Classifications

• • C—CHEMISTRY; METALLURGY
  • 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
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4804—Two or more polyethers of different physical or chemical nature
  • C08G18/4812—Mixtures of polyetherdiols with polyetherpolyols having at least three hydroxy groups
• • C—CHEMISTRY; METALLURGY
  • 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
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
• • C—CHEMISTRY; METALLURGY
  • 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
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
  • C08G18/72—Polyisocyanates or polyisothiocyanates
  • C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
  • C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
  • C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
• • C—CHEMISTRY; METALLURGY
  • 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
  • C08G2110/00—Foam properties
  • C08G2110/0008—Foam properties flexible
• • C—CHEMISTRY; METALLURGY
  • 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
  • C08G2110/00—Foam properties
  • C08G2110/0041—Foam properties having specified density
  • C08G2110/0058—≥50 and <150kg/m3
• • C—CHEMISTRY; METALLURGY
  • 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
  • C08G2110/00—Foam properties
  • C08G2110/0083—Foam properties prepared using water as the sole blowing agent

Definitions

• This invention relates to a process for the preparation of a polyurethane foam.
• this invention relates to a process for the preparation of a visco-elastic polyurethane foam using an isocyanate component based on MDI (diphenylmethane diisocyanate).
• visco-elastic polyurethane foam refers particularly to block and moulding (hot and cold) polyurethane expanded materials or foams with a density substantially from 50 to 100 kg/m 3 and suitably having a resilience value, measured according to the test method UNI 6357-68 (Flexible Urethane Cellular Material - Determination of resilience (ball rebound)), lower than 30% and a 50 % compression set value at 23°C, measured according to the test method ISO 1856-80, of less than 4%, preferably less than 3%. These foams have the characteristic of slowly returning to their original form after being compressed.
• Materials having this characteristic are used in the preparation of impact absorption articles, in the furnishing industry for the preparation of mattresses and cushions and, more generally, in applications where an object capable of moving without bouncing or rebounding needs to be supported and in healthcare furniture market for example in the production of anti-sore seats and beds.
• Visco-elastic polyurethane foams may be prepared by reacting toluene diisocyanate (TDI) with a polyol compound which comprises a polyol polyether or polyester, as well as conventional additives for this type of reaction.
• TDI toluene diisocyanate
• the use of TDI may cause problems of a hygienic- environmental nature both in the preparation phase of the foam and during use, due to the possible presence of non-reacted monomer which may be released from the end-product after its preparation.
• MDI isocyanates
• polyethers typically requires the use of certain materials, polyethers, polyesters or additives to secure the desired visco-elastic properties.
• MDI with conventional raw materials typically produces traditional flexible foams (resilience higher than 30 %) or non-expanded materials (collapsed products) since MDI is difficult to process.
• visco-elastic polyurethane foams may be prepared from an isocyanate component based on MDI and certain types of conventional polyether polyols and drawbacks for example, high resilience and collapsing foam typical in the art may be reduced or avoided.
• the invention provides a process for the preparation of a visco-elastic foam having a density from 50 to 100 kg/m 3 which comprises reacting: a) an isocyanate component with a functionality from 2.1 to 2.7 having general formula (I):
• ⁇ represents a phenyl group and n is an integer greater than or equal to 1 ;
• a polyol component comprising: i) 80 to100% and preferably 85 to 95% by weight based on the total polyol component, of a bifunctional polyol polyether having an average molecular weight from 1000 to 4000, preferably from 1500 to 3000; ii) 0 to 5% and preferably 1 to 5% by weight based on the total polyol component, of a monofunctional alcohol R-OH wherein R is selected from a Ci to C 2 o.and preferably a Ci to C ⁇ 2 , alkyl and/or isoalkyl radical (referred to herein as an (iso)alkyl radical) and a group obtained by the condensation of a C to C 6 olefinic oxide on a Ci to C 2 o alkyl and/or isoalkyl radical; iii) 0 to 20% and preferably 5 to15% by weight, based on the total polyol
• the amount of water present is selected so as to ensure that the desired density of the polyurethane foam is secured.
• the isocyanate component having general formula (I) is suitably obtained from the phosgenation of formaldehyde-aniline condensates and generally called raw MDI or polymeric MDI.
• the isocyanate component having formula (I) may be diluted with 4,4'-diphenylmethane diisocyanate, optionally mixed with 2,4'-diphenylmethane diisocyanate.
• the bifunctional polyol polyether (i) used in the preparation of visco- elastic expanded materials according to the process is suitably selected from polyol polyethers obtained by the condensation of a C 2 to C 6 olefinic oxide on a compounds having two active hydrogen atoms (referred to herein as a "starter"), for example diethyleneglycol and dipropyleneglycol or water. Ethylene oxide, propylene oxide or mixtures of them are preferred olefinic oxides.
