CN102428116B - 制备硬质聚氨酯泡沫材料的方法 - Google Patents
制备硬质聚氨酯泡沫材料的方法 Download PDFInfo
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- CN102428116B CN102428116B CN201080021548.4A CN201080021548A CN102428116B CN 102428116 B CN102428116 B CN 102428116B CN 201080021548 A CN201080021548 A CN 201080021548A CN 102428116 B CN102428116 B CN 102428116B
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Abstract
本发明涉及一种制备硬质聚氨酯泡沫材料的方法，其中以下物质的混合物用作组分：一种或多种高官能度聚醚醇，其具有(3.5)-(5.5)的官能度和(350)-(550)mg KOH/g的羟值；一种或多种基于脂族和/或芳族胺的聚醚醇，其具有(3)-(4)的官能度和(150)-(800)mg KOH/g的羟值；含羟基的脂肪酸酯；和任选地一种或多种低分子量扩链剂和/或交联剂，其具有(2)-(3)的官能度和小于(400)g/mol的分子量Mw。所获得的硬质聚氨酯泡沫材料的特征是具有优异的表面性能。
Description
本发明涉及一种制备硬质聚氨酯泡沫材料的方法。
长期以来已经知道并广泛描述了硬质聚氨酯泡沫材料。硬质聚氨酯泡沫材料主要用于隔热，例如在冷冻设备、运输工具或建筑物中，和用于生产结构元件，尤其是夹心元件。
硬质聚氨酯泡沫材料的重要应用领域是复合材料元件。目前在大规模上实施了在连续操作型双带装置上生产复合材料元件的工艺，复合材料元件尤其由金属覆盖层和泡沫材料芯组成，泡沫材料芯是基于异氰酸酯，通常是聚氨酯(PUR)或聚异氰酸酯(PIR)泡沫材料，通常也称为夹心元件。除了用于冷冻室隔绝的夹心元件之外，具有着色的覆盖层的元件也对于各种建筑物表面结构而言越来越重要。除了涂覆的钢片之外，不锈钢片、铜片或铝片用作覆盖层。
重要的是硬质聚氨酯泡沫材料均匀地填充中空空间且没有空隙，使得与覆盖层之间的极好粘合能获得稳定的结构，确保优良的隔热。为了防止泡沫材料缺陷，必须在短时间内将可发泡的PU反应混合物引入要隔绝的中空空间。低压或优选高压机器通常用于用泡沫材料填充这种制品。
关于制备硬质聚氨酯泡沫材料的方法以及它们作为在复合材料元件中的覆盖层或芯层的用途以及它们在冷冻或加热工程中作为隔绝层的用途可以参见例如“聚氨酯”，Kunststoff-Handbuch，第7卷，第3版1993，编辑Dr.Günter Oertel，Carl-Hanser-Verlag，Munich/Vienna。
合适的硬质聚氨酯泡沫材料可以按照公知的方法通过有机多异氰酸酯与一种或多种具有至少两个活泼氢原子的化合物在发泡剂、催化剂和任选助剂和/或添加剂的存在下反应获得。
作为具有至少两个对异氰酸酯有活性的氢原子的化合物，优选使用聚醚醇和/或聚酯醇来制备聚氨酯。多元醇的选择尤其是基于成本和所需的使用性能(例如EP-A-1632511、US-B-6495722、WO 2006/108833)。
EP-A-728783描述了一种制备硬质聚氨酯泡沫材料的方法，其中使有机多异氰酸酯与至少三种不同的具有不同官能度的较高分子量聚醚醇b1)至b3)与含羟基的脂肪酸酯b4)(8-20重量份)、尤其是蓖麻油在发泡剂和催化剂的存在下反应。按照20-60重量份比例存在的聚醚醇b1)具有6-8的官能度和125-200的平均当量质量。按照5-30重量份比例存在的聚醚醇b2)是基于脂族胺并具有3-4的官能度和70-130的平均当量质量。按照3-25重量份比例存在的聚醚醇b3)具有2-3的官能度和67-250的平均当量质量。多元醇组分优选具有350-390mg KOH/g的平均羟值。
