 3,304,273, 3,383,351 and 3,523,093), 1,152,536 (GB 1,040,452) and 1,152,537 (GB 987,618), and puly.,~ olyul dispersions which contain, as the disperse phase, usually in an amount of 30 from I to 50, preferably from 2 to 25, % by weight, for example . _ - z2 -polyureas, polyh.~id~,~, tert-amino-containing poly.~.cll._...,~ or melamine or mixtures of two or more thereof and which are described, for example, in EP-B 011 752 (US 4,304,708), US-A-4 374 209 and DE-A-32 31 497.

s Like the pvly~.~t~ July-ls, the poly.lh~ ,olyuls may be used individually or in the form of mixtures. They may also be mixed with the graft pul.~ olyul~ or poly"~",.l,ulyuls and with tbe hydroxyl-containing pol.~ ;A-'. polyacetals, pc~lyc~ and/or puly~,~h.,l~Ok~ iu.,~.

o Examples of suitable hydroxyl-containing polyacetals are the compounds which can be prepared from glycols, such as diethylene glycol, triethylene glycol, 4,4'-vil..~u~y~ w~ydi~ ,.llyllll~,.h.ul~, hexanediol and formal-dehyde. Suitable polyacetals can also be prepared by poly of cyclic acetals.

Suitable hydroxyl-containing poly~ are those of the type known per se, which can be prepared, for example, by reacting diols, such as 1,3-alleliul, 1,4-butanediol or 1,6-hexanediol, diethylene glycol, triethylene glycol or t~ lyh,ll~, glycol, or mixtures of two or more thereof, with zo diaryl carbonates, e.g. diphenyl carbonate, or phosgene.

The poly. ~ include, for example, the l~lcdom;~ ly linear obtained from polybasic, saturated or unsaturated carboxylic acids or anhydrides thereof or mixtures of two or more thereof and 25 polyhydric saturated or unsaturated ~min~l ' ' or mixtures of polyhydric alcohols and ' ' '~ or poly ~ , or mixtures of two or more of the stated compounds and mixtures.

Suitable l)ul.~ Jol~ can be prepared from the <Ibu,.
30 puly~,dl~ Olyu15 by known processes. The ~,.y~v~lkyl~iul~ of , _ .

polyoxyalkyl~ ,vlyul, and subsequent L~Lub ~Liull of the resulting nitrile (US 3 267 û50 9) or the partial or complete amination of polyu,.~lkyl~,...,-polyols with amines or ammonia in the presence of hydrogen and catalysts (DE 1,215,373) may be mentioned by way of example.

In a preferred ~ ' ' of the invention, polyols which have four or more hydroxyl groups are used at least IJ~U~JUli' ' Iy for the preparation of the pOl~,Lh~,a.

o Suitable novel, ~ . containing ll~l.. ,~ uùrlLg agents are in principle dialkyl L~u~ ' .' .' of the formula I

p2 o / CH
R1--o where Rl and R2, '. ' '~, of one another, are each a linear or branched, I ' ' or halogen- or hydroxyl ' ' Cl-C10-alkyl radical or C6-CI6-aryl or C7-CI4-benzyl radical and R3 is hydrogen or a linear or branched Cl-C10-alkyl radical or a C6-CI3-aryl, C7-CI4-benzyl or furfuryl radical.
~5 In particular, these are compounds which were prepared with the aid of the novel process.

In the context of the present invention, preferred compounds of the formula 1 are those in which Rl and R2,; ~ ly of one another, are each a linear Cl-C6-alkyl radical and R3 is a hydrogen or a linear Cl-C6-alkyl radical. It is particularly preferred if Rl and R2, ~ ly of one another, are each a linear Cl-C3-alkyl radical and R3 is hydrogen or a linear Cl-C4-alkyl radical.

The novel polyul~ ' foams can be prepared in the presence or absence of chain extenders or Ull ' ' ,, agents or mixtures thereof. However, the addition of chain extenders, Cl~ agents or, if required, mixtures thereof may prove adv ~ in modifying the mechanical properties, for o example the hardness.

