CN114080410A - 用于制备阻燃pur/pir硬质泡沫的方法 - Google Patents
用于制备阻燃pur/pir硬质泡沫的方法 Download PDFInfo
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- CN114080410A CN114080410A CN202080050824.3A CN202080050824A CN114080410A CN 114080410 A CN114080410 A CN 114080410A CN 202080050824 A CN202080050824 A CN 202080050824A CN 114080410 A CN114080410 A CN 114080410A
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- Prior art keywords
- polyol
- acid
- pur
- polyol formulation
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- 238000004519 manufacturing process Methods 0.000 title claims description 6
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- FEUQNCSVHBHROZ-UHFFFAOYSA-N ricinoleic acid Natural products CCCCCCC(O[Si](C)(C)C)CC=CCCCCCCCC(=O)OC FEUQNCSVHBHROZ-UHFFFAOYSA-N 0.000 description 5
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Abstract
本发明涉及一种用于制备阻燃聚氨酯‑/聚异氰脲酸酯硬质泡沫(以下也单独或统称为“PUR/PIR硬质泡沫”)的多元醇配制品,其含有OH值≤250 mg KOH/g、官能度为1.5‑2.5并且Mn<150 g/mol的游离二醇的含量<6重量%的聚酯多元醇、平均分子量<700 g/mol且平均官能度<2.5的聚乙二醇和一定的聚乙二醇‑烷基苯基醚,以及涉及使用这种多元醇配制品制备PUR/PIR硬质泡沫的方法和由此制备的PUR/PIR硬质泡沫。
Description
本发明涉及一种用于制备阻燃聚氨酯-/聚异氰脲酸酯硬质泡沫(以下也单独或统称为“PUR/PIR硬质泡沫”)的多元醇配制品,其含有OH值≤250 mg KOH/g、官能度为1.5-2.5并且Mn<150 g/mol的游离二醇的含量<6重量%的聚酯多元醇,平均分子量<700 g/mol且平均官能度<2.5的聚乙二醇和一定的聚乙二醇-烷基苯基醚,以及涉及使用这种多元醇配制品制备PUR/PIR硬质泡沫的方法和由此制备的PUR/PIR硬质泡沫。
在本申请中,术语“PUR/PIR硬质泡沫”是指具有氨基甲酸酯结构和异氰脲酸酯结构的硬质泡沫。
如同所有有机聚合物一样,PUR/PIR硬质泡沫也是可燃的,其中硬质泡沫中每质量单位的大表面积还加剧了这种行为。PUR/PIR硬质泡沫经常用作阻隔材料,例如在建筑工业中用作保温材料。因此,在PUR/PIR硬质泡沫的许多应用领域中,需要通过添加的阻燃剂来配备阻燃性。
已知添加较大量阻燃剂具有缺点,尤其对于聚合物的机械性能。特别是含有卤素的化合物也因其潜在的环境危害作用或健康危害作用而受到批评。
在聚氨酯化学中,聚合物主链的燃烧性能(Brandeigenschaft)可以通过单体的选择和组成在一定限度内加以控制。例如,异氰脲酸酯结构的存在对燃烧性能(Brandverhalten)有积极影响。使用如US 2013/184366 A 和 US 2014/364528 A 中的高分子量的聚酯结构单元,据说导致阻燃性提高,但由于玻璃化转变温度过早升高,通常也阻碍异氰酸酯三聚成异氰脲酸酯结构,异氰脲酸酯结构为泡沫赋予其强度。
这种高分子量并因此高粘度的多元醇结构单元的加工是复杂的并且在技术上是有问题的,由此使用受限。
一种降低粘度的构思可能是混合聚醚多元醇。然而,如果要使用工业上容易获得的聚乙二醇 (PEG) 来建立通常用于许多 PUR/PIR 应用的约 3500-4000 mPa*s 的多元醇配制品粘度,则获得的泡沫通常具有不够好的泡孔结构,导致表面糟糕和对于大规模工业应用而言性能不足。
因此,本发明的目的是提供一种用于制备PUR/PIR硬质泡沫的包含高分子量聚酯多元醇的多元醇配制品A,其中该PUR/PIR硬质泡沫表现出良好的阻燃性和良好的机械性能。
US 2012/0202903 A描述了使用平均HLB值为10至15的烷基乙氧基化醇作为增容剂用于含有高比例水的多元醇配制品和用于制备水发泡聚氨酯喷涂泡沫。
所述目的令人惊讶地能够通过多元醇配制品A得以实现,所述多元醇配制品A包含
A1 基于多元醇配制品A的总质量计,35-89重量%的聚酯多元醇组分,其具有190-310mg KOH/g的OH值,
其由A1-1和A1-2构成
A1-1 至少一种聚酯多元醇,其OH值为≤250 mg KOH/g,平均官能度为1.5-2.5并且Mn<150 g/mol的游离二醇的含量<6重量%,基于A1-1的总质量计,
