CN117106151A - 降低从聚氨酯泡沫中排放的醛类的量的组合物 - Google Patents
降低从聚氨酯泡沫中排放的醛类的量的组合物 Download PDFInfo
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- CN117106151A CN117106151A CN202310829625.8A CN202310829625A CN117106151A CN 117106151 A CN117106151 A CN 117106151A CN 202310829625 A CN202310829625 A CN 202310829625A CN 117106151 A CN117106151 A CN 117106151A
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- isocyanate
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Classifications
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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Abstract
本发明公开了降低从聚氨酯泡沫中排放的醛类的量的组合物。一种异氰酸酯反应性组合物,其包含:至少一种选自异氰酸酯反应性组分的组分;选自被至少一个异氰酸酯反应性基团取代的环脲、自由基清除剂、或聚合物酸、或其混合物的处理剂;一种或多种胺组分,所述胺组分各自具有给定结构。
Description
本申请为一项发明专利申请的分案申请,其母案的申请日为2015年07月09日,申请号为201580037264.7,发明名称为“降低从聚氨酯泡沫中排放的醛类的量的组合物”。
本发明涉及异氰酸酯反应性组合物和通过使用所述异氰酸酯反应性组合物降低从聚氨酯泡沫中排放的醛类和/或二甲基甲酰胺的量的方法。
聚氨酯和聚脲材料在本领域中是公知的。聚氨酯和聚脲泡沫,特别是所谓的柔性聚氨酯和聚脲泡沫,用于多种应用。
越来越多地,某些组分(尤其诸如醛组分和二甲基甲酰胺)的排放被视为缺点。
已经进行了各种尝试以便在聚氨酯泡沫中整合所谓的清除剂。作为一个实例,DE10003157A1公开了溶解在溶剂中的高分子聚乙烯亚胺,随后将该溶液吸入到泡沫结构中。在干燥或蒸发溶剂后,该聚合物分子残留在泡沫结构中并充当醛清除剂。
应用这些聚合物的方法是成本和劳动密集型的,需要大量的清除聚合物,而且该聚合物不一定全部结合到化学聚氨酯或聚脲结构上。
WO2009/117479公开了一种方法,包括向叔胺催化剂中添加含伯胺化合物,由此将所述叔胺催化剂中甲醛的量减少至少50%。WO2009/117479的目的是减少催化剂中醛的生成,并由此采用CERTIPUR标准测试方法来定量泡沫中的甲醛。
如今,聚氨酯泡沫的排放标准和法规变得越来越严格,尤其在汽车行业中。汽车行业中的要求仅允许来自这些聚氨酯泡沫的醛类(如甲醛)和二甲基甲酰胺的极低排放或几乎无排放。取代使用CERTIPUR标准测试方法,必须采用更严格的测试方法,即VDA 276测试方法。迄今为止,当使用VDA 276测试方法时,现有技术的方法均不适于实现来自这些聚氨酯泡沫的极低醛排放至几乎无醛排放。一些汽车OEM规定根据VDA276测试方法测量的对于1千克泡沫低于30μg/m3的甲醛排放。专利申请WO2014/026802描述了一种泡沫,其中在使用VDA 276测试时降低了甲醛的排放,并且其中使用包含胺组分的组合物制造该泡沫。但是,与使用不具有该胺组分的组合物制得的泡沫相比,乙醛的排放提高。
本发明的一个目的是提供一种方法,使得容易在聚氨酯或聚脲材料,特别是聚氨酯或聚脲发泡结构中整合醛类,特别是甲醛和乙醛的清除剂。
本发明的另一目的是提供适于用作聚氨酯或聚脲材料中的醛类,特别是甲醛和乙醛的清除剂的组分的选择。并同时保持根据VDA 278测量的来自这些泡沫的低的总VOC(TVOC)排放。
令人惊讶地看到,与环脲和/或自由基清除剂结合的特定胺组分能够减少来自聚氨酯或聚脲材料的甲醛和乙醛的排放,使得如使用VDA 276标准测试方法测得的醛类的排放值满足汽车行业所设定的要求。
