CN115433335A - 用异氰酸酯反应性胺晶体制得的低排放聚氨酯泡沫 - Google Patents
用异氰酸酯反应性胺晶体制得的低排放聚氨酯泡沫 Download PDFInfo
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- CN115433335A CN115433335A CN202211122214.7A CN202211122214A CN115433335A CN 115433335 A CN115433335 A CN 115433335A CN 202211122214 A CN202211122214 A CN 202211122214A CN 115433335 A CN115433335 A CN 115433335A
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Abstract
本发明公开了具有异氰酸酯反应性基团的叔胺催化剂，其能够形成能够耐受120℃和更高以及高达250℃的温度的热稳定的共价键。这些催化剂可以用于生产具有以下所需特征的聚氨酯泡沫：a)在宽范围的环境条件和异氰酸酯指数(例如，低至约65但高于约60的指数)下的非常低的化学排放；b)即使在高于环境温度(温度范围约25℃至约90℃)下，当泡沫暴露于水或水溶液时，仍然有足够的水解稳定性，以保持催化剂共价结合到泡沫上而不浸出叔胺催化剂；和c)聚氨酯聚合物和其它聚合物(如聚碳酸酯)之间的稳定的接触界面，其中叔胺催化剂从聚氨酯聚合物到其它聚合物的迁移最小，甚至在热和湿度条件下也不会在接触点处产生显著的聚合物劣化。
Description
本申请是2015年9月11日提交的名称为“用异氰酸酯反应性胺晶体制得的低排放聚氨酯泡沫”的“201580061036.3”号申请的分案申请。
本申请要求享有2014年9月12日提交的申请号62/049568的权益。申请号62/049568的公开内容在此以引用方式并入。
技术领域
本发明涉及具有异氰酸酯反应性基团的叔胺催化剂，其能够形成热稳定的共价键，并耐受约120℃和更高以及高达约250℃的温度。本发明还涉及使用本发明的催化剂来制备具有以下所需特征的聚氨酯泡沫：a)在宽范围的环境条件和异氰酸酯指数(例如，低至约65但高于约60 的指数)下的非常低的化学排放；b)即使在高于环境的温度(例如温度范围约25℃至约90℃)下，当泡沫暴露于水或水溶液时仍然有足够的水解稳定性，以保持催化剂共价结合到泡沫上而不浸出叔胺催化剂；和c)聚氨酯聚合物和其它聚合物(例如聚碳酸酯)之间的稳定的接触界面，其中叔胺催化剂从聚氨酯聚合物到其它聚合物的迁移最小，甚至在热和湿度条件下也不会在接触点处产生显著的聚合物劣化。
背景技术
开孔软质聚氨酯泡沫的生产采用各种添加剂，其中每一种都起到决定产品的最终特性和物理性质的作用。尽管这些添加剂在整体配制品中占比很小且预计排放量相对较低，但对成品中低挥发性有机物含量(VOC)的不断增加的环境需求使得额外需要添加剂，以达到这些较低的排放，同时保持泡沫性能。在本领域中需要无排放物的添加剂，其与常规的较不环保的标准产品表现一样好。
众所周知，制备聚氨酯泡沫的常规制造程序使用排放性添加剂。叔胺，例如三亚乙基二胺和双(二甲基氨基乙基)醚是工业上用于生产聚氨酯泡沫的常规的排放性催化剂。
用于减少泡沫排放的策略之一是基于在能够与异氰酸酯反应的叔胺催化剂上引入官能团。使用这种途径，叔胺催化剂将会保持与聚氨酯聚合物的共价结合，从而防止其释放至环境中。这种方法可能具有一些限制，这是因为官能化叔胺可以过早地与异氰酸酯反应，从而导致不期望的副作用，例如聚合物链终止(这将导致差的物理性能)、过多的孔开口或泡沫破裂或过度的交联(这可导致广泛的收缩和差的尺寸稳定性)。减少气味和排放的另一种替代途径是基于利用增加的分子量和/或极性的材料。与工业标准相比，诸如二甲基氨基丙基脲、双(二甲基氨基丙基)脲、双(二甲基氨基丙基)胺和N,N-双(二甲基氨基丙基)-N-(2-羟丙基)胺的产物可以提供可接受的物理性质，而大多数常规的反应性催化剂不能始终实现当前的消费者和制造商的要求。使用这些催化剂可以显著降低泡沫的总体排放。然而，所生产的成品通常不是无排放的，VOC和 FOG值根据VDA 278检测方法可达几百ppm。异氰酸酯反应性叔胺催化剂所需的一个关键特征在于其与生长的聚氨酯聚合物形成热稳定的共价键的能力。当泡沫样品被加热并且通过恒定的惰性气体流从加热室除去排放物时，所述共价键应足够稳定，以将胺催化剂保留在聚氨酯聚合物中。目前，存在能够在聚合过程期间与异氰酸酯反应的各种各样的官能化的胺聚氨酯催化剂。然而，在许多情况下，由于将胺催化剂保持在聚氨酯聚合物中的共价化学键在测试温度下不够稳定，所以用这些反应性催化剂中的一些制得的泡沫仍然可具有胺排放。不希望受任何理论或解释的约束，相信此类排放物可导致胺催化剂从聚氨酯聚合物释放，或导致来自胺-聚合物加合物的热分解的副产物和化学碎片的释放。
除了热稳定性之外，这些催化剂优选在各种条件和pH下形成水解稳定的共价键。叔胺与聚氨酯聚合物之间的化学键的水解稳定性在聚氨酯泡沫与可以暴露于湿气和/或水的纺织物接触的应用中或在泡沫可以直接暴露于水同时与皮肤接触的应用中起重要作用。如果聚合物与叔胺之间的化学键的水解稳定性不够高，那么叔胺催化剂可以从聚氨酯聚合物中浸出，并且可能使胺直接接触皮肤，从而导致皮肤刺激或皮肤过敏。
最后，在较低的异氰酸酯指数下的热稳定性和催化剂固定是额外的性能需求。除了诸如90-115的典型指数下的热稳定性之外，新催化剂需要能够与聚氨酯聚合物形成共价键，其在低至65且通常高于60的指数下具有热稳定性并且没有排放。这是一个难以满足的需求，因为在低异氰酸酯指数下，没有足够的能够与多元醇和水的所有OH基团反应的NCO基团，因此新的胺添加剂需要能够同时提供足够的催化活性以提供良好质量的泡沫，并与多元醇和水中的OH基团有效竞争以成为聚氨酯聚合物的一部分，且一旦聚合过程完成则保留在聚合物中。
美国专利US 5,859,079公开了包含N,N'-双(3-二甲基氨基丙基)脲和3-二甲基氨基丙基脲的聚氨酯催化剂组合物。然而，当将固化的聚合物加热到高达120℃的温度时，可能发生胺排放。此外，使用所述催化剂生产的水接触泡沫可具有增加的碱度。
美国专利US 6,858,654公开了用于促进聚氨酯形成反应的催化剂组合物，其包括凝胶化催化剂和发泡催化剂。凝胶化催化剂选自叔氨基烷基取代的伯胺或仲胺，发泡催化剂选自包含烷醇部分、伯胺部分或衍生自此类伯胺部分的脲基部分的双(氨基烷基)醚。用所述催化剂生产的泡沫可能具有恶臭气味，以及聚碳酸酯沾污能力。
