CN103635257B - 减少聚氨酯泡沫的排放物 - Google Patents
减少聚氨酯泡沫的排放物 Download PDFInfo
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- CN103635257B CN103635257B CN201280032500.2A CN201280032500A CN103635257B CN 103635257 B CN103635257 B CN 103635257B CN 201280032500 A CN201280032500 A CN 201280032500A CN 103635257 B CN103635257 B CN 103635257B
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- Prior art keywords
- acid
- catalyst
- foam
- amine
- tertiary amine
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Abstract
本发明公开内容涉及制造具有最佳机械性质和最低化学排放物的软质开孔聚氨酯泡沫的方法。使用选择的叔胺催化剂以及根据本公开内容的羧酸类型,可以产生具有最佳性质和最低化学散发物的泡沫产物。
Description
相关申请的交叉引用
本申请要求2011年6月29日提交的美国申请No.61/502570的权益。申请No.61/502570的公开内容在此通过引用并入。
技术领域
本发明涉及制造开孔软质聚氨酯泡沫的方法,所述方法包括选择某些羧酸与特定类型的具有异氰酸酯反应性基团的叔胺胶凝催化剂组合,产生化学排放物相对低的泡沫。
背景技术
生产开孔软质聚氨酯泡沫需要使用各种添加剂,它们每一种都在决定产品的最终特性和物理性质中发挥关键作用。虽然这些添加剂在总制剂中占小百分比并且预期排放物是相对低的,但对成品中低挥发性有机物含量(VOC)的日益增长的环境要求对添加剂提出了较低排放物同时保持泡沫性能的额外要求。因此,关于聚氨酯泡沫制剂中存在的催化剂、表面活性剂和任何其它组分的排放物的日渐严格的检查已经变得更加普遍,并且这种趋势现在是全球性的。聚氨酯制造商需要没有排放物的添加剂,所述添加剂的性能与常规的环境友好性较低的标准产品一样好。众所周知,制造聚氨酯泡沫的常规制造程序需要使用排放性的添加剂。叔胺例如三亚乙基二胺和双(二甲基氨乙基)醚是工业中使用的生产聚氨酯泡沫的通用标准物。生产速度和最终物理性质是所述催化剂组合的反映。虽然这些催化剂被广泛使用,但由于这些产品的挥发性,存在若干环境和质量问题。
用于减少泡沫排放物的一种策略是基于在叔胺催化剂上引入能与异氰酸酯官能团反应的官能团。利用这种方式,叔胺催化剂将保持与聚氨酯聚合物共价结合,防止它释放到环境中。这种方式可能具有一些局限性,因为所述官能化叔胺可与异氰酸酯过早反应,造成不想要的副作用,例如聚合物链终止,这将导致物理性质差、开孔过多或泡沫塌陷、或者过度交联,后者可导致广泛的收缩和尺寸稳定性差。减少气味和排放物的另一种备选方式是基于利用具有增加的分子量和/或极性的材料。产品例如二甲基氨丙基脲、双(二甲基氨丙基)脲、双(二甲基氨丙基)胺和N,N-双(二甲基氨丙基)-N-(2-羟丙基)胺可提供与行业标准相比可接受的物理性质,然而大多数常规的反应性催化剂不能始终达到现今消费者和制造商的要求。利用这些催化剂可显著减少泡沫的总排放物。然而,产生的成品决不是没有排放物的,并且根据VDA278检测方法,VOC和(FOG)值可达到数百ppm。
当制造软质聚氨酯泡沫时,通常向聚氨酯制剂添加羧酸,以减慢所述叔胺的活性并防止粘度快速增加,这使得模具填充操作更加有效,特别是在需要复杂的形状和几何形状的模具的情况下。这种方式允许填充小的空洞和空隙,将有缺陷的制品数量降至最小。最常用于这种目的的酸是一元酸,例如乙酸、丙酸、丁酸、己酸、2-乙基己酸等等。然而,已知这些酸与所述聚合物的结合弱,因此即使在含有异氰酸酯反应性官能团的叔胺存在下也产生显著的排放物。用于最小化来自酸的排放物的典型策略与已经描述的对叔胺催化剂的相似。换句话说,使用含有能与异氰酸酯反应的官能团的羧酸可让所述羧酸固定在聚氨酯聚合物中。然而,这种方式的局限性与已经描述的非排放性叔胺的局限性类似。所述官能化羧酸可与异氰酸酯反应,引起不想要的效果,例如取决于官能化酸的选择,导致聚合物链终止,其将导致物理性质差、过度开孔或泡沫塌陷、以及可导致过度收缩和尺寸稳定性差的过度交联。
美国专利公布No.US2007/0197760A1公开了用于生产聚氨酯的催化剂,它是非腐蚀性的并且表现出有效的催化剂作用延迟。所述催化剂包含排放性叔胺与饱和羧酸的混合物,所述羧酸由通式HOOC-(CH2)n-COOH表示,其中n是2至14的整数。然而,US2007/0197760A1中使用的催化剂与酸的组合产生具有高排放物的泡沫。