公知的硬质聚氨酯泡沫材料的表面性能仍然需要改进，尤其是在复合材料元件的生产中，这是因为这些性能对覆盖层与泡沫材料之间的粘合性有显著影响。在通过喷雾泡沫工艺生产泡沫材料的过程中，优良的表面是十分重要的。
本发明的目的是开发一种制备硬质聚氨酯泡沫材料的方法，此方法能获得具有改进的粘合性和表面质量的泡沫材料，并且其多元醇组分具有低粘度和进而具有优良的加工性能，尤其是具有优良的流动性和固化性能。
惊奇的是，此目的能通过一种制备硬质聚氨酯泡沫材料的方法实现，其中以下物质的混合物用作多元醇组分：
一种或多种高官能度聚醚醇，其具有3.5-5.5的官能度和350-550mgKOH/g的羟值，
一种或多种基于脂族和/或芳族胺的聚醚醇，其具有3-4的官能度和150-800mg KOH/g的羟值，
含羟基的脂肪酸酯，和
任选地一种或多种低分子量扩链剂和/或交联剂，其具有2-3的官能度和小于400g/mol的分子量Mw。
本发明提供一种制备硬质聚氨酯泡沫材料的方法，其中：
a)有机多异氰酸酯与
b)具有至少两个对异氰酸酯基团有活性的氢原子的化合物在以下物质的存在下反应：
c)发泡剂，
d)催化剂，和
任选地e)助剂和添加剂，
其中以下物质的混合物用作组分b)：
b1)一种或多种高官能度聚醚醇，其具有3.5-5.5的官能度和350-550mgKOH/g的羟值，
b2)一种或多种基于脂族和/或芳族胺的聚醚醇，其具有3-4的官能度和150-800mg KOH/g的羟值，
b3)至少一种含羟基的脂肪酸酯，和
任选地b4)一种或多种低分子量扩链剂和/或交联剂，其具有2-3的官能度和小于400g/mol的分子量Mw。
多元醇组分b)也可以包含催化剂、稳定剂以及常规的助剂和添加剂。
本发明还提供通过本发明方法制备的硬质聚氨酯泡沫材料。
在一个特别有利的实施方案中，多元醇组分(b)包含以下物质的混合物：
b1)20-70重量份、尤其20-60重量份的一种或多种高官能度聚醚醇，其具有3.5-5.5的官能度和350-550mg KOH/g的羟值，
b2)5-30重量份、尤其5-25重量份的一种或多种基于脂族和/或芳族胺的聚醚醇，其具有3-4的官能度和150-800mg KOH/g的羟值，
b3)5-30重量份、尤其5-20重量份的含羟基的脂肪酸酯，和
任选地b4)1-20重量份、尤其2-10重量份的一种或多种低分子量扩链剂和/或交联剂，其具有2-3的官能度和小于400g/mol的分子量Mw。
作为甘油和含羟基的脂肪酸的酯b3)，特别优选使用蓖麻油。
根据本发明使用的多元醇组分b)优选具有300-600mg KOH/g的平均羟值，尤其是400-550mg KOH/g。羟值是按照DIN 53240检测的。
关于在本发明方法中使用的各组分，可以参见以下描述：
a)可能的有机多异氰酸酯是本身已知的脂族、脂环族、芳脂族和优选芳族的多官能异氰酸酯。
具体例子是：在亚烷基中具有4-12碳原子的亚烷基二异氰酸酯，例如十二烷1，12-二异氰酸酯，2-乙基四亚甲基1，4-二异氰酸酯，2-甲基五亚甲基1，5-二异氰酸酯，四亚甲基1，4-二异氰酸酯，和优选六亚甲基1，6-二异氰酸酯；脂环族二异氰酸酯，例如环己烷1，3-和1，4-二异氰酸酯以及这些异构体的任何混合物，1-异氰酸酯基-3，3，5-三甲基-5-异氰酸甲酯基环己烷(异佛尔酮二异氰酸酯)，六氢甲苯2，4-和2，6-二异氰酸酯以及相应的异构体混合物，二环己基甲烷4，4’-、2，2’-和2，4’-二异氰酸酯以及相应的异构体混合物；和优选芳族二异氰酸酯和多异氰酸酯，例如甲苯2，4-和2，6-二异氰酸酯以及相应的异构体混合物，二苯基甲烷4，4’-、2，4’-和2，2’-二异氰酸酯的混合物，多苯基多亚甲基多异氰酸酯，二苯基甲烷4，4’-、2，4’-和2，2’-二异氰酸酯与多苯基多亚甲基多异氰酸酯的混合物(粗MDI)，以及粗MDI与甲苯二异氰酸酯的混合物。有机二异氰酸酯和多异氰酸酯可以单独使用或者作为它们的混合物形式使用。
通常使用改性的多官能异氰酸酯，即通过有机二异氰酸酯和/或多异氰酸酯的化学反应获得的产物。可以例如提到含有酯、脲、缩二脲、脲基甲酸酯、碳二酰亚胺、异氰脲酸酯、脲二酮和/或氨基甲酸酯基团的二异氰酸酯和/或多异氰酸酯。