A1-2 任选的不属于A1-1定义的其它聚酯多元醇,
A2 基于多元醇配制品A计,10-40重量%的一种或多种聚乙二醇,其平均分子量<700g/mol且平均官能度<2.5;
A3 其它异氰酸酯反应性组分
A4 基于多元醇配制品A计,0.2-5重量%的一种或多种选自下组的化合物
A4-1 聚乙二醇-2,4,6-三烷基苯基醚(结构I,其中R5、R6、R7 = H、C1- 至 C8-烷基)和
A4-2 聚乙二醇-2,4,6-三芳烷基苯基醚(结构I,其中R5、R6和/或R7 = 芳基)和
A4-3 聚乙二醇-烷基苯基醚(结构II)
结构I
R1、R2、R3、R4 = H、C1-C4-烷基,
R5、R6、R7 = H、C1- 至 C8-烷基、芳基
n = 7-20,优选 10-18,特别优选11-15
结构II
R1、R3 = H、C(CH3)2CR4R5R6
R2 = C(CH3)2CR4R5R6
R4、R5 = H或CH3
R6 = C2- 至C5-烷基、芳基
n = 3-8
其中化合物A4具有小于1.5 kg/mol的分子量和25-70%环氧乙烷,优选40-60%环氧乙烷的含量,和
A5 任选其它助剂和添加剂,
A6 基于多元醇配制品A的总质量计,0-2重量%的水。
本发明的主题同样是通过含有下述组分的反应混合物的反应来制备PUR/PIR硬质泡沫的方法:
多元醇配制品A,
多异氰酸酯组分B,和
发泡剂C,
任选地在催化活性组分D的存在下,
其中所述制备在150至600,优选240-400的特征数下进行。
令人惊讶地,用根据本发明的组分A,可以提供一种配制品,该配制品包含高分子量聚酯结构单元并且尽管如此却具有低粘度,并且可以加工成具有良好泡孔结构的PUR/PIR硬质泡沫。 用根据本发明的组分A制备的聚酯还具有良好的阻燃性和改进的机械性能,如PUR/PIR硬质泡沫的拉伸强度、断裂伸长率、韧性和开孔率。
所述聚酯多元醇-组分A1-1是一种聚酯多元醇,其OH值≤240 mg KOH/g,优选≤200 mg KOH/g,官能度为1.5-2.5并且分子量<150 g/mol的游离二醇的含量小于6重量%,基于A1-1的总质量计。由于其分子量,这种多元醇组分通常具有对于PUR/PIR硬质泡沫应用而言的高粘度,特别是>5Pa*s的粘度。
聚酯多元醇A1-1在聚酯多元醇组分A1中的比例优选≥60重量%,特别是≥80重量%,非常特别优选≥90重量%。因此,A1-1与A1-2的质量比优选为至少6:1,特别是至少8:1。
具有低游离二醇含量的聚酯多元醇本身是已知的,并且它们的制备和在基于FCKW的PUR/PIR配制品中的用途例如公开在US 5,109,301中。
组分A1的聚酯多元醇例如可以是得自具有2至12个碳原子,优选具有2至6个碳原子的多元醇,优选二醇,与多元羧酸,例如二-、三-或者甚至四羧酸,或羟基羧酸或内酯的缩聚物,优选使用芳族二羧酸或芳族和脂族二羧酸的混合物。代替游离多元羧酸,也可以使用相应的多元羧酸酐或低级醇的相应多元羧酸酯来制备聚酯。优选使用邻苯二甲酸酐、对苯二甲酸和/或间苯二甲酸。
作为羧酸尤其考虑:琥珀酸、戊二酸、己二酸、辛二酸、壬二酸、癸二酸、癸烷二甲酸、四氢邻苯二甲酸、六氢邻苯二甲酸、环己烷二甲酸、四氯邻苯二甲酸、衣康酸、丙二酸、呋喃二甲酸、2-甲基琥珀酸、3,3-二乙基戊二酸、2,2-二甲基琥珀酸、十二烷二酸、内亚甲基四氢邻苯二甲酸、二聚脂肪酸、三聚脂肪酸、柠檬酸、偏苯三酸、苯甲酸、偏苯三酸、马来酸、富马酸、邻苯二甲酸、间苯二甲酸和对苯二甲酸。同样可以使用这些羧酸的衍生物,例如对苯二甲酸二甲酯。在此,羧酸可以单独使用也可以混合使用。作为羧酸优选使用己二酸、癸二酸和/或琥珀酸,特别优选己二酸和/或琥珀酸。
在制备具有末端羟基的聚酯多元醇时可以作为反应参与物共同使用的羟基羧酸是例如羟基己酸、羟基丁酸、羟基癸酸、羟基硬脂酸等。合适的内酯尤其是己内酯、丙内酯、丁内酯和同系物。
还特别适用于制备聚酯多元醇的是生物基原料和/或其衍生物,例如蓖麻油,多羟基脂肪酸,蓖麻油酸,羟基改性油,葡萄籽油,黑孜然油,南瓜籽油,琉璃苣籽油,大豆油,小麦胚油,菜籽油,葵花籽油,花生油,杏仁油,阿月浑子油,扁桃油,橄榄油,澳洲坚果油,鳄梨油,沙棘油,芝麻油,麻籽油,榛子油,樱草油,野蔷薇油,蓟子油,核桃油,脂肪酸,羟基改性脂肪酸以及环氧化脂肪酸和脂肪酸酯,例如基于肉豆寇脑酸,棕榈油酸,油酸,11-十八碳烯酸,岩芹酸,鳕油酸,芥酸,神经酸,亚油酸,α-和γ-亚麻酸,十八碳四烯酸,花生四烯酸,二十碳五烯酸,鰶鱼酸和二十二碳六烯酸(Cervonsäure)。特别优选的是蓖麻油酸与多官能醇例如甘油的酯。还优选的是使用此类生物基酸与其它羧酸,例如邻苯二甲酸的混合物。
合适的二醇的实例是乙二醇,丁二醇,二甘醇,三甘醇,多亚烷基二醇如多亚乙基二醇,此外1,2-丙二醇,1,3-丙二醇,环己烷二甲醇,1,3-丁二醇,1,4-丁二醇,1,6-己二醇和异构体,新戊二醇或羟基新戊酸新戊二醇酯。优选使用乙二醇,二甘醇,1,4-丁二醇,1,5-戊二醇,1,6-己二醇或所述二醇中的至少两种的混合物,特别是1,4-丁二醇、1,5-戊二醇和1,6-己二醇的混合物。
另外还可以使用多元醇,如,三羟甲基丙烷,甘油,赤藓糖醇,季戊四醇,三羟甲基苯或三羟乙基异氰脲酸酯,其中优选的是甘油和三羟甲基丙烷。
此外也可以共同使用一元链烷醇。