美国专利No6,387,972公开了提高聚氨酯泡沫性能的改进方法。聚氨酯泡沫通过多异氰酸酯与多官能异氰酸酯反应性组分之间的反应而制备,其中所述反应在催化剂存在下进行,所述催化剂由以下组分构成:(a)特定的反应性叔胺催化剂,选自双(二甲基氨丙基)氨基-2-丙醇、双(二甲基氨丙基)胺、二甲基氨丙基二丙醇胺、双(二甲基氨基)-2-丙醇、N,N,N'-三甲基-N'-羟乙基-双(氨乙基)醚及其混合物;和(b)特定的反应性叔胺化合物的至少一种羧酸盐,所述羧酸盐选自羟基羧酸盐和卤代羧酸盐。所述羟基羧酸由于它与异氰酸酯的反应引起的固定化而产生排放物降低形式的泡沫。然而,这种方式的缺点在于需要过量异氰酸酯来使所述酸固定化,而这种反应不利地影响聚氨酯泡沫的物理性质。此外,固定化的酸不能自由迁移通过所述泡沫,使得它是无效的封闭剂。
美国专利No6,432,864公开了新的酸封闭的胺催化剂以及它们在制备聚氨酯泡沫中的应用。所述酸封闭的胺催化剂通常通过合并叔胺与从有机环酐和乙二醇制备的酸来制造。因为通过乙二醇与酸酐反应产生的酸得到含有羟基的产物,因此用这种酸制成的聚氨酯泡沫需要额外的异氰酸酯来对付所述OH基团。另外,所述醇-酸由于在分子中存在单个羟基,可停止聚合物增长,这可对泡沫物理性质具有不利的影响。此外,所述方法产生水解不稳定的酯官能团,其随着聚氨酯制剂体系老化而引起反应性改变。
美国专利No4,066,580公开了制造含有氨基甲酸酯基团的多异氰脲酯泡沫的方法,所述泡沫通过在助催化剂体系存在下混合多异氰酸酯和多元醇和起沫剂、辅助剂和添加剂而产生,所述助催化剂体系由1,3,5-三(N,N-二烷基氨基烷基)-s-六氢三嗪和有机单或多羧酸、酸值大于4的聚酯多元醇(polyesterol)、或多羧酸的单酯构成。特别地,本发明描述了一种方法,其中通过使用由1,3,5-三(N,N-二烷基氨基烷基)-s-六氢三嗪和有机羧酸、所述酸的单酯或酸值大于4的聚酯多元醇组成的特定催化剂,可改变乳白时间和起发时间。因此,本发明使用酸和多酸,但目的在于控制专门用1,3,5-三(N,N-二烷基氨基烷基)-s-六氢三嗪制造PIR泡沫的加工条件。
美国专利No7,351,859公开了一种叔胺-羧酸盐,其中选择羧酸和叔胺使得所述催化剂盐在室温下是封闭的并且在升高的温度下解封闭。所述化合物可用作热活化氨基甲酸酯催化剂。该发明的公开内容具体涉及利用草酸和/或水杨酸与某种叔胺催化剂组合,所述叔胺催化剂可以含有异氰酸酯反应性基团。该发明不涉及制造潮湿老化稳定并且低排放的聚氨酯泡沫,而是涉及制造泡沫的方法,其中草酸和水杨酸的叔胺羧酸盐在较高温度下去封闭。由于缺乏异氰酸酯反应性基团,使用8、或5将产生具有高排放物的泡沫产物。另一方面,T、DMEA和ZR70将产生环境物理性质和潮湿老化物理性质差的泡沫,如实施例1所示。15可产生具有可接受的物理性质和排放物的泡沫。然而,15与草酸组合使用可具有若干环境问题。软质泡沫的标准排放试验通常在120℃进行,而草酸在100℃的温度下升华。因此,任何这些催化剂-草酸组合产生对于使用不可接受的腐蚀性排放物,例如在终端消费者可能暴露于酸和腐蚀性散发物的汽车应用中。草酸由于它的酸度非常高(pKa=1.27),所以腐蚀性特别高。这对汽车内部存在严重问题,因为夏天期间,小汽车内部的温度可以很高,引起草酸排放,从而腐蚀金属零件或损害其它材料。另一方面,水杨酸的缺点是具有异氰酸酯反应性基团,其具有上面论述的化学迁移性和聚合物链终止的局限性。
美国专利No5,464,560公开了向HCFC发泡剂或向组合物、优选其中存在HCFC发泡剂的异氰酸酯反应性组合物添加具有至少两个羧基、没有叔胺基团并且pKa高达3.1的有机酸,以减少所述HCFC发泡剂的分解。所生成的组合物可用于生产多异氰脲酯、聚氨酯和/或聚脲泡沫。在挥发性HCFC存在下使用有机酸将产生具有高排放水平的泡沫,在开孔软质泡沫应用中是高度不希望得到的。
美国专利No6,576,682涉及在制备聚氨酯泡沫中组合使用蓖麻油酸金属盐与反应性胺催化剂,以及在制备聚氨酯泡沫中它们在水性或有机溶剂中的溶液与反应性胺的组合使用。该发明的目的是减少因辛酸锡盐水解而导致的来自挥发性酸的排放物。该专利描述了由有机单羧酸例如2-乙基己酸引起的排放物,以及如何通过与蓖麻油酸中一样的方式(增加所述酸的分子量和掺入羟基官能团)来帮助最小化酸排放物。还说明了使用其中R是氢或烷基的式R-CO2H的标准有机羧酸,可以引起泡沫发出有机排放物的事实。
前面所述的专利和专利申请的公开内容在此通过引用并入。
本领域需要具有减少排放物的改进泡沫和泡沫制造方法。
发明概述