具体例子是：有机、优选芳族的多异氰酸酯，其含有氨基甲酸酯基团并具有基于总重量计33.6-15重量％、优选31-21重量％的NCO含量，例如低分子量二醇、三醇、二亚烷基二醇、三亚烷基二醇或者聚氧亚烷基二醇的反应产物，并且具有最多6000的分子量，尤其是分子量最多为1500，改性的二苯基甲烷4，4’-二异氰酸酯、改性的二苯基甲烷4，4’-和2，4’-二异氰酸酯混合物或改性的粗MDI或甲苯2，4-或2，6-二异氰酸酯，其中可以单独或作为混合物使用的二亚烷基二醇或聚氧亚烷基二醇的例子是：二甘醇、双丙甘醇，聚氧亚乙基、聚氧亚丙基和聚氧亚乙基-聚氧亚丙基二醇、三醇和/或四醇。也合适的是含有NCO基团的预聚物，其具有基于总重量计25-3.5重量％、优选21-14重量％的NCO含量，并且是从下面描述的聚酯多元醇和/或优选聚醚多元醇和二苯基甲烷4，4’-二异氰酸酯、二苯基甲烷4，4’-和2，4’-二异氰酸酯混合物、甲苯2，4-和/或2，6-二异氰酸酯或粗MDI制备的。
也可以使用含有碳二酰亚胺基团和/或异氰脲酸酯环并具有基于总重量计33.6-15重量％、优选31-21重量％的NCO含量的液体多异氰酸酯，例如基于二苯基甲烷4，4’-、2，4’-和/或2，2’-二异氰酸酯和/或甲苯2，4-和/或2，6-二异氰酸酯的化合物。
改性的多异氰酸酯可以任选地彼此混合或与未改性的有机多异氰酸酯混合，后者是例如二苯基甲烷2，4’-、4，4’-二异氰酸酯、粗MDI、甲苯2，4-和/或2，6-二异氰酸酯。
所以，发现特别有用的优选的有机多异氰酸酯是：甲苯二异氰酸酯和粗MDI的混合物，或含氨基甲酸酯基团并具有33.6-15重量％NCO含量的改性有机多异氰酸酯的混合物，尤其是基于甲苯二异氰酸酯、二苯基甲烷4，4’-二异氰酸酯、二苯基甲烷二异氰酸酯异构体混合物或粗MDI和尤其是具有25-80重量％、优选30-55重量％二苯基甲烷二异氰酸酯异构体含量的粗MDI。
b)所用的聚醚多元醇b1)和b2)是通过公知方法制备的，例如从一种或多种在亚烷基中具有2-4个碳原子的环氧烷通过使用碱金属氢氧化物或碱金属醇盐作为催化剂并同时添加至少一种含有2-8个、优选2-6个键合形式的活泼氢原子的起始剂分子进行阴离子聚合来制备，碱金属氢氧化物是例如氢氧化钠或氢氧化钾，碱金属醇盐是例如甲醇钠、乙醇钠、乙醇钾或异丙醇钾；或通过使用路易斯酸例如五氯化锑、氟化硼醚合物等或漂白土作为催化剂进行阳离子聚合来制备。也可以使用多金属氰化物，称为DMC催化剂。也可以使用叔胺作为催化剂，例如三乙胺、三丁胺、三甲胺、二甲基乙醇胺和/或二甲基环己基胺。
适用于制备聚醚多元醇b1)和b2)的环氧烷是例如氧化乙烯、1，2-氧化丙烯、1，3-氧化丙烯、1，2-或2，3-氧化丁烯、四氢呋喃、氧化苯乙烯，优选氧化乙烯和1，2-氧化丙烯。环氧烷可以单独使用，连续使用，或作为混合物使用。
可以用于制备本发明所用聚醚醇的起始剂分子是以下化合物：
b1)作为起始剂物质，尤其使用含羟基的高官能度化合物，尤其是糖、淀粉或木素。葡萄糖、蔗糖和山梨糖在这里也是特别重要的。因为这些化合物是在常规烷氧基化反应条件下以固体形式存在的，所以一般将这些化合物与助引发剂一起烷氧基化。合适的助引发剂尤其是水和多官能的低级醇，例如甘油、三羟甲基丙烷、季戊四醇、乙二醇、丙二醇和它们的同系物。
b2)作为在分子中具有至少两个伯氨基的起始剂分子，优选使用芳族二胺和/或多胺，例如亚苯基二胺，2，3-、2，4-、3，4-和2，6-甲苯二胺(TDA)和4，4’-、2，4’-和2，2’-二氨基二苯基甲烷。
所用的脂族起始剂分子尤其是氨，多官能脂族胺，尤其是具有2-6个碳原子和伯氨基和仲胺基的那些，以及在主链中具有2-6个碳原子的氨基醇。优选使用乙二胺、单烷基乙二胺、1，3-亚丙基二胺以及各种亚丁基二胺和六亚甲基二胺；以及乙醇胺、二乙醇胺和三乙醇胺，作为氨基醇。
聚醚醇b1)优选具有3.7-5.2的官能度和370-500mg KOH/g的羟值。
优选基于芳族或芳族和脂族胺的聚醚醇b2)。非常特别优选聚醚醇b2)是基于芳族胺，并具有3-4的官能度和150-500mg KOH/g的羟值。