具有聚醚结构的这种聚酯多元醇也可用于聚酯多元醇组分中。这些通常也称为“聚醚酯多元醇”。 可使用的聚醚酯多元醇是含有醚基、酯基和OH基团的化合物。具有至多12个碳原子的有机二羧酸适合于制备聚醚酯多元醇,优选具有4-6个碳原子的脂族二羧酸或芳族二羧酸,单独或混合使用。示例性地可提及辛二酸,壬二酸,癸烷二甲酸,呋喃二甲酸,马来酸,丙二酸,邻苯二甲酸,庚二酸和癸二酸,以及尤其是戊二酸,富马酸,琥珀酸,己二酸,邻苯二甲酸,对苯二甲酸和间/对苯二甲酸。除了有机二羧酸外,还可以使用这些酸的衍生物,例如它们的酸酐以及它们与具有1-4个碳原子的低分子量单官能醇的酯和半酯。按比例使用上述生物基原料,尤其是脂肪酸/脂肪酸衍生物(油酸,大豆油等)同样是可行的并且能够具有优点,例如在下述的方面:多元醇配制品的储存稳定性,泡沫的尺寸稳定性、燃烧性能和抗压强度。
作为用于制备聚醚酯多元醇的其它组分使用通过起始剂分子如多元醇的烷氧基化获得的聚醚多元醇。起始剂分子是至少双官能的,但是可以任选地还包含各种比例的更高官能的,特别是三官能的起始剂分子。
起始剂分子是例如二醇如1,2-乙二醇,1,3-丙二醇,1,2-丙二醇,1,4-丁二醇,1,5-戊烯二醇,1,5-戊二醇,新戊二醇,1,6-己二醇,1,7-庚二醇,1,8-辛二醇,1,10-癸二醇,2-甲基-1,3-丙二醇,2,2-二甲基-1,3-丙二醇,3-甲基-1,5-戊二醇,2-丁基-2-乙基-1,3-丙二醇,2-丁烯-1,4-二醇和2-丁炔-1,4-二醇,醚二醇如二甘醇,三甘醇,四甘醇,一缩二丁二醇,二缩三丁二醇,三缩四丁二醇,一缩二己二醇,二缩三己二醇,三缩四己二醇和烷撑二醇如二甘醇的低聚混合物。具有不同于OH的官能团的起始剂分子也可以单独或混合使用。
除了二醇之外,也可以共同使用具有多于2个泽尔维季诺夫-活性氢、特别是具有3-8,尤其是3-6的数均官能度的化合物作为制备聚醚的起始剂分子,例如,1,1,1-三羟甲基丙烷,三乙醇胺,甘油,脱水山梨糖醇和季戊四醇,以及由三醇或四醇起始的聚氧化乙烯多元醇。
聚醚酯多元醇也可以由通过有机二羧酸和它们的衍生物与具有泽尔维季诺夫-活性氢的组分,尤其是二醇和多元醇的反应获得的反应产物的烷氧基化,特别是由乙氧基化和/或丙氧基化来制备。作为这些酸的衍生物可以使用例如它们的酸酐,例如邻苯二甲酸酐。
作为组分A2使用聚乙二醇,即,低分子量的2-3官能的羟基官能起始剂分子与环氧乙烷的反应产物,其中所述环氧乙烷占分子量的≥80%。起始剂分子特别是水、乙二醇、二甘醇、丙二醇、甘油和/或三羟甲基丙烷。这种聚乙二醇的制备是本领域技术人员已知的,并且这些物质中的许多是商购可得的。合适的聚乙二醇优选在298K下是液体,并且特别具有≤700 g/mol的分子量和<2.5的平均官能度,其特别优选具有200-600 g/mol的平均分子量,非常特别优选具有≤ 2.12的平均官能度。
所述其它异氰酸酯反应性组分A3例如是不属于组分A1和A2定义的多元醇,如聚醚多元醇、聚碳酸酯多元醇和聚醚-聚碳酸酯多元醇。
添加长链多元醇,特别是聚醚多元醇,可以改善反应混合物的流动性和含发泡剂的配制品的乳化性。对于制造复合元件而言,这些例如可以实现具有柔性或刚性覆盖层的元件的连续生产。
在一个优选的实施方式中,长链多元醇具有≥1.2至≤3.5的官能度并且具有10至100 mg KOH/g、优选20至50 mg KOH/g的羟值,并且具有多于70mol%、优选多于80mol%,特别是多于90mol%的伯OH基团。长链多元醇优选为官能度为≥1.2至≤3.5且羟值为10至100 mgKOH/g的聚醚多元醇。
添加中链多元醇,特别是聚醚多元醇,和低分子量异氰酸酯反应性化合物可以改善所得泡沫的粘附性和尺寸稳定性。对于用根据本发明的方法制造复合元件而言,这些中链多元醇可以实现具有柔性或刚性覆盖层的元件的连续生产。中链多元醇,其尤其是聚醚多元醇,具有≥2至≤6的官能度并且具有300至700mg KOH/g的羟值。
所使用的聚醚多元醇是本领域技术人员已知的、具有所述特征的可用于聚氨酯合成中的聚醚多元醇。
可以使用的聚醚多元醇例如是聚四亚甲基二醇聚醚,如其可借助于阳离子开环通过四氢呋喃的聚合而获得。
聚醚多元醇通过本领域技术人员已知的制备方法获得,例如,使用至少一种键合包含2-8个、优选2-6个反应性氢原子的起始剂分子,通过一种或多种具有2-4个碳原子的氧化烯与碱金属氢氧化物,如氢氧化钠或氢氧化钾,碱金属醇盐,如甲醇钠、乙醇钠或乙醇钾或异丙醇钾,或胺类烷氧基化催化剂,如二甲基乙醇胺(DMEOA),咪唑和/或咪唑衍生物的阴离子聚合。
合适的氧化烯例如是四氢呋喃,1,3-氧化丙烯,1,2-和2,3-氧化丁烯,氧化苯乙烯,优选氧化乙烯和1,2-氧化丙烯。氧化烯可单独使用,交替依次使用或作为混合物使用。优选的氧化烯是氧化丙烯和氧化乙烯,特别优选的是氧化乙烯。氧化烯可以与CO2组合来反应。
作为起始剂分子可以考虑例如:水,有机二元羧酸,如琥珀酸,己二酸,邻苯二甲酸和对苯二甲酸,脂族和芳族的任选N-单-、N,N-和N,N'-二烷基取代的在烷基中具有1-4个碳原子的二胺,如任选单-和二烷基取代的乙二胺,二亚乙基三胺,三亚乙基四胺,1,3-丙二胺,1,3-和1,4-丁二胺,1,2-、1,3-、1,4-、1,5-和1,6-己二胺,苯二胺,2,3-、2,4-和2,6-甲苯二胺和2,2'-、2,4'-和4,4'-二氨基二苯基甲烷。