美国专利US 4,101,470公开了具有能够与异氰酸酯反应并与其形成共价键的OH基的化合物。当双(二甲基氨基丙基)胺与环氧丙烷反应得到双(3-二甲基氨基丙基)(2-羟丙基)胺时，可获得此类组合物的实例。所公开的组合物和方法的一个限制是缺乏化学键的热稳定性，如美国专利US 6858654中所示实施例阐释的，其中当将泡沫加热至120℃时在根据VDA278排放测定方法进行测试期间观察到了190ppm来自双(3- 二甲基氨基丙基)(2-羟丙基)胺的分解产物。
美国专利US 4,049,591要求保护用于生产聚氨酯泡沫的方法，所述方法包括在催化量的具有通式[R”R”N-(CH2)3-]2NCH2CHRY的化合物存在下使有机多异氰酸酯与有机聚酯多元醇或聚醚多元醇反应，其中R”是低级烷基，R是氢或低级烷基且Y选自由CN、CONH2、CO2R’、CONR2’和COR’组成的组，其中R'独立地是H、低级烷基或芳基。这些化合物的限制包括排放，原因在于缺乏能够与NCO反应的官能团或不能形成热稳定的共价键以及水解不稳定性。
在先确定的专利的公开内容在此以引用方式并入。
在本领域中需要用聚氨酯催化剂制成的泡沫，其中所得的泡沫通过排放测试。在本领域还需要与异氰酸酯反应并形成热稳定的共价键的催化剂，其能够耐受反映极端环境条件的测试条件。由于异氰酸酯指数降低到低水平(指数低至65但高于60)，这种需求可能会成为挑战，因为NCO的化学计量的量不足以与多元醇和水中的所有OH反应。此外，所需的催化剂应该能够形成水解稳定的共价化学键，以防止胺催化剂从聚氨酯制品中浸出，以避免胺暴露于最终用户(例如，当泡沫直接或间接接触湿度/湿气和热量时)。此外，叔胺催化剂与聚氨酯聚合物之间的共价键在热和湿度极端环境条件下应该是稳定的，使得在聚氨酯与其它材料(例如与聚氨酯接触的聚碳酸酯)接触的情况下，其它材料不会被损坏或劣化。
发明内容
本发明解决了与常规反应性催化剂相关的问题和减少胺排放且因而减少来自开孔软质聚氨酯泡沫的总体排放的方法。本发明还解决了与在水接触期间泡沫中的催化剂浸出相关的问题，从而避免最终用户暴露于胺。本发明还解决了当某些材料与聚氨酯聚合物接触时的材料劣化的问题(例如，在热和湿度的极端环境条件下聚氨酯泡沫中的催化剂迁移可能引起的问题)。本发明解决了这些问题，同时提供了具有最佳物理性质和发泡速率或上升动力学的泡沫产品。
本发明使用至少一种在其结构中具有伯胺官能团的叔胺凝胶化催化剂以生产聚氨酯泡沫。在本发明的一个方面，本发明的胶凝胺 (gelling amine)包含具有化学结构为[Me2N-(CH2)3]2N-(CH2)3-NH2的N,N- 双(二甲基氨基丙基)-N-(3-氨基丙基)-胺，其中Me是CH3基团。
本发明的胶凝胺催化剂可以提供以下益处：a)在从约120℃和高达约250℃的温度的严格条件下，消除源自胺催化剂的排放物；b)聚氨酯聚合物的形成，其中当在不同温度和pH下暴露于湿度或水时，所述胺催化剂都保留在聚合物中；c)与由本发明的催化剂制成的聚氨酯聚合物接触的其它材料如聚碳酸酯的最小劣化或不劣化；d)当使用根据本发明的催化剂时，VOC和FOG的总体排放减少；和e)叔胺催化剂由于其高活性而使用水平显著降低。
当使用本发明的催化剂时，所生产的泡沫的特征在于：a)如通过VDA 278法测量的低至无胺排放和减少的总体排放；b)优异的物理性质，例如拉伸和撕裂强度、压缩形变、ILD、支撑因子和回弹性；c) 与聚氨酯聚合物接触的其它材料(例如聚碳酸酯)的最小或不劣化；d)由于高达约250℃的强和热稳定的共价键而保留在聚氨酯聚合物中的胺；e) 足够的水解稳定性，当在各种温度和pH下暴露于湿气或水时，其允许叔胺保留在聚氨酯聚合物中；和f)胶凝胺催化剂由于其高催化活性而使用量显著降低。
在本发明的一个方面，本发明的胺催化剂可以与选择的胺发泡催化剂组合使用，例如至少一个选自由以下组成的组的成员：N,N,N’- 三甲基-N'-3-氨基丙基-双(氨基乙基)醚或2-[N-(二甲基氨基乙氧基乙基)- N-甲基氨基]乙醇，但更优选使用N,N,N’-三甲基-N'-3-氨基丙基-双(氨基乙基)醚。
本发明的另一方面涉及通过使用本发明的催化剂制备聚氨酯泡沫的方法和所得的泡沫。
本发明的一个方面涉及用于制备催化剂的方法，其包括使丙烯腈和双(二甲基氨基丙基)胺在足以获得双(二甲基氨基丙基)-氰基乙基- 胺的条件下接触；并使双(二甲基氨基丙基)-氰基乙胺与氢气在足以获得 N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺的条件下接触。
本发明的另一方面涉及用于制备聚氨酯泡沫的方法，其包括在催化剂存在下使至少一种多元醇与至少一种多异氰酸酯接触，所述催化剂包括N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺。
本发明的另一方面涉及根据前述方面中的任一者产生的泡沫，其中所述泡沫在根据VDA 278测量时不含胺排放。
本发明的另一方面涉及根据前述任一方面产生的泡沫，其中所述泡沫具有改进的物理性质。
本发明的各个方面可以单独使用或组合使用。
附图说明
图1所示为根据实施例3制成的泡沫的上升速率对时间的图。具体而言，图1所示为标准催化剂
NE1070和胺-1的上升速率数据。
图2所示为用于测量与泡沫接触的聚碳酸酯表面的劣化的实施例5中使用的测试设备的图示说明。即，图2所示为聚碳酸酯稳定性的实验装置。
图3所示为根据实施例5测试的聚碳酸酯表面的图示说明。具体而言，图3所示为在热-湿度条件下与用
NE1070制成的聚氨酯泡沫接触后聚碳酸酯板的外观。
图4所示为根据实施例5测试的聚碳酸酯表面的图示说明。具体而言，图4所示为在热-湿度条件下与用胺-1制成的聚氨酯泡沫接触后聚碳酸酯板的外观。
具体实施方式
本发明涉及胺催化剂组合物、制备和使用所述催化剂组合物来制备聚氨酯泡沫的方法。本发明的胺催化剂N,N-双(二甲基氨基丙基)- N-(3-氨基丙基)-胺可用于：a)最小化泡沫排放而不损害泡沫物理性质(例如，当根据VDA-278测量时)；b)当泡沫在各种极端环境条件下暴露于水或湿气时提供水解稳定的泡沫，而不增加水相上的pH；c)由于催化剂不从聚氨酯聚合物迁移出来(例如当聚碳酸酯表面在温度和湿度的各种极端条件下暴露于聚氨酯泡沫时)，不会损害与聚氨酯接触的材料；d)最佳的物理性质，例如约28至约80kg/m3范围内的目标密度(ASTM 3574-A)、范围约40至约120L/M的空气流量(ASTM 3574-G)、范围为约150至约 600N的ILD(压痕载荷变形方法ASTM 3574-B1)、范围为约2.5至约3.5、优选约3的支撑因子(ASTM 3574-B1)和约40至约80％的回弹性(ASTM 3574-H)范围。