For example, diols or triols having molecular weights of less than 400, preferably from about 60 to about 300, or mixtures of two or more thereof, are used as chain extenders or w~ agents. For example, 15 aliphatic, uy~,lu~ Jllali~; or araliphatic diols or mixtures of two or more thereof having 2 to 14, preferably 4 to 10, carbon atoms, e.g. ethylene glycol, 1,3-1~1u~ iol, l,10-decanediol, o-, m- and p-dilly~uAy1y~.1ùLc~ c, diethylene glycol, dipropylene glycol and preferably 1,4-butanediol, 1,6-hexanediol and bis(2-L~J~uA~ yl)lly~L~, , triols, such as 1,2,4- and 20 1,3,5-11illydluAy~.y~.lullc~.~.. ~, glycerol and IlLlu,iLyLJl~Jlu~J,.~, and low molecular weight hydroxyl-containing pOlyaLk.~l.,..~, oxides based on etbylene oxide or 1,2-propylene oxide or mixtures tbereof, and the ,.I,u.
diols or triols, or mixtures thereof, are suitable as initiator molecules.

25 If the preparation of the pol~.clll~lc foams is carried out using chain extenders, ulu~ t, agents or mixtures tbereof, these are adv~l~6.,~,..1y used in an amount of from 0 to 20, preferably from 1 to 8, % by weight, based on the weight of tbe component E.

30 The chlululluuluc~l~u... (CFCs) generally known from P~JIYUICIL~

chemistry and highly fluorinated and/or p~.nuV~ ' Lydlu~uLù~ may be used as blowing agents. However, for ecological reasons the use of these substances is greatly restricted or has been completely stopped. In addition to the HCFCs and the HFCs, low-boiling organic liquids, in particular 5 aliphatic or .,y.,loali~L~, hyLu~,culJu.." in particular pentane and cyclo-hexane, or acetals, e.g. methylal, or mixtures of two or more thereof, are possible alternative blowing agents.

These physical blowing agents are usually added to the polyol component of o the system. However, they may also be added in the isocyanate component or as a ~,uulb ' of both the polyol component and the isocyanate c -They may also be used, together with highly fluorinated or p~,llLJ.
15 Lydlul"ul)u~ or mixtures thereof, in the form of an emulsion of the polyol connrf~n~n~ Where they are used, the emulsifiers employed are usually oligomeric acrylates which contain pulyw~y,llkyl~, and '' , " radicals bonded as pendent groups and have a fluorine content of from about 5 to 30% by weight. Such products are sufficiently well known from plastics 20 chemistry, e.g. EP-A-0 351 614.

The amount of the blowing agent or of the blowing agent mixture used is from I to 25, preferably from 1 to 15, % by weight, based in each case on the component E.
~5 It is also possible and customary to add water in an amount of from 0.5 to 15, preferably from I to 5, % by weight, based on the component E, as a blowing agent to the component E. The addition of water may be effected in cu,ul,u~liu.. with the use of the other blowing agents described.

.26 -Catalysts used for the preparation of the novel POIY~ foams are the catalysts customary in pol~ ' chemistry. Particularly used compounds are those which greatly accelerate the reaction of the compounds of the C----r E and, if required, F, containing rcactive hydrogen atoms, in s particular hydroxyl groups, with the unmodified or modified organic isocyanates (component D). Organic metal cnmrolln~lC such as iron(ll) chloride, zinc chloride, lead octanoate and preferably organotin rnmrou~ c~
such as tin(ll) salts of organic carboxylic acids, e.g. tin(ll) acetate, tin(ll)octanoate, tin(ll) cllly" and tin(ll) laurate, and dialkyltin(lV) salts 10 of organic carboxylic acids, e.g. dibutyltin diacetate, dibutyltin dilaurate,dibutyltin maleate and dioctyltin diacetate, are suitable. The organic metal compounds are used alone or, preferably, in Culllb;ll~ltiull with strong basic amines. Examples are amidines, such as 2,3-dimethyl-3,4,5,6-t~ Lyd~u,uylilllidill~i, tertiary amines, such as ~ hyLIlill." LliL ~
15 ~'' '' y~ llLyl~llilD~, N-methyl-, N-ethyl- and N-~,yC ~ yh ..I.I,nli....
N,N,N',N'~."I~ul,~Lyl.,lly' " , N,N,N',N'.~,..~Il.,l,y'' N,N,N',N' .~ u"~,;llyl-1,6-1 " , p.,~t~...._Lllyl~ ,llylcll~t~i~ullil~
tetramethyldiaminoethyl ether, bis(dimethylimidazole), 1-azabicyclo[3.3.0]octane and preferably 1,4-.li~l,i"y~,1O[2.2.2]octarle, and 20 alkanol cnmroml~lc~ such as Ll h 1~ u~l,r ' , N-methyl-and N-c~hyl~ i and ~ ' ' ' , or mixtures of two or more thereof. Other suitable catalysts are: tris(,' " yl~lllh~ lkyl)-s-' ydluLIi~ill~,~, in particular tris(N,N-dill~llyL.,Iliu~,lu~ yl)-s-hexahydro-triazine, tetraalhy' hydroxides, such as t~,; ' ~' 25 hydroxide, alkali metal hydroxides, such as sodium hydroxide, and alkali metal r~ ', such as sodium methylate and potassium i~U~JlU~/y' , and alkali metal salts of fatty acids having I to 20 carbon atoms and, if required, pendent OH groups, for example potassium formate, potassium acetate and potassium 2-clhy" , or mixtures of two or more thereof.

