CN104321360B - 减少醛排放的聚氨酯泡沫、用于制备该泡沫的方法和用于减少聚氨酯泡沫中醛排放的方法 - Google Patents
减少醛排放的聚氨酯泡沫、用于制备该泡沫的方法和用于减少聚氨酯泡沫中醛排放的方法 Download PDFInfo
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Classifications
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- C08G18/0857—Manufacture of polymers in the presence of non-reactive compounds in the presence of liquid diluents in the presence of solvents for the polymers the solvents being organic the solvent being a polyol
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08G18/724—Combination of aromatic polyisocyanates with (cyclo)aliphatic polyisocyanates
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- C08G18/7614—Polyisocyanates or polyisothiocyanates cyclic aromatic containing only one aromatic ring
- C08G18/7621—Polyisocyanates or polyisothiocyanates cyclic aromatic containing only one aromatic ring being toluene diisocyanate including isomer mixtures
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08G18/78—Nitrogen
- C08G18/79—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
- C08G18/791—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups
- C08G18/792—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups formed by oligomerisation of aliphatic and/or cycloaliphatic isocyanates or isothiocyanates
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0008—Foam properties flexible
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Dispersion Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Polyurethanes Or Polyureas (AREA)
Abstract
本发明涉及呈现减少的醛排放的聚氨酯泡沫、用于制备这些泡沫的方法和减少泡沫中醛排放的方法。本文所述的聚氨酯还包括添加至异氰酸酯反应性组分的少量聚亚肼基二甲酰胺分散体多元醇，或者添加至多异氰酸酯组分的三聚六亚甲基二异氰酸酯。
Description
发明背景
本发明涉及呈现减少的醛排放的聚氨酯泡沫，用于制备这些具有减少的醛排放的泡沫的方法，和减少聚氨酯泡沫中醛排放的方法。
NIOSH和OSHA已经规定了醛暴露限制，特别包括用于甲醛和乙醛的限制。对于汽车工业和板材工业而言，这些暴露极限具有重要意义，因为这些工业整体努力来提高汽车车厢和床上用品的空气质量。汽车和床上用品的终端用户暴露于任意过量的VOC(挥发性有机化合物)，包括可能从泡沫排放的醛。
从之前的研究已知，当在存在空气加热时，泡沫和用来制备泡沫的聚醚多元醇同时排放醛。因此，大多数的聚氨酯泡沫和用来制备这些泡沫的方法将导致醛的排放。
日本汽车制造商协病态居室症候群会(JAMA)已确认了几种VOC，包括甲醛和乙醛，是所谓的“病态居室症候群(sick-house syndrome)”的来源。逐渐地，通常要求汽车泡沫通过丰田测试(Toyota)，即TSM0508G测试，且要求板材泡沫通过CertiPUR/LGA/-EUROPUR/IKEA测试。在欧洲，可给予满足这些测试中的一种或更多种的泡沫产品一个印章或标志来表示之。因此，在欧洲客户寻找具有这些印章或标志的泡沫产品不是不常见的。
已尝试了多种方法来减少醛排放。美国专利申请公开第20080281013号揭示了可通过在用来制备聚氨酯树脂的多元醇组分中包括至少一种含硫化合物，来减少聚氨酯树脂加热储存时的醛排放。合适的含硫化合物选自下组：亚硫酸氢盐和二亚硫酸盐。通常，对于每100份的多元醇组分，以重量计添加0.02-2份的含硫化合物。
能制备和/或出售可通过这些严厉的要求的聚氨酯泡沫的任意制造商，特别是相对于醛排放而言，比它们的竞争者具有显著的竞争优势。工业上高度期望减少醛排放和降低终端用户和客户暴露于这些排放的新方式。