在本发明的一个方面，期望的泡沫具有拉伸/HA拉伸/伸长率 /HA伸长率＝DIN53571-约80％至约200％的范围，50％压缩形变＝ ASTM D3574-D-约1％至约20％的范围，HA压缩形变＝ASTM D3574-J1 和J2-约5％至约15％的范围，和撕裂＝ASTM D3574-F-约150至约400的范围。
根据本发明的方法使用具有以下化学结构的叔胺催化剂： [Me2N-(CH2)3]2N-(CH2)3-NH2，其中Me是CH3基团。本发明的催化剂可以约0.1pphp至约20pphp、约0.1pphp至约10pphp且在一些情况下约0.1 pphp至约5pphp范围内的量使用。本发明的胺催化剂可以通过任何合适的方法制备。合适方法的实例包括丙烯腈与双(二甲基氨基丙基)胺的反应以产生双(二甲基氨基丙基)-氰基乙基胺，随后腈官能团的催化氢化，得到N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺。制备本发明的催化剂的合适方法的实例在下面的实施例1中描述。
本发明催化剂可用于制造如下泡沫：当与本领域已知的其它类似催化剂相比时，具有低化学排放、最佳物理性质、最佳泡沫速率或上升动力学、甚至在约120℃和高达约250℃的温度下胺排放显著减少、当泡沫暴露于不同温度和pH下的湿气或水时叔胺凝胶与聚氨酯聚合物之间的水解稳定化学键、以及相对低的用量。
在本发明的一个方面，本发明的催化剂可与至少一种选自由以下组成的组的发泡胺催化剂组合用作凝胶化催化剂：N,N,N’-三甲基- N'-3-氨基丙基-双(氨基乙基)醚或2-[N-(二甲基氨基乙氧基乙基)-N-甲基氨基]乙醇，且通常为N,N,N'-三甲基-N'-3-氨基丙基-双(氨基乙基)醚。发泡胺催化剂的量通常为约0pphp至约5pphp、约0.01pphp至约2pphp且在一些情况下为约0.05pphp至约1pphp。这些催化剂可以通过任何合适的方法进行组合，例如将各个分离的催化剂添加到预混物中，或者预混合催化剂，并将催化剂的混合物添加到多元醇预混物中。
本发明还涉及使用异氰酸酯反应性叔胺凝胶化催化剂的选择组与本发明的催化剂N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺的组合制备低或无胺排放的聚氨酯泡沫的方法。选择的反应性凝胶化叔胺催化剂包括以下官能团中的任意一种：脲、仲胺、伯胺、酰胺或仲羟基。本发明的异氰酸酯反应性叔胺催化剂与凝胶化催化剂N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺的组合产生与利用现有技术中描述的任何唯一常规排放或非排放凝胶化催化剂产生的泡沫相比具有最少排放的泡沫。本发明催化剂与前述凝胶化催化剂的％比率通常为约100％至约5％、约80％至约10％，在一些情形下为约70％至约20％。这些催化剂可以通过任何合适的方法进行组合，例如将各个分离的催化剂添加到预混物中，或者预混合催化剂并将催化剂的混合物添加到多元醇预混物中。
泡沫的制备
本领域已知的各种类型的泡沫可以使用本发明的方法、使用已添加适量的N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺的典型聚氨酯配制品来制备。例如，具有本文所述优异特性的软质开孔聚氨酯泡沫通常可以以所指示量包含下表I中所示的组分。下面将详细论述表I中所示的组分。
表I聚氨酯组分
| 组分 | 重量份数 |
| 基础多元醇 | 20-100 |
| 聚合物多元醇 | 0-80 |
| 硅酮表面活性剂 | 0.5-10 |
| 发泡剂 | 2-4.5 |
| 交联剂 | 0.5-2 |
| 催化剂 | 0.25-10 |
| 羧酸(任选的) | 0.05-3.0 |
| 多异氰酸酯 | 提供NCO指数＝60-115 |
根据本发明的聚氨酯配制品中使用的多异氰酸酯的量不受限制，但通常在本领域技术人员已知的那些范围内。示例性范围在表I中给出，通过参考“NCO指数”(异氰酸酯指数)表示。如本领域已知的， NCO指数定义为异氰酸酯的当量数除以活性氢的总当量乘以100。NCO 指数由以下公式表示：
NCO指数＝[NCO/(OH+NH)]*100
软质泡沫通常使用作为泡沫组合物中总多元醇含量的一部分的共聚物多元醇以及约4000-5000的重均分子量和羟基数约28-35的基础性多元醇。下文将详细描述所述基础多元醇和共聚物多元醇。
催化剂
本发明的N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺的催化剂可以用作唯一的凝胶化催化剂，但是本发明的催化剂可以与其它的含有异氰酸酯反应性基团的叔胺组合使用。存在于替代性叔胺胶凝助催化剂中的异氰酸酯反应性基团基本上由伯胺、仲胺、仲羟基、酰胺和脲组成。凝胶化催化剂的实例包括选自由以下组成的组的至少一员：N,N-双 (3-二甲基氨基-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- 二甲基氨基丙胺(
15)、二甲基氨基丙基脲和N,N'-双(3-二甲基氨基丙基)脲(
NE1060、
NE1070、
NE1080和
NE1082)、1,3-双(二甲基氨基)-2-丙醇、6-二甲基氨基-1-己醇、N-(3-氨基丙基)咪唑、N-(2-羟丙基)咪唑、N,N'-双(2-羟丙基) 哌嗪，N-(2-羟丙基)-吗啉和N-(2-羟基乙基咪唑)。本发明的催化剂以及上述催化剂组合可与至少一种发泡催化剂一起使用。可以与上述凝胶化催化剂组合使用的含有异氰酸酯反应性基团的发泡助催化剂的实例包括 2-[N-(二甲基氨基乙氧基乙基)-N-甲基氨基]乙醇(
NE200)和 N,N,N'-三甲基-N'-3-氨基丙基-双(氨基乙基)醚(
NE300)。
例如当所需的聚氨酯泡沫是软质板坯(slab stock)时，催化剂组合物还可以包括其它组分，例如过渡金属催化剂，例如有机锡化合物或羧酸铋。金属催化剂还可以包括至少一个选自由以下组成的组的成员：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、二(2-乙基己基硫醇乙酸) 二甲基锡、二(2-乙基己基硫醇乙酸)二丁基锡、辛酸亚锡、其它合适的有机锡催化剂或其组合。也可以包括其它金属和盐，例如铋(Bi)。合适的金属盐包括羧酸盐，包括以下酸的盐：戊酸、新戊酸、己酸、2-乙基己基甲酸、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、新十二烷酸和其它合适的羧酸。铅(Pb)、铁(Fe)、锌(Zn)与戊酸、新戊酸、己酸、2-乙基己基甲酸、辛酸、新辛酸、新庚酸、新癸酸、新十一弯酸、新十二烷酸和其它合适的羧酸的过渡金属的其它盐也可以包括在内。金属催化剂和金属催化剂盐的量可在约0.01至约0.2和约0.1至约0.16的范围内。