From 0.001 to 5, in particular from 0.05 to 2, % by weight, based on the weight of the component E, of a catalyst or catalyst, ' are preferably used.

5 Further assistants or additives or mixtures thereof may, if required, also be ~ x~, ' into the reaction mixture for the preparation of the pol~u., ' foams. Examples are surfactants, foam stabilizers, cell regulators, fillers, dyes and pigments.
~o Examples of suitable surfactants are compounds which serve for assisting the of the starting materials and may also be suitable for regulating the cell structure of the plastics. Examples are; ' - , such as the sodium salts of castor oil sulfates or of the fatty acids and salts or fatty acids with amines, for example the salt of d;~LIIYL~ with oleic 15 acid, the salt of .li. ~ with stearic acid or the salt of diethanol-amine with ricinoleic acid, salts of sulfonic acids, for example alkali metal or ammonium salts of dodLv.yll-vll4~ or ' I' '.Y' ' " '' acid and ricinoleic acid, foam stabilizers, such as ~;lu~ lvv~ .llcylene copolymers and other UI~S~IU~JVIY ' , w~,lly' ' ahk~l~' ' u,.~vh.1' ' fatty ~o alcohols, liquid paraffins, castor oil esters or ricinoleic acid esters, Turkey red oil and peanut oil, and cell regulators, such as paraffins, fatty alcohols and di.llvLh.11uuly~;1u~. ~,. r, Lh~ the oligomeric acrylates described above and having pol~w~lkylL.lv and A U~ . radicals as pendent groups are suitable for improving the ' '~ v effect, the cell structure 25 and the foam ' ' The surfactants are usually used in amounts of from 0.01 to 5 parts by weight, based on 100 parts by weight of component E.

Fillers, in particular fillers having a reinforcing effect, are to be understoodas meaning the vUIl~ organic and inorganic fillers, reinforcing agents, weighting materials, materials for improving the abrasion behavior in surface coatings, coating materials, etc. which are known per se. Specific examples are: inorganic fillers, such as silicate minerals, for example sheet silicates, such as antigorite, serpentine, hnrnhlPn~P, qmphih~lPc, chrysotile and talc, s metal oxides, such as kaolin, aluminas, titanium oxides and iron oxides, metal salts, such as chalk and barite, and inorganic pigments, such as potas-sium sulfide and zinc sulfide, and glass, etc. Kaolin (china clay), aluminum silicate and Wylcc;y of barium sulfate and aluminum silicate and natural and synthetic fibrous materials, such as wollastonite, metal fibers in o particular glass fibers of different lengths, which may or may not have been sized, are preferably used. Examples of suitable organic fillers are: carbon, rosin, ~,y~ y~ . " ~ 1 resins and graft polymers and cellulose fibers, polyamide, yuly.l~,lylull;L~ " pol~. cLl.~u.c and polyester fibers based on aromatic and/or aliphatic d;c~ul)u~yliu esters and in particular carbon fibers.

The inorganic and organic filler may be used individually or as a mixture of two or more of the stated substances and are h~,u~yl ' into the reaction mixture dd~ / in amounts of from 0.5 to 50, preferably from I to 40, % by weight, based on the weight of the ~ D to 20 F, but the content of mats, nonwovens and woven fabrics of natural and synthetic fibers may reach values of up to 80% by weight.

More detailed inf~rmq~ n on the ~IhU._Ill.,llL;U.l.,d other col~.,ll.;ulldl assistants and additives are to be found in the technical literature, for ~5 example the monograph by J.H. Saunders and K.C.Frish, High Polymers, Volume XVI, Poly,.l, ' , Parts I and 2, 1 Publishers 1962 and 1964, ~c~y~,~,Li~,ly, or K Polyul, , Volume Vll, Hanser-Verlag Munich, Vienna, 1st, 2nd and 3rd editions, 1966, 1983 and 1993.