本发明通过减少开孔软质聚氨酯泡沫的总排放物,解决了与常规的催化剂和方法有关的问题。本发明使用某些叔胺催化剂以及某些二羧酸。这样的酸包含选自富马酸、丙二酸、马来酸、琥珀酸、戊二酸、己二酸、庚二酸、辛二酸、壬二酸、癸二酸、邻苯二甲酸、间苯二甲酸和对苯二甲酸的至少一种;它们全部不含OH、NH=、NH2-、脲、酰胺、或羧酸官能团以外的任何其它官能团。所述二酸可以保留在泡沫中,并且其特征在于不存在异氰酸酯反应性基团(例如,最小化异氰酸酯的消耗和它对物理性质的影响)。
当这些酸与包含选自脲、仲胺、伯胺、酰胺和仲羟基的至少一种的叔胺胶凝催化剂组合使用时,产生的泡沫具有通过VDA278方法测量的减少的总排放物、以及出色的物理性质。因此,根据本发明使用某些胺催化剂和羧酸可以允许:a)消除源自所述胺催化剂的排放物;b)消除源自所述羧酸的排放物;和c)当使用根据本发明选择的酸/胺时,进一步降低VOC和FOG的总排放。
本发明的一个方面涉及减少来自于软质开孔泡沫的化学排放物同时保持出色的物理性质的方法,所述方法通过在选定类型的具有以下官能团:脲、酰胺、仲胺、伯胺或仲羟基的叔胺存在下,使用某些羧酸并且特别是二羧酸或三羧酸。本发明可以产生根据VDA278方法没有叔胺或羧酸排放物的泡沫。本发明还可以产生根据VDA278方法测量的10%或更低的总排放物减少。
本发明的一个方面涉及一种催化剂,所述催化剂包含选自二羧酸和三羧酸的至少一种酸、和包含选自脲、酰胺、仲胺、伯胺或仲羟基的至少一个官能团的至少一种叔胺,并且其中所述酸没有异氰酸酯反应性基团和叔胺基本上不含伯羟基。
本发明的另一个方面涉及一种催化剂,所述催化剂基本由选自二羧酸和三羧酸的至少一种酸、和包含选自脲、酰胺、仲胺、伯胺或仲羟基的至少一个官能团的至少一种叔胺组成。
本发明的其它方面涉及通过使用本发明的催化剂来制造聚氨酯泡
沫的方法以及所生成的泡沫。
发明详述
本发明涉及最小化泡沫排放物并且不损害泡沫物理性质的催化剂和方法。因此,本发明的方法在选自富马酸、丙二酸、马来酸、琥珀酸、戊二酸、己二酸、庚二酸、辛二酸、壬二酸、癸二酸、邻苯二甲酸、间苯二甲酸和对苯二甲酸的羧酸存在下,使用具有脲、酰胺、仲胺、伯胺和仲羟基中至少一种的非排放性胶凝叔胺催化剂。这些组合可以产生化学排放物低和物理性质最优的泡沫。
本发明还涉及制造低排放物的聚氨酯泡沫的方法,所述方法使用选定类型的异氰酸酯反应性叔胺胶凝催化剂与二羧酸(或三羧酸)的组合,所述二羧酸(或三羧酸)包括富马酸、丙二酸、马来酸、琥珀酸、戊二酸、己二酸、庚二酸、辛二酸、壬二酸、癸二酸、邻苯二甲酸、间苯二甲酸和对苯二甲酸。所述选定的反应性胶凝叔胺催化剂包括任何下列官能团:脲、仲胺、伯胺、酰胺或仲羟基。当与用现有技术中描述的任何单一的常规排放性或非排放性胶凝催化剂产生的泡沫相比较时,本发明的异氰酸酯反应性叔胺催化剂与羧酸在一起的组合产生的泡沫具有最少的排放物。
泡沫制备
使用本发明的方法、使用已经添加了合适的选定叔胺和羧酸的典型聚氨酯制剂,可以制造本领域已知的任何各种型式的泡沫。例如,本文中描述的具有出色的潮湿老化特性的软质聚氨酯泡沫通常将包含下面表I中显示的指示的量的组分。表I中显示的组分将在后面详细地论述。
表I聚氨酯组分
组分 | 重量份 |
基础多元醇 | 20-100 |
聚合物多元醇 | 0-80 |
硅氧烷表面活性剂 | 0.5-10 |
发泡剂 | 2-4.5 |
交联剂 | 0.5-2 |
催化剂 | 0.25-10 |
羧酸 | 0.05-3.0 |
多异氰酸酯 | 要提供NCO指数=70-115 |
在本发明的聚氨酯制剂中使用的多异氰酸酯的量没有限制,但是它典型地在本领域技术人员已知的范围之内。示例性的范围在表1中给出,由指称“NCO指数”(异氰酸酯指数)标出。正如在本技术领域中已知的,NCO指数被定义为异氰酸酯的当量数除以活性氢的总当量数乘以100。NCO指数由下式表示。
NCO指数=[NCO/(OH+NH)]×100
软质泡沫典型地使用作为泡沫组合物中全部多元醇含量的一部分的共聚物多元醇与重均分子量约为4000-5000、羟基数约为28-35的基础多元醇。基础多元醇和共聚物多元醇将在后文中详细描述。
催化剂
本发明的催化剂包含含有异氰酸酯反应性基团的叔胺,并且为了减少排放物而基本由所述叔胺构成。存在于所述叔胺胶凝催化剂中的异氰酸酯反应性基团基本由伯胺、仲胺、仲羟基、酰胺和脲组成。胶凝催化剂的例子包括N,N-双(3-二甲基氨丙基)-N-(2-羟丙基)胺;N,N-二甲基-N',N'-双(2-羟丙基)-1,3-丙二胺;二甲基氨基丙胺(DMAPA);N-甲基-N-2-羟丙基-哌嗪,双-二甲基氨丙基胺(15),二甲基氨丙基脲和N,N'-双(3-二甲基氨丙基)脲(NE1060,NE1070,DABNE1080和NE1082),1,3-双(二甲基氨基)-2-丙醇,6-二甲基氨基-1-己醇,N-(3-氨丙基)咪唑,N-(2-羟丙基)咪唑,N,N'-双(2-羟丙基)哌嗪,N-(2-羟丙基)-吗啉,N-(2-羟乙基咪唑)。