优选使用二元或多元醇,如乙二醇,1,2-和1,3-丙二醇,二甘醇,二丙二醇,1,4-丁二醇,1,6-己二醇,三乙醇胺,双酚,甘油,三羟甲基丙烷,季戊四醇,山梨醇和蔗糖。
可以使用的聚碳酸酯多元醇是具有羟基的聚碳酸酯,例如聚碳酸酯二醇。这些是在碳酸衍生物,如碳酸二苯酯、碳酸二甲酯或光气与多元醇,优选二醇的反应中形成的。
这种二醇的实例是乙二醇,1,2-和1,3-丙二醇,1,3-和1,4-丁二醇,1,6-己二醇,1,8-辛二醇,新戊二醇,1,4-双羟基甲基环己烷,2-甲基-1,3-丙二醇,2,2,4-三甲基戊二醇-1,3,二丙二醇,聚丙二醇,一缩二丁二醇,聚丁二醇,双酚和内酯改性的上述类型的二醇。
代替纯聚碳酸酯二醇或除纯聚碳酸酯二醇之外,还可以使用聚醚-聚碳酸酯二醇,其例如可通过氧化烯(例如氧化丙烯)与CO2的共聚获得。
多元醇的制备方法例如由Ionescu描述于"Chemistry and Technology ofPolyols for Polyurethanes", Rapra Technology Limited, Shawbury 2005, 第55页及以后几页(第4章: Oligo-Polyols for Elastic Polyurethanes), 第263页及以后几页(第8章: Polyester Polyols for Elastic Polyurethanes)和尤其是在第321页及以后几页(第13章: Poly醚 Polyols for Rigid Polyurethane Foams)和第419页及以后几页(第16章: Polyester Polyols for Rigid Polyurethane Foams)中。也可以通过合适的聚合物回收物的糖酵解获得聚酯-和聚醚多元醇。合适的聚醚-聚碳酸酯多元醇及其制备描述于例如EP 2 910 585A1,[0024]-[0041]中。聚碳酸酯多元醇及其制备的实例尤其可以在EP 1359 177 A1中找到。合适的聚醚酯多元醇的制备尤其描述在WO 2010/043624A和EP 1 923417A中。
如果低分子量异氰酸酯反应性化合物用于制备PUR/PIR硬质泡沫,例如作为增链剂和/或交联剂,则其适宜地以基于多元醇配制品A的总重量计最大6 重量%的量来使用。由于其结构因而不仅属于组分A3的定义而且属于上述多元醇化合物A1或A2的定义之一的化合物在量上被认为属于组分A1或A2而不属于组分A3。
多元醇A1和A2的混合物优选具有≤4Pa*s的粘度,特别是2-4Pa*s的粘度。
多元醇A1和A2的混合物优选具有≤260 mg KOH/g,特别是≤230 mg KOH/g的OH值。
多元醇配制品中聚酯多元醇A1与聚乙二醇A2的质量比优选为2-10。
在本申请范围内,组分的单一名称-“多元醇”、“聚酯多元醇”等-在每种情况下是指属于相应定义下的所有组分的混合物。
化合物A4是一种或多种选自下组的化合物:
A4 基于多元醇配制品A计,0.2-5重量%的一种或多种选自下组的化合物
A4-1 聚乙二醇-2,4,6-三烷基苯基醚(结构I,其中R5、R6、R7 = H、C1- 至 C8-烷基) 和
A4-2 聚乙二醇-2,4,6-三芳烷基苯基醚(结构I,其中R5、R6和/或R7 = 芳基) 和
A4-3 聚乙二醇-烷基苯基醚(结构II)
结构I
R1、R2、R3、R4 = H、C1-C4-烷基,
R5、R6、R7 = H、C1- 至 C8-烷基、芳基
n = 7-20,优选 10-18,特别优选11-15
结构II
R1、R3 = H、C(CH3)2CR4R5R6
R2 = C(CH3)2CR4R5R6
R4、R5 = H或CH3
R6 = C2- 至C5-烷基、芳基
n = 3-8
其中化合物A4具有小于1.5 kg/mol的分子量和25-70%环氧乙烷,优选40-60%环氧乙烷的含量。
其中化合物A4具有小于1.5 kg/mol的分子量和25-70%环氧乙烷,优选40-60%环氧乙烷的含量。
优选的化合物A4示于表1中并且具有结构IV(属于化合物A4-2的定义)、结构V(属于化合物A4-1的定义)和结构VI(属于化合物A4-3的定义)。
任选地,除了化合物A4之外,也还可以使用一种或多种其它添加剂作为组分A5。组分A5的实例是表面活性物质、泡沫稳定剂、泡孔调节剂、阻燃剂、填料、染料、颜料、水解保护剂、起抑制真菌和抑制细菌作用的物质。
作为表面活性物质可以考虑例如促进起始物质均质化并且任选地还适合于调节塑料的泡孔结构的化合物。示例性地可提及乳化剂,如蓖麻油硫酸酯或脂肪酸的钠盐以及脂肪酸与胺的盐,例如油酸二乙胺,硬脂酸二乙醇胺,蓖麻油酸二乙醇胺,磺酸的盐,例如十二烷基苯二磺酸或二萘基甲烷二磺酸和蓖麻油酸的碱金属或铵盐;泡沫稳定剂,如硅氧烷氧化烯-混合聚合物和其他有机聚硅氧烷,不同于A4的乙氧基化烷基酚,乙氧基化脂肪醇,石蜡油,蓖麻油酯或蓖麻油酸酯,土耳其红油和花生油以及泡孔调节剂,如石蜡,脂肪醇和二甲基聚硅氧烷。此外,具有聚氧化烯-和氟代烷烃基团作为侧链基团的上述低聚丙烯酸酯适用于改善泡沫的乳化作用、泡孔结构和/或稳定化。在其结构中属于组分A4定义的乳化剂在量上也被认为属于组分A4而不属于组分A5。