For the preparation of the pvlyu~ foams, the organic, unmodified or modifled isocyanates (! . D), higher molecular weight compounds having at least two reactive hydrogen atoms (component E) and, if required, chain extenders or Ul~ ' ' ,, agents (g) are reacted in arnounts such that 5 the ratio of the number of equivalents of NCO groups of the isocyanates (. . D) to the sum of the reactive hydrogen atoms of C~
E and F is from 0.80:1 to 1.25:1, preferably from 0.90:1 to 1.15:1.

It is preferred if polyols which have a f~ iuu~llity of at least 3, preferably o of at least 4, are present in the preparation of the novel pvlyul~Lllauc;
foams. The presence of l/uly. ' . '~,uls based on sorbitol andtor sucrose and alkylene oxides is ~uLiuuLly preferred. It has also been found that the foam rvl-l~uLI~iu..s for the preparation of ILu~ nuur~d pûlyulGlLauc foams have .ldv processing properties if their l,lu~alL~illg index Ic Of all s compounds having hydrogen atoms reactive toward iav~.y ', including the novel Ik~ luurll.D agent, is at least 3Ø

The present invention therefore also relates to a process for the preparation of pvlyuu~ ul~,a by reacting at least three r ' D, E and F, d) an organic pulyi~ul,;. being used as component D and e) a higher molecular weight compound having at least two functional groups which are reactive toward isocyanates and carry hydrogen atoms being used as component E and ~5 f) a diaLkyl LY~UAY " ,' .' of the formula I being used as component F.

In the context of the present invention, the wua~liull!iu~ index is understood as meaning a ' ' index which describes the ulu~alil~illg capability 30 of the totality of all compounds which carry hydrogen atoms capable of .

reacting with isocyanate c . The ~ ~ ' ' v index Ic is calculated according to the following formula:

(m;Zfi + m2Z2f2 + ... + m;Z, f") (m;Zl + m2Z2 + ... + m;Z") where the individual symbols have the following meanings:

c .,lu~ index, ~o mi = ml; m2; ..- mn mass fractions of all compounds which have groups carrying hydrogen atoms capable of reacting with the isocyanate ~ r t~

Zi = Zl; Z2; Zn hydroxyl numbers of all compounds which have groups carrying hydrogen atoms capable of reacting with the isocyanate r t, fi = fl; f2; ~-- fn r - ~-- of all compounds which have groups carrying hydrogen atoms capable of reacting with the isocyanate component.

The pol~ulc~c foams are ad~ ,, 1y prepared by the one-shot process, for example with the aid of high-pressure or low-pressure technology in open or closed molds, for example metallic molds. The 25 continuous application of the reaction mixture to suitable belts for the production of foam blocks is also customary.

The novel PUJ~ foams have a density of from 10 to 800, preferably from 35 to 100, in particular from 25 to 80, kg/m3. The novel flexible ~ul~ .' foams are particularly suitable as upholstery material in the furniture and automotive sectors, in particular for the production of vehicle 5 seats. They can also be used as flexible sealing material in the building industry With cull. r ' _'y higher densities, they may also be used as integral foam parts in the vehicle safety sector. The novel rigid pulyull ' foams are preferably used as ~ u~lion materials and in particular as cu..~u~iùn materials having heat ' _ prûperties.

The present invention therefore also relates to the use of a novel ~ul~u.~ , or of a pol~ lLu.., which is prepared by a novel process as an insulating material, upholstery material, flexible sealing material or inte-gral foam.

The content, preferred according to the invention, of L' ,' of the formula I is from about 0.1 to about 30, preferably from about I to about 15, particularly preferably from about 2 to about 8, % by weight, based on the total pol ~ ~, Preferably used 1' .'of the formula I are dimethyl 1-L~Lu~.~ ' .' .', dimethyl l-L~Lw~, ' .' .' , dimethyl I~LYd~UAY~U~', dimethyl l-Lyd~u~.y; . ' , ' , diethyl l-Lyd~u~.~, ' .' .'and diethyl l-Lydlu~.~ ' .' .' In a further preferred' ' of the invention, at least one further liquid or solid n~.l.,"., ~_ agent or a mixture thereof is additionally present in the reaction.