美国专利第7,678,840号揭示了一种反应性系统和用于减少腔体填充NVH聚氨酯泡沫中游离MDI排放的方法。这些系统包括聚亚甲基聚(异氰酸苯酯)，其具有大于70重量％的聚合物MDI含量和小于30重量％的单体MDI含量，且所述单体MDI包括小于或等于25重量％的4,4’-异构体，小于或等于5重量％的2,4’-异构体和小于或等于2％的2,2’-异构体。这些反应性系统适于吸音泡沫和结构泡沫，其具有减少的异氰酸酯排放，即减少量的游离MDI。
美国专利申请公开第20080125507号揭示了反应性系统和用于减少来自低密度腔体填充NVH聚氨酯泡沫的VOC(挥发性有机化合物)排放的方法。这些反应性系统包括：(A)聚亚甲基聚(异氰酸苯酯)，其具有大于或等于55重量％的聚合物含量，小于或等于45重量％的单体含量；以及(B)一种异氰酸酯反应性组分，其中包括(1)具有分子量为约1,000-约10,000、官能度为约2-约6且OH值为约10-约340的至少一种异氰酸酯反应性化合物；以及(2)具有分子量为约60-小于1,000、官能度为约2-约4且OH值为约110-约3750的至少一种异氰酸酯反应性化合物；其中(B)(1)和(B)(2)中的至少一种包括胺起始化合物；存在(C)至少一种催化剂；以及(D)含水的发泡剂。
美国专利第5,373,028号揭示了在固化时具有减少的可见排放的泡沫。这些泡沫由一种配方来制备，该配方包括(a)多异氰酸酯，(b)异氰酸酯反应性组分，(c)可见排放产生组分，以及(d)可见排放减少剂，这些组分在一定条件下反应来形成聚氨酯泡沫和/或聚脲泡沫，并冷却泡沫，其中在冷却时排放可见排放。在泡沫配方中存在(d)可见排放减少剂，导致在固化时从泡沫排放更低量的可见排放。抗氧化剂被描述为可见排放产生组分。所揭示的合适的可见排放减少剂是(a)碱金属二氢磷酸盐和碱金属二氢多磷酸盐，(b)碱金属硫酸盐，(c)硫酸铝、磷酸铝、聚磷酸铝、硼酸铝和链烷酸铝，(d)硫酸铵、磷酸铵、聚磷酸铵、硼酸铵和链烷酸铵，(e)酰基氯，以及(f)其混合物。
填充多元醇(filled polyol)是已知的，且在现有技术中描述。这些填充多元醇通常是用其它有机聚合物“填充”的聚醚多元醇，来产生粘性的、白色至灰白色流体，其适用于制备具有比常规的未改性多元醇可产生的增加的(即更高的)硬度水平的泡沫。总的来说，使用自由基加成或逐步加成方法，通过在多元醇基础中的一种或更多种单体的原位聚合来制备填充多元醇。通用类型的填充多元醇包括苯乙烯-丙烯腈聚合物多元醇(即，SAN聚合物多元醇)，聚亚肼基二甲酰胺(即，PHD)多元醇，和多异氰酸酯聚加成多元醇(即，PIPA多元醇)。
如美国专利第4,324,716号所述，PHD多元醇或聚亚肼基二甲酰胺(polyhydrazodicarbonamide)多元醇可包括下述物质的反应产物：(a)一种或更多种多异氰酸酯，与(b)一种或更多种酰肼、多胺、二酰肼、氨、脲和/或低分子量多元醇，以及(c)任选地更高分子量的多元醇，以及(d)任选地，甲醛，且存在一种或更多种具有分子量为62-450的一种或更多种多元醇。这些分散体的固含量为约5-70重量％，且是具有低粘度的透明、储存稳定的溶液。在参考文献的实施例中，从常规的聚醚多元醇和PHD多元醇制备泡沫。在美国专利第4,324,716号中没有揭示或提及在泡沫产品中减少醛排放。
尽管已经使用了各种方法来减少来自聚氨酯泡沫和/或聚脲泡沫的不同类型的排放，现有方法都没有包括将少量的三聚六亚甲基二异氰酸酯添加至多异氰酸酯组分，或者将少量的聚亚肼基二甲酰胺分散体添加至异氰酸酯反应性组分。本发明的目的是减少泡沫产品中的醛排放。
本发明的优势包括能通过将低水平的三聚六亚甲基二异氰酸酯添加至多异氰酸酯组分，或者将少量的聚亚肼基二甲酰胺添分散体多元醇添加至异氰酸酯反应性组分来形成具有减少的醛排放的产品，以及能制备符合如上所述的不同排放规定的泡沫产品。
发明内容
本发明涉及一种聚氨酯泡沫，其包括下述物质的反应产物：
(1)多异氰酸酯组分(优选的包括甲苯二异氰酸酯)，
和
(2)异氰酸酯-反应性组分，其包含：
(a)至少一种聚醚多元醇，其具有2-6的官能度、18-238的OH值以及160-8000的数均分子量，
和
(b)至少一种填充多元醇，其具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％的固体，其选自下组：(i)苯乙烯/丙烯腈聚合物多元醇，(ii)多异氰酸酯聚加成(PIPA)多元醇，它是由异氰酸酯和链烷醇胺原位反应形成的聚氨酯分散体，以及(iii)其混合物；
在以下物质的存在下
(3)至少一种发泡剂，
(4)至少一种催化剂，
和
(5)至少一种表面活性剂。
根据本发明，这些聚氨酯泡沫还包括：0.5-8份的三聚六亚甲基二异氰酸酯每100份的(1)多异氰酸酯组分，或者2-5.5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的(2)异氰酸酯反应性组分。
本发明还涉及一种制备这些聚氨酯泡沫方法。所述方法包括：
(A)使下述物质反应：
(1)多异氰酸酯组分(优选的包括甲苯二异氰酸酯)，
和
(2)异氰酸酯-反应性组分，其包含：
(a)至少一种聚醚多元醇，其具有2-6的官能度、18-238的OH值以及160-8000的数均分子量，
和
(b)至少一种填充多元醇，其具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％的固体，其选自下组：(i)苯乙烯/丙烯腈聚合物多元醇，(ii)多异氰酸酯聚加成(PIPA)多元醇，它是由异氰酸酯和链烷醇胺原位反应形成的聚氨酯分散体，以及(iii)其混合物；
在以下物质的存在下