可以与上述胶凝催化剂一起使用的含异氰酸酯反应性基团的发泡助催化剂的例子包括2-[N-(二甲基氨基乙氧基乙基)-N-甲氨基]乙醇(NE200)、N,N,N'-三甲基-N'-3-氨丙基-双(氨乙基)醚(NE300)。例如当想要的聚氨酯泡沫是软质板材时,所述催化剂组合物还可以包括其它组分,例如过渡金属催化剂,如有机锡化合物或羧酸铋。金属催化剂还可以包含选自二月桂酸二丁基锡、二月桂酸二甲基锡、二乙酸二甲基锡、二乙酸二丁基锡、二月桂基硫醇二甲基锡、二月桂基硫醇二丁基锡、二异辛基马来酸二甲基锡、二异辛基马来酸二丁基锡、双(2-乙基己基巯基乙酸)二甲基锡、双(2-乙基己基巯基乙酸)二丁基锡、辛酸亚锡、其它合适的有机锡催化剂中的至少一种、或其组合。其它金属还可以包括例如铋(Bi)。合适的羧酸铋盐包括戊酸、新戊酸、己酸、2-乙基己基羧酸、新己酸、辛酸、新辛酸、庚酸、新庚酸、壬酸、新壬酸、癸酸、新癸酸、十一烷酸、新十一烷酸、十二烷酸、新十二烷酸、和其他合适的羧酸的盐。还可以包括过渡金属铅(Pb)、铁(Fe)、锌(Zn)与戊酸、新戊酸、己酸、2-乙基己基羧酸、辛酸、新辛酸、新庚酸、新癸酸、新十一烷酸、新十二烷酸和其它合适羧酸的其它盐。
虽然本发明可以使用除上面列出的那些胺以外的胺,但这样的用法可能增加来自于泡沫和泡沫制造方法的排放物。另外,所述胺通常将基本上不含伯羟基。“基本上不含”是指本发明的胶凝催化剂缺乏伯羟基或含有这类基团的量不足以显著影响老化期间泡沫的物理性质。
通常,对于制造本发明的泡沫来说,排放减少或非逃逸型叔胺催化剂的负载量将在约0.1至约20pphp范围内,更通常约0.1至约10pphp,并最通常约0.1至约5pphp。然而,可以使用任何有效量。术语“pphp”是指每百份多元醇的份数。
有机异氰酸酯
合适的有机异氰酸酯化合物包括但不限于六亚甲基二异氰酸酯(HDI)、亚苯基二异氰酸酯(PDI)、甲苯二异氰酸酯(TDI)和4,4'-二苯甲烷二异氰酸酯(MDI)。在本发明的一个方面,2,4-TDI、2,6-TDI或其任何混合物用来生产聚氨酯泡沫。其它合适的异氰酸酯化合物是商业上称为“粗MDI”的二异氰酸酯混合物。一个实例是由Dow Chemical Company以名称PAPI销售的,并且它含有约60%的4,4'-二苯甲烷二异氰酸酯以及其它异构体和类似的更高级多异氰酸酯。虽然可以使用任何合适的异氰酸酯,但这类的例子包括指数范围从约80至约120并且通常从约90至约110的异氰酸酯。异氰酸酯的量通常为约95至约105。
多元醇组分
聚氨酯由有机异氰酸酯与多元醇的、典型为多元醇混合物的羟基反应来生产。反应混合物的多元醇组分包括至少一种主要或“基础”多元醇。作为非限制性的实例,适合用于本发明的基础多元醇包括聚醚多元醇。聚醚多元醇包括聚环氧烷聚合物例如聚环氧乙烷和聚环氧丙烷聚合物,以及具有源自于多羟基化合物包括二醇和三醇的端羟基的共聚物。用于与环氧乙烷或环氧丙烷反应的二醇和三醇的实例,包括乙二醇、丙二醇、1,3-丁二醇、1,4-丁二醇、1,6-己二醇、新戊二醇、二乙二醇、二丙二醇、季戊四醇、甘油、双甘油、三羟甲基丙烷和类似的低分子量多元醇。本技术领域中已知的其他基础多元醇实例包括多羟基封端的缩醛树脂、端羟基胺和端羟基多胺。这些和其他适合的异氰酸酯反应性材料的实例可以在美国专利号4,394,491中发现,在此通过引用并入。适合的聚醚多元醇还包括含有能够催化聚氨酯的胶凝和发泡反应的叔胺基团的多元醇,例如在WO03/016373A1、WO01/58976A1、WO2004/060956A1、WO03/016372A1和WO03/055930A1中所描述的,前述WO公布的公开内容在此通过引用并入。其他有用的多元醇可以包括基于聚亚烷基碳酸酯的多元醇和基于多磷酸酯的多元醇。
在本发明的一个方面,可以使用单一高分子量聚醚多元醇作为基础多元醇。备选地,可以使用高分子量聚醚多元醇的混合物,例如二和三官能性材料和/或不同分子量或不同化学组成材料的混合物。这样的二和三官能性材料包括但不限于聚乙二醇、聚丙二醇、基于甘油的聚醚三醇、基于三羟甲基丙烷的聚醚三醇和其他类似化合物或混合物。
除了上述的基础多元醇之外或代替它们,在用于本发明的多元醇组分中可以包含通常被称为“共聚物多元醇”的材料。共聚物多元醇可以用于聚氨酯泡沫中以增加对变形的抗性,例如提高承载性质。取决于承载要求,共聚物多元醇以重量计可以占总多元醇含量的0至约80%。共聚物多元醇的实例包括但不限于接枝多元醇和聚脲改性的多元醇,二者在本技术领域中都是已知的并可商购。
接枝多元醇通过将乙烯基单体、典型为苯乙烯和丙烯腈在起始多元醇中进行共聚来制备。起始多元醇典型为甘油引发的三醇,并典型地用环氧乙烷封端(约80-85%的伯羟基)。一些共聚物接枝到一些起始多元醇上。接枝多元醇还包含苯乙烯和丙烯腈的均聚物和未改变的起始多元醇。接枝多元醇的苯乙烯/丙烯腈固体含量典型地在5wt%至45wt%范围内,但是可以使用本技术领域已知的任何类型的接枝多元醇。