根据本发明的第一方面,提供了一种组合物,其包含:
o至少一种选自聚醚多元醇、聚酯多元醇、聚醚多胺和聚酯多胺的多异氰酸酯反应性组分;
o选自被至少一个异氰酸酯反应性基团取代的环脲、自由基清除剂、聚合物酸或其混合物的处理剂;和
o一种或多种具有根据下式之一的结构的胺组分:
Ra和Rb各自独立地为单元R1、R2和/或R3的随机序列,其中:
o R1是
o R2是
o R3是
o所述R4、R5、R6和R7各自独立地为-H或-CH3;
其中Ra包含3至17个氮原子,Rb包含2至16个氮原子。
单元R1、R2和/或R3的随机序列指的是胺组分可以具有R1、R2和/或R3的序列,其中式R1、R2和/或R3各自在胺组分中出现数次,并且其中胺组分可以包含式R1、R2或R3的至少一种或R1、R2和/或R3的组合。胺组分中R1、R2或R3的单元的序列优选为1-10次,更优选为1-5次。在一个实施方案中,胺组分包含R1、R2或R3的单元的序列。在另一实施方案中,胺组分包含R1和R2、R1和R3或R2和R3的单元的序列。
根据本发明的组合物还可以被称为异氰酸酯反应性组合物,适于与例如多异氰酸酯组分的异氰酸酯基团反应。该反应可以获得聚脲或聚氨酯材料。
根据一些实施方案,所述一种或多种胺组分的氮原子的平均数量为5至10个。
根据以下定义计算氮原子的平均数量:
F=∑Vi*(fi)2/∑Vi*fi,其中
Vi=组分i的体积分数;
fi=组分i中的氮原子。
根据一些实施方案,所述一种或多种胺组分的氮原子的平均数量可以为5至8个。
典型的平均值为6.5至7.5,例如大约7。
一种或多种胺组分可以包含至少两种,优选多于两种根据所述式的胺。这可以合计多达10种或更多种不同的胺,其均具有根据所述式之一的结构。这些至少两种并优选多于两种的胺可以被称为胺混合物。
发现一种或多种具有上述式的胺组分并且当其用于通过使包含所述一种或多种胺组分的异氰酸酯反应性组合物与多异氰酸酯组分反应来提供PU泡沫的方法中时,充当醛组分(如甲醛、乙醛和丙醛)的清除剂并任选也充当二甲基甲酰胺(DMF)的清除剂。所述一种或多种具有上述式的胺组分本身可以容易地包括在聚氨酯的化学结构中,因为伯胺和仲胺对多异氰酸酯的异氰酸酯基团具有显著的反应性。由此,考虑到其低分子量和可能使用的极少量,所述一种或多种具有上述式的胺组分结合在泡沫中,而它们几乎不影响或甚至完全不影响该泡沫的化学和物理性质。
根据优选的实施方案,所述一种或多种具有上述式的胺组分具有至少一个伯胺基团和至少一个仲胺基团。更优选地,所述一种或多种胺组分具有至少一种组分,该组分具有至少两个伯胺基团和至少一个仲胺基团。
根据替代实施方案,所述一种或多种具有上述式的胺组分具有至少两个仲胺基团。
由于所述一种或多种具有上述式的胺组分是适于提供聚脲或聚氨酯的反应混合物的一部分,泡沫一旦制成将不需要进行后处理(如通过浸渍)以便在该泡沫中构建醛清除性质。
在优选实施方案中,该组合物中一种或多种胺组分的量为基于所述组合物总重量计算的0.05重量%至2.5重量%。更优选地,所述一种或多种胺组分的量总计可以提供根据本发明的所述组合物的0.05重量%至1重量%、0.1至1重量%或甚至0.2至0.7重量%。
根据一些实施方案,胺组分中的所有R4-、R5-、R6-和R7-基团可以是氢。由此提供一种组合物,该组合物包含:
o至少一种选自聚醚多元醇、聚酯多元醇、聚醚多胺和聚酯多胺的组分;
o一种或多种胺组分,所述胺组分各自具有根据下式之一的结构:
其中Ra和Rb各自独立地为单元R1、R2和/或R3的随机序列,其中:
o R1是
o R2是
o R3是
其中Ra包含3至17个氮原子且Rb包含2至16个氮原子。
该组合物中一种或多种胺组分的量为基于该组合物总重量计算的0.05重量%至1.0重量%。