关于聚醚醇b1)和b2)及其制备方法的其它信息可以参见例如Kunststoffhandbuch，第7卷“聚氨酯(Polyurethane)”，编辑GünterOertel，Carl-Hanser-Verlag，Munich，第3版，1993。
多元醇组分b)可以有利地在同时使用低分子量扩链剂和/或交联剂b4)的情况下制备。作为扩链剂和/或交联剂b4)，使用二醇和/或三醇，以及具有小于400、优选60-300的分子量的氨基醇。
可以例如使用脂族、脂环族和/或芳脂族的具有2-14个碳原子、优选2-10个碳原子的二醇，例如乙二醇、1，2-丙二醇、1，3-丙二醇、1，10-癸二醇、邻-二羟基环己烷、间-二羟基环己烷、对-二羟基环己烷、二甘醇、双丙甘醇、1，4-丁二醇、1，6-己二醇和二(2-羟基乙基)氢醌，三醇例如1，2，4-三羟基环己烷、1，3，5-三羟基环己烷、甘油和三羟甲基丙烷，以及低分子量的含羟基的聚氧化烯，后者基于氧化乙烯和/或1，2-氧化丙烯以及上述二醇和/或三醇作为起始剂分子，以及氨基醇例如二乙醇胺和三乙醇胺。
特别优选使用具有2-6个碳原子的脂族二醇作为扩链剂b4)，尤其是1，2-氧化丙烯。
如果上述低分子量扩链剂、交联剂或它们的混合物用于制备多元醇组分b)，则它们的用量有利地是1-20重量％，优选2-10重量％，基于多元醇化合物(b)的重量计。
c)作为用于本发明方法的发泡剂，可以使用常规用于制备硬质聚氨酯泡沫材料的发泡剂。
作为发泡剂c)，可以使用水和另外公知的化学和/或物理作用化合物。为了本发明目的，化学发泡剂是能与异氰酸酯反应形成气态产物的化合物，例如水或甲酸。物理发泡剂是在用于制备聚氨酯的原料中溶解或乳化并在聚氨酯形成条件下气化的化合物。这些是例如烃、卤代烃和其它化合物，例如全氟化烷烃，例如全氟化己烷，氯氟烃，以及醚、酯、酮、缩醛，以及能在加热时释放氮气的无机和有机化合物，或它们的混合物，例如具有4-8个碳原子的(环)脂族烃或氟化烃，例如1，1，1，3，3-五氟丙烷(HFC245fa)、三氟甲烷、二氟甲烷、1，1，1，3，3-五氟丁烷(HFC 365mfc)、1，1，1，2-四氟乙烷、二氟乙烷和七氟丙烷。
低沸点的脂族烃有利地用作发泡剂，优选正戊烷和/或异戊烷，尤其是正戊烷。
正戊烷具有36℃的沸点，异戊烷具有28℃的沸点。所以，沸点是在有利于发泡工艺的范围内。
因为适合作为发泡剂的脂族烃是可燃和爆炸性的，所以发泡设备必须配备合适的安全装置，当使用环戊烷作为发泡剂时也是如此。
有利的是使用脂族烃与水一起作为发泡剂。脂族烃的用量是2-25重量％，优选5-15重量％，基于组分b)计。水的比例取决于硬质聚氨酯泡沫材料的所需泡沫密度。
d)用于制备硬质聚氨酯泡沫材料的催化剂(d)尤其是能强烈加速组分(b)的含活泼氢原子、尤其羟基的化合物与有机、改性或未改性的多异氰酸酯(a)反应的化合物。
合适的催化剂(d)是强碱性胺，例如脒，例如2，3-二甲基-3，4，5，6-四氢嘧啶，叔胺例如三乙胺、三丁胺、二甲基环己基胺、二甲基苄基胺、N-甲基吗啉、N-乙基吗啉、N-环己基吗啉、N，N，N’，N’-四甲基乙二胺、N，N，N’，N’-四甲基丁二胺、N，N，N’，N’-四甲基-1，6-己二胺、五甲基二亚乙基三胺、四甲基二氨基乙基醚、二(2-二甲基氨基乙基)醚、二(二甲基氨基丙基)脲、二甲基哌嗪、1，2-二甲基咪唑、1-氮杂双环[3.3.0]辛烷和优选1，4-二氮杂双环[2.2.2]辛烷，以及链烷醇胺化合物，例如三乙醇胺、三异丙醇胺、N-甲基二乙醇胺和N-乙基二乙醇胺、N，N-二甲基氨基乙氧基乙醇、N，N，N’-三甲基氨基乙基乙醇胺和二甲基乙醇胺。
其它可能的催化剂是：三(二烷基氨基烷基)-s-六氢三嗪，尤其是三(N，N-二甲基氨基丙基)-s-六氢三嗪，四烷基氢氧化铵例如四甲基氢氧化铵，碱金属氢氧化物例如氢氧化钠，以及碱金属醇盐例如甲醇钠和异丙醇钾，以及具有10-20个碳原子和可能的侧链羟基的长链脂肪酸的碱金属盐。
如果要将异氰脲酸酯基团引入硬质泡沫材料中，则需要使用特殊的催化剂。作为异氰脲酸酯催化剂，通常使用金属羧酸盐，尤其是乙酸钾及其溶液。根据需要，这些催化剂可以单独使用或者作为彼此的混合物使用。
基于组分(b)的重量计，优选使用0.001-7重量％、尤其0.05-5重量％的催化剂或催化剂组合物。