作为填料,尤其是起增强作用的填料,可提及本身已知的常规有机和无机填料,增强剂,增重剂,用于改善色料、涂料等中的磨损性能的试剂。详细地可示例性提及:无机填料如硅质矿物,例如层状硅酸盐,例如叶蛇纹石(Antigorit),蛇纹石(Serpentin),海泡石,角闪石(Hornblenden),闪石(Amphibole),纤蛇纹石(Chrisotil),蒙脱石和滑石,金属氧化物如高岭土,铝氧化物,钛氧化物和铁氧化物,金属盐,如白垩,碳酸钙镁石,重晶石和无机颜料,如磁铁矿,针铁矿,硫化镉和硫化锌以及玻璃等,以及天然的和合成的纤维状矿物如硅灰石,各种长度的金属纤维并且尤其是玻璃纤维,其可以任选地上浆。作为有机填料例如可以考虑:碳,三聚氰胺,松脂,环戊二烯基树脂和接枝聚合物以及纤维素纤维,聚酰胺纤维,聚丙烯腈纤维,聚氨酯纤维,基于芳族和/或脂族二羧酸酯的聚酯纤维和碳纤维。
为了制备PUR/PIR硬质泡沫,还优选使用阻燃剂A5。
阻燃剂原则上是本领域技术人员已知的并且例如描述在“Kunststoffhandbuch”,第7卷“Polyurethane”,第6.1章中。这些例如可以是卤化聚酯和多元醇、溴化和氯化石蜡或磷化合物,例如同样可以含有卤素的正磷酸和偏磷酸的酯。优选选择在 298 K下为液态的阻燃剂。实例是磷酸三乙酯、乙烷膦酸二乙酯、甲苯基二苯基磷酸酯和其它磷酸三芳基酯、丙烷膦酸二甲酯、羟甲基膦酸酯和三(β-氯异丙基)磷酸酯。特别优选选自磷酸三(氯-2-丙基)酯(TCPP)和磷酸三乙酯(TEP)及其混合物的阻燃剂。优选地,基于异氰酸酯反应性组合物A)的总重量计,以1至30重量%,特别优选5至30重量%的量使用阻燃剂,从而实现0.4-1.3重量%的泡沫中的磷含量。将不同的阻燃剂彼此组合以实现特定的性能曲线(粘度、脆性、可燃性、卤素含量等)也可能是有利的。在某些实施方式中,在阻燃剂混合物中存在磷酸三乙酯(TEP)或作为唯一的阻燃剂是特别有利的。
基于多元醇配制品A的总质量计,多元醇配制品还包含A6最多2重量%,优选最多2.0重量%,特别优选最多1.2重量%的水。
在本发明范围内,数均分子量 Mn(亦称:分子量)根据DIN 55672-1(2007年8月)通过凝胶渗透色谱法来测定。
在单一添加的多元醇的情况中,OH数(亦称:羟值)给出了其OH数。对于混合物给出的OH数涉及混合物的数均OH数,由各组分的OH数按它们各自的 mol 比例来计算。OH数给出了以 毫克计的氢氧化钾的量,其等价于在乙酰化一克物质的情况下所结合的乙酸的量。在本发明范围内,其根据标准DIN 53240-1(2013年6月)来确定。
在本发明范围内,"官能度"是指由已知原料及其量比计算的理论平均官能度(分子中或在分子的各自混合物上得到的异氰酸酯反应性官能团或多元醇反应性官能团的数目)。
当量重量给出了异氰酸酯-反应性组分的数均摩尔质量与官能度的比率。对于混合物给出的当量重量由各组分的当量重量按它们各自的摩尔比例来计算并且涉及混合物的数均当量重量。
作为发泡剂C可以使用物理发泡剂,例如低沸点有机化合物,例如烃,卤代烃,醚,酮,羧酸酯或碳酸酯。对异氰酸酯组分B呈惰性并且沸点在大气压下低于100℃,优选低于50℃的有机化合物是特别合适的。这些沸点的优点在于,有机化合物在放热的加聚反应的影响下蒸发。这种优选使用的有机化合物的实例是烷烃,例如庚烷,己烷,正和异戊烷,优选由正和异戊烷、正和异丁烷和丙烷构成的工业混合物,环烷烃,例如环戊烷和/或环己烷,醚,例如呋喃,二甲醚和二乙醚,酮,例如丙酮和甲乙酮,羧酸烷基酯,如甲酸甲酯,草酸二甲酯和乙酸乙酯和卤代烃,例如二氯甲烷,二氟甲烷,三氟甲烷,二氟乙烷,四氟乙烷和七氟丙烷。优选不使用已知对地球臭氧层起有害作用的发泡剂。还优选使用(氢)氟化的烯烃,例如HFO1233zd(E)(反-1-氯-3,3,3-三氟-1-丙烯)或HFO1336mzz(Z)(顺-1,1,1,4,4,4-六氟-2-丁烯)或添加剂,如3M的FA188(1,1,1,2,3,4,5,5,5-九氟-4-(三氟甲基)戊-2-烯)。也可以使用两种或更多种所述有机化合物的混合物。所述有机化合物在此也可以以小滴乳液的形式来使用。
作为发泡剂C也可以使用化学发泡剂,例如水、羧酸及其混合物。它们与异氰酸酯基团反应,形成发泡气体,在此,例如在水的情况下形成二氧化碳,在例如甲酸的情况下形成二氧化碳和一氧化碳。作为羧酸优选使用至少一种选自甲酸,乙酸,草酸和蓖麻油酸的化合物。特别优选使用水作为化学发泡剂。
优选不使用卤代烃作为发泡剂。
使用至少一种选自物理和化学发泡剂的化合物作为发泡剂C。优选仅使用物理发泡剂。在一个优选的实施方式中,所使用的发泡剂C具有<120的平均全球变暖潜势(GWP),优选<20的GWP。
作为用于制备PUR/PIR硬质泡沫的催化剂D,使用加速含有反应性氢原子,特别是羟基的化合物与异氰酸酯组分B的反应的化合物,例如叔胺或金属盐。催化剂组分可以计量加入到反应混合物中,或者完全或部分地预先加入多元醇配制品A中。
使用例如叔胺,如三乙胺、三丁胺、二甲基苄胺、二环己基甲胺、二甲基环己胺、N,N,N',N'-四甲基二氨基二乙醚、双(二甲氨基丙基)脲、N-甲基-或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-四甲基己二胺-1,6、五甲基二亚乙基三胺、双[2-(二甲氨基)乙基]醚、二甲基哌嗪、N-二甲氨基乙基哌啶、1,2-二甲基-咪唑、1-氮杂双环-(3,3,0)-辛烷、1,4-二氮杂-双环(2,2,2)-辛烷(Dabco)和烷醇胺化合物如三乙醇胺,三异丙醇胺、N-甲基-和N-乙基二乙醇胺、二甲氨基乙醇、2-(N,N-二甲氨基乙氧基)乙醇、N,N',N"-三(二烷基氨基烷基)六氢三嗪,例如N,N',N"-三-(二甲氨基丙基)六氢三嗪和三亚乙基二胺。