根据一些实施方案,所述一种或多种胺组分可以是包含三亚乙基四胺(TETA)和/或四亚乙基五胺(TEPA)和/或五亚乙基六胺(PEHA)和/或六亚乙基七胺(HEHA)和/或七亚乙基八胺(HEOA)和/或八亚乙基九胺(OENO)和/或更高级的多亚乙基胺的混合物。该混合物通常进一步包含在其结构中具有总计9至18个氮原子的胺组分。该混合物可以通过使二氯乙烷(EDC)与氨在升高的压力和温度下反应来获得。该混合物随后用苛性碱(caustic)中和,随后蒸馏可以从混合物中分离各种胺组分。如本领域技术人员已知的那样,TETA、TEPA、PEHA、HEHA、HEOA和OENA各自包含具有接近的沸点的亚乙基胺的混合物。例如,TEPA除N-(2-氨基乙基)-N'-{2-{(2-氨基乙基)氨基}乙基}-1,2-乙二胺)之外还包含AETETA(4-(2-氨基乙基)-N-(2-氨基乙基)-N'-{2-{(2-氨基乙基)氨基}乙基}-1,2-乙二胺)、APEEDA(1-(2-氨基乙基)-4-[(2-氨基乙基)氨基]乙基)-哌嗪)和PEDETA(1-[2-[[2-[(2-氨基乙基)氨基]乙基]-氨基]乙基]-哌嗪)。作为另一实例,TETA可包含TETA(N,N'-双(2-氨基乙基)-1,2-乙二胺)、Bis AEP(N,N'-双-(2-氨基乙基)哌嗪)、PEEDA(N-[(2-氨基乙基)2-氨基乙基]哌嗪)、支化TETA(三-(2-氨基乙基)胺)的混合物。
根据一些实施方案,所述一种或多种胺组分可以是三亚乙基四胺(TETA)和/或四亚乙基五胺(TEPA)。在这些实施方案中,特别是在根据本发明的组合物中仅包含三亚乙基四胺(TETA)或仅包含四亚乙基五胺(TEPA)时,一种胺组分可以提供根据本发明的所述组合物的0.1至1重量%或甚至0.2至0.7重量%。该实施方案还可以进一步包含在其结构中具有总计9至18个氮原子的胺组分。
根据本发明的组合物具有进一步的优点,在于其在环境条件下作为液体提供,有利于将该组合物添加到适于提供聚氨酯或聚脲泡沫的反应混合物中。
如所述那样,该组合物进一步包含选自聚醚多元醇、聚酯多元醇、聚醚多胺和聚酯多胺的多异氰酸酯反应性组分。
作为聚醚多元醇的实例给出的是聚乙二醇、聚丙二醇、聚丙二醇-乙二醇共聚物、聚丁二醇、聚己二醇、聚庚二醇、聚癸二醇和通过环氧烷(如环氧乙烷和/或环氧丙烷)与官能度为2至8的异氰酸酯反应性引发剂的开环共聚合获得的聚醚多元醇。优选地,该聚醚多元醇基于环氧丙烷,任选与最多20重量%(基于全部的环氧烷)的环氧乙烷组合。
作为聚酯多元醇的实例给出通过使多元醇与多元酸反应获得的聚酯二醇。作为多元醇的实例,可以给出乙二醇、聚乙二醇、1,4-丁二醇、聚丁二醇、1,6-己二醇、3-甲基-1,5-戊二醇、1,9-壬二醇、2-甲基-1,8-辛二醇等等。作为多元酸的实例,可以给出邻苯二甲酸、二聚酸、间苯二甲酸、对苯二甲酸、马来酸、富马酸、己二酸、癸二酸等等。
本文中所用的术语“异氰酸酯反应性组分”或“多异氰酸酯反应性组分”包括具有“一个或多个异氰酸酯反应性基团”或“一个或多个异氰酸酯反应性部分”的任何组分。本文中所用的术语“异氰酸酯反应性基团”包括含有活性氢基团或部分的任何基团或部分。对于本公开的目的来说,含有活性氢的基团指的是含有因其在分子中的位置而表现出按照Zerewitnoff试验的显著活性的氢原子的基团,所述Zerewitnoff试验由Wohler描述在Journal ofthe American Chemical Society,第49卷,第3181页(1927)中。此类活性氢基团的说明性实例是-COOH、-OH、-NH2和-NH。
如所述那样,根据本发明的组合物进一步包含处理剂。处理剂可以是被至少一个异氰酸酯反应性基团取代的环脲。处理剂还可以是自由基清除剂。处理剂还可以是聚合物酸。处理剂可以是被至少一个异氰酸酯反应性基团取代的环脲和自由基清除剂的混合物。处理剂可以是单独的聚合物酸,或是聚合物酸与自由基清除剂或环脲的混合物,或是聚合物酸、自由基清除剂与环脲的混合物。
根据一个特定实施方案,处理剂是被至少一个异氰酸酯反应性基团取代的环脲。该环脲可以是在环结构中具有结构要素-NH-CO-NH-的脂环族或双环脂族化合物。在一个实施方案中,环脲具有5至7的总环原子数。这样的环脲在-N或-C原子或二者上被至少一个异氰酸酯反应性基团取代。在一个特定实施方案中,被至少一个异氰酸酯反应性基团取代的环脲具有式(I):
其中R'、R0'、R1'、R2'、R3'和R4'独立地选自H、OH、R11'OH、NH或COOH,和R11'是C1-C4烷基,条件是R'或R0'的至少一个是H,并且进一步的条件是至少:R'、R0'、R1'、R2'、R3'和R4'之一为OH、COOH、R11'OH或NH;或者R1'R2'或R3'R4'为NH2。
此类式(I)的化合物的实例包括但不限于4,5-二羟基-2-咪唑啉酮、4,5-二甲氧基-2-咪唑啉酮、4-羟乙基乙烯脲、4-羟基-5-甲基丙烯脲、4-甲氧基-5-甲基丙烯脲、4-羟基-5,5-二甲基丙烯脲、1-(2-羟乙基)-2-咪唑啉酮或其混合物。