e)任选地助剂和/或添加剂(e)可以被引入反应混合物中以生产硬质聚氨酯泡沫材料。可以提到例如表面活性物质、泡沫稳定剂、泡孔调节剂、填料、染料、颜料、阻燃剂、水解抑制剂、抗真菌和抗细菌物质。
可以使用的表面活性物质是例如用于帮助原料的均化并且也适用于调节塑料的孔结构的化合物。可以提到例如乳化剂，例如蓖麻油硫酸酯的钠盐或脂肪酸的钠盐，以及脂肪酸与胺形成的盐，例如油酸二乙胺、硬脂酸二乙醇胺、蓖麻酸二乙醇胺，磺酸的盐，例如十二烷基苯磺酸或二萘基甲烷二磺酸和蓖麻油酸的碱金属盐或铵盐；泡沫稳定剂，例如硅氧烷-氧亚烷基共聚物和其它有机聚硅氧烷，乙氧基化烷基酚，乙氧基化脂肪醇，石蜡油，蓖麻油酯，蓖麻油酸酯，土耳其红油和花生油，以及泡孔调节剂例如链烷烃、脂肪醇和二甲基聚硅氧烷。具有聚氧亚烷基和氟化烷基团的上述低聚丙烯酸酯也适用于改进乳化作用、泡孔结构和/或用于稳定泡沫材料。表面活性物质的用量通常是0.01-5重量份，基于100重量份的组分(b)计。
为了本发明的目的，填料、尤其增强填料是公知的常规的有机和无机填料、增强材料、增重剂，在油漆、涂料组合物中用于改进摩擦性能的试剂等。具体例子是：无机填料，例如含硅的矿物质，例如片状硅酸盐例如叶蛇纹石、蛇纹石、角闪石、纤蛇纹石、滑石；金属氧化物，例如高岭土、铝氧化物、钛氧化物和铁氧化物；金属盐，例如白垩、锌钡白，以及无机颜料，例如硫化镉、硫化锌，以及玻璃等。优选使用高岭土(粘土)、硅酸铝，以及硫酸钡和硅酸铝的共沉淀物，以及天然和合成的纤维矿物质，例如硅灰石，金属纤维，以及尤其是具有各种长度的玻璃纤维，其可以用胶料涂覆。可能的有机填料是例如：碳、蜜胺、松香、环戊二烯基树脂和接枝聚合物，以及纤维素纤维，聚酰胺，聚丙烯腈，聚氨酯，基于芳族和/或脂族二羧酸酯的聚酯纤维，和尤其是碳纤维。
无机和有机填料可以单独使用，或作为混合物使用，并且有利地按照基于组分(a)和(b)的重量计的0.5-50重量％、优选1-40重量％的量引入反应混合物中，但是天然和合成纤维的垫、非织造物和织造织物可以达到至多80重量％的值。
作为阻燃剂，可以使用有机磷酸酯和/或膦酸酯。优选使用对异氰酸酯基团没有反应性的化合物。含氯的磷酸酯也是优选的化合物。合适的阻燃剂是例如三(2-氯丙基)磷酸酯、磷酸三乙基酯、磷酸二苯基甲酚基酯、乙烷次膦酸二乙基酯、磷酸三甲酚基酯、三(2-氯乙基)磷酸酯、三(1，3-二氯丙基)磷酸酯、三(2，3-二溴丙基)磷酸酯、四(2-氯乙基)亚乙基二磷酸酯、二甲基甲烷膦酸酯、二乙基二乙醇氨基甲基膦酸酯，以及商购的含卤素的阻燃剂多元醇。
另外，也可以使用含溴的阻燃剂。作为含溴的阻燃剂，优选使用对异氰酸酯基团有反应性的化合物。这些化合物是例如四溴邻苯二甲酸与脂族二醇形成的酯，以及二溴丁烯二醇的烷氧基化产物。也可以使用从含有羟基的溴化新戊基化合物衍生的化合物。
除了上述被卤素取代的磷酸酯之外，也可以使用无机或有机的阻燃剂，例如红磷、氧化铝水合物、三氧化锑、氧化砷、多磷酸铵和硫酸钙，可膨胀性石墨或氰尿酸衍生物，例如蜜胺，或至少两种阻燃剂的混合物，例如多磷酸铵和蜜胺和任选的玉米淀粉，或者多磷酸铵、蜜胺和可膨胀性石墨和/或芳族或非芳族的聚酯，用于制备多异氰酸酯聚加成产物阻燃剂。一般而言，发现有利的是使用5-50重量份、优选5-25重量份的上述阻燃剂/100重量份组分(b)。
关于上述其它常规助剂和添加剂的其它细节可以参见专业文献，例如J.H.Saunders和K.C.Frisch”High Polymers”，第XVI卷，聚氨酯(Polyurethanes)，部分1和2，Interscience Publishers 1962和1964，或Kunststoff-Handbuch，聚氨酯(Polyurethane)，第VII卷，Hanser-Verlag，Munich，Vienna，第3版，1993。
为了生产硬质聚氨酯泡沫材料，多异氰酸酯a)和多元醇组分b)按照这样的量反应，使得异氰酸酯指数在100-150的范围内，优选105-140，特别优选110-130。异氰酸酯指数是异氰酸酯基团与对异氰酸酯基团有反应性的基团之间的摩尔比再乘100.