聚脲改性的多元醇由二胺和二异氰酸酯在起始多元醇存在下的反应来形成,其中产物含有聚脲分散体。也适合使用的聚脲改性的多元醇的变化形式是多异氰酸酯多加成(PIPA)多元醇,其通过异氰酸酯和烷醇胺在多元醇中的原位反应来形成。
本发明可以使用的其它合适的多元醇包括天然油多元醇或从可再生天然资源例如植物油获得的多元醇。高度期望可用于从廉价且可再生资源制备聚氨酯泡沫的多元醇,以最小化化石燃料和其它不可持续资源的消耗。天然油由饱和和不饱和脂肪酸的甘油三酯构成。一种天然油多元醇是蓖麻油,它是蓖麻油酸的天然甘油三酯,通常用于制造聚氨酯泡沫,虽然它具有某些局限性,例如羟基含量低。其它天然油需要化学改性,以引入足够的羟基含量,使得它们可用于生产聚氨酯聚合物。当尝试将天然油或脂肪改性为有用的多元醇时,有两个化学反应性部位可以考虑:1)不饱和部位(双键);和2)酯官能团。油或脂肪中存在的不饱和部位可以通过环氧化然后通过开环或加氢甲酰基化然后氢化而发生羟基化。或者,也可以利用酯交换将OH基团引入天然油和脂肪中。利用环氧化途径制备天然多元醇的化学方法涉及一种反应混合物,其需要环氧化的天然油、开环酸催化剂和开环剂。环氧化的天然油包括环氧化的植物基油(环氧化植物油)和环氧化的动物脂肪。所述环氧化天然油可以完全或部分环氧化,这些油包括大豆油、玉米油、向日葵油、橄榄油、芥花油、芝麻油、棕榈油、菜籽油、桐油、棉籽油、红花油、花生油、亚麻籽油及其组合。动物脂肪包括鱼油、牛油和猪油。这些天然油是脂肪酸的甘油三酯,脂肪酸可以是饱和或不饱和的,且具有从C12至C24的各种链长。这些酸可以是:1)饱和的:月桂酸、肉豆蔻酸、棕榈酸、硬脂酸、花生酸和二十四酸;2)单不饱和的:棕榈油酸,油酸;3)多不饱和的:亚油酸,亚麻酸,花生四烯酸。当过氧酸在合适的反应条件下反应时,可以制备部分或完全环氧化的天然油。油的环氧化中使用的过氧酸的例子描述在WO2006/116456A1中;所述公布在此通过引用并入。可以使用用醇、水及其他具有一个或多个亲核基团的化合物对环氧化油开环。取决于反应条件,还可以发生所述环氧化油的低聚。开环产生可以用于制造聚氨酯产物的天然油多元醇。在所述加氢甲酰基化/氢化过程中,所述油在填充有氢气/一氧化碳混合物的反应器中在合适的催化剂(通常是钴或铑)存在下加氢甲酰基化,形成醛,醛在钴或镍催化剂存在下氢化,形成多元醇。或者,通过利用碱金属或碱土金属碱或盐作为酯交换催化剂,与合适的含多羟基的物质进行酯交换,可以从天然油和脂肪产生多元醇。在所述酯交换方法中可以使用任何天然油或者备选地任何部分氢化油。油的例子包括但不限于大豆油、玉米油、棉籽油、花生油、蓖麻油、向日葵油、芥花油、油菜籽油、红花油、鱼油、海豹油、棕榈油、桐油、橄榄油或任何掺合物。还可以使用任何多官能羟基化合物,例如乳糖、麦芽糖、棉子糖、蔗糖、山梨糖醇、木糖醇、赤藓糖醇、甘露糖醇、或任何组合。
多元醇的量通过pphp限定。上面限定了3种类型的多元醇:标准多元醇或聚醚多元醇,其可以使用的范围为约100pphp(唯一的多元醇)至约10pphp。共聚物多元醇(CPP)可以使用的范围为约0至约80pphp。最后,NOP(天然油多元醇)通常以约0至约40pphp存在。
发泡剂
可以通过包含发泡剂(BA)以在聚合反应期间在聚氨酯基质中产生空隙,以帮助聚氨酯泡沫生产。可以使用任何合适的发泡剂。适合的发泡剂包括具有低沸点,在放热聚合反应期间挥发的化合物。这样的发泡剂一般是惰性的或者它们具有低反应性,因此它们在聚合反应期间将不分解或反应是可能的。低反应性发泡剂的实例包括但不限于二氧化碳、氯氟烃(CFC)、氢氟烃(HFC)、氢氯氟烃(HCFC)、氟烯烃(FO)、氯氟烯烃(CFO)、氢氟烯烃(HFO)、氢氯氟烯烃(HCFO)、丙酮和低沸点烃类例如环戊烷、异戊烷、正戊烷及其混合物。其他适合的发泡剂包括与异氰酸酯化合物反应产生气体的化合物,例如水。BA的量典型为约0(水发泡)至约80pphp。水(通过与异氰酸酯反应制造CO2来发泡泡沫)可以以约0(如果包含BA)至约60pphp(极低密度泡沫)、典型约1.0pphp至约10pphp并且在某些情况下约2.0pphp至约5pphp的范围存在。
其它任选的组分
在用于制造本发明的泡沫的制剂中可以包含各种其他成分。任选的组分的实例包括但不限于孔稳定剂、交联剂、扩链剂、颜料、填充剂、阻燃剂、辅助聚氨酯胶凝催化剂、辅助聚氨酯发泡催化剂、过渡金属催化剂、碱金属和碱土金属羧酸盐以及这些组分的任何组合。