(3)一种或更多种发泡剂；
(4)至少一种催化剂；
和
(5)至少一种表面活性剂；
其中(1)所述多异氰酸酯组分还包括：0.5-8份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯组分，或者(2)所述异氰酸酯反应性组分还包括：2-5.5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的(2)异氰酸酯反应性组分。
本发明还涉及减少聚氨酯泡沫中醛排放的方法。所述方法包括：
(A)使下述物质反应：
(1)多异氰酸酯组分(优选的包括甲苯二异氰酸酯)，
和
(2)异氰酸酯-反应性组分，其包含：
(a)至少一种聚醚多元醇，其具有2-6的官能度、18-238的OH值以及160-8000的数均分子量，
和
(b)至少一种填充多元醇，其具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％的固体，其选自下组：(i)苯乙烯/丙烯腈聚合物多元醇，(ii)多异氰酸酯聚加成(PIPA)多元醇，它是由异氰酸酯和链烷醇胺原位反应形成的聚氨酯分散体，以及(iii)其混合物；
在以下物质的存在下
(3)一种或更多种发泡剂；
(4)至少一种催化剂，
和
(5)至少一种表面活性剂；
其中(1)所述多异氰酸酯组分还包括：0.5-8份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯组分，或者(2)所述异氰酸酯反应性组分还包括：2-5.5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的所述异氰酸酯反应性组分。
发明详述
除工作实施例，或者另有说明以外，说明书中表示数量、百分数、OH值、官能度等的所有数字应理解为在所有情况中都用词“约”修饰。
除非另有说明，文中所述的所有范围包括端点。
如本文中所用，以下术语具有以下含义。
如本文中所用，羟值定义为由1克多元醇制备的完全邻苯二甲酸酯化的衍生物全部水解所需的氢氧化钾的毫克数。羟值也可以用以下等式定义：
OH＝(56.1x1000)/当量重量
式中：
OH:表示多元醇的羟值，
当量重量：表示多元醇的平均当量重量。
如文中所用，多元醇的官能度表示多元醇的平均官能度，即每个分子的平均羟基数。
如本文所用，术语分子量表示数均分子量，除非另外指出。
术语“异氰酸酯指数(通常也称为“NCO指数”)在本文中定义为异氰酸酯的当量数除以含异氰酸酯-活性氢的物质的总当量数再乘以100。
如文中所用，除非另有清楚的说明，所有数值范围，量，值和百分数(例如材料的量，反应的时间和温度，量的比值，分子量值和以下说明书部分中的其它表示)可以认为前有词"约"修饰，即使该词"约"并未清楚地与值、量或范围一起出现。
根据本发明，合适的多异氰酸酯组分包括工业上易于获取的多异氰酸酯，例如2,4-和2,6-甲苯二异氰酸酯和这些异构体的任意所需混合物("TDI")；聚苯基-聚亚甲基-多异氰酸酯，例如通过苯胺-甲醛缩合和后续的光气化反应制备的("粗MDI")，以及包含碳化二亚胺基团、氨基甲酸酯基团、脲基甲酸盐基团、异氰脲酸酯基团、尿素基团或缩二脲基团的多异氰酸酯(改性多异氰酸酯)，特别是衍生自2,4-和/或2,6-甲苯二异氰酸酯或者衍生自4,4'-和/或2,4'-二苯基甲烷二异氰酸酯的那些。优选的，多异氰酸酯组分包括芳香族二异氰酸酯或多异氰酸酯。更优选地，多异氰酸酯组分包括选自下组的至少一种化合物：2,4-和2,6-甲苯二异氰酸酯，4,4'-和2,4'-和2,2'-二苯基甲烷二异氰酸酯，以及聚苯基-聚亚甲基-多异氰酸酯(“多核MDI”)。甲苯二异氰酸酯是本文的特别优选的多异氰酸酯组分。
总的来说，优选地将甲苯二异氰酸酯作为2,4-和/或2,6-甲苯二异氰酸酯和这些异构体的混合物("TDI")来使用。例如，本文所述的甲苯二异氰酸酯可包括35-20重量％的甲苯二异氰酸酯2,6-异构体和65％-80重量％的甲苯二异氰酸酯2,4-异构体，且所述2,6-异构体和2,4-异构体之和总计为100％的甲苯二异氰酸酯。此外，如果多异氰酸酯是100％甲苯二异氰酸酯，所述2,6-异构体和2,4-异构体之和总计为100％的多异氰酸酯组分。
更优选地，本文所述的甲苯二异氰酸酯包括19-21重量％的2,6-异构体和79-81重量％的2,4-异构体，且2,6-异构体和2,4-异构体之和总计为100％的甲苯二异氰酸酯(且总计为100％的多异氰酸酯组分，如果如果多异氰酸酯是100％甲苯二异氰酸酯)。
多异氰酸酯和二异氰酸酯的残留产物不适于用作根据本发明的组分(1)。
此外，从多异氰酸酯组分(1)中不包括三聚六亚甲基二异氰酸酯。
本发明的合适的异氰酸酯反应性组分包括：(a)至少一种聚醚多元醇，其具有2-6的官能度、18-238的OH值以及160-8000的数均分子量，以及(b)至少一种填充多元醇，其具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％的固体，其选自下组：(i)苯乙烯/丙烯腈聚合物多元醇，(ii)多异氰酸酯聚加成(PIPA)聚合物，它是由异氰酸酯和链烷醇胺原位反应形成的聚氨酯分散体，以及(iii)其混合物。
根据本发明，(2)异氰酸酯反应性组分通常包括(a)20-90重量％(优选地40-90重量％)的一种或更多种聚醚多元醇，以及(b)10-80重量％(优选地10-60重量％)的一种或更多种填充多元醇，且(a)和(b)的重量％之和总计为100重量％的(2)异氰酸酯反应性组分。