也可以使用金属盐,例如碱金属盐或过渡金属盐。作为过渡金属盐例如使用锌盐、铋盐、铁盐、铅盐或优选锡盐。使用的过渡金属盐的实例是氯化铁(II)、氯化锌、辛酸铅、二辛酸锡、二乙基己酸锡和二月桂酸二丁基锡。过渡金属盐特别优选选自二辛酸锡、二乙基己酸锡和二月桂酸二丁基锡中的至少一种。碱金属盐的实例是碱金属醇盐,例如甲醇钠和异丙醇钾,碱金属羧酸盐,例如乙酸钾,以及具有10至20个碳原子和任选侧链OH基团的长链脂肪酸的碱金属盐。优选使用一种或多种碱金属羧酸盐作为碱金属盐。
作为催化剂D此外考虑:脒类,例如2,3-二甲基-3,4,5,6-四氢嘧啶,氢氧化四烷基铵,例如氢氧化四甲基铵,碱金属氢氧化物,例如氢氧化钠,和羧酸四烷基铵或羧酸鏻。此外,曼尼希碱和酚盐是合适的催化剂。也存在这样的可能性,可以在没有催化的情况下进行反应。在这种情况下,利用了以胺开始的多元醇的催化活性。
如果在发泡时使用较大过量的多异氰酸酯,则作为用于过量的 NCO 基团彼此的三聚反应的催化剂此外考虑: 形成异氰脲酸酯基团的催化剂,例如铵离子-或碱金属盐,尤其是铵或碱金属的羧酸盐,单独地或与叔胺组合。异氰脲酸酯的形成导致特别阻燃的 PIR硬质泡沫。
催化剂组分可以计量加入到反应混合物中,或者完全或部分地预先加入到多元醇配制品A中。
该反应混合物的反应性通常借助于催化剂组分与需求相匹配。例如,制造薄板比制造较厚的板需要具有更高反应性的反应混合物。典型的参数是开始时间和凝固时间,作为反应混合物开始反应的时间和已经形成足够稳定的聚合物网络的时间点的量度。
上述催化剂可以单独使用或相互组合使用。
作为合适的异氰酸酯组分B可以考虑例如多异氰酸酯,即,NCO官能度为至少2的异氰酸酯。此类合适的多异氰酸酯的实例是1,4-丁二异氰酸酯、1,5-戊二异氰酸酯、1,6-六亚甲基二异氰酸酯(HDI)、异佛尔酮二异氰酸酯(IPDI)、2,2,4-和/或2,4,4-三甲基六亚甲基二异氰酸酯、异构的双(4,4'-异氰酸根合环己基)甲烷或其任意异构体含量的混合物、1,4-亚环己基二异氰酸酯、1,4-苯二异氰酸酯、2,4-和/或2,6-甲苯二异氰酸酯(TDI)、1,5-萘二异氰酸酯、2,2'-和/或2,4'-和/或4,4'-二苯基甲烷二异氰酸酯(MDI)和/或更高的同系物(聚合MDI)、1,3-和/或1,4-双(2-异氰酸根合-丙-2-基)苯(TMXDI)、1,3-双(异氰酸根合甲基)苯(XDI)以及具有C1至C6烷基的2,6-二异氰酸根合己酸烷基酯(赖氨酸二异氰酸酯)。异氰酸酯组分B优选选自MDI、聚合MDI和TDI中的至少一种化合物。
除了上述的多异氰酸酯外,还可以按比例共同使用具有脲二酮-、异氰脲酸酯-、氨基甲酸酯-、碳二亚胺-、脲酮亚胺-、脲基甲酸酯-、缩二脲-、酰胺-、亚氨基噁二嗪二酮-和/或噁二嗪三酮结构的改性二异氰酸酯以及每分子具有多于2个NCO基团的未改性多异氰酸酯,例如4-异氰酸根合甲基-1,8-辛烷二异氰酸酯(壬烷三异氰酸酯)或三苯基甲烷-4,4',4”-三异氰酸酯。
代替上述多异氰酸酯或除上述多异氰酸酯之外,也可以使用合适的NCO预聚物作为异氰酸酯组分B。所述预聚物可通过一种或多种多异氰酸酯与一种或多种多元醇的反应来制备,所述多元醇相应于在异氰酸酯反应性组分A1中描述的多元醇。
对于用作多异氰酸酯组分而言,相对于单体异氰酸酯,在硬质泡沫中特别优选聚合MDI类型。
多异氰酸酯组分A)的NCO含量优选为≥29.0重量%至≤33.0重量%并且优选具有在25℃下≥80mPas至≤2900mPas,特别优选在25℃下≥95mPas至≤850mPas的粘度。
NCO值(也称为NCO含量,异氰酸酯含量)借助于ENISO11909:2007来确定。其是在25℃下的数值,除非另有说明。
给出的粘度是在25℃下的动态粘度(除非另有说明),借助于DINENISO3219:1994-10“Kunststoffe - Polymere/Harze in flüssigem, emulgiertem oder dispergiertemZustand”来确定。
将异氰酸酯特征数(也称为特征数或异氰酸酯指数)理解为是指实际使用的异氰酸酯基团的物质的量[mol]与实际使用的异氰酸酯反应性基团的物质的量[mol]的商乘以100:
特征数 = (异氰酸酯基团的摩尔数/异氰酸酯反应性基团的摩尔数) * 100
根据本发明,反应混合物中的特征数为150至600,优选240至400。该特征数特别优选在240至400的范围内,在该范围中存在高比例的聚异氰脲酸酯(PIR)(该泡沫被称为作为PIR泡沫或PUR/PIR泡沫)并导致PUR/PIR泡沫本身具有较高的阻燃性。
NCO值(也称为NCO含量,异氰酸酯含量)借助于EN ISO 11909(2007年5月)确定。除非另有说明,否则其是在25℃下的值。
本发明同样涉及通过根据本发明的方法制备的PUR / PIR泡沫。
通过混合由组分A-D产生反应混合物,其产生 PUR/PIR 泡沫。该制备通常通过经由常规高压或低压混合头混合所有组分来进行。
根据本发明的PUR/PIR硬质泡沫通过本领域技术人员已知的一步法来制备,其中使反应组分连续或不连续地彼此反应,然后手动或借助机械设施以高压-或低压方法排放到传送带上或放入合适的模具中进行固化。