孔稳定剂可以包括例如硅氧烷表面活性剂以及有机阴离子型、阳离子型、两性离子型或非离子型表面活性剂。适合的硅氧烷表面活性剂的实例包括但不限于聚烷基硅氧烷、聚氧化烯多元醇改性的二甲基聚硅氧烷、亚烷基二醇改性的二甲基聚硅氧烷或其任何组合。适合的阴离子型表面活性剂包括但不限于脂肪酸的盐、硫酸酯的盐、磷酸酯的盐、磺酸的盐及其任何组合。合适的阳离子型表面活性剂包括但不限于季铵盐(pH依赖性或永久带电荷的)例如十六烷基三甲基氯化铵、十六烷基氯化吡啶啶鎓、聚乙氧基化牛油胺、苯扎氯铵、苄索氯铵等等。合适的两性离子型或两性表面活性剂包括但不限于磺基甜菜碱、氨基酸、亚氨基酸、甜菜碱和磷酸盐。合适的非离子型表面活性剂包括但不限于脂肪醇、聚氧亚乙基二醇烷基醚、聚氧亚丙基二醇烷基醚、糖苷(例如癸基、月桂基和辛基葡糖苷)、聚氧亚乙基二醇烷基酚醚、二醇烷基酯等等。
交联剂包括但不限于含有至少两个组成部分的低分子量化合物,所述组成部分选自羟基、伯氨基、仲氨基和与异氰酸酯基团具有反应性的其他含有活性氢的基团。交联剂包括例如多元醇(特别是三元醇例如甘油和三羟甲基丙烷)、多胺及其组合。多胺交联剂的非限制性实例包括二乙基甲苯二胺、氯代二氨基苯、二乙醇胺、二异丙醇胺、三乙醇胺、三丙醇胺、1,6-己二胺及其组合。典型的二胺交联剂包含12个或更少碳原子,更常见为7个或更少碳原子。
扩链剂的实例包括但不限于具有羟基或氨基官能团的化合物,例如二醇、胺、二元醇和水。扩链剂的具体的非限制性实例包括乙二醇、二乙二醇、丙二醇、二丙二醇、1,4-丁二醇、1,3-丁二醇、1,5-戊二醇、新戊二醇、1,6-己二醇、1,10-癸二醇、1,12-十二烷二醇、乙氧基化的对苯二酚、1,4-环己二醇、N-甲基乙醇胺、N-甲基异丙醇胺、4-氨基环己醇、1,2-二氨基乙烷、2,4-甲苯二胺或其任何混合物。
颜料可用于在制造期间对聚氨酯泡沫进行颜色编码,以例如识别产品等级或掩饰黄变。颜料可以包括聚氨酯技术领域中已知的任何适合的有机或无机颜料。例如,有机颜料或着色剂包括但不限于偶氮/重氮染料、酞菁染料、二噁嗪类和炭黑。无机颜料的实例包括但不限于二氧化钛、氧化铁或氧化铬。
填充剂可用于提高聚氨酯泡沫的密度和承载性质。适合的填充剂包括但不限于硫酸钡或碳酸钙。
阻燃剂可用于降低聚氨酯泡沫的可燃性。例如,适合的阻燃剂包括但不限于氯化磷酸酯、氯化石蜡或三聚氰胺粉末。
孔稳定剂的用量可以从约0.1至约20pphp,通常从约0.1至约10pphp,在有些情况下从约0.1至约5.0pphp。阻燃剂的用量可以从约0至约20pphp,并从约0至约10pphp,并从约0至约5pphp。
本发明的某些方面通过以下实施例说明。这些实施例只是说明性的,并且将不会限制所附的任何权利要求的范围。泡沫利用如下所述的手混评价或机器评价进行评价。
实施例
手混(Handmix)评价
使用下列程序执行手混实验。使用装备有直径为7.6cm的高剪切混合叶片、以5000rpm旋转的机械混合器,将制剂在一起掺混约10分钟。使用低温保温器将预混合的制剂保持在23±1℃下。以正确的化学计量向预混物加入Mondur TD-80(80/20的甲苯二异氰酸酯的2,4/2,6-异构体的掺混物)或改性的MDI,以获得每种泡沫的报告的指数。使用PremierMill Corporation2000系列89型混合器将混合物掺混在一起并分散约5秒。将发泡混合物转移至Imperial Bondware#GDR-170纸桶,并允许其自由起发,同时记录数据。
机器评价
软质模塑泡沫的机器运行在Hi Tech Sure Shot MHR-50汽缸排气系列和高压机器上执行。将用于每种制剂的由适合的多元醇、水、交联剂、表面活性剂和催化剂构成的新鲜预混物装入机器。在整个研究期间使用Mondur TD-80。通过机器的内部温度控制装置将所有化学品的温度保持在23±2℃。将泡沫浇注到保持在63±2℃下的等温控制的加热铝制模具中。所述模具是典型的物理性质工具,其被设计成具有40.6cm x40.6cm x10.2cm的内部尺寸。模具具有5个直径各为约1.5mm的通气孔,其中心位于每个角落距每条边10.0cm处和顶盖的几何中心处。在每次浇注之前,用基于溶剂的脱模剂喷洒模具,并在浇注前允许其干燥1分钟。将泡沫预混物搅拌浇注到模具中心,使得化学品装料的湿重能够完全填充模具并获得报告的期望的芯部密度。对每种评价的制剂建立最小填充要求。在最初浇注(在下一段中详细描述)后240秒(4分钟)时将泡沫制品脱模。脱模后,将泡沫通过机械压碎机,或者测试以获得压碎力(FTC)测量值,或者冷却下来以测定尺寸稳定性(下文详述)。
每个催化剂组制造的泡沫,在脱模后1分钟,使用间隙设定为2.54cm的BlackBrothers Roller压碎机进行机械压碎。在每个部件上执行三次压碎,在每次通过辊后将泡沫旋转90度。将所生产的用于物理测试的所有部件在恒定温度和湿度的房间(23±2℃,50±2%相对湿度)中养护至少7天。
FTC测量在脱模后45秒进行。将所述垫从模具取出,称重并置于FTC装置中。力检测装置装备有2.2kg容量的压力变换器,其安装在323cm2的圆形板十字头与传动轴之间。实际的力显示在数字显示器上。该装置模拟ASTM D-3574压痕力挠曲试验,并提供新鲜脱模泡沫的初始硬度或软度的数值。将所述垫以每分钟275mm的十字头速度压缩至其原始厚度的50%,并以牛顿为单位记录获得最高压缩循环所需的力。完成10个压缩循环。每个循环花费约30秒完成