适于用作本文所述的组分(2)(a)的聚醚多元醇通常具有2-6的官能度、18-238的OH值以及160-8000的数均分子量。优选地，这些聚醚多元醇具有2.5-3.5的官能度和28-42的OH值。
总的来说，适于本发明的聚醚多元醇通常是在碱性催化剂如KOH,NaOH,BF3等的存在下，合适的引发剂或起始剂化合物和一种或更多种环氧烷的反应产物。这些聚醚多元醇满足如上所述的用于官能度、OH值和数均分子量的范围。
可用于聚氧化乙烯多元醇的合适的起始剂或引发剂是各种合适的引发剂分子的环氧烷加合物。非限制性例子包括二羟基引发剂，例如乙二醇、二乙二醇、三乙二醇、丙二醇、二丙二醇、三丙二醇、新戊二醇、1,3-丙二醇、1,4-丁二醇、1,6-己二醇、1,4-环己二醇、1,4-环己烷二甲醇、氢醌、氢醌二(2-羟乙基)醚、各种双酚如双酚A和双酚F和它们的双(羟烷基)醚衍生物、苯胺、各种N-N-双羟烷基苯胺、烷基伯胺和各种N-N-双(羟烷基)胺；三羟基引发剂，例如甘油、三羟甲基丙烷、三羟甲基乙烷、各种烷醇胺如乙醇胺、二乙醇胺、三乙醇胺、丙醇胺、二丙醇胺、三丙醇胺；四氢化的引发剂，例如季戊四醇、乙二胺、N,N,N',N'–四[2-羟基烷基]乙二胺、甲苯二胺和N,N,N',N'–四[羟基甲基]甲苯二胺；五氢化的引发剂，例如各种烷基葡糖苷、尤其是α-甲基葡糖苷；六氢化的引发剂，例如山梨醇、甘露醇、羟乙基葡糖苷、羟丙基葡萄糖苷；八氢化的引发剂，例如蔗糖；更高官能度的引发剂，例如各种淀粉和部分水解基于淀粉的产品和含羟甲基的树脂和酚醛清漆树脂，例如通过醛优选为甲醛与苯酚、甲酚或其它芳香族含羟基化合物反应来制备的那些。
这种起始剂或引发剂通常与一种或更多种环氧烷共聚，来形成本文所用的聚醚多元醇。这种环氧烷的示例包括环氧乙烷、环氧丙烷、环氧丁烷、氧化苯乙烯，以及它们的混合物。可同时或按顺序添加这些环氧烷的混合物，来提供所述环氧烷基团在在聚醚多元醇中的内部嵌段、端部嵌段或无规分布。
用来聚合这种多元醇的最常用的方法是将在碱催化下将氧化物单体加成至多羟基引发剂的活性氢基团，和后续加成至低聚体多元醇部分。氢氧化钾和氢氧化钠是最常用的常见碱催化剂。通过这种方法制备的多元醇可包含显著数量的不饱和一元醇，它是在反应条件下由氧丙烯单体异构化成烯丙基醇而形成的。然后，这种单官能度醇可用作用于进一步氧化加成的活性氢位点。
另一类合适的聚醚多元醇是包含低不饱和度(低一元醇)含量的聚氧化亚烷基多元醇。文中所定义的这些聚氧化亚烷基多元醇是通过在双金属氰化物催化剂存在下，用环氧丙烷和环氧乙烷对合适的含羟引发剂化合物进行烷氧基化反应而制备的。优选地，使用例如美国专利第5,158,922号和第5,470,813号中揭示的那些双金属氰化物配合物催化剂，以上各文的全部内容通过引用纳入本文。特别优选的多元醇包括如美国专利第5,605,939号所述的具有低不饱和度的无规聚(氧丙烯/氧乙烯)多元醇，该专利文献的内容通过参考结合于此。在聚合反应的后期，环氧乙烷/环氧丙烷混合物中环氧乙烷的量可以增加，以提高多元醇的伯羟基含量。或者，可以使用非DMC催化剂用环氧乙烷对低不饱和度多元醇进行封端。
用作本发明的组分(2)(a)的一种特别优选的聚醚多元醇包括甘油与重量比例为80:20(PO:EO)的环氧丙烷和环氧乙烷的反应产物。该聚醚氧氧化亚烷基多元醇的官能度为约3，OH值为约35。
用作本发明的组分(2)(a)的另一种特别优选的聚醚多元醇包括含甘油和更高官能度起始剂化合物的起始剂混合物，与重量比例为约80:20～85:15(PO:EO)的环氧丙烷和环氧乙烷的反应产物。该聚醚多元醇的官能度为约3，OH值为约30-35。
适用于根据本发明的组分(2)(b)的填充多元醇通常具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％优选1-50重量％的固体。这些填充多元醇选自下组：(i)SAN聚合物多元醇，(ii)多异氰酸酯聚加成(PIPA)多元醇，以及(iii)其混合物。
本文所述的合适的SAN聚合物多元醇通过下述来制备：在多元醇载体(或基础多元醇)中，使单体(即，苯乙烯和丙烯腈)进行自由基聚合以产生分散于多元醇载体(或基础多元醇)中的自由基聚合物。具体来说，聚合物多元醇常规地，以所述组合物(即自由基聚合物和多元醇载体)的总重量为基准计，SAN聚合物多元醇的固含量为约5％至最高达约60％，且优选在约10％-约50％的范围。一般地，这些SAN聚合物多元醇的粘度范围是约2000-约8000厘泊。
适于用作本文所述的组分(2)(b)(i)的示例聚合物多元醇包括例如但不限于以下文献所揭示的那些聚合物多元醇：美国专利5,321,077、5,324,774、5,364,906、5,358,984、5,453,469、5,488,085、5,496,894、5,554,662、5,594,066、5,814,699、5,824,712、5,916,994、5,995,534、5,990,185、6,117,937、6,455,603、6,472,447、6,624,209、6,713,599、6,756,414、7,179,882和7,759,423等，以上各文的全部内容通过引用纳入本文。
适用于本发明的SAN聚合物多元醇通过丙烯腈和苯乙烯在基础多元醇中的原位聚合来制备。合适的基础多元醇可以是常规的聚醚多元醇、聚酯多元醇、聚(氧化亚烷基)多元醇等。用于制备SAN聚合物多元醇的方法是已知的，其描述见例如美国专利3,304,273、3,383,351、3,523,093、3,652,639、3,823,201、4,104,236、4,111,865、4,119,586、4,125,505、4,148,840、4,172,825、4,524,157、4,690,956、Re-28,715和Re-29,118，其内容通过参考结合于此。