根据另一实施方案,处理剂是具有式(II)的被至少异氰酸酯反应性基团取代的环脲:
其中R'、R0'、R1'、R2'、R3'、R4'、R5'和R6'独立地选自H、OH、R11'OH、NH或COOH,和R11'是C1-C4烷基,
X是C、O或N,条件是当X为O时,R3'和R4'各自为零,并且当X为N时,R3'或R4'之一为零,
并且进一步的条件是R'或R0'的至少一个是H,并且至少:R0'、R1'、R2'、R3'、R4'、R5'、R6'之一为OH、COOH、R11'OH或NH;或者R1'R2'或R5'R6'为NH2。
此类式(II)的化合物的实例包括但不限于四氢-5-(2-羟乙基)-1,3,5-三嗪-2-酮、四氢-5-(乙基)-1,3,5-三嗪-2-酮、四氢-5-(丙基)-1,3,5-三嗪-2-酮、四氢-5-(丁基)-1,3,5-三嗪-2-酮或其混合物。
根据另一实施方案,处理剂是自由基清除剂。该自由基清除剂包括例如但不限于以下的化合物:甲巯咪唑、苯基甲巯咪唑及其衍生物;别嘌呤醇(allupurinol)、丙基硫脲嘧啶、谷氨酰胺、二氨基苄胺;烟酰胺;受阻酚或受阻脂族或芳族胺;亚磷酸酯;硫代双丙酸双十三醇酯;和天然抗氧化剂如维生素C、维生素E和/或谷胱甘肽。尤其优选的自由基清除剂是甲巯咪唑、空间位阻酚、空间位阻芳族胺或亚磷酸酯。
根据一个实施方案,自由基清除剂是受阻酚。在另一实施方案中,受阻酚是空间位阻酚。本文中所用的术语“空间位阻酚”指的是在芳环的位置2和6处具有基于其三维尺寸屏蔽酚环的OH基团并导致减弱的反应性的取代基的酚。由此,在一个特定实施方案中,空间位阻酚是具有式(III)的化合物:
其中R7'、R8'和R9'独立地选自H或C1-C10烷基,并且R10'为H或C1-C12烷基基团。
在一个实施方案中,R7'、R8'和R9'独立地选自H或CH3基团,并且R10'是H或C1-C4烷基。在再一实施方案中,R7'、R8'和R9'各自为CH3基团,并且R10'为H、甲基、乙基、丙基或异丙基。
此类具有式(III)的化合物的实例包括但不限于2,6-二叔丁基-4-甲基苯酚、2,6-二叔丁基-4-异丙基苯酚、2,6-二叔丁基-4-乙基苯酚、2,4-二甲基-6-辛基苯酚、2,6-二叔丁基-4-正丁基苯酚和2,4-二甲基-6-叔丁基苯酚、3,5-双(1,1-二甲基乙基)-4-羟基-苯丙酸支链C13-15烷基酯。
在另一实施方案中,自由基清除剂是亚磷酸酯。亚磷酸酯的实例包括但不限于亚磷酸三苯酯、亚磷酸三壬基苯酯、亚磷酸三(对甲苯基)酯、亚磷酸三乙酯、亚磷酸三(2-乙基己基)酯、亚磷酸三癸酯、亚磷酸三月桂基酯、亚磷酸三(十三烷基)酯、亚磷酸三油醇酯、亚磷酸三(二丙二醇)酯、亚磷酸二苯基单(2-乙基己基)酯、亚磷酸二苯基单癸酯、亚磷酸二苯基单(十三烷基)酯、三硫代亚磷酸三月桂基酯、亚磷酸二异癸基(苯基)酯、亚磷酸氢二乙酯(diethyl hydrogen phosphite)、亚磷酸氢双(2-乙基己基)酯、亚磷酸氢二月桂基酯、亚磷酸氢二油醇酯、亚磷酸氢二苯酯、四苯基二丙二醇二亚磷酸酯、四苯基四(十三烷基)季戊四醇四亚磷酸酯/邻苯二甲酸双(2-乙基己基)酯、二亚磷酸四(C12-C15烷基)-4,4'-亚异丙基二苯酯、双(十三烷基)季戊四醇二亚磷酸酯/双(壬基苯基)季戊四醇二亚磷酸酯、双(癸基)季戊四醇二亚磷酸酯、双(十三烷基)季戊四醇二亚磷酸酯、亚磷酸三硬脂基酯、二硬脂基季戊四醇二亚磷酸酯、亚磷酸三(2,4-二叔丁基苯基)酯、氢化双酚A季戊四醇亚磷酸酯聚合物、氢化双酚A亚磷酸酯聚合物及其混合物。
在另一实施方案中,自由基清除剂是空间位阻胺。根据本发明,“空间位阻胺”是具有两个取代的苯基的仲胺,所述苯基基于其三维尺寸屏蔽胺基团并导致减弱的反应性。
在一个特定实施方案中,空间位阻胺是具有式(IV)的经取代的二苯基胺芳族胺化合物:
(IV)其中R11和R11'独立地选自H或C1-C12烷基或芳基,并且在R11或R11'不位于该位置的情况下,R12和R12'是H或C1-C4烷基。
受阻芳族胺的实例是4,4'-双(α,α-二甲基苄基)二苯胺;4-辛基-N-(4-辛基苯基)苯胺;4-(1-甲基-1-苯基乙基)-N-4[4-91-甲基-1-苯基乙基]苯基]苯胺;ar-壬基-N-壬基苯基苯胺;N-苯基苯胺与2,4,4-三甲基戊烯的反应产物;苯乙烯化-N-苯基苯胺;2-乙基-N-(2-乙基苯基)-(三丙烯基)苯胺衍生物。