尽管本发明的发明性胺催化剂N,N-双(二甲基氨基丙基)-N- (3-氨基丙基)-胺可与上文所列举的胺一起使用，但由于所述异氰酸酯反应性助催化剂之间的化学键的热稳定性不如本发明的催化剂那样稳定，此种使用会增加在泡沫的有用寿命期间及泡沫制造期间从泡沫的排放。通常，根据本发明的用于制备泡沫的所述排放性叔胺催化剂的用量(loading)可以在约0.1至约20pphp、更通常约0.1至约10pphp且最典型地约0.1至约5pphp的范围内。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。
在一个方面，本发明的胺或含有本发明胺的组合物通过与酸接触而被酸阻断。合适的酸可包括含有具有或不具有异氰酸酯反应性基团的单个或多个酸基团的饱和或不饱和及取代或未取代的芳族基团的任何有机羧酸。实例如果是酸则包括甲酸、乙酸、丙酸、丁酸、戊酸、己酸、特戊酸、新戊酸、新癸酸、新十二烷酸、2-乙基己酸、乙醇酸、葡萄糖酸、水杨酸、乳酸、苯甲酸、邻苯二甲酸、由邻苯二甲酸酐与二醇获得的邻苯二甲酸单酯、多元酸如聚丙烯酸等。
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'-二苯基甲烷二异氰酸酯(MDI)。在本发明的一个方面，使用2,4-TDI、2,6-TDI或其任何混合物来产生聚氨酯泡沫。其它合适的异氰酸酯化合物是商业上称作“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，并且含有约60％的4,4'-二苯基甲烷二异氰酸酯以及其它异构体和类似的高级多异氰酸酯。尽管可以使用任何合适的异氰酸酯，但其实例包括指数范围为约60至约120、在一些情况下为约 60至约65且通常为约90至约110的异氰酸酯。异氰酸酯的量通常在约95 至约105的范围内。
多元醇组分
聚氨酯是通过有机异氰酸酯与多元醇(通常为多元醇的混合物)的羟基的反应而产生。反应混合物的多元醇组分至少包括主要或“基础”多元醇。适合用于本发明的基础多元醇包括作为非限制性实例的聚醚多元醇。聚醚多元醇包括聚(环氧烷)聚合物，例如具有衍生自多元化合物(包括二醇和三醇)的端羟基的聚(环氧乙烷)和聚(环氧丙烷)聚合物和共聚物。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、二甘醇、二丙二醇、季戊四醇、甘油、二甘油、三羟甲基丙烷和类似的低分子量多元醇。本领域已知的其它基础多元醇实例包括多羟基封端的缩醛树脂、羟基封端的胺和羟基封端的聚胺。这些和其它合适的异氰酸酯反应性材料的实例可参见美国专利US 4,394,491，其在此以引用方式并入。合适的聚醚多元醇还包括含有可以催化聚氨酯的胶凝和发泡反应的叔胺基团的聚醚多元醇，例如U.S.8,367,870、WO 03/016373A1、WO 01/58976 A1、WO2004/060956A1、WO03/016372A1和WO03/055930A1中所述的聚醚多元醇，上述US和WO公开的公开内容在此以引用方式并入。其它有用的多元醇可以包括基于聚碳酸亚烷基酯的多元醇和基于聚磷酸酯的多元醇。
在本发明的一个方面，可以使用单一的高分子量聚醚多元醇作为基础多元醇。或者，可以使用高分子量聚醚多元醇的混合物，例如二官能和三官能材料和/或不同分子量或不同的化学组成材料的混合物。所述二官能和三官能材料包括但不限于聚乙二醇、聚丙二醇、甘油基聚醚三醇、三羟甲基丙烷基聚醚三醇和其它类似化合物或混合物。
除了上述的基础多元醇，或代替它们，通常称为“共聚物多元醇”的材料可以包括在根据本发明使用的多元醇组分中。共聚物多元醇可用于聚氨酯泡沫中以增加抗变形性，例如改善负载性质。根据负载要求，共聚物多元醇可以占总多元醇含量的约0至约80重量％。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，这两者都是本领域已知的并且可商购。
接枝多元醇是通过在起始多元醇中共聚乙烯基单体(通常为苯乙烯和丙烯腈)来制备。起始多元醇通常是甘油引发的三醇，并且通常用环氧乙烷(大约80-85％的伯羟基)封端。一些共聚物接枝到一些起始多元醇。接枝多元醇还含有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/丙烯腈固含量通常介于5wt％至45wt％范围内，但可以使用本领域已知的任何种类的接枝多元醇。
聚脲改性的多元醇是通过二胺和二异氰酸酯在起始多元醇的存在下反应形成，其中产物含有聚脲分散体。也适于使用的聚脲改性的多元醇的变体是通过异氰酸酯和烷醇胺在多元醇中的原位反应而形成的多异氰酸酯多加成(PIPA)多元醇。
根据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由可再生自然资源如植物油获得的多元醇。用于从廉价和可再生资源制备聚氨酯泡沫的多元醇对于最小化化石燃料和其它不可持续资源的消耗高度满意。天然油由饱和和不饱和脂肪酸的甘油三酯组成。一种天然油多元醇是蓖麻油，其是蓖麻油酸的天然甘油三酯，即使它具有某些限制如低羟基含量，但还是通常用于制备聚氨酯泡沫。其它天然油需要进行化学改性以引入足够的羟基含量，使其可用于生产聚氨酯聚合物。当尝试将天然油或脂肪改性成有用的多元醇时，可以考虑两个化学反应性位点：1)不饱和位点(双键)；和2)酯官能团。存在于油或脂肪中的不饱和部位可通过环氧化进行羟基化，然后进行开环或加氢甲酰化，随后进行加氢。或者，也可以使用酯交换以在天然油和脂肪中引入OH基。使用环氧化途径制备天然多元醇的化学方法包括需要环氧化天然油、开环酸催化剂和开环剂的反应混合物。环氧化的天然油包括环氧化基于植物的油(环氧化植物油)和环氧化动物脂肪。环氧化天然油可以是完全或部分环氧化的，并且这些油包括大豆油、玉米油、向日葵油、橄榄油、菜籽油、芝麻油、棕榈油、菜籽油、桐油、棉籽油、红花油、花生油、亚麻籽油和其组合。动物脂肪包括鱼、牛油和猪油。这些天然油是脂肪酸的甘油三酸酯，其可以是饱和的或不饱和的，且具有C12到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、花生四烯酸和木蜡酸；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。部分或完全环氧化的天然油可以通过过氧酸在合适的反应条件下反应时制备。