优选用作本发明的组分(2)(b)(i)的SAN聚合物多元醇包括苯乙烯和丙烯腈在基础多元醇中的自由基聚合产物，其中所述基础多元醇的官能度为约3、分子量约4750，且OH值为约20。这种SAN聚合物多元醇的固含量是约43％固体，其中苯乙烯相对于丙烯腈的含量是约64％对36％。
优选用于本发明的组分(2)(b)(i)的另一种SAN聚合物多元醇包括苯乙烯和丙烯腈在基础多元醇中的自由基聚合产物，其中所述基础多元醇的官能度为约3、分子量约3000，且OH值为约28。这种SAN聚合物多元醇的固含量是约44％固体，其中苯乙烯相对于丙烯腈的含量是约67％对33％。
适用于组分(2)(b)(ii)的多异氰酸酯聚加成多元醇包括分散于多元醇载体(即基础多元醇)中的聚氨酯颗粒。通过异氰酸酯和烷醇胺(如，三乙醇胺)的反应来原位形成在PIPA多元醇中的聚氨酯颗粒。以所述组合物(即，聚氨酯颗粒和多元醇载体)的总重量为基准计，PIPA多元醇的固含量可通常从5％变化至最高达约60％，且优选地从约10％变化至约50％。一般地，PIPA多元醇的粘度范围是约4,000-约50,000厘泊。合适的PIPA多元醇的示例可参见例如美国专利第4,374,209号和第5,292,778号，以上各文的全部内容通过引用纳入本文。
适用于根据本发明的(3)发泡剂包括卤代烃、水、液体二氧化碳、低沸点溶剂例如戊烷和其它已知的发泡剂。水可单独使用，或与其它发泡剂例如戊烷、丙酮、环戊酮、环己烷、部分或完全氟化烃、二氯甲烷和液体二氧化碳组合使用。优选地，将水用作唯一的发泡剂。总的来说，以重量计以100份的组分(2)异氰酸酯反应性组分的重量为基准计，存在的发泡剂的数量以重量计是约1份-约7份，优选地约1份-约5份。
优选地，适用于本发明的(4)催化剂包括基于胺的催化剂和基于锡的催化剂。可以使用其它催化剂。胺催化剂的示例是二乙三胺、三乙二胺、双(2,2'-二甲基氨基)乙基醚，N,N,N',N",N"-戊甲基二乙三胺等。合适的锡催化剂包括二月桂酸二丁基锡、二乙酸二丁基锡、辛酸亚锡等。最优选地，同时使用胺和锡催化剂，通常以重量计为约0.001-2份每100份组分(2)即异氰酸酯反应性组分的水平。
本发明的泡沫还可包括低分子量增链剂和/或交联剂，其分子量优选在约300道尔顿以下。这些通常用来稳定发泡的(rising)泡沫和控制性质。示例包括，但不限于：甘油、季戊四醇、乙二醇、山梨醇、和烷醇胺例如单乙醇胺、二乙醇胺(DEOA)和三乙醇胺(TEOA)。DEOA是优选地，以重量计它的量为约0-5份每100份组分(2)，优选地以重量计为约0.4-约3.5份每100份组分(2)。
本发明的泡沫还可存在表面活性剂。市售的聚醚聚硅氧烷泡沫稳定剂是优选的。
根据本发明，已发现将少量的(6)三聚六亚甲基二异氰酸酯添加至(1)多异氰酸酯组分，或者将(7)至少一种聚亚肼基二甲酰胺(PHD)多元醇添加至(2)异氰酸酯反应性组分，得到呈现减少的醛排放的泡沫。
根据本发明，所述多异氰酸酯组分(1)还可包括：(6)以重量计0.5-8(优选地0.5-3)份三聚六亚甲基二异氰酸酯每100份以重量计的多异氰酸酯组分(1)。还在本发明的范围之内的是：(2)异氰酸酯反应性组分还包括(7)以重量计2-5.5(优选地2-5，更优选地2-3)份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份以重量计的异氰酸酯反应性组分(2)。将少量的三聚六亚甲基二异氰酸酯添加至多异氰酸酯组分，或者将少量的聚亚肼基二甲酰胺分散体多元醇添加至异氰酸酯反应性组分，有效地减少聚氨酯泡沫和制备聚氨酯泡沫过程中的醛排放。具体来说，已发现这些额外的组分使得能泡沫能通过排放测试例如丰田(Toyota)测试、LGA测试等。
适于使用的三聚六亚甲基二异氰酸酯即组分(6)的官能度为约3，NCO基团含量为约24，异氰酸酯含量为约2且单体含量小于或等于约0.5％。
适用于本发明的组分(7)的聚亚肼基二甲酰胺多元醇(也常称为PHD多元醇或PHD分散体多元醇)，包括例如下述化合物：该化合物通常由异氰酸酯混合物与含胺基团的化合物如二胺和/或肼在基础多元醇中的原位聚合来制备。优选地基础多元醇包括聚醚多元醇和聚氧化亚烷基多元醇。用于制备PHD聚合物多元醇的方法参见例如美国专利第4,089,835号和第4,260,530号所述，以上各文的全部内容通过引用纳入本文。
以PHD多元醇的总重量为基准计，PHD多元醇的固含量范围通常为约3-约30重量％，优选地约5-约25重量％。如上所述，通过通过异氰酸酯混合物在多元醇中的原位聚合来制备PHD多元醇。具体来说，以异氰酸酯混合物的总重量为基准计，异氰酸酯混合物通常以重量计包括约80份的2,4-甲苯二异氰酸酯，以及以异氰酸酯混合物的总重量为基准计，包括以重量计约20份的2,6-甲苯二异氰酸酯。
在制备PHD多元醇时，适于与异氰酸酯化合物聚合的含胺基化合物包括例如：化合物如多胺、肼、酰肼、氨或氨和/或脲和甲醛的混合物。
合适的多胺包括：二价和/或更高化合价的伯和/或仲脂肪族胺、芳脂族胺、脂环族胺和芳香族胺，如乙二胺；1,2-丙二胺和1,3-丙二胺；四亚甲基二胺；六亚甲基二胺；十二亚甲基二胺；三甲基二氨基己烷；N,N’-二甲基乙二胺；2,2'-双氨基丙基甲胺；更高的乙二胺同系物，如二乙三胺、三乙四胺和四乙五胺；丙二胺同系物，如二丙三胺、哌嗪、N,N’-双氨基乙基-哌嗪、三嗪、4-氨基苄胺、4-氨基苯基乙胺、1-氨基-3,3,5-三甲基-5-氨基甲基环己烷、4,4’-二氨基二环己基－甲烷和4,4’-二氨基二环己基丙烷、1,4-二氨基环己烷、苯二胺、萘二胺；苯胺和甲醛的缩合物；甲苯二胺；双氨基甲基苯和在上述芳香族胺的一个或两个氮原子上单烷基化的衍生物。多胺的分子量通常为60-10000，优选地为60-1000，且最优选地为60-200。