根据本发明的PUR/PIR硬质泡沫优选用于制造复合元件。在此,通常以连续或不连续的方式逆向于至少一个覆盖层进行发泡。
因此,本发明进一步提供了根据本发明的PUR/PIR硬质泡沫作为阻隔泡沫和/或作为复合元件中的增粘剂的用途,其中所述复合元件包括包含根据本发明的PUR/PIR硬质泡沫的层和至少一个覆盖层。在这种情况下,覆盖层至少部分地与包含根据本发明的PUR/PIR硬质泡沫的层接触。这里感兴趣类型的复合元件也称为夹层元件或阻隔板,通常用作用于隔音、隔热、用于大厅构建或用于外立面构建的建筑元件。取决于复合元件的使用目的,在此,覆盖层可以例如由金属带、塑料带或至多7mm厚的刨花板形成。所述一个或两个覆盖层在每种情况下可以是柔性覆盖层,例如是铝箔、纸、由纸和铝或由矿物无纺布制成的多层覆盖层和/或是刚性覆盖层,例如由钢板或刨花板制成的覆盖层。
实施例
原料:
A1-1-a 芳族/脂族聚酯,f=2,含有1.5重量%的游离乙二醇, 2.4重量%的游离二乙二醇(根据Monte Carlo计算),OH值195mg KOH/g,酸值0.55 mg KOH/g。
A2-a 聚乙二醇 PEG 400, 粘度0.12 Pa*s (25℃)
A2-b 三羟甲基丙烷与环氧乙烷的反应产物,OH:环氧乙烷的摩尔比为1:4。OH值为250mgKOH/g,粘度为在25℃下0.37Pa*s。
A3-a 邻苯二甲酸酐与二乙二醇以1:1的摩尔比的反应产物
A4-1-a 聚乙二醇单(2,4,6-三仲丁基苯基)醚(结构 I,其中 n = 11,R1=R2=R3 =CH3,R4 = H,R5=R6=R7 = C2H5;67重量%环氧乙烷;HLB = 13)
A4-2-a 聚乙二醇 2,4,6-三苯乙烯基苯基醚(n = 10,R1=R2=R3 = CH3,R4 = H,R5=R6=R7 = C6H5;54重量%环氧乙烷;HLB = 10)
A4-2-b 聚乙二醇 2,4,6-三苯乙烯基苯基醚(n = 16,R1=R2=R3 = CH3,R4 = H,R5=R6=R7 = C6H5,65重量%环氧乙烷;HLB = 13)
A4-2-c 聚乙二醇 2,4,6-三苯乙烯基苯基醚(n = 29,R1=R2=R3 = CH3,R4 = H,R5=R6=R7 = C6H5,77重量%环氧乙烷;HLB = 15)
A4-2-d 聚乙二醇 2,4,6-三苯乙烯基苯基醚(n = 60,R1=R2=R3 = CH3,R4 = H,R5=R6=R7 = C6H5,87重量%环氧乙烷;HLB = 17)
A5-a 聚醚改性的低聚二甲基硅氧烷
A5-b Levagard® PP与Levagard® TEP的混合物,重量比4:1(两者Lanxess AG)
B-a 聚合MDI,粘度为在25℃下700 mPas,NCO含量 31.5重量% (Desmodur®44V70L, Covestro Deutschland AG)
C-a 正戊烷
D-a 25重量%乙酸钾在二乙二醇中。
PUR/PIR硬质泡沫的制备和测试
根据DIN 4102-1(1998 年 5 月)在18 cm x 9 cm x 2 cm 大小的样品上使用小燃烧器实验通过边缘燃烧测量PUR/PIR硬质泡沫的火焰蔓延。报告了以厘米为单位的最大垂直火焰高度的值。
平均热释放率及其最大值(MARHE)、CO产率和作为烟气密度量度的比光吸收面积SEA的测量根据ISO标准 5660-1:1990,用“锥形量热仪”来测量。在此,1 dm x 1 dm x 0.3dm的试样体被热辐射器以 50 kW/m2 辐照20 分钟长的时间。所确定的CO产率在此由两次测量的平均值给出。
OH 值(羟值)根据 DIN 53240-1(2013 年 6 月)测定。
酸值的测定根据DIN EN ISO 2114(2006年11月)进行。
在 Anton Paar公司的Physica MCR 501 流变仪上测定粘度。选择具有1mm间距的锥-板结构(测量系统DCP25)。将多元醇(0.1 g)施加到流变仪板上,并在25℃下经受0.01至1000 1/s的剪切,测量10分钟每10s的粘度。给出的粘度是所有测量点的平均值。
根据 DIN EN ISO 4590(2003 年 8 月),用 Accupyk-1330 仪在尺寸为 5 cm x3 cm x 3 cm 的试样体上测量PUR/PIR硬质泡沫的开孔率。
根据DIN ISO 826(2013 年 5 月)测量上升方向的抗压强度。
泡沫的泡孔结构通过目测确定。
粗密度的测量根据 DIN EN ISO 845(2009 年 10 月)进行。
根据 DIN 53430(1975 年 9 月)的拉伸试验在拉伸棒(根据 DIN 53430 5.1 研磨)上测定拉伸强度 (σFmax)、断裂伸长率 (ε断裂) 和韧性的量度(σFmax*ε断裂/2)。
配制品
各自的多元醇配制品由基础-多元醇组分获得,所述基础-多元醇组分包含:
46 重量份A1-1-a
5 重量份A2-b
2 重量份A3-a
4 重量份A5-a
25 重量份A5-b。
该基础多元醇组分此外已经包含5重量份的催化剂D-a。
为了制备不同的PUR-PIR泡沫,在每种情况下,在纸杯中还向该基础多元醇组分中搅入根据表2的其它多元醇组分和作为发泡剂的正戊烷。
PUR/PIR泡沫