用于油的环氧化中的过氧酸的实例已经描述于WO 2006/116456 A1中；以引用方式并入本文。可使用环氧化油与醇、水和具有一个或多个亲核基团的其它化合物的开环。根据反应条件，也可发生环氧化油的低聚。开环产生可用于制造聚氨酯产品的天然油多元醇。在加氢甲酰化/氢化过程中，在合适的催化剂(通常为钴或铑)存在下，在填充有氢/一氧化碳混合物的反应器中将油加氢甲酰化以形成醛，醛又在钴或镍催化剂存在下氢化以形成多元醇。或者，可使用碱金属或碱土金属的碱或盐作为酯交换催化剂，通过与合适的含多羟基的物质进行酯交换从天然油和脂肪产生多元醇。任何天然油或另一选择为任何部分氢化油都可用于酯交换过程。油的实例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、芸苔油、油菜籽油、红花油、鱼油、海豹油、棕榈油、桐油、橄榄油或任何共混物。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、甘露醇或任何组合。
多元醇的量由pphp定义。上文定义了三种类型的多元醇：标准多元醇或聚醚多元醇，其可以在约100pphp(仅多元醇)至约10pphp 的范围内使用。共聚物多元醇(CPP)可以在约0至约80pphp的范围内使用。最后，NOP(天然油多元醇)通常可以约0至约40pphp存在。
在本发明的一个方面，至少一种多元醇的官能度为3至5、3 至4且在一些情况下为3至3.5。在本发明的另一方面，至少一种多元醇具有介于约15至约50范围内的OH数。
发泡剂
聚氨酯泡沫的生产可通过在聚合过程中包含发泡剂(BA)以在聚氨酯基质中产生孔隙来辅助。可以使用任何合适的发泡剂。合适的发泡剂包括在放热聚合反应期间汽化的低沸点化合物。这种发泡剂通常是惰性的或其具有低反应性，因此它们在聚合反应期间可能不会分解或反应。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，如环戊烷、异戊烷、正戊烷和其混合物。其它合适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的量通常为约0(水发泡)至约80pphp。水 (通过与异氰酸酯反应制备CO2的发泡泡沫)可以介于约0(如果包括BA) 至约60pphp(极低密度泡沫)，以及通常约1.0pphp至约10pphp，在一些情况下约2.0pphp至约5pphp的范围内存在。
其它可选组分
根据本发明，用于制造泡沫的配制品中可以包括各种其它成分。可选组分的实例包括但不限于，泡孔稳定剂、交联剂、扩链剂、颜料、填料、阻燃剂、辅助氨基甲酸酯凝胶化催化剂、辅助氨基甲酸酯发泡催化剂、过渡金属催化剂、碱金属和碱土金属羧酸盐和任何这些的组合。
泡孔稳定剂可以包括例如硅酮表面活性剂以及有机阴离子、阳离子、两性离子或非离子表面活性剂。合适的硅酮表面活性剂的实例包括但不限于聚烷基硅氧烷、聚氧基亚烷基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。合适的阴离子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、磺酸的盐以及任何这些的组合。合适的阳离子表面活性剂包括但不限于季铵盐 (pH依赖性或永久带电荷)，例如十六烷基三甲基氯化铵、十六烷基吡啶鎓氯化物、聚乙氧基化牛脂胺、苯扎氯铵、苄索氯铵等。合适的两性离子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。合适的非离子表面活性剂包括但不限于脂肪醇、聚氧乙二醇烷基醚、聚氧丙二醇烷基醚、葡糖苷(如癸基、月桂基和辛基葡糖苷)、聚氧乙二醇烷基苯酚醚、二醇烷基酯等。细胞稳定剂可以约0.1至约20pphp、且通常约0.1至约10pphp且在一些情况下约0.1至约5.0pphp 的量使用。阻火剂可以约0至约20pphp和约0至约10pphp和约0至约5 pphp的量使用。
交联剂包括但不限于含有至少两个选自羟基、伯氨基、仲氨基和其它含活性氢的基团(其与异氰酸酯基反应)的部分的低分子量化合物。交联剂包括例如多元醇(特别是三元醇，如甘油和三羟甲基丙烷)、多胺和其组合。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-己二胺和其组合。典型的二胺交联剂包含十二个或更少碳原子，更常见的是七个或更少。交联剂可以约0.1至约20pphp、通常约0.1至约10pphp且在一些情况下约0.1至约5.0pphp的量使用。
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，例如甘醇、胺、二醇和水。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、1,12十二二醇、乙氧基化氢醌、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。扩链剂可以约0.1至约 100pphp且通常约0.1至约50pphp且在一些情况下约0.1至约5.0pphp的量使用。
颜料可用于在制造过程中对聚氨酯泡沫进行颜色编码(color code)，例如识别产品等级或隐藏黄变。颜料可以包括在聚氨酯领域已知的任何合适的有机或无机颜料。例如，有机颜料或着色剂包括但不限于偶氮/重氮染料、酞菁、二噁嗪和炭黑。无机颜料的实例包括但不限于二氧化钛、氧化铁或氧化铬。颜料的量可介于约0pphp(不添加颜料)至约40pphp的范围内。
填料可用于增加聚氨酯泡沫的密度和负载性质。合适的填料包括但不限于硫酸钡或碳酸钙。填料的量可介于约0pphp(不添加填料) 至约40pphp的范围内。
阻燃剂可用于降低聚氨酯泡沫的可燃性。例如，合适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。阻燃剂可以约 0至约20pphp和约0至约10pphp和约0至约5pphp的量使用。
在本发明的一个方面，本发明的催化剂不含或基本上不含某些胺催化剂。可以排除的材料的实例是无异氰酸酯基团且通常称作逃逸 (fugitive)催化剂的胺催化剂，特别是当它们的用量为>0.20pphp和在一些情况下>0.10pphp和在一些情况下>0.05pphp时，因为这些材料是胺排放的贡献者。该类别中的胺的实例列表包括三乙二胺(TEDA)、N-甲基咪唑、1,2-二甲基-咪唑、N-甲基吗啉、N-乙基吗啉、三乙胺、N,N'-二甲基-哌嗪、1,3,5-三(二甲基氨基丙基)六氢三嗪、2,4,6-三(二甲基氨基甲基) 苯酚、N-甲基二环己胺、五甲基二丙三胺、N-甲基-N'-(2-二甲基氨基)- 乙基-哌嗪、三丁胺、五甲基二乙三胺、六甲基三乙四胺、七甲基四乙五胺、二甲基氨基-环己胺、五甲基二丙三胺、双(二甲基氨基乙基)醚、三(3-二甲基氨基)丙胺、1,8-二氮杂双环[5.4.0]十一碳烯或其酸封闭的衍生物等，以及其任何混合物。