本发明的硬质聚氨酯泡沫材料优选在连续操作的双带装置上生产。在这里，多元醇组分和异氰酸酯组分是通过高压机器计量加入并且在混合头中混合。可以在分离泵之前将催化剂和/或发泡剂加入多元醇混合物。将反应混合物连续地施用到较下层的覆盖层。含有反应混合物的下层覆盖层和上层覆盖层进入双带。在这里，反应混合物发泡并固化。在离开双带之后，连续条料被切成所需的尺寸。以此方式，可以生产具有金属覆盖层或夹心元件或具有柔性覆盖层的隔绝元件。
起始组分是在15-90℃的温度混合，优选20-60℃，尤其是20-45℃。反应混合物可以通过高压或低压计量设备被铸塑到闭合的支撑工具中。通过此技术生产例如不连续的夹心元件。
通过本发明方法生产的硬质聚氨酯泡沫材料具有0.02-0.75g/cm3的密度，优选0.025-0.24g/cm3，尤其是0.03-0.1g/cm3。它们尤其适合作为建筑和冷冻领域中的隔绝材料，例如作为用于夹心元件的中间层，或用于用泡沫材料填充冰箱和冷冻器腔室的外壳。
通过本发明方法生产的硬质聚氨酯泡沫材料具有缺陷很少的优异表面，并且显示优异的固化性能。使用含羟基的脂肪酸酯b3)以及低分子量扩链剂和/或交联剂b4)能降低多元醇组分b)的粘度。多元醇组分b)的低粘度简化了双带装置上的加工。
下面通过实施例说明本发明。
硬质泡沫材料是在设定为40℃温度的双带装置上生产的。
对比例
多元醇组分是通过混合以下物质制备的：
71.5重量份的具有490mg KOH/g羟值的聚醚醇，且基于氧化丙烯以及蔗糖和甘油的混合物作为起始剂，
15重量份的具有390mg KOH/g羟值的聚醚醇，且基于氧化乙烯/氧化丙烯以及连位TDA作为起始剂，
10重量份的三-2-氯异丙基磷酸酯，
2重量份的
B8496，来自Goldschmidt，
0.5重量份的乙酸钾，在乙二醇中，50％浓度溶液，和
1重量份的水。
此组分与具有31.5重量％NCO含量的聚合MDI(
M50，来自BASF SE)在正戊烷(7.5重量份)、二甲基环己基胺和水的存在下在异氰酸酯指数为120下反应。选择二甲基环己基胺和水的量，使得胶凝时间是45秒，所得的泡沫材料具有36g/l的密度。
实施例1
多元醇组分是通过混合以下物质制备的：
46.5重量份的具有490mg KOH/g羟值的聚醚醇，且基于氧化丙烯以及蔗糖和甘油的混合物作为起始剂，
15重量份的具有390mg KOH/g羟值的聚醚醇，且基于氧化乙烯/氧化丙烯以及连位TDA作为起始剂，
10重量份的三-2-氯异丙基磷酸酯，
25重量份的蓖麻油，
2重量份的
B8496，来自Goldschmidt，
0.5重量份的乙酸钾，在乙二醇中，50％浓度溶液，和
1重量份的水。
此组分与具有31.5重量％NCO含量的聚合MDI(
M50，来自BASF SE)在正戊烷(7.5重量份)、二甲基环己基胺和水的存在下在异氰酸酯指数为120下反应。选择二甲基环己基胺和水的量，使得胶凝时间是45秒，所得的泡沫材料具有36g/l的密度。
实施例2
多元醇组分是通过混合以下物质制备的：
38.5重量份的具有490mg KOH/g羟值的聚醚醇，且基于氧化丙烯以及蔗糖和甘油的混合物作为起始剂，
15重量份的具有390mg KOH/g羟值的聚醚醇，且基于氧化乙烯/氧化丙烯以及连位TDA作为起始剂，
10重量份的三-2-氯异丙基磷酸酯，
25重量份的蓖麻油，
8重量份的1，2-丙二醇，
2重量份的
B8496，来自Goldschmidt，
0.5重量份的乙酸钾，在乙二醇中，50％浓度溶液，和
1重量份的水。
此组分与具有31.5重量％NCO含量的聚合MDI(
M50，来自BASF SE)在正戊烷(7.5重量份)、二甲基环己基胺和水的存在下在异氰酸酯指数为120下反应。选择二甲基环己基胺和水的量，使得胶凝时间是45秒，所得的泡沫材料具有36g/l的密度。
固化是通过压头实验测定的。为此目的，在聚苯乙烯杯中混合各组分之后3、4、5和6分钟时，用拉伸/压缩实验机将具有半径为10毫米的半球形端部的钢压头向所形成的泡沫材料压入10毫米深度。单位为N的所需最大力是衡量泡沫材料固化的手段。在各情况下报告在3、4、5和6分钟之后检测的最大力以及在3、4、5和6分钟之后固化的总和。
对于粘合实验，将具有金属覆盖层的夹心元件(200×200×80mm)在实验室中在闭合的加热模具中发泡。模具的温度是40℃，泡沫材料的总密度是36g/l。在体系固化之后，锯下尺寸为100×100×80mm的实验样品，并且按照DIN EN ISO 527-1/DIN 53292检测泡沫材料对覆盖层的粘合性。
表面缺陷的频率是通过光学方法定量地检测的。为此目的，将泡沫材料样品切到距离下层覆盖层1毫米的平面，下层覆盖层即在双带工艺中已经施用聚氨酯反应溶液的覆盖层。
在表面的定量评价中，泡沫材料的表面从右侧照明，然后从左侧照明，并且在每种情况下拍照。图像通过图像分析软件叠加并分析。在表面上的缺陷是作为黑色区域出现的。黑色区域基于总表面积的百分比是衡量表面缺陷在泡沫材料中的出现频率的手段。
此外，对泡沫材料表面的性质的额外定性评价是通过从1m×2m泡沫样品除去覆盖层并目测表面进行的。
结果列在表1中。
表1
表1中的结果显示通过本发明方法显著改进了泡沫材料的表面性能和粘合性。此外，多元醇组分的粘度显著降低，从而简化了加工，这表现为优良的流动性以及满意的固化性能。
Claims (7)
1.一种制备硬质聚氨酯泡沫材料的方法，其中：
a)有机多异氰酸酯与
b)具有至少两个对异氰酸酯基团有活性的氢原子的化合物在以下物质的存在下反应：
c)发泡剂，
d)催化剂，和
任选地e)助剂和添加剂，
其中包含以下物质并且具有400-550mg KOH/g平均羟值的混合物用作多元醇组分b)：
b1)20-70重量份的一种或多种高官能度聚醚醇，其是基于含羟基的高官能度起始剂分子，其具有3.7-5.2的官能度和370-500mg KOH/g的羟值，
b2)5-30重量份的一种或多种基于芳族胺的聚醚醇，其具有3-4的官能度和150-500mg KOH/g的羟值，
b3)5-20重量份的至少一种含羟基的脂肪酸酯，和
b4)1-20重量份的一种或多种低分子量扩链剂和/或交联剂，其具有2-3的官能度和小于400g/mol的分子量Mw。
2.权利要求1的方法，其中使用2-10重量份的低分子量扩链剂和/或交联剂b4)。
3.权利要求1或2的方法，其中蓖麻油用作甘油和含羟基的脂肪酸的酯。
4.权利要求1或2的方法，其中1,2-氧化丙烯用作低分子量扩链剂b4)。
5.权利要求1或2的方法，其中所述反应在100-150的异氰酸酯指数下进行。
6.权利要求1或2的方法，其中正戊烷和/或异戊烷用作发泡剂。
7.通过权利要求1的方法制备的硬质聚氨酯泡沫材料。
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| EP (1) | EP2408835B1 (zh) |
| JP (1) | JP5758874B2 (zh) |
| KR (1) | KR101740742B1 (zh) |