将得到的异氰酸酯反应性混合物与异氰酸酯混合,并将该反应混合物倾倒入纸模具(3 x 3 x 1 dm3)中并在其中完全反应。下表给出了各个实验的确切配方,以及对所得样品的物理测量的结果。
表4中给出了反应参数和泡沫性能。
根据本发明的实施例3-5尤其在良好阻燃性和泡孔结构的性能的组合方面优于非根据本发明的对比例1*、2*、6*和7*。
Claims (14)
1.多元醇配制品A,其包含
A1 基于多元醇配制品A的总质量计,35-89重量%的聚酯多元醇组分,其具有190-310mg KOH/g的OH值,
其由A1-1和A1-2构成
A1-1 至少一种聚酯多元醇,其OH值为≤ 250 mg KOH/g,官能度为1.5-2.5并且Mn<150 g/mol的游离二醇的含量<6重量%,基于A1-1的总质量计,
A1-2 任选的不属于A1-1定义的其它聚酯多元醇,
A2 基于多元醇配制品A计,10-40重量%的一种或多种聚乙二醇,其数均分子量Mn<700g/mol且平均官能度<2.5;
A3 任选其它异氰酸酯反应性组分
A4 基于多元醇配制品A计,0.2-5重量%的一种或多种选自下组的化合物
A4-1 聚乙二醇-2,4,6-三烷基苯基醚(结构I,其中R5、R6、R7 = H、C1- 至 C8-烷基)和
A4-2 聚乙二醇-2,4,6-三芳烷基苯基醚(结构I,其中R5、R6和/或R7 = 芳基)和
A4-3 聚乙二醇-烷基苯基醚(结构II)
结构I
R1、R2、R3、R4 = H、C1-C4-烷基,
R5、R6、R7 = H、C1- 至 C8-烷基、芳基
n = 7-20,优选 10-18,特别优选11-15
结构II
R1、R3 = H、C(CH3)2CR4R5R6
R2 = C(CH3)2CR4R5R6
R4、R5 = H或CH3
R6 = C2- 至C5-烷基、芳基
n = 3-8
其中所述化合物A4具有小于1.5 kg/mol的数均分子量Mn和25-70%环氧乙烷,优选40-60%环氧乙烷的含量,和
A5 任选其它助剂和添加剂,
A6 基于多元醇配制品A的总质量计,0-2重量%的水
[Mn - 根据 DIN 55672-1(2007 年 8 月)测定的值]。
2.根据权利要求1所述的多元醇配制品A,其中所述多元醇组分A1-1具有>5Pa*s的动态粘度(25℃,借助于DIN EN ISO 3219:1994-10测定)。
3.根据权利要求1或2所述的多元醇配制品,其中A1-1与A1-2的质量比为至少6:1,特别是至少8:1。
4.根据前述权利要求中任一项所述的多元醇配制品,其中所述多元醇组分A2具有200-600g/mol的Mn。
5.根据前述权利要求中任一项所述的多元醇配制品A,其中所述多元醇组分A2具有≤2.12的平均官能度。
6.根据权利要求1-3中任一项所述的多元醇配制品A,其中所述多元醇组分A2具有≤2.12的平均官能度和200-600 g/mol的Mn。
7.根据前述权利要求中任一项所述的多元醇配制品A,其中所述多元醇组分A5包含阻燃剂。
8.根据前述权利要求中任一项所述的多元醇配制品A,其中所述多元醇A1和A2的混合物具有≤4Pa*s的动态粘度(25℃,借助于DIN EN ISO 3219:1994-10测定),特别是2-4Pa*s的粘度。
9.根据前述权利要求中任一项所述的多元醇配制品用于制备PUR/PIR硬质泡沫的用途。
10.用于制备PUR/PIR硬质泡沫的反应混合物,其包含
根据前述权利要求1-8中一项或多项所述的多元醇配制品A,
多异氰酸酯组分B,
发泡剂C,
任选的催化活性组分D,
其具有 150 至 600的异氰酸酯特征数。
11.根据权利要求8所述的反应混合物,其中所述多异氰酸酯组分B选自至少一种选自下述的化合物:MDI,聚合MDI和TDI,特别是聚合MDI。
12.用于制备PUR/PIR硬质泡沫的方法,所述方法包括根据权利要求10或11所述的反应混合物的反应。
13.PUR/PIR硬质泡沫,其能够通过根据权利要求12所述的方法获得。
14.根据权利要求12所述的PUR/PIR硬质泡沫用于制造阻隔材料和/或复合元件的用途。
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PCT/EP2020/069002 WO2021008921A1 (de) | 2019-07-12 | 2020-07-06 | Verfahren zur herstellung von flammwidrigen pur-/pir-hartschäumen |
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- 2020-07-06 EP EP20737011.5A patent/EP3997161A1/de not_active Withdrawn
- 2020-07-06 WO PCT/EP2020/069002 patent/WO2021008921A1/de unknown
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CA3140032A1 (en) | 2021-01-21 |
EP3997161A1 (de) | 2022-05-18 |
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