所用的肼可以是肼本身或单取代的或N,N'-双取代的肼。取代基可以是C1-C6烷基基团、环己基团或苯基基团。肼的分子量通常为32-200。肼自身是特别优选地。
合适的酰肼包括二价或更高化合价羧酸的酰肼，该羧酸包括例如碳酸、草酸、丙二酸、丁二酸、己二酸、癸二酸、壬二酸、马来酸、富马酸、邻苯二甲酸、间苯二甲酸和对苯二甲酸；肼单羧酸和二元醇或多元醇和苯酚的酯，例如乙二醇、丙烷-1,2-二醇、丁烷-1,2-二醇、丁烷-1,3-二醇、丁烷-1,4-二醇、己二醇、二乙二醇、三乙二醇、四乙二醇、二丙二醇、三丙二醇和氢醌；和亚肼基单羧酸的酰胺(氨基脲)，例如和上述的二胺和多胺。酰肼的分子量通常为90-10000，优选地为90-1000，且最优选地为90-500。
在特别的情况下，也可使用一定比例的官能度大于2的异氰酸酯或胺、肼和酰肼，特别是与相应的单官能化合物一起使用时。
根据本发明，用于制备PHD多元醇的优选基础多元醇包括聚醚多元醇和聚(氧化亚烷基)多元醇。
通常通过异氰酸酯混合物和二胺和/或肼在基础多元醇优选地在聚醚多元醇中的原位聚合，来制备PHD聚合物改性的多元醇。用于制备PHD聚合物多元醇的方法参见例如美国专利第4,089,835号、第4,260,530号和第4,324,715号所述，以上各文的全部内容通过引用纳入本文。
以PHD多元醇的总重量为基准计，PHD多元醇的聚合物固含量范围通常为约3-约30重量％，优选地约5-约25重量％。如上所述，通常通过异氰酸酯混合物在多元醇优选地在聚(氧化亚烷基)多元醇中的原位聚合来制备PHD多元醇，以异氰酸酯混合物的总重量为基准计，所述异氰酸酯混合物通常以重量计包括约80份的2,4-甲苯二异氰酸酯，以及以异氰酸酯混合物的总重量为基准计，包括以重量计约20份的2,6-甲苯二异氰酸酯。
本文所述的聚氨酯泡沫配方中可存在的其它添加剂包括例如常规添加剂和助剂，例如着色剂、无机填料、阻燃剂等。
如上所述，通过存在作为发泡剂的水、和一种或更多种催化剂、一种或更多种表面活性剂和任选地常规添加剂和助剂时，使多异氰酸酯组分和异氰酸酯反应性组分反应，来制备本发明的HR(高弹性)泡沫。常规添加剂和助剂包括例如着色剂、无机填料、阻燃剂等。适用于本发明的添加剂和助剂的示例可参见美国专利第5,171,759号，该文的全部内容通过引用纳入本文，以及参见J.H.沙努德斯(J.H.Saunders)和K.C.氟里斯茨(K.C.Frisch)的《聚氨酯：化学和技术》(POLYURETHANES:CHEMISTRY AND TECHNOLOGY),因特赛斯出版社(Inter-science Publishers)，纽约，1963，以及《聚氨酯手册》(POLYURETHANE HANDBOOK)，昆特奥尔特(Gunter Oertel)编辑，汉沙出版社(Hanser Publications)，慕尼黑，版权1985。
根据本发明，多异氰酸酯组分应以足以提供约70-约130、优选地约80-120且特别优选地约90-115的异氰酸酯指数量存在。
制备自由起发泡沫通常要求将所有组分(除了异氰酸酯组分)一起混合，然后将该异氰酸酯组分添加至该混合物，并简单混合。然后，将混合物倒入箱子中，并允许自由起发。测量泡沫的沉降，并在烘箱中于125℃下固化5分钟。在室温下放置16小时后，可观察到收缩，并随后可通过各种测试测定泡沫性质。
制备模塑的泡沫通常要求多元醇组分与添加剂组分预先一起混合。然后，将异氰酸酯组分以足以产生所需异氰酸酯(NCO)指数的量添加至预先混合物中。然后，手动或通过机器将反应混合物分配进入金属模具中，通常将该模具预热至约62-66℃的温度。反应混合物发泡，填充该模具。在4-5分钟以后，从模具取出泡沫并(物理性的)粉碎，以确保打开所有的孔；然后陈化2小时。
以下实施例进一步详细说明本发明组合物的制备和用途。在上文中陈述的本发明的精神或范围不受这些实施例的限制。本领域技术人员容易理解，可用以下制备步骤的条件和过程的已知变化来制备这些组合物。除非另有说明，所有温度是摄氏度，所有份数和百分数分别是重量份数和重量百分数。
实施例
以下材料用于工作实施例中。
多元醇1：一种甘油起始的聚醚多元醇，其具有约3的官能度和约36的OH值；通过甘油与重量比例为约79％对约19％的环氧丙烷和环氧乙烷混合物的烷氧基化来制备
多元醇2：一种聚醚多元醇，其具有约3的官能度和约56的OH值；通过多元醇1与2.0％六亚甲基二胺己内酯(HMDA-CL)加合物丙氧基化来制备
PMPO 1:SAN填充的聚合物多元醇，其具有约43％的固含量，通过在用作基础多元醇组分的多元醇1中聚合丙烯腈和苯乙烯(重量比例为约36.5重量％对约63.5重量％)的混合物来制备
PHD多元醇1：一种聚亚肼基二甲酰胺分散体多元醇，其具有约20％的固含量，通过在基础多元醇中的甲苯二异氰酸酯(其包括20重量％的2,6-TDI和80％的2,4-TDI)与肼水合物的原位聚合来制备，该基础多元醇具有约3的官能度和约35的OH值且通过甘油与重量比例为约83％对约17％的环氧丙烷和环氧乙烷的烷氧基化来制备
DEOA-LF:在水中(15重量％)的二乙醇胺(85重量％)，是一种交联剂
DC-5164:硅酮表面活性剂
DC-5169:硅酮表面活性剂
催化剂1：在二丙二醇(67重量％)中的1,4-二氮杂-双环[2.2.2]辛烷(33重量％)，市售牌号为Niax A-33
催化剂2：在二丙二醇(30重量％)中的双[2-二甲基氨基乙基]醚(70重量％)，市售牌号为Niax A-1