实施例1
选择具有异氰酸酯反应性基团的叔胺催化剂
通过向32oz(951ml)纸杯中的约302g预混合物(按照表2制备)添加叔胺催化剂来制备泡沫垫。所述制剂利用装有2-英寸(5.1cm)直径搅拌桨叶的顶置式搅拌器以约6,000RPM混合约10秒。
然后添加甲苯二异氰酸酯,并使用相同搅拌器将所述制剂以约6,000RPM再充分混合约6秒,然后将它倒入70℃的预热模具中并在4分钟之后脱模。从模具取出泡沫垫,手工挤压,称重并在75%垫厚度下机器挤压。泡沫垫储存在恒温恒湿条件下48小时,然后被切割和测试。
表1:预混合物组分
1高分子量、官能度和伯羟基含量的高官能度封端聚醚多元醇,基础多元醇分子量约5500,可得自Dow Chemical Company,Midland,MI。
2含有共聚苯乙烯和丙烯腈的接枝聚醚多元醇,基础多元醇分子量约4800,可得自Dow Chemical Company,Midland,MI。
3硅氧烷表面活性剂可得自Air Products and Chemicals,Inc。
4胺催化剂可得自Air Products and Chemicals,Inc。
然后添加甲苯二异氰酸酯,并使用相同搅拌器将所述制剂以约6,000RPM再充分混合约6秒,然后将它倒入70℃的预热模具中并在4分钟之后脱模。从模具取出泡沫垫,手工挤压,称重并在75%垫厚度下机器挤压。通过让所述泡沫垫冷却并观察是否发生收缩来评价尺寸稳定性(泡沫收缩率)。泡沫垫储存在恒温恒湿条件下48小时,然后被切割和测试。
表2显示了对于具有不同分子结构和异氰酸酯反应性官能团的胶凝催化剂,软质模制聚氨酯垫的环境物理性质。软质模制垫使用单一胶凝胺催化剂制造,以显示每个单个结构对物理性质的影响。发泡剂在每种情况下都是NE300(N,N,N'-三甲基-N'-3-氨丙基-双(氨乙基)醚)。所述评价显示含有异氰酸酯反应性基团例如脲(-NHCONH2或-NHCONH-)或胺(=NH或NH2)和仲羟基(R2CH-OH)的催化剂产生物理性质可接受的泡沫。然而,含有伯羟基的胶凝催化剂产生物理性质差的泡沫,以(表2中的催化剂7)和(表2和3中的催化剂6)的很高的50%压缩形变为证据。胶凝催化剂二甲基氨基乙氧基乙醇(表2和3中的催化剂3)在环境条件下显示了良好的物理性质,然而在潮湿老化条件(表3)下观察到机械完整性的完全损失,以极低值的潮湿老化拉伸强度和伸长率以及高的50%压缩形变为证据。用含有伯羟基官能团的其它胶凝催化剂,例如(表2和3中的催化剂7;N-二甲基氨乙基-N-(2-羟乙基)-N-甲胺)和(表2和3中的催化剂6;N-二甲基氨丙基-N-(2-羟乙基)-N-甲胺),观察到类似的趋势。因此,存在于所述叔胺胶凝催化剂中的异氰酸酯反应性基团应该含有以下官能团:a)胺基(=NH或-NH2),b)脲(-NHCONH2,-NHCONH-),c)仲羟基(R2CH-OH),d)酰胺。含有伯羟基的胶凝催化剂将产生在老化期间会发生物理性质全面劣化的泡沫。
表2:环境数据下的物理性质
表3:在潮湿老化条件下的物理性质
实施例2
对用没有异氰酸酯反应性基团的标准胺催化剂制成的泡沫测量的排放物
通过向32oz(951ml)纸杯中的约302g预混合物(按照表4制备)添加叔胺催化剂来制备泡沫垫。所述制剂利用装有2-英寸(5.1cm)直径搅拌桨叶的顶置式搅拌器以约6,000RPM混合约10秒。
然后添加甲苯二异氰酸酯,并使用相同搅拌器将所述制剂以约6,000RPM再充分混合约6秒,然后将它倒入70℃的预热模具中并在4分钟之后脱模。从模具取出泡沫垫,手工挤压,称重并在75%垫厚度下机器挤压。通过让所述泡沫垫冷却并观察是否发生收缩来评价尺寸稳定性(泡沫收缩率)。泡沫垫储存在恒温恒湿条件下48小时,然后被切割和测试。
表4:预混合物组分
1高分子量、官能度和伯羟基含量的高官能度封端聚醚多元醇,基础多元醇分子量约5500,可得自Dow Chemical Company,Midland,MI。
2含有共聚苯乙烯和丙烯腈的接枝聚醚多元醇,基础多元醇分子量约4800,可得自Dow Chemical Company,Midland,MI。
3硅氧烷表面活性剂,可得自Air Products and Chemicals,Inc。
4胺催化剂,可得自Air Products and Chemicals,inc。
利用热解吸附分析测量来自于泡沫的排放物,并根据VDA278方法量化在90℃(VOC)和120℃(FOG)下散发的物质。为了这个目的,试验材料样品在惰性气流中加热,并且释放的物质在气相色谱的冷冻进样器中冻析。所述混合物然后通过气相色谱柱和定量总排放物。用同一样品测量VOC和FOG。相对于外标甲苯进行气态排放物(VOC)的定量,同时相对于十六烷(C16-正烷烃)定量可冷凝的排放物(FOG)。浓度以甲苯和十六烷类似物作为总排放物以ppm报告。