30 Liquid ~ . uurlllg agents which may be present are, for example, dimethyl I ' ,' .' , diethyl ' .' .' , triethyl phosphate, tributyl phosphate, i ' y~ yl phosphate, triphenyl phosphate dissolved in triethyl phosphate, diphenyl cresyl phosphate, resorcinol l~;ob~' yl phosphate, tris(2-l.yd.uAy~..u,uyl) phosphate, tris(S-hydroxy-3-oxapentyl) 5 phosphate, tris(5-hydroxy-2,5-dimethyl-3-oxapentyl)phosphate, tris(2-l.yd,uAy,u,uuyl) phosphite, tris(5-hydroxy-3-oxapentyl) phosphite, tris(5-hydroxy-2,5-dimethyl-3-oxapentyl) phosphite, pentakis(.li~,.u,u;lc.lc glycol) di, ' . ' , h~ p~ iC(d.l u~,yll,.~ glycol) i . ' . ' , pentakis(.li,u.u~.yl.,~
glycol) ~ 'i ' . ' , hPpt~l~ic(~ u~uyl~u~ glycol) i . ' . ' , tris(2-o chloroethyl) phosphite, N,N-bis(2 h,yd~UA~ ' '' diethyl phosphite, N,N-bis(2-l.y~uAyulu~,yl) ~ ' diethyl phosphite, alkoxylation products of phosphoric acid, poly~llu~Jhuliu acids and 1' .' u..O acid, ethylene oxide or propylene oxide or butylene oxide or a mixture of two or more thereof preferably being used as " yl.~
15 agents; tris(2-chloropropyl) phosphate, tris(2,3-~' '' ulJ~uy,~l) phosphate, tetrakis(2-chloroethyl) ethylene di,' .' , dissolved ~lil,l~ . ~.yl glycol and its reaction products, dissolved ilil,l~ . .;yl alcohol and its reaction products, dissolved dil,l~ ~ ' ' and its reaction products, dissolved 2,3-dil/1ulllu~lu~dllol and its reaction products, dissolved 20 tu~dl,l~ .' ' ' anhydride and its reaction products, dissolved tclldblulllulJ'.' ' A and its reaction products, dissolved i~iblullw~ ol and its reaction products, bromine-containing phosphoric esters and gf ' Ly~LucdllJu..., N,N',N"-hexa(2-hyd.uA~ yl) ' , N,N',N''-hexa(2-hydroxypropyl)melamine, N,N',N''-hexa(5-hydroxy-3-25 oxapentyl)melamine and hr-~( ' y ' yl)mclamine and mixtures of two or more of the stated rnmro~n"C

Solid llal.~ luuGI~g agents which may be present are, for example, ammonium phosphate, ammonium polyl' .' , ' ' hydrogen 30 phosphate, ammonium dihydrogen phosphate, phospham, melamine, melamine cyanurate, melamine phosphate, melamine ~1".' .' , melamine borate, melamine barbiturate, tris(L~LuA~,dl~l) cyanurate, aluminum trihydrate, magnesium hydroxide, graphite, expanded graphite, calcium borate, barium borate, zinc borate, zinc h~uA~ , natural and modifled starches, 5 cellulose, lignin, zeolite, bentonite, guanidine carbonate, guanidine barbiturate, magnesium carbonate, L~ulll~ , or huntite, and mixtures of two or more thereof The present invention also relates to the use of a dialkyl 10 IIYdlUA~ " .' .' ' of the formula I as a ILu~ luur~llg agent in pOI~ LLall~,.

The examples which follow illustrate the invention.

15 Examples Svnthesis of dirnethvl 1 h..' ~

110 g of dimethyl phosphite and 30 g of ~ar~ '''yd~, were initially 20 taken in succession in 1 liter standard reaction apparatus comprising a four-necked flask, reflux condenser, a dropping funnel and a KPG stirrer and were heated to 35~C. Thereafter, 4.15 g of Lli.,L~' were added and the t~,UI,u~ Ul~ of the reaction mixture was increased to 135~C. This t~ IC was maintained for three minutes. Thereafter, the batch was 25 cooled as rapidly as possible (within from about 2 to about 10 minutes) to 37~C and was stirred for from about 10 to about 30 minutes at this t~ L~.c. The reaction mixture was then subjected to a distillation at 50~C and 0.5 mbar to remove readily volatile byproducts.