异氰酸酯1：甲苯二异氰酸酯，其包括80重量％的2,4-TDI和20重量％的2,6-TDI
异氰酸酯2：六亚甲基二异氰酸酯三聚体，其NCO基团含量为约24％，官能度为约3.1，且最大单体含量为0.5％，其中HDI是单体
Irganox 1076：3,5-二叔丁基-4-羟基氢化肉桂酸十八烷基酯，一种抗氧化剂
泡沫配方如下表所详述。
通过下述以常规方式来制备一系列自由起发泡沫：充分混合非异氰酸酯成分，添加异氰酸酯并简单混合；然后将混合物倒入标准的14英寸(35.6厘米)×14英寸(35.6厘米)×6英寸(15.2厘米)的蛋糕盒(cake box)，并允许自由起发，然后测量沉降，并将泡沫在烘箱中于125℃下固化5分钟。在室温下放置最少16小时之后，观察到收缩(如果有的话)，切割12英寸(30厘米)×12英寸(30厘米)×4英寸(10厘米)的部分来评估泡沫的质量。
实施例1-15是自由起发泡沫。使用丰田方法TSM0508G和CertiPUR测试方法来测试这些泡沫的醛排放。这些是用于模塑泡沫和板坯泡沫的全球协议。
表1A:用于实施例1-8的泡沫配方
表1B:用于实施例1-8的泡沫加工和表征：
表2A:用于实施例9-15的泡沫配方
表2B:用于实施例9-15的泡沫加工和表征：
表3：在实施例1,2,4,5,6,8,9,12,13和15中的醛1浓度(单位是微克/样品)
1通过丰田(Toyota)方法TSM0508G测定
表4：在实施例1,3,6,7,10,11,13,14和15中的醛1浓度(单位是微克/样品)
1通过丰田(Toyota)方法TSM0508G测定
通过预先混合多元醇和添加剂组分来制备模塑泡沫。然后，根据各实施例所列的异氰酸酯(NCO)指数(通常90-110)，将异氰酸酯组分添加至预先混合物。手动或通过机器将所述反应混合物分配进入带水夹套的铝模具中，该铝模具已预热至145°F-155°F(即，约62℃-66℃)的温度。反应混合物发泡，填充该模具。4.5分钟之后，将最终泡沫从模具取出，并物理性的粉碎以确保打开所有的孔；在通风柜中陈化2小时，然后用铝箔包裹，然后根据CertiPUR和丰田包装协议，立即将泡沫置于塑料袋(每种泡沫一个袋子)中。这防止VOC逃逸/洗脱。
实施例16-19中的泡沫是如上所述制备的模塑泡沫。
表5：泡沫16-19
1 丰田方法TSM0508G
2 没有空白校正
虽然在前文中为了说明起见对本发明进行了详细的描述，但应理解，这些详细描述仅仅是为了说明，在不偏离本发明的精神和范围的情况下本领域技术人员可对其进行修改，本发明仅由权利要求书限定。
Claims (18)
1.一种聚氨酯泡沫材料，其包括下述物质的反应产物：
(1)多异氰酸酯组分，
和
(2)异氰酸酯-反应性组分，其包含：
(a)至少一种聚醚多元醇，其具有2-6的官能度、18-238的OH值以及160-8000的数均分子量；
和
(b)至少一种填充多元醇，其具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％的固体，其选自下组：(i)苯乙烯-丙烯腈聚合物多元醇，(ii)多异氰酸酯聚加成多元醇，以及(iii)其混合物；
其中，所述反应产物是所述(1)和(2)在以下物质存在下的反应产物：
(3)至少一种发泡剂；
(4)至少一种催化剂；
和
(5)至少一种表面活性剂；
其中(1)所述多异氰酸酯组分还包括(6)0.5-8份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯，或者(2)所述异氰酸酯反应性组分还包括2-5.5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的所述异氰酸酯反应性组分。
2.如权利要求1所述的聚氨酯泡沫材料，其特征在于，(1)所述多异氰酸酯组分包括甲苯二异氰酸酯。
3.如权利要求1所述的聚氨酯泡沫材料，其特征在于，(2)所述异氰酸酯-活性组分包含：
(a)20-90重量％的一种或更多种聚醚多元醇，
和
(b)10-80重量％的一种或更多种填充多元醇，
且(a)和(b)之和总计为100重量％的(2)所述异氰酸酯-反应性组分。
4.如权利要求1所述的聚氨酯泡沫材料，其特征在于，(2)(a)所述聚醚多元醇具有2.5-3.5的官能度、28-42的OH值。
5.如权利要求1所述的聚氨酯泡沫材料，其特征在于，(2)(b)所述填充多元醇具有10-50重量％的固含量。
6.如权利要求1所述的聚氨酯泡沫材料，其特征在于，其中(1)所述多异氰酸酯组分以重量计还包括(6)0.5-3份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯，或者(2)所述异氰酸酯反应性组分还包括2-5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的所述异氰酸酯反应性组分。
7.一种制备聚氨酯泡沫的方法，该方法包括:
(A)使下述物质反应：
(1)多异氰酸酯组分，
和
(2)异氰酸酯-反应性组分，其包含：
(a)至少一种聚醚多元醇，其具有2-6的官能度、18-238的OH值以及160-8000的数均分子量，
和
(b)至少一种填充多元醇，其具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％的固体，其选自下组：(i)苯乙烯-丙烯腈聚合物多元醇，(ii)多异氰酸酯聚加成多元醇，以及(iii)其混合物；
所述反应在以下物质存在下进行：
(3)至少一种发泡剂；
(4)至少一种催化剂；
和
(5)至少一种表面活性剂；