表5:用没有异氰酸酯反应性基团的标准胺催化剂制成的聚氨酯泡沫排放物
排放物类型 | 测量值(ppm) |
VOC | 801 |
FOG | 90 |
总排放物 | 891 |
实施例3
用以常规酸2-乙基己酸封闭的标准胺催化剂制成的泡沫发出的聚氨酯排放物
泡沫垫按照实施例2制备,但在这种情况下,如泡沫试样#2所示,在所述聚氨酯制剂中使用2-乙基己酸。
泡沫试验显示来自于单羧酸的排放物显著影响成品的总VOC和FOG。
表6:用标准胺催化剂和单羧酸制成的泡沫的排放物
实施例4
用以丙二酸封闭的标准胺催化剂制成的泡沫发出的聚氨酯排放物
泡沫垫按照实施例2制备,但在这种情况下向所述聚氨酯制剂添加丙二酸。
泡沫试验显示当使用排放性催化剂时,在存在或不存在丙二酸下的排放物是相似的。
表6:用标准胺催化剂和丙二酸制成的泡沫的排放物
排放物类型 | 测量值(ppm) |
VOC | 791 |
FOG | 91 |
总排放物 | 882 |
实施例5
用含有异氰酸酯反应性基团的胺催化剂制成的泡沫发出的聚氨酯排放物
泡沫垫按照实施例1制备,但在这种情况下向所述聚氨酯制剂添加丙二酸。
泡沫试验显示,正如所料,当使用含有异氰酸酯反应性基团的叔胺催化剂时,排放物减少
表7:用具有异氰酸酯反应性基团的胺催化剂制成的泡沫发出的排放物
排放物类型 | 测量值(ppm) |
VOC | 339 |
FOG | 101 |
总排放物 | 440 |
实施例6
用含有异氰酸酯反应性基团的胺催化剂和选定的酸制成的泡沫发出的排放物
下表概括了在制备泡沫样品中使用的催化剂和有机酸的使用水平。
表8:用不同的一些代表性二酸获得的总排放物减少
这些实施例证明了当:a)选择具有来自脲、仲羟基和仲胺的异氰酸酯反应性官能团的胶凝叔胺催化剂;b)选择本发明的有机二羧酸和c)适当的a)和b)组合时,可以获得具有希望的物理特性和低化学排放物的泡沫。所述结果是令人惊讶的和出乎意料的,并且不能仅仅通过消除胺和酸排放物来解释。
虽然本发明已经参考优选实施方式进行了描述,但本领域技术人员应理解,在不背离本发明的范围的情况下,可以做出各种改变并且可以等价代替其要素。另外,可以进行许多修改以使具体情况或材料适应本发明的教导而不背离其基本范围。因此,旨在本发明不限于将公开的具体实施方式作为所考虑的执行本发明的最佳方式,而是本发明将包括落在所附权利要求书范围内的所有实施方式。
Claims (8)
1.一种催化剂,所述催化剂包含选自二羧酸和三羧酸的至少一种酸、和包含选自脲、酰胺、仲胺、伯胺或仲羟基的至少一个官能团的至少一种叔胺,并且其中所述酸没有异氰酸酯反应性基团和叔胺基本上不含伯羟基,
其中所述叔胺包含选自N,N-双(3-二甲基氨丙基)-N-(2-羟丙基)胺;N,N-二甲基-N',N'-双(2-羟丙基)-1,3-丙二胺;二甲基氨基丙胺(DMAPA);N-甲基-N'-2-羟丙基-哌嗪;双(二甲基氨丙基)胺,二甲基氨丙基脲;N,N'-双(3-二甲基氨丙基)脲,双(二甲基氨基)-2-丙醇,N-(3-氨丙基)咪唑,N-(2-羟丙基)咪唑,N-(2-羟乙基咪唑),N,N'-双(2-羟丙基)哌嗪,N-(2-羟丙基)-吗啉和6-二甲基氨基-1-己醇的至少一种;以及
其中所述催化剂还包含选自2-[N-(二甲基氨基乙氧基乙基)-N-甲氨基]乙醇和N,N,N'-三甲基-N'-3-氨丙基-双(氨乙基)醚的至少一种。
2.权利要求1的催化剂,其中所述酸包含选自富马酸、丙二酸、马来酸、琥珀酸、戊二酸、己二酸、庚二酸、辛二酸、壬二酸、癸二酸、戊烯二酸、愈伤酸、粘康酸、邻苯二甲酸、间苯二甲酸和对苯二甲酸的至少一种。
3.权利要求1的催化剂,所述催化剂由选自二羧酸和三羧酸的至少一种酸,包含选自脲、酰胺、仲胺、伯胺或仲羟基的至少一个官能团的至少一种叔胺,和选自2-[N-(二甲基氨基乙氧基乙基)-N-甲氨基]乙醇和N,N,N'-三甲基-N'-3-氨丙基-双(氨乙基)醚的至少一种组成。
4.权利要求3的催化剂,其中所述酸不含OH、NH=、NH2-、脲、酰胺、或除羧酸官能团以外的任何其它官能团。
5.用于制造聚氨酯泡沫的方法,所述方法包括在权利要求1的催化剂存在下的同时,将至少一种多元醇、和至少一种有机多异氰酸酯接触。
6.用于制造聚氨酯泡沫的方法,所述方法包括在权利要求3的催化剂存在下的同时,将至少一种多元醇和至少一种有机多异氰酸酯接触。
7.权利要求5的方法,其中所述泡沫包括软质开孔泡沫。
8.权利要求7的方法,其中根据VDA 278方法,所述泡沫没有叔胺或羧酸排放物。
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