| CN (1) | CN102428116B (zh) |
| AU (1) | AU2010224939C1 (zh) |
| CA (1) | CA2755754A1 (zh) |
| ES (1) | ES2449874T3 (zh) |
| MX (1) | MX2011009801A (zh) |
| PL (1) | PL2408835T3 (zh) |
| PT (1) | PT2408835E (zh) |
| RU (1) | RU2525240C2 (zh) |
| WO (1) | WO2010106067A1 (zh) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| MX2013010111A (es) * | 2011-03-18 | 2013-10-03 | Basf Se | Metodo para producir materiales basados en poliurea porosa resistentes a la flama. |
| US20120259030A1 (en) * | 2011-04-07 | 2012-10-11 | Basf Se | Producing pu rigid foams |
| KR20140026487A (ko) | 2011-04-15 | 2014-03-05 | 바스프 에스이 | 경질 폴리우레탄 발포체의 제조 방법 |
| KR20140026488A (ko) | 2011-04-15 | 2014-03-05 | 바스프 에스이 | 경질 폴리우레탄 발포체의 제조 방법 |
| US9334383B2 (en) | 2011-04-15 | 2016-05-10 | Basf Se | Process for producing rigid polyurethane foams |
| US20120264842A1 (en) * | 2011-04-15 | 2012-10-18 | Basf Se | Process for producing rigid polyurethane foams |
| US9353234B2 (en) | 2012-03-01 | 2016-05-31 | Basf Se | Rigid polyurethane foams |
| EP2634201A1 (de) | 2012-03-01 | 2013-09-04 | Basf Se | Polyurethan-Hartschaumstoffe |
| JP2015532315A (ja) | 2012-09-27 | 2015-11-09 | ビーエーエスエフ ソシエタス・ヨーロピアＢａｓｆ Ｓｅ | 脂肪酸変性ポリエーテルポリオールを主原料とする硬質ポリウレタン及びポリイソシアヌレート |
| US9475220B2 (en) * | 2013-02-13 | 2016-10-25 | Basf Se | Process for producing composite elements |
| WO2014140014A1 (de) * | 2013-03-15 | 2014-09-18 | Basf Se | Verfahren zur herstellung von verbundelementen sowie erhaltenes verbundelement |
| CA2918686C (en) | 2013-08-13 | 2017-05-30 | Enerlab 2000 Inc. | Process for the preparation of lignin based polyurethane products |
| WO2015022273A1 (de) * | 2013-08-13 | 2015-02-19 | Bayer Materialscience Ag | Polyurethanschaumstoffe und ihre verwendung |
| EP3036267B1 (de) * | 2013-08-20 | 2017-10-11 | Basf Se | Verbesserte polyurethan- und polyisocyanurat-hartschaumstoffe auf basis von fettsäuremodifizierten polyetherpolyolen |
| CN103483534A (zh) * | 2013-09-26 | 2014-01-01 | 南京年吉冷冻食品有限公司 | 一种无卤阻燃型聚氨酯硬质泡沫塑料的制备方法 |
| CN103483546A (zh) * | 2013-09-26 | 2014-01-01 | 南京年吉冷冻食品有限公司 | 一种拒水拒油型含氟聚氨酯硬质泡沫塑料的制备方法 |
| JP2015101592A (ja) * | 2013-11-21 | 2015-06-04 | 三洋化成工業株式会社 | ポリウレタン樹脂およびその成形品 |
| KR20190109742A (ko) * | 2017-01-31 | 2019-09-26 | 바스프 에스이 | Hfo 함유 pu 제제 |
| MX2020004851A (es) * | 2017-11-08 | 2020-08-13 | Basf Se | Aceite vegetal como estabilizador de espuma en la fabricacion de botas de pu. |
| BR112021006063A2 (pt) * | 2018-10-24 | 2021-07-20 | Basf Se | processo de produção de espumas, espuma e uso |
| CN114829436A (zh) | 2019-12-24 | 2022-07-29 | 科思创知识产权两合公司 | 用于形成具有空气渗透率的硬质聚氨酯泡沫的组合物和硬质聚氨酯泡沫 |
| US20240262950A1 (en) * | 2021-05-18 | 2024-08-08 | Auckland Uniservices Limited | Polyurethane foams comprising phase change materials |
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| US5886062A (en) * | 1996-08-28 | 1999-03-23 | Bayer Aktiengesellschaft | Process for the production of rigid polyurethane foams |
| CN101035826A (zh) * | 2004-10-05 | 2007-09-12 | 巴斯福股份公司 | 生产硬聚氨酯泡沫材料的方法 |