其中(1)所述多异氰酸酯组分还包括(6)0.5-8份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯，或者(2)所述异氰酸酯反应性组分还包括2-5.5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的所述异氰酸酯反应性组分。
8.如权利要求7所述的方法，其特征在于，(1)所述多异氰酸酯组分包括甲苯二异氰酸酯。
9.如权利要求7所述的方法，其特征在于，(2)所述异氰酸酯-活性组分包含：
(a)20-90重量％的一种或更多种聚醚多元醇，
和
(b)10-80重量％的一种或更多种填充多元醇，
且(a)和(b)之和总计为100重量％的(2)所述异氰酸酯-反应性组分。
10.如权利要求7所述的方法，其特征在于，(2)(a)所述聚醚多元醇具有2.5-3.5的官能度、28-42的OH值。
11.如权利要求7所述的方法，其特征在于，(2)(b)所述填充多元醇具有10-50重量％的固含量。
12.如权利要求7所述的方法，其特征在于，其中(1)所述多异氰酸酯组分以重量计还包括(6)0.5-3份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯，或者(2)所述异氰酸酯反应性组分还包括2-5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的所述异氰酸酯反应性组分。
13.一种减少泡沫中醛排放的方法，所述方法包括：
(A)使下述物质反应：
(1)多异氰酸酯组分，
和
(2)异氰酸酯-反应性组分，其包含：
(a)一种或更多种聚醚多元醇，其具有2-6的官能度、18-238的OH值以及160-8000的数均分子量，
和
(b)一种或更多种填充多元醇，其具有18-32的OH值、2000-8000的数均分子量，且包含5-60重量％的固体；
所述反应在以下物质存在下进行：
(3)至少一种发泡剂；
(4)至少一种催化剂；
和
(5)至少一种表面活性剂；
其中(1)所述多异氰酸酯组分还包括(6)0.5-8份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯，或者(2)所述异氰酸酯反应性组分还包括2-5.5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的所述异氰酸酯反应性组分。
14.如权利要求13所述的方法，其特征在于，(1)所述多异氰酸酯组分包括甲苯二异氰酸酯。
15.如权利要求13所述的方法，其特征在于，(2)所述异氰酸酯-活性组分包含：
(a)20-90重量％的一种或更多种聚醚多元醇，
和
(b)10-80重量％的一种或更多种填充多元醇，
且(a)和(b)之和总计为100重量％的(2)所述异氰酸酯-反应性组分。
16.如权利要求13所述的方法，其特征在于，(2)(a)所述聚醚多元醇具有2.5-3.5的官能度、28-42的OH值。
17.如权利要求13所述的方法，其特征在于，(2)(b)所述填充多元醇具有10-50重量％的固含量。
18.如权利要求13所述的方法，其特征在于，其中(1)所述多异氰酸酯组分以重量计还包括(6)0.5-3份的三聚六亚甲基二异氰酸酯每100份的所述多异氰酸酯，或者(2)所述异氰酸酯反应性组分还包括2-5份的至少一种聚亚肼基二甲酰胺分散体多元醇每100份的所述异氰酸酯反应性组分。
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| CN101263173A (zh) * | 2005-09-16 | 2008-09-10 | 拜尔材料科学股份公司 | 基于聚氨酯的凝胶物料，其制备和用途 |
| CN102027033A (zh) * | 2008-05-20 | 2011-04-20 | 旭硝子株式会社 | 硬质聚氨酯泡沫塑料的制造方法 |
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| WO2019119196A1 (en) * | 2017-12-18 | 2019-06-27 | Huntsman International Llc | A composition with reduced aldehyde emission |
| EP3617246A1 (en) | 2018-09-03 | 2020-03-04 | Covestro Deutschland AG | Nco-terminated polyurethane prepolymer and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| EP2809701A1 (en) | 2014-12-10 |
| US10066047B2 (en) | 2018-09-04 |
| EP2809701A4 (en) | 2016-01-20 |
| CN104321360A (zh) | 2015-01-28 |
| US20130203880A1 (en) | 2013-08-08 |
| EP3159364A1 (en) | 2017-04-26 |
| EP3159364B1 (en) | 2020-07-08 |
| ES2816924T3 (es) | 2021-04-06 |
| PL3159364T3 (pl) | 2021-04-06 |
| WO2013116092A1 (en) | 2013-08-08 |
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