本发明的某些方面通过以下实施例说明。这些实施例仅是说明性的，且不应限制所附权利要求的范围。泡沫是通过使用Handmix评估或机器评估进行评估，如下所述。
实施例
手混(Handmix)评估
使用以下程序进行手混实验。使用装备有7.6cm直径的高剪切混合叶片且以5000rpm旋转的机械混合器将配制品共混在一起约10分钟。使用低温培养箱将预混合配制品保持在23±1℃。将Mondur TD-80 (甲苯二异氰酸酯的80/20的2,4/2,6异构体共混物)或改性MDI以对于每个泡沫的报告指数正确的化学计量量添加到预混物中。将混合物用Premier Mill Corporation 2000系列型号89共混在一起，并分散约5秒。将起泡混合物转移到Imperial Bondware编号GDR-170纸桶中，并在数据记录时允许泡沫自由上升。
机器评估
软质模制泡沫的机器运行是在Hi Tech Sure Shot MHR-50气缸位移系列和高压机器上进行。将由每一配制品的适当的多元醇、水、交联剂、表面活性剂和催化剂组成的新鲜预混物装入机器中。在整个研究中使用Mondur TD-80。通过机器的内部温度控制单元将所有化学品的温度保持在23±2℃。将泡沫倒入维持在63±2℃的等温控制的加热铝模具中。模具是一种典型的物理性质工具，其经设计内部尺寸为40.6cm x 40.6cm x10.2cm。模具有五个通风孔，每个孔直径约为1.5mm，其中心位于每个角距离每边缘10.0cm处和盖子的几何中心处。在每次倒出之前，用基于溶剂的脱模剂喷洒模具，并使其干燥1分钟，然后倾倒。将泡沫预混物以能够完全填充模具并获得报告的所需核心密度的湿化学填料重量搅拌倒入模具中心。为每个评估的配制品确立最低填充要求。在初次倾倒后240秒(4分钟)将泡沫制品脱模(详见下一段)。脱模时，将泡沫放置通过机械破碎机或测试强力破碎(FTC)测量值或将其冷却以确定尺寸稳定性(详见下文)。
使用设定为2.54cm的间隙的Black Brothers Roller破碎机将利用每个催化剂组制成的泡沫在脱模后1分钟机械破碎。在每个部件上进行三次破碎，每次穿过辊后将泡沫旋转90度。将所有产生用于物理测试的部件在恒温恒湿室(21±2℃，50±2％相对湿度)中调理化至少7天。
脱模后45秒进行FTC测量。将垫从模具中取出，称重并放置在FTC(强力破碎)设备(型号ISCO HGI压力泵)中。力检测装置配备有2.2kg容量的压力传感器，其安装在323cm2的圆形板十字头和驱动轴之间。实际的力显示在数字显示器上。该装置根据ASTM D-3574压痕力变形测试进行操作，并提供新鲜脱模泡沫的初始硬度或柔软度的数值。以275mm/分钟的十字头速度以达到最高压缩循环所需的力(以牛顿记录) 将垫压缩到原始厚度的50％。完成十个压缩循环。一个周期耗时约30秒来完成。
实施例1
N,N-双-(二甲基氨基丙基)-N-(3-氨基丙基)-胺(胺-1)的合成
在第一步骤中，向1000ml不锈钢反应器中装入424g双(二甲基氨基丙基)胺和23g水。将反应器用氮气吹扫，加热至75℃，并经历 1.5小时的时段将126g丙烯腈缓慢进进料至反应器中。将所有的丙烯腈转移到反应器中后，将温度在75℃下再保持4.0小时。将反应混合物冷却至25℃，将产物从反应器中取出并通过GC分析，得到96％产率的所需产物2-氰基乙基-双(二甲基氨基丙基)胺。在第二步骤中，向1000ml不锈钢反应器中装入198g异丙醇和6.9g标准拉尼钴催化剂。将反应器用氮气吹扫三次，并将温度升至120℃。将反应器用800psi的氢气加压，并将氰基乙基-双(二甲基氨基丙基)胺(344g)以约100ml/小时的速率进料至反应器中，历时约4小时的时段。一旦氰基乙基-双(二甲基氨基丙基)胺的转移完成，将温度升至130℃并保持1小时。通过GC分析产物，得到 93％的所需产物N,N-双-(二甲基氨基丙基)-N-(3-氨基丙基)-胺(胺-1)和5％的双(二甲基氨基丙基)胺、1.5％的N,N-双-(二甲基氨基丙基)-N-(3-丙基氨基丙基)-胺和0.5％的N,N-(双-(3-(N,N-双-(二甲基氨基丙基))-氨基)-丙基)-胺。
实施例2
使用各种凝胶化催化剂制备的PU泡沫的物理性质和其与标准催化剂二甲基氨基丙基脲和双(二甲基氨基丙基)脲的比较
通过在32盎司(951ml)纸杯中添加叔胺催化剂至约302g预混物(根据表II所示的配方制备)制备泡沫垫。使用配备有2英寸(5.1cm)直径搅拌桨的顶置式搅拌器以约6,000RPM将配制品混合约10秒。然后添加甲苯二异氰酸酯(TDI)，并使用相同的搅拌器以约6,000RPM将配制品再充分混合约6秒，之后将其在70℃下倒入预热的模具中，并在4分钟后脱模。将泡沫垫从模具中取出，手工压碎，称重并以75％垫厚度机械压碎。泡沫垫在恒温恒湿条件下储存48小时，然后进行切割和测试。
表II：配制品组分
1具有约5500的基础多元醇分子量的高分子量、高官能度和高伯羟基含量的高官能度封端的聚醚多元醇，得自Midland，MI的Dow Chemical Company。2含有共聚的苯乙烯和丙烯腈的接枝聚醚多元醇，基础多元醇分子量为约4800，得自Midland，MI的Dow ChemicalCompany。3硅酮表面活性剂可从Air Products and Chemicals公司获得。4胺催化剂可得自Air Products and Chemicals公司。
这种高度增加也可以显示为针对时间的高度变化率(速度)。可通过记录混合泡沫达到标准高度(TOC＝杯子顶部)所需的时间、最大泡沫上升速度、混合后达成最大速度所需的时间、以及串(string)凝胶时间(SGT)(其是当与木舌抑制器接触时聚合物料能够形成聚合物串的时间)，对起泡反应的速率进行有用比较。
表III显示了在软质开孔模制聚氨酯泡沫垫中评估的催化剂列表。软质模制垫是使用单一胶凝胺催化剂(在表III的泡沫实例中不使用发泡催化剂)来制备，以显示每种单个催化剂化学结构对最终物理性质的影响。用三乙二胺(TEDA)获得所需物理性质。然而，TEDA是不能与异氰酸酯反应的排放性催化剂，从而在成品中导致相对较高的胺排放，从而损害总体质量(汽车中的窗户雾化、PVC沾污、胺气味等)。在具有异氰酸酯反应性基团的催化剂中，因为
NE1070具有最佳的 50％的压缩形变、湿气老化的拉伸强度和相当的拉伸、撕裂和伸长率，所有其是有效的。