在又一实施方案中,处理剂是上述被至少一个异氰酸酯反应性基团取代的环脲和上述空间位阻酚的混合物。
在再一实施方案中,处理剂是上述被至少一个异氰酸酯反应性基团取代的环脲和上述亚磷酸酯的混合物。
在再一实施方案中,处理剂是“聚合物酸”。对于本公开的目的而言,以两种方式定义“聚合物酸”。首先,“聚合物酸”是含有三个或更多个不饱和羧酸或酸酐的相同重复单体的任何材料。其次,“聚合物酸”是含有至少两种重复单体的任何材料,其中第一单体是不饱和羧酸或酸酐,第二单体不同于第一单体。由此,在其中第一单体是不饱和羧酸的实施方案中,第二单体可以是不同的不饱和羧酸、酸酐、或替代单体。或者,在其中第一单体是酸酐的实施方案中,第二单体可以是不饱和羧酸、不同的酸酐或替代单体。在一个实施方案中,不饱和羧酸和酸酐的替代单体是乙烯基单体,例如但不限于苯乙烯、乙烯、丙烯、丁烯、丙烯腈和氯乙烯。
聚合物酸的不饱和羧酸和酸酐可以是含有至少一个双键的任何酸,其能够与其自身或另一种酸或酸酐单体,或任何非含酸单体聚合。不饱和羧酸和酸酐的实例包括但不限于丙烯酸、甲基丙烯酸、马来酸、马来酸酐、琥珀酸、琥珀酸酐、糠酸、富马酸、山梨酸、惕各酸、亚油酸、亚麻酸、里卡利酸(licanic acid)和能够与烯属不饱和单体或二聚体反应的含双键的其它酸。
在一个实施方案中,聚合物酸含有至少三个或更多个相同的重复单体,所述重复单体选自丙烯酸、甲基丙烯酸、马来酸、马来酸酐、糠酸、富马酸、山梨酸、惕各酸、亚油酸、亚麻酸和里卡利酸。
在另一实施方案中,聚合物酸含有至少两种重复单体,其中第一单体是不饱和羧酸,第二单体是不同的不饱和羧酸、酸酐或替代单体。在一个特定实施方案中,不饱和羧酸可以选自丙烯酸、甲基丙烯酸、马来酸、糠酸、富马酸、山梨酸、惕各酸、亚油酸、亚麻酸和里卡利酸。在又一实施方案中,酸酐和替代单体在存在时可以选自马来酸酐、苯乙烯、乙烯、丙烯、丁烯、丙烯腈和氯乙烯。
在再一实施方案中,聚合物酸含有至少两种重复单体,其中第一单体是酸酐,第二单体是不同的酸酐、不饱和羧酸或替代单体。在一个特定实施方案中,酸酐可以是马来酸酐。在另一实施方案中,不饱和羧酸或替代单体在存在时可以选自丙烯酸、甲基丙烯酸、马来酸、糠酸、富马酸、山梨酸、惕各酸、亚油酸、亚麻酸、里卡利酸、苯乙烯、乙烯、丙烯、丁烯、丙烯腈和氯乙烯。
向根据本发明的组合物中加入聚合物酸的优点在于,由该组合物制成的泡沫与未向组合物中加入聚合物酸时相比可以更均匀和稳定。这是因为该组合物中胺的反应性被聚合物酸降低。
根据本发明的第二方面,提供了通过在反应混合物中使用如上文在本发明的第一方面中描述的组合物来制备聚氨酯或聚脲泡沫以减少来自所述聚氨酯或聚脲泡沫的甲醛和/或乙醛排放的方法。
要理解的是,对于描述本发明的组合物的第一方面所描述的实施方案、优选实施方案和优点经必要修正适用于本发明的第二方面,其中制备聚氨酯或聚脲泡沫的方法使用本发明的第一方面的组合物。
本发明的方法中的反应混合物由此包含至少一种选自聚醚多元醇、聚酯多元醇、聚醚多胺和聚酯多胺的异氰酸酯反应性组分;选自被至少一个异氰酸酯反应性基团取代的环脲、自由基清除剂以及其混合物的处理剂;和一种或多种胺组分,其均如上文中本发明的第一方面中所述。
在一个实施方案中,本发明的方法中的反应混合物进一步包含异氰酸酯组分、选自发泡和/或胶凝催化剂的催化剂、以及任选的阻燃剂、抗氧化剂、表面活性剂、物理或化学发泡剂、填料、颜料或任何其它用于聚氨酯材料的典型添加剂。
在一个实施方案中,反应混合物中一种或多种胺组分的量为基于该反应混合物总重量计算的0.05重量%至0.50重量%。
根据优选的实施方案,所述一种或多种胺组分全部一起的总重量为制备所述聚氨酯或聚脲泡沫的反应混合物的0.10重量%至0.35重量%。
在一个实施方案中,反应混合物中处理剂的量为基于该反应混合物总重量计算的0.05重量%至2重量%,优选,更优选0.05至0.5重量%。
根据优选的实施方案,处理剂全部一起的总重量为制备所述聚氨酯或聚脲泡沫的反应混合物的0.05至1重量%或甚至0.10重量%至0.45重量%。
根据优选的实施方案,反应混合物进一步包含异氰酸酯组分。
异氰酸酯组分优选是多异氰酸酯,并可以包含任何数量的多异氰酸酯,包括但不限于甲苯二异氰酸酯(TDI)、二苯基甲烷二异氰酸酯(MDI)–类型的异氰酸酯以及这些异氰酸酯的预聚物。