30 The dimethyl l-LyLuA~ ' .' .' obtained in a yield of 97% had an OH number of 382 mg KOH/g, a P content of 22.1% and a viscosity of 20 mPas at 25~C.

2. Examples of the use of the novel 1' ,' as na.~ ,.uurlt a~ents in ~,ul~u., ' F,l,l,.,.-l;.,.. for the examples/~ , examples:

Polyol 1: polyether alcohol based on sucrose, glycerol and propylene o oxide (OH number 402) Polyol 2: polyether alcohol based on sucrose, glycerol and propylene oxide (OH number 490) ~5 Polyol 3: polyester alcohol based on phthalic anhydride and diethylene glycol Polyol 4: polyether alcohol based on sorbitol, propylene glycol and propylene oxide Polyol 5: polyether alcohol based on sorbitol, water and propylene oxide Fl~uur~ agent 1: chlorine- and bromine-containing polyether alcohol (Ixol B251 from Solvay) Fl~agent 2: tris(~,LIu.u~,lul,~l) phosphate r~. uurug agent 3: diethyl N,N-bis(2-hydroxyethyl)-.. . .

Fl . u,' agent 4: diphenyl cresyl phosphate Fl.~ uurlllD agent 5: ammonium polyl' .' s Foam stabili~er 1: ulD ..u~ili.,ull-based surfactant (Tegostab B 8466 from Gf'' ' '~

Isocyanate 1: crude 'i' ~' ' d;ii~ul,~ (NCO
content 31.1 %) Examples I and 2 and Comparison 1:

These examples are intended to ' the ad.. " effect of the novel r~ .~ on the fire behavior and the curing in comparison with fla.ll~,"luur...D agent 3, which ~,Ullt~JUlld:~ to the prior art at present.

From the amounts stated in Table I below, 1000 g of polyol component were mixed in each case. The rigid foam was prepared by mixing portions of the polyol component with the blowing agent and the isocyanate in the ratio stated in Table 1. The test specimens for the small burner test according to DIN 4102 were prepared by expanding 500 g of reaction mixture in an aluminum mold measuring 20 cm x 20 cm x 20 cm. The fire behavior was tested 24 hours after preparation. The curing was deter-mined from 80 g of a free-rising reaction mixture in a I I beaker. For this 2s purpose, a steel bolt was pressed 10 mm deep into the curing foam surface 6 minutes after the beginning of mixing and the force required for this purpose was measured.

- _ ~o oo o. o o ~ ~ g oo o ~ o o, o, o, ~ o V~ o~ g ~ o ~ . ~ o ~ ~. ~o o V~ o~ ~ ~o E ,~, ~ CG r~ ~ ~ ~ ~ ~ o ~ ~ ~ o ~ o o o o D
O ~ O O 1~ ~
~ ~, ~~ ~ X ~o I

1~ ~ X

--~ ~ D ~P
~ o ~ :~ cn D~ ~ ~. P a L ~ ~ :LI ~ ~; ~

Examples 3 and 4:

These examples ' the effect of various novel l' .' in c ' with the solid A I Ul~- _ agent ammonium pol~
5 The ' ' used and results are listed in Table 2. The procedure was as in Examples I and 2. The curing was not rlr~ rrl in~

Table 2 Hydroxyl number Example 3 Example 4 Polyol 1 402 33.0 33.0 Polyol 2 490 10.0 10.0 Diethyl l-h~d~U~ 311 18.0 1' Diethyl l-hyd~u~ ,- 265 18.0 I . . .
Fl . uurl.lg agent 4 5.0 5.0 Fl . u~ _ agent 5 1805 29.0 29.0 Foam stabilizer 1 2.0 2.0 D '.yh,.y~ ,l~ine 1.4 1.4 Water 6230 1.6 1.6 Total 100.0 100.0 C~,lu~ e blowing agent 5.0 5.0 NCO [%]
Isocyanate 1 31.1 100 100 Fire behavior according to B 2 B 2 Flame height in cm 11.4 12.1 Examples S to 7:

These examples ~'~~~ the effect of the w~ ' ' ,, index lC on the processing properties.

From the amounts stated in Table 3 below, 200 kg of polyol component were mixed in each case. The rigid foam was prepared on a 12 m twin conveyor belt line by processing the polyol component with the blowing agent and the isocyar,ate.