表III：各种常见催化剂的物理性质
实施例3
N,N-双-(二甲基氨基丙基)-N-(3-氨基丙基)-胺的泡沫上升速率动力学和使用量的比较
起泡性能可以通过比较标准品和新型胺催化剂的泡沫高度与时间进行比较。泡沫高度轮廓可以通过自动化上升速率设备利用具有FOMAT声纳上升率装置(下文称为“ROR”)的自由上升杯泡沫样品来测量。FOMAT装置包括声纳传感器，其在混合配制品的所有组分之后直接测量并记录上升发泡泡沫样品的高度(毫米，mm)与时间(秒，s)。 FOMAT标准软件生成高度与时间图以及速度与时间图。这些图可用于比较不同催化剂配方的相对反应性。软质开孔泡沫可以通过在32盎司 (951ml)纸杯中组合总重量约300g的表II中除了异氰酸酯之外的成分来制备。然后使用装配有2英寸(5.1cm)直径的搅拌桨的顶置式搅拌器以约 6,000rpm将该预混物配制品混合约10秒。然后添加足够的甲苯二异氰酸酯以达到约100的所需异氰酸酯指数，并且使用相同的搅拌器以约6,000 rpm将配制品再充分混合约6秒。然后将杯子放置在FOMAT传感器的下方。使ROR测量的开始时间针对FOMAT自动化，并在最终混合结束后直接开始。一旦将杯放置在ROR之下，化学混合物开始聚合。由于杯子的壁限制了除垂直方向外所有方向的膨胀，所以该膨胀在本实验中自身表现为高度随经过的时间而增加，如图1所示。
表IV：上升速率1数据和串凝胶时间
| 轮编号 | 凝胶催化剂 | pphp | TOC<sup>2</sup>(秒) | SGT<sup>2</sup>(秒) |
| 1 | DABCO NE1070 | 1.26 | 33 | 62 |
| 2 | 胺-1 | 0.43 | 42 | 63 |
| 3 | 胺-1 | 0.50 | 36 | 56 |
| 4 | 胺-1 | 0.63 | 32 | <49 |
1仅使用凝胶化催化剂
NE1070或胺-1(在这些实验中不存在发泡催化剂)进行的上升速率数据；2TOC和SGT如上所定义
实施例4
利用N,N-双-(二甲基氨基丙基)-N-(3-氨基丙基)-胺制得的聚氨酯泡沫的物理性质
通过在32盎司(951ml)纸杯中添加叔胺催化剂至约302g 预混物(如表2中制备)制备泡沫垫。使用配备有2英寸(5.1cm)直径的搅拌桨的顶置式搅拌器以约6,000RPM将配制品混合约10秒。然后添加甲苯二异氰酸酯(TDI)，并使用相同的搅拌器以约6,000RPM将配制品再充分混合约6秒，之后将其在70℃下倒入预热的模具中，并在4分钟后脱模。将泡沫垫从模具中取出，手工压碎，称重并以75％垫厚度机械压碎。泡沫垫在恒定温度(21℃)和湿度(50％相对湿度)条件下储存48小时，然后进行切割和测试。
模具数据记录在仅用凝胶化催化剂
NE1070或胺-1制得的泡沫垫上(在这些实验中不存在发泡催化剂)
表V：环境数据下的物理性质
仅用凝胶化催化剂
NE1070或胺-1制得的泡沫垫物理性质 (在这些实验中不存在发泡催化剂)
表V显示了使用市售的具有异氰酸酯反应性基团的标准叔胺催化剂(即
NE1070催化剂)以及新的异氰酸酯反应凝胶化催化剂“胺-1”(全化学名称：N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺)制成的软质模制聚氨酯泡沫垫的环境物理性质。表V显示，两种催化剂的环境物理性质非常相似，在两种情况下都提供了具有优异物理性质的泡沫垫。
表VI：湿气老化的物理特性
所用湿气老化程序如下：将样品在90℃的干燥烘箱中放置24小时进行干燥。一旦干燥，在90℃和100％相对湿度下，将样品老化 200小时。在老化后，然后将样品在70℃的干燥的烘箱中干燥22小时。将样品从干燥烘箱中取出，并在测量物理性质之前使其在环境条件下平衡。
使用单一的胺催化剂制备软质模制垫，以显示每个单独结构对物理性质的影响。评估结果显示，新型凝胶化催化剂N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺类似于标准反应催化剂如
NE1070催化剂起作用。
实施例5
利用N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺与聚碳酸酯表面接触产生的PU泡沫的老化
通过将4cm x4cm x4mm的聚碳酸酯板(Makrolon GP Clear 099 4mm厚，无抗紫外线剂)与4cm x4cm x5cm的泡沫片在底部约有 300毫升水的约4升玻璃罐内部接触来测定聚碳酸酯表面的稳定性。使罐达到温度(90℃)，并将与聚碳酸酯板接触的泡沫放置在内置玻璃支架上的罐内，高于水位约5cm。然后将罐密封并置于90℃下调理的烘箱中放置6天。现在参考图2，图2是其中放置有板和泡沫的用于测试的罐的图示说明。
用于该试验的泡沫是根据以90的异氰酸酯指数制得的表VII 所示配方(MDI软质泡沫)、使用在软质模制泡沫的机器运行期间制得的泡沫样品制备，所述机器运行是使用如上所述Hi Tech Sure Shot MHR- 50气缸位移系列和高压机器进行。
表VII：聚碳酸酯测试的配方
1具有28mgKOH/g的羟值约6000的标称分子量的反应性三官能多元醇，可自ShellChemicals商购得。2环氧乙烷封端的聚醚多元醇，可从 Huntsman商购得。3硅酮表面活性剂可从Air Products and Chemicals公司商购得。4胺催化剂可从Air Products andChemicals公司商购得，如上文所定义。5常规MDI异氰酸酯
在热-湿度下暴露于用
NE1070和胺-1催化剂制成的聚氨酯泡沫后聚碳酸酯板的外观可以分别在图3和图4中看出。在图3和图4中也示出了在测试时聚碳酸酯板搁置的泡沫表面的外观。用“胺-1”制成的泡沫似乎没有变化，而与用
NE1070制成的泡沫接触的泡沫似乎受损和被沾污。在聚碳酸酯样品表面引起的损坏是胺催化剂从聚氨酯泡沫样品中浸出并到达聚碳酸酯表面的明显指示。当胺-1用作催化剂时，这种效果明显最小。
可以通过测量样本的重量损失来监测聚碳酸酯板表面损害的程度。具有较少表面损害的样本重量减少较少，如表VIII中所示。因此，在该测试条件下暴露于用胺-1制成的泡沫2的聚碳酸酯板比暴露于用标准胺催化剂
NE1070制成的泡沫1的聚碳酸酯板具有更少的质量损失。
表VIII：聚碳酸酯测试的配制品
| 样品 | Δmg | 质量变化％ | 泡沫表面 |
| 空白PC板 | 16.4 | 0.34 | NA |
| 1 | -355.9 | -7.44 | 发粘且被沾污 |
| 2 | 15.5 | 0.32 | 不发粘 |