本发明中使用的二苯基甲烷二异氰酸酯(MDI)可以是其2,4'-、2,2'-和4,4'-异构体及其混合物的形式、二苯基甲烷二异氰酸酯(MDI)及其具有大于2的异氰酸酯官能度的在本领域中称为“粗”或聚合MDI(多亚甲基多亚苯基多异氰酸酯)的低聚物的混合物的形式、或其具有氨基甲酸酯、异氰脲酸酯、脲基甲酸酯、缩二脲、脲酮亚胺、脲二酮和/或亚氨基噁二嗪二酮基团的任意衍生物以及其混合物的形式。
其它合适的多异氰酸酯的实例是甲苯二异氰酸酯(TDI)、六亚甲基二异氰酸酯(HDI)、异佛尔酮二异氰酸酯(IPDI)、亚丁基二异氰酸酯、三甲基六亚甲基二异氰酸酯、二环己基甲烷二异氰酸酯(H12MDI)、二(异氰酸根合环己基)甲烷、异氰酸根合甲基-1,8-辛烷二异氰酸酯和四甲基二甲苯二异氰酸酯(TMXDI)。
也可以使用通过使多异氰酸酯与含有异氰酸酯反应性氢原子的化合物反应获得的半预聚物和预聚物。含有异氰酸酯反应性氢原子的化合物的实例包括醇、二醇或甚至相对高分子量的聚醚多元醇和聚酯多元醇、硫醇、羧酸、胺、脲和酰胺。合适的预聚物的实例是多异氰酸酯与一元醇或多元醇的反应产物。
该预聚物通过常规方法制备,例如通过使分子量为400至5000的多羟基化合物,特别是单-或多羟基聚醚(任选与分子量低于400的多元醇混合),与过量的多异氰酸酯,例如脂族、脂环族、芳脂族、芳族或杂环多异氰酸酯反应。
根据本发明的方法可用于提供聚氨酯或聚脲(PU)泡沫,如柔性PU泡沫、半刚性PU泡沫、刚性PU泡沫、粘弹性PU泡沫、自结皮PU泡沫、水培(hydroponic)PU泡沫等等。其特别可用于诸如床垫、床用泡沫和汽车用PU泡沫的PU泡沫应用,特别是传统的柔性泡沫、HR柔性泡沫、粘弹性柔性泡沫,但也可以是半刚性和刚性泡沫。
根据第三方面,本发明涉及制造根据本发明的组合物的方法,包括以下步骤:
· 提供一种或多种具有如在本发明的第一方面中所述的结构的胺组分;
· 添加如上文在本发明的第一方面中所述的处理剂;
· 添加至少一种如上文在本发明的第一方面中所述的异氰酸酯反应性组分。
在这方面的一个实施方案中,该方法进一步包括在添加处理剂之前向一种或多种胺组分中添加如上文在本发明的第一方面中所述的聚合物酸。在该组合物包含聚合物酸的情况下,重要的是在将处理剂添加到混合物中之前将该酸加入到胺组分中,以获得均匀的组合物。
独立和从属权利要求列出了本发明的特定和优选特征。来自从属权利要求的特征可以在适当情况下与独立权利要求或其它从属权利要求的特征组合。
本发明的上述和其它特性、特征和优点将由下列详述而变得明显,所述详述通过实施例的方式示出了本发明的原理。该描述仅出于示例的目的给出,而不限制本发明的范围。
就特定的实施方案来描述本发明。
应当注意,用于权利要求书中的术语“包括”不应解释为限于其后列举的手段;其不排除其它要素或步骤。其由此应解释为规定如所提及的所述特征、步骤或组分的存在,但不排除存在或添加一个或多个其它特征、步骤或组分,或其组合。由此,表述“包括手段A和B的装置”的范围不应限于仅由组件A和B组成的装置。这意味着就本发明而言,该装置的相关组件仅有A和B。
在本说明书通篇中,提及“一个实施方案”或“实施方案”。此类引述表示,就该实施方案所描述的特定特征包括在至少一个本发明的实施方案中。因此,在本说明书通篇中各个地方出现短语“在一个实施方案中”或“在实施方案中”不一定均指同一实施方案,尽管它们可能是同一实施方案。此外,特定特征或特性可以以任何合适的方式在一个或多个实施方案中组合,如对本领域普通技术人员而言明显的那样。
在本发明的上下文中,下列术语具有下列含义:
1)除非另行说明,提及给定组分的重量%、w%或重量百分比指的是以百分比表示的所述组分的重量与此刻所述组分存在于其中的组合物的总重量之比。
2)VDA 276测试方法是在1立方米室内进行的测量来自泡沫样品的排放的排放测量方法,在所述室内,泡沫暴露于65℃和5%RH数小时。VDA 276(Verband Der Automobilindustrie)是汽车OEM(原设备制造商)的主办方(host)使用的规定可允许的来自汽车内部件的排放水平的特定汽车排放方法。
3)异氰酸酯指数或NCO指数或指数:NCO-基团相对于配制品中存在的异氰酸酯反应性氢原子之比,以百分比给出:
换言之,NCO-指数表示在配制品中实际使用的异氰酸酯相对于与配制品中使用的异氰酸酯反应性氢的量反应在理论上所需的异氰酸酯的量的百分比。