Blocks having a thickness of 150 mm were produced. To assess the test results, the curing on leaving the twin conveyor belt and the . b3il~
to tearing after the blocks had been cut to length are observed.
F~ I c, the fire behavior of the rigid foam is tested according to DIN
S 4102. The results are iL~,d in Table 3 below.

.

o O ~ V. O O 1~ ~ ~~ O ~ ' î m "' ~' o o. ~ ~. ~ o O ~0- v~ ~ O oo ~ m ~ ~~

~ O O .t ~~o O V~ ~

c 1~ o ~ ~' J ~t V) ~ o~o ~ o o , C C j ~ O

~ , z _ -- -- -- g ' ~ ' ~ ' ~ C :g 8 8 -~ ~ ~ o ~ ~ ~ o ~ 2 ~ C

t-- ' C X ~o ~~
:C g .g E ~ ~ ~ o o 6 -- ~ _ 8 c . 4~

E ~
C ~
~ ~ o E ~ ~
C ~ o _ ,o c ~

C
o 2 ~ ~,

Claims (12)

1. A process for the preparation of dialkyl hydroxyalkanephosphonates of the formula I

where R1 and R2, independently of one another, are each a linear or branched, unsubstituted or halogen- or hydroxyl-substituted C1-C10-alkyl radical or C6-C13-aryl or C7-C14-benzyl radical and R3 is hydrogen or a linear or branched C1-C10-alkyl radical or a C6-C13-aryl, C7-C14-benzyl or furfuryl radical, in which a reaction mixture containing a) a phosphonate of the formula II

where R1 and R2, independently of one another, are each a linear or branched, unsubstituted or halogen- or hydroxyl-substituted C1-C10-alkyl radical or C6-C13-aryl or C7-C14-benzyl radical, as component A, and b) an aldehyde of the formula III

where R3 is hydrogen or a linear or branched C1-C10-alkyl radical or a C6-C13-aryl, C7-C14-benzyl or furfuryl radical, as component B, is reacted together with c) a basic catalyst, as component C, wherein a mixture of the components A and B and C is brought to a temperature of from 20 to 60°C, or a mixture of the components A and B or a mixture of the components A and C is brought to a temperature of from 20 to 60°C, the missing component B or C in each case being added after the temperature of from 20 to 60°C has been reached, and the temperature of the reaction mixture is then brought to a value of from about 61 to 300°C for from 1 to 30 minutes.

2. A process as claimed in claim 1, wherein dimethyl phosphonate or diethyl phosphonate or a mixture thereof is used as component A.

3. A process as claimed in claim 1 or 2, wherein formaldehyde, paraformaldehyde, acetaldehyde, propionaldehyde, butraldehyde, benzaldhyde, or furfural or a mixture of two or more thereof is used as component B.

4. A process as claimed in any of the preceding claims, wherein triethylamine or N,N-dimethylcyclohexylamine or a mixture thereof is used as component C.

5. A process as claimed in any of the preceding claims, wherein the component C is contained in the reaction mixture in an amount of from 0.1 to 5% by weight.

6. A polyurethane which contains a dialkyl hydroxyalkanephosphonate of the formula I.

7. A polyurethane as claimed in claim 6, wherein the totality of all compounds used for the preparation of the polyurethane and having hydrogen atoms reactive toward isocyanates has a crosslinking index I c of at least 3.

8. A polyurethane obtainable by reacting at least three components D, E
and F, d) an organic polyisocyanate being used as component D and e) a higher molecular weight compound having at least two functional groups which are reactive toward isocyanates and carry hydrogen atoms being used as component E and f) a dialkyl hydroxyalkanephosphonate of the formula I being used as component F.

9. A polyurethane as claimed in claim 8, wherein a polyether alcohol or a mixture of polyether alcohols, which were initiated with sorbitol or sucrose or a mixture thereof, is used as component E for the preparation of the novel polyurethane.

10. A process for the preparation of polyurethanes by reacting at least three components D, E and F, d) an organic polyisocyanate being used as component D and e) a higher molecular weight compound having at least two functional groups which are reactive toward isocyanates and carry hydrogen atoms being used as component E and f) a dialkyl hydroxyalkanephosphonate of the formula I being used as component F.

11. The use of at least one polyurethane as claimed in any of claims 6 to 9 or prepared as claimed in claim 10 as an insulating material, upholstery material, flexible sealing material or integral foam.

12. The use of at least one dialkyl hydroxyalkanephosphonate of the formula I as a flameproofing agent in polyurethanes.