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| US5523334A (en) * | 1995-11-01 | 1996-06-04 | Basf Corporation | Insulating rigid polyurethane foams |
| DE19623065A1 (de) * | 1996-06-10 | 1997-12-11 | Bayer Ag | Verfahren zur Herstellung von Polyurethan Hartschaumstoffen mit geringer Wärmeleitfähigkeit |
| DE19639121A1 (de) * | 1996-09-24 | 1998-03-26 | Basf Ag | Verfahren zur Herstellung von Polyurethan-Hartschaumstoffen |
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| EP2000487B1 (de) | 2007-06-01 | 2010-06-16 | Basf Se | Verfahren zur Herstellung von Polyurethan-Hartschaumstoffen |
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2010
- 2010-03-16 PT PT107089971T patent/PT2408835E/pt unknown
- 2010-03-16 CN CN201080021548.4A patent/CN102428116B/zh active Active
- 2010-03-16 AU AU2010224939A patent/AU2010224939C1/en not_active Ceased
- 2010-03-16 US US13/257,391 patent/US8889756B2/en not_active Expired - Fee Related
- 2010-03-16 EP EP10708997.1A patent/EP2408835B1/de active Active
- 2010-03-16 MX MX2011009801A patent/MX2011009801A/es active IP Right Grant
- 2010-03-16 ES ES10708997.1T patent/ES2449874T3/es active Active
- 2010-03-16 JP JP2012500220A patent/JP5758874B2/ja not_active Expired - Fee Related
- 2010-03-16 WO PCT/EP2010/053392 patent/WO2010106067A1/de active Application Filing
- 2010-03-16 RU RU2011141875/04A patent/RU2525240C2/ru not_active IP Right Cessation
- 2010-03-16 PL PL10708997T patent/PL2408835T3/pl unknown
- 2010-03-16 CA CA2755754A patent/CA2755754A1/en not_active Abandoned
- 2010-03-16 KR KR1020117024342A patent/KR101740742B1/ko active IP Right Grant
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| US5451615A (en) * | 1994-10-20 | 1995-09-19 | The Dow Chemical Company | Process for preparing polyurethane foam in the presence of a hydrocarbon blowing agent |
| US5688835A (en) * | 1995-01-31 | 1997-11-18 | Basf Elastogran Gmbh | Preparation of polyurethane rigid foams |
| US5886062A (en) * | 1996-08-28 | 1999-03-23 | Bayer Aktiengesellschaft | Process for the production of rigid polyurethane foams |
| CN101035826A (zh) * | 2004-10-05 | 2007-09-12 | 巴斯福股份公司 | 生产硬聚氨酯泡沫材料的方法 |
Also Published As
| Publication number | Publication date |
|---|---|
| PL2408835T3 (pl) | 2014-06-30 |
| US8889756B2 (en) | 2014-11-18 |
| US20120010313A1 (en) | 2012-01-12 |
| WO2010106067A1 (de) | 2010-09-23 |
| AU2010224939A1 (en) | 2011-10-13 |
| EP2408835B1 (de) | 2014-01-15 |
| JP5758874B2 (ja) | 2015-08-05 |
| CA2755754A1 (en) | 2010-09-23 |
| AU2010224939B2 (en) | 2015-05-14 |
| KR101740742B1 (ko) | 2017-05-26 |
| MX2011009801A (es) | 2011-11-04 |
| RU2011141875A (ru) | 2013-04-27 |
| CN102428116A (zh) | 2012-04-25 |
| AU2010224939C1 (en) | 2015-08-27 |
| PT2408835E (pt) | 2014-03-06 |
| EP2408835A1 (de) | 2012-01-25 |
| RU2525240C2 (ru) | 2014-08-10 |
| KR20110139273A (ko) | 2011-12-28 |
| JP2012520915A (ja) | 2012-09-10 |
| ES2449874T3 (es) | 2014-03-21 |
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