实施例
实施例1
提供了几种异氰酸酯反应性组合物,其包含如表1中进一步所示的下列成分。
o 100克由Huntsman International供应的F428;
o 4克由Huntsman International供应的F526;
o 4克水;
o 0.15克由Huntsman International供应的LED-103;
o 1克由Huntsman International供应的DPA;
o 0.25克二乙醇胺(DELA);
o 0.9克作为Tegostab B8734 LF2可获自Evonik的泡沫稳定剂。Tegostab B8734LF2是低雾度硅氧烷(low fogging siloxane)基表面活性剂;
o 0.33克胺组分——在该实施例中为四亚乙基五胺(由Huntsman供应的TEPA);o0.67克处理剂1e,其含有羟乙基乙烯脲和亚磷酸三(二丙二醇)酯的混合物。
表1:几种组合物中的化合物的概览。
在对比例A中,未加入处理剂和胺组分。
在实施例B中,加入0.33重量%的如上所述的胺组分。所述重量%基于反应混合物的重量,即多元醇、多异氰酸酯以及所有添加剂的重量之和。
在实施例E中,根据上面的描述加入0.67重量%的处理剂(其是包含异氰酸酯反应性基团的环脲和自由基清除剂的混合物)和0.33重量%的胺组分。所述重量%基于反应混合物的重量,即多元醇、多异氰酸酯以及所有添加剂的重量之和。
这些异氰酸酯反应性组合物与52克具有32的NCO值的聚合改性MDI变体反应。
根据VDA 276对所得聚氨酯泡沫施以排放测试,VDA 276是来自“Verband DerAutomobil industrie”的测试方法。
通过以2000rpm手动混合组分5秒来制造所有泡沫。反应混合物随后倾倒在6.5升开放模具中。在室温下固化大约2小时后,从模具中取出泡沫(3×350克),压碎并放置在TEDLAR/ALU袋中并密封。
随后对各泡沫体系(3×350克)施以VDA 276测试方法。测量并定量醛排放。测得的排放总结在表2中。
表2:使用表1的组合物制得的聚氨酯的VDA276测试的概览。
由实施例A可以清楚地看出,当使用不含有胺化合物和处理剂的组合物来制造聚氨酯泡沫时,泡沫中甲醛的排放非常高。
实施例B显示,当包含胺组分的组合物用于制造聚氨酯泡沫时,甲醛的排放消失,或大大减少。这种效果也显示在编号WO2014/026802的专利申请中。
但是,可以看出,加入胺化合物引发了泡沫中乙醛排放的增加。
令人惊讶地发现,当组合物除了胺化合物之外还包含处理剂(如被至少一个异氰酸酯反应性基团取代的环脲和自由基清除剂)时,该组合物用于制造聚氨酯泡沫,泡沫中的甲醛排放仍非常低,而且与使用单独的胺化合物(实施例E)相比乙醛的增加少得多。
根据VDA278测得的总计的TVOC排放仍然很低。
要理解的是,尽管为了提供根据本发明的实施方案已经讨论了优选的实施方案和/或材料,但可以在不背离本发明的范围与精神的情况下进行各种修改或改变。
实施例2
如实施例1中所述制备聚氨酯泡沫,该聚氨酯泡沫包含如表3中提供的成分。
该泡沫包含Weston 430,其是一种亚磷酸酯,并可商购自Addivant LLC。羟基乙烯脲可商购自BASF,聚合物酸是5000Mw的聚丙烯酸。
表3:PU泡沫的成分。
表4提供了醛排放的VDA276测试的结果。明显的是,胺化合物与抗氧化剂和环脲的组合(F)、胺化合物与抗氧化剂、环脲和聚合物酸的组合(G)和胺化合物与聚合物酸的组合(H)提供了降低的醛排放。
表4:PU泡沫中的醛排放。
Claims (11)
1.组合物,包含:
至少一种选自聚醚多元醇、聚酯多元醇、聚醚多胺和聚酯多胺的异氰酸酯反应性组分;
包含被至少一个异氰酸酯反应性基团取代的环脲和自由基清除剂以及聚合物酸的混合物的处理剂;和
一种或多种胺组分,其为包含三亚乙基四胺(TETA)、四亚乙基五胺(TEPA)、五亚乙基六胺(PEHA)、六亚乙基七胺(HEHA)、七亚乙基八胺(HEOA)和/或八亚乙基九胺(OENO)的混合物;
其中所述被至少一个异氰酸酯反应性基团取代的环脲具有式(I):
其中R’、R0’、R1’、R2’、R3’、R4’独立地选自H、OH、R11’OH、NH或COOH,R11’是C1-C4烷基,并且其中R’或R0’的至少一个是H,并且至少:R0’、R1’、R2’、R3’、R4’之一为OH、COOH、R11’OH或NH;或者R1’R2’为NH2,