Δmg＝最终质量-初始质量，质量变化％＝最终质量-初始质量/初始质量。空白PC板＝对照聚碳酸酯板，其暴露于热湿度，不与任何聚氨酯表面接触
实施例6
在用标准反应性胺催化剂和新型胺N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺以低异氰酸酯指数制成的泡沫上测量的排放
如上所述使用Hi Tech Sure Shot MHR-50气缸位移系列和高压机器以65的计算异氰酸酯指数制备机器泡沫垫。这些泡沫样品用于热解吸排放研究，这些研究按照表VIII所示的配方1和2进行。
表VIII：FOR VDA278排放测试的配制品
1反应性三官能多元醇，羟值为35mgKOH/g，可从BASF商购得。2高填充共聚物多元醇，用于羟基数为20mgKOH/g且固含量为45％的高回弹性软质泡沫。3硅酮表面活性剂可从Air Products and Chemicals公司商购得。4胺催化剂可从Air Products and Chemicals公司获得，如上文定义。5具有80％2,4-甲苯二异氰酸酯和20％2,6-甲苯二异氰酸酯的常规TDI混合物，NCO含量为48％，可从BASF商购得。
表IX：使用VDA278方法的排放结果
使用热解析分析测量表IX中所示的泡沫排放，并根据 VDA 278方法量化在90℃(VOC)和120℃(FOG)下排放的物质。为此目的，在惰性气体流下将测试材料的样品调理至相应的温度，并将释放的物质在气相色谱仪的冷冻注射器中冷冻。然后使混合物通过气相色谱柱，并量化总排放量。使用相同的样品测量VOC和FOG。气态排放量 (VOC)是针对外部甲苯标准物进行量化，而可冷凝排放物(FOG)则针对十六烷(C16-正烷烃)量化。浓度是以甲苯和十六烷当量的总排放量报告 (ppm)。如表IX所示，在用胺-1的N,N-双-(二甲基氨基丙基)-N-(3-氨基丙基)-胺制成的泡沫样品2中未检测到胺排放。
实施例7
在指数105下用N,N-双-(二甲基氨基丙基)-N-(3-氨基丙基)-胺制得的MDI聚氨酯泡沫的物理性质
根据上述程序，按照表X所示的配方以105的异氰酸酯指数制备机制泡沫垫，以确定在
NE300作为标准发泡催化剂存在下与
NE1070相比N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺的性能。
表X：用于物理性质的配制品
1具有28mgKOH/g的羟值、约6000的标称分子量的反应性三官能多元醇，可自ShellChemicals商购得。2环氧乙烷封端的聚醚多元醇，可从 Huntsman商购得。3硅酮表面活性剂可从Air Products and Chemicals公司获得。4胺催化剂可从Air Products andChemicals公司获得，如上文所定义。5常规MDI异氰酸酯。
表XI：具有指数105的MDI泡沫的物理性质
| 性质 | 单位 | 调理 | 方法 | 泡沫1 | 泡沫2 |
| 拉伸强度 | kPa | 环境 | DIN 53571 | 140 | 142 |
| 拉伸伸长率 | ％ | 环境 | DIN 53571 | 97 | 92 |
| HA拉伸强度 | kPa | 大众 | DIN 53571 | 119 | 94 |
| HA拉伸伸长率 | ％ | 大众 | DIN 53571 | 108 | 113 |
| 50％压缩形变 | ％ | 环境 | ASTM 3574-D | 6.1 | 6.5 |
| 50％HA压缩形变 | ％ | 大众 | ASTM 3574-D | 31 | 31 |
| CLD | kPa | 环境 | ASTM 3574-D | 10 | 11 |
| HA CLD | kPa | 大众 | ASTM 3574-D | 8.5 | 8 |
| HALLS | ％ | 大众 | ISO-3386-1 | -13 | -26 |
虽然已经参考某些方面或实施方案描述了本发明，但是本领域技术人员应当理解，可以进行各种改变，并且可以将等同物替代其要素，只要不脱离本发明的范围。此外，在不脱离本发明的本质范围的情况下，可以进行许多修改以适应本发明的教导。因此，本发明并不打算限于作为实施本发明的最佳模式所公开的特定实施方案，而是本发明将包括落入所附权利要求的范围内的所有实施方案。
Claims (4)
1.一种用于制备聚氨酯泡沫的方法，其包括在包含N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺的催化剂存在下使至少一种多元醇和至少一种多异氰酸酯接触；其中所述聚氨酯泡沫在60至65的NCO指数下制备，并且，其中还使用N,N,N’-三甲基-N'-3-氨基丙基-双(氨基乙基)醚或2-[N-(二甲基氨基乙氧基乙基)-N-甲基氨基]乙醇作为发泡催化剂。
2.一种根据权利要求1所述的方法制备的泡沫，其中在根据VDA 278测量时，所述泡沫无胺排放。
3.一种用于在60至65的NCO指数下制备聚氨酯泡沫的预混物，其包含至少一种多元醇、一种包含凝胶化催化剂和至少一种发泡催化剂的组合的催化剂组合物、至少一种硅酮表面活性剂、水和至少一种交联剂，其中所述凝胶化催化剂由N,N-双(二甲基氨基丙基)-N-(3-氨基丙基)-胺和至少一种选自以下的发泡催化剂组成：N,N,N’-三甲基-N'-3-氨基丙基-双(氨基乙基)醚和2-[N-(二甲基氨基乙氧基乙基)-N-甲基氨基]乙醇。
4.根据权利要求3所述的预混物，其中所述交联剂包括二乙醇胺。
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| EP3774961A1 (en) * | 2018-04-13 | 2021-02-17 | Covestro Intellectual Property GmbH & Co. KG | Adducts of amine catalysts for producing isocyanurate polymers |
| US20210015269A1 (en) * | 2019-07-19 | 2021-01-21 | Evonik Operations Gmbh | Shaped pu foam articles |
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| US11104757B2 (en) | 2021-08-31 |
| CA2960527C (en) | 2023-01-24 |
| EP3191537A1 (en) | 2017-07-19 |
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