• the monofunctional alcohol ii) suitably has a molecular weight of 200 to 1500 and especially 250 to 1200.
• the alcohol ii) is a group obtained by the condensation of an olefin oxide on a C, to C 20 alkyl and/or isoalkyl radical
• the olefin oxide preferably comprises ethylene oxide and/or propylene oxide.
• R is a group obtained by the condensation of ethylene oxide, and optionally propylene oxide, on a C, to C 12 and especially a C 2 to C 8 alkyl and/or isoalkyl radical.
• suitable polyols with a functionality of three or higher include polyol polyethers based on ethylene oxide and/or propylene oxide and in which the starter is a triol such as glycerin or trimethylolpropane; a tetrol such as pentaerythritol; an alkanolamine such triethanolamine, or a polyfu notional hydroxy alkane such as xylitol, arabitol, sorbitol, mannitol, and the like.
• the starter is a triol such as glycerin or trimethylolpropane
• a tetrol such as pentaerythritol
• an alkanolamine such triethanolamine
• a polyfu notional hydroxy alkane such as xylitol, arabitol, sorbitol, mannitol, and the like.
• polyols can be used as such or they may contain, in dispersion or partially grafted to the polyol chains, solid particles, preferably polymeric, which suitably have dimensions lower than 20 micrometers.
• Solid particles preferably polymeric, which suitably have dimensions lower than 20 micrometers.
• Polymers suitable for this purpose include polyacrylonitrile, polystyrene, polyvinylchloride polyurea, mixtures of them, copolymers of them and .
• These solid particles may be prepared by means of polymerization in situ in the polyol or, as desired they may be prepared separately and subsequently added to the polyol.
• the polyol composition may also comprise further additives commonly used in the preparation of polyurethane expanded products such as amine catalysts, for example triethylenediamine, and/or metal catalysts such as stannous octoate, crosslinkers, cell regulators, thermo-oxidation stabilizers, pigments, antiflame agents, etc. Details on the polymerization of polyurethanes are provided in the test "Saunders & Frisch - Polyurethanes, Chemistry and Technology" Interscience, New York, 1964, and in "Polyurethane Handbook, edited by G. Oertel, Hanser Publishers, Kunststoff, New York, 1993.
• the expanding agent suitably comprises water and an auxiliary blowing agent for example CO 2 in liquid or gaseous form, and preferably consists of water.
• Water has a critical function as it causes the formation of urea bonds associated with the development of carbon dioxide which causes the expansion process of the polyurethane polymer , obtaining visco- elasticity.
• Quantities of water from 1 to 3 parts by weight with respect of 100 parts of polyol component are suitably employed.
• the resiliency of the foam is lower than 30% and desirably lower than 10 %.
• the polyol component comprises at least some mono alcohol of formula R-OH as herein defined as this assists in providing a lower resiliency.
• a visco-elastic foam is obtained, having a density of 65 kg/m 3 , a compression set of 2.35% and resilience of 24%.
• a visco-elastic foam is obtained, having a density of 55 kg/m 3 , a compression set of 3.5% and resilience of 29%.
• a visco-elastic foam is obtained, having a density of 77 kg/m 3 , a compression set of 2.70% and resilience of 28%.
• TEDIMON 4420 60.5 parts by weight of TEDIMON 4420 are reacted, according to the "free rising" technique, with a polyol formulation consisting of 90 parts by weight of a trifunctional polyol polyether having an average molecular weight 5 equal to 6000 (TERCAROL 427 of Enichem S.p.A.); 10 parts by weight of trifunctional polyol polyether having an average molecular weight of 4000 (TERCAROL 241); 3.1 parts by weight of water; 3.5 parts by weight of diethanolamine; 0.15 parts by weight of tertiary aliphatic amine (DABCO 33 LV); 0.6 parts of a siliconic surface-active agent (TEGOSTAB B 8636); 0.15 o parts of a solution of tin dibutyldilaurate (DABCO T-12 of Air Products).
• the reaction index is equal to 100.
• a visco-elastic foam is obtained, having a density of 100 kg/m 3 , a compression set of 2.1% and resilience of 18%.

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Polyurethanes Or Polyureas (AREA)
• Medicines That Contain Protein Lipid Enzymes And Other Medicines (AREA)

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Publications (1)

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• 2001
  • 2001-03-23 IT IT2001MI000619A patent/ITMI20010619A1/it unknown
• 2002
  • 2002-03-22 MX MXPA03008624A patent/MXPA03008624A/es active IP Right Grant
  • 2002-03-22 WO PCT/EP2002/003249 patent/WO2002077056A1/en active Application Filing
  • 2002-03-22 CN CNB028071166A patent/CN1229413C/zh not_active Expired - Fee Related
  • 2002-03-22 JP JP2002576512A patent/JP2004523632A/ja active Pending
  • 2002-03-22 BR BR0208607-7A patent/BR0208607A/pt not_active IP Right Cessation
  • 2002-03-22 CA CA002441694A patent/CA2441694A1/en not_active Abandoned
  • 2002-03-22 EP EP02726203A patent/EP1373351A1/de not_active Withdrawn
  • 2002-03-22 KR KR10-2003-7012345A patent/KR20030085039A/ko not_active Application Discontinuation

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