其中所述自由基清除剂是甲巯咪唑、空间位阻酚、空间位阻芳族胺或亚磷酸酯;
其中所述聚合物酸含有至少三个相同的不饱和羧酸或酸酐的重复单体;或
其中所述聚合物酸含有至少两种重复单体,其中第一单体是不饱和羧酸或酸酐,且第二单体不同于所述第一单体,
其中所述组合物中的所述一种或多种胺组分的量为基于所述组合物总重量计算的0.05重量%至1重量%,所述组合物中的所述处理剂的量为基于所述组合物总重量计算的0.05重量%至2.5重量%。
2.根据权利要求1所述的组合物,其中所述被至少一个异氰酸酯反应性基团取代的环脲选自4,5-二羟基-2-咪唑啉酮、4,5-二甲氧基-2-咪唑啉酮、4-羟乙基乙烯脲、4-羟基-5-甲基丙烯脲、4-甲氧基-5-甲基丙烯脲、4-羟基-5,5-二甲基丙烯脲、1-(2-羟乙基)-2-咪唑啉酮或其混合物。
3.根据权利要求1或2所述的组合物,其中所述自由基清除剂包含空间位阻酚,所述空间位阻酚具有式(III):
其中R7’、R8’和R9’独立地选自H或C1-C10烷基,并且R10’为H或C1-C12烷基。
4.根据权利要求1或2所述的组合物,其中所述自由基清除剂是亚磷酸酯。
5.根据权利要求1或2所述的组合物,其中所述自由基清除剂是空间位阻胺,其是具有式(IV)的经取代的二苯基胺化合物:
(IV)其中R11和R11’独立地选自H或C1-C12烷基或芳基,并且在R11或R11’不位于该位置的情况下,R12和R12’是H或C1-C4烷基。
6.根据权利要求1或2所述的组合物,其中所述一种或多种胺组分包括至少一种包含至少两个伯胺基团和至少一个仲胺基团的组分。
7.通过在反应混合物中使用根据权利要求1至6任一项所述的组合物来制备聚氨酯或聚脲泡沫以减少来自所述聚氨酯或聚脲泡沫的甲醛和/或乙醛的排放的方法,
其中所述反应混合物中一种或多种胺组分的量为基于所述反应混合物总重量计算的0.05重量%至0.5重量%,所述反应混合物中处理剂的量为基于所述反应混合物总重量计算的0.05重量%至2重量%。
8.根据权利要求7所述的方法,其中所述反应混合物进一步包含至少异氰酸酯组分、选自发泡催化剂和/或胶凝催化剂的催化剂、以及任选的阻燃剂、抗氧化剂、表面活性剂、物理或化学发泡剂、填料、或颜料。
9.根据权利要求7或8所述的方法,其中将所述一种或多种胺组分作为所述异氰酸酯反应性组分的一部分提供到反应混合物中,所述异氰酸酯反应性组分选自聚醚多元醇、聚酯多元醇、聚醚多胺和聚酯多胺,其是包含反应性氢原子的异氰酸酯反应性组分。
10.制造根据权利要求1至6任一项所述的组合物的方法,包括以下步骤:
提供一种或多种胺组分,其为包含三亚乙基四胺(TETA)、四亚乙基五胺(TEPA)、五亚乙基六胺(PEHA)、六亚乙基七胺(HEHA)、七亚乙基八胺(HEOA)和/或八亚乙基九胺(OENO)的混合物;
添加包含被至少一个异氰酸酯反应性基团取代的环脲和自由基清除剂以及聚合物酸的混合物的处理剂;和
添加至少一种选自聚醚多元醇、聚酯多元醇、聚醚多胺和聚酯多胺的异氰酸酯反应性组分;
其中所述被至少一个异氰酸酯反应性基团取代的环脲具有式(I):
其中R’、R0’、R1’、R2’、R3’、R4’独立地选自H、OH、R11’OH、NH或COOH,R11’是C1-C4烷基,并且进一步的条件是R’或R0’的至少一个是H,并且至少:R0’、R1’、R2’、R3’、R4’之一为OH、COOH、R11’OH或NH;或者R1’R2’为NH2,
其中所述自由基清除剂是甲巯咪唑、空间位阻酚、空间位阻芳族胺或亚磷酸酯;
其中所述聚合物酸含有至少三个相同的不饱和羧酸或酸酐的重复单体;或
其中所述聚合物酸含有至少两种重复单体,其中第一单体是不饱和羧酸或酸酐,且第二单体不同于所述第一单体,
其中所述组合物中的所述一种或多种胺组分的量为基于所述组合物总重量计算的0.05重量%至1重量%,所述组合物中的所述处理剂的量为基于所述组合物总重量计算的0.05重量%至2.5重量%。
11.根据权利要求10所述的方法,其中所述处理剂包含被至少一个异氰酸酯反应性基团取代的环脲和自由基清除剂以及聚合物酸的混合物,并且其中在添加其它处理剂之前将所述聚合物酸加入到所述一种或多种胺组分中。
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