EP4363476A1 - Production de mousses de pu à l'aide de polyols recyclés - Google Patents

Production de mousses de pu à l'aide de polyols recyclés

Info

Publication number
EP4363476A1
EP4363476A1 EP22738450.0A EP22738450A EP4363476A1 EP 4363476 A1 EP4363476 A1 EP 4363476A1 EP 22738450 A EP22738450 A EP 22738450A EP 4363476 A1 EP4363476 A1 EP 4363476A1
Authority
EP
European Patent Office
Prior art keywords
foam
carbon atoms
polyol
recycling
radicals
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22738450.0A
Other languages
German (de)
English (en)
Inventor
Roland Hubel
Annegret Terheiden
Felix Mühlhaus
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Evonik Operations GmbH
Original Assignee
Evonik Operations GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Evonik Operations GmbH filed Critical Evonik Operations GmbH
Publication of EP4363476A1 publication Critical patent/EP4363476A1/fr
Pending legal-status Critical Current

Links

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
    • C08G18/08—Processes
    • C08G18/16—Catalysts
    • C08G18/22—Catalysts containing metal compounds
    • C08G18/24—Catalysts containing metal compounds of tin
    • C08G18/244—Catalysts containing metal compounds of tin tin salts of carboxylic acids
    • 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
    • C08G18/2805—Compounds having only one group containing active hydrogen
    • C08G18/2815—Monohydroxy compounds
    • C08G18/282—Alkanols, cycloalkanols or arylalkanols including terpenealcohols
    • C08G18/2825—Alkanols, cycloalkanols or arylalkanols including terpenealcohols having at least 6 carbon atoms
    • 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
    • C08G18/4829—Polyethers containing 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
    • C08G18/70—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
    • C08G18/7614—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
    • 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

Definitions

  • the invention is in the field of polyurethanes and relates to the production of PU foams using recycled polyols.
  • polyurethanes Due to their excellent mechanical and physical properties, polyurethanes are used in a wide variety of areas.
  • the area of PU foams represents a particularly important market for the most diverse types of polyurethanes.
  • polyurethanes are understood to mean all reaction products starting from isocyanates, in particular from polyisocyanates, and corresponding isocyanate-reactive molecules, in particular polyols. This also includes, inter alia, polyisocyanurates, polyureas and isocyanate or polyisocyanate reaction products containing allophanate, biuret, uretdione, uretimine or carbodiimide.
  • Polyurethanes are now so widespread around the world that recycling these materials is becoming increasingly important. In the prior art, therefore, there are already different recycling processes for the utilization of polyurethane waste.
  • the well-known chemical recycling processes such as hydrolysis, e.g. described in US Pat - position can be used. These polyol mixtures are generally referred to as recycled polyols.
  • the subject of the invention is a process for producing PU foams by reacting (a) at least one polyol component, comprising recycling polyol, (b) at least one isocyanate component in the presence of
  • the polydispersity of the respective recycling polyol being ⁇ 2, preferably ⁇ 1.5, in particular ⁇
  • the subject of the invention makes it possible to provide polyurethane foams using larger amounts of recycled polyol, which correspond to the quality of conventional polyurethane foams, but which have been produced in the same way with conventional polyols. Due to the achievable, high proportion of recycling polyol, the subject of the invention enables a significant increase in the total proportion of recycled raw materials in the polyurethane foams produced according to the invention, which is an important advance with regard to the recyclability of polyurethane foams.
  • the number-average molar mass M n , the weight-average molar mass M and the polydispersity (M / M n ) are preferably determined in the context of the present invention by means of gel permeation chromatography (GPC), preferably based on ISO 13885-1: 2020, in particular as in described in the examples, unless explicitly stated otherwise.
  • the invention also makes it possible to use large amounts of the appropriate recycling polyol, with no or only an insignificant reduction in the foam quality compared with a foam made from conventionally produced polyol. It therefore corresponds to a preferred embodiment of the invention if more than 30% by weight, preferably more than 50% by weight, preferably more than 70% by weight, based on the total polyol component used, is more preferred in the process according to the invention more than 80 wt. %, in particular more than 95 wt. 2 has.
  • the recycling polyol used is a polyol that results in particular from the recycling of polyurethane waste.
  • Polyurethane waste includes all those polyurethanes, especially PU foams, which are no longer used but are intended for disposal. It therefore corresponds to a preferred embodiment of the invention if the recycling polyol used is a recycling polyol produced from polyurethane waste, preferably obtained from the depolymerization of PU foam, in particular of PU hot flexible foam (PU standard foam), viscoelastic PU Foam and / or HR PU foam, wherein the recycling polyol by solvolysis, preferably by hydrolysis, aminolysis, or acidolysis Glycolysis, in particular by hydrolysis, as described, for example, in the as yet unpublished European patent applications with the file numbers 20192354.7 or 20192364.6.
  • the recycling polyol can be freed from other recycling products, such as in particular the primary aromatic amines that also occur and the reagents added for the respective depolymerization process, using conventional separation methods.
  • Some exemplary methods for the purification and recovery of the recycling polyol from the recycling crude product mixture that is present after the respective depolymerization step are given below.
  • One way of separating water from the raw recycle product mixture is to remove it by distillation.
  • Primary aromatic amines such as 2,4-toluylenediamine, 2,6-toluylenediamine or isomers of methylenediphenyldiamine can be removed from the respective recycling polyol by distillation, by extraction with aromatic solvents or by washing with acidic washing water or by other methods be removed. Any solid components such as recycling catalysts, salts or remaining polyurethane components can be separated from the raw product mixture or separated from recycling polyols by filtration with various types of filters.
  • the recycling polyol used can be obtained from the hydrolysis of polyurethane, comprising reacting the polyurethane with water in the presence of a base-catalyst combination (I) or (II), where (I) comprises a base having a pKb value of at 25°C from 1 to 10, and a catalyst selected from the group consisting of quaternary ammonium salts containing an ammonium cation containing 6 to 30 carbon atoms and organic sulfonates containing at least 7 carbon atoms, or wherein (II) comprises a base with a pKb value at 25 ° C of ⁇ 1, and a catalyst from the group of quaternary ammonium salts containing an ammonium cation with 6 to 14 carbon atoms, provided the ammonium cation does not include a benzyl radical, or containing an ammonium cation with 6 to 12 carbon atoms, provided that the ammonium cation comprises a benzyl radical.
  • a particularly preferred variant, referred to here as preferred variant 1, of depolymerization by hydrolysis is described below.
  • a catalyst selected from the group consisting of (i) quaternary ammonium salts containing an ammonium cation containing from 6 to 30 carbon atoms and (ii) organic sulfonate containing at least 7 carbon atoms.
  • Preferred bases include an alkali metal cation and/or an ammonium cation.
  • Preferred bases here are alkali metal phosphates, alkali metal hydrogen phosphates, alkali metal carbonates, alkali metal silicates, alkali metal hydrogen carbonates, alkali metal acetates, alkali metal sulfites, ammonium hydroxides or mixtures of the aforementioned.
  • Preferred alkali metals are Na, K or Li or mixtures of the aforementioned, in particular Na or K or mixtures thereof; preferred ammonium cation is NhV.
  • Particularly preferred bases are K2CO3, Na2SiC>3, NH4OH, K3PO4, NH4OH or KOAc.
  • the base is preferably used as a saturated alkaline solution in water, the weight ratio of saturated alkaline solution to PU being in the range of preferably 0.5 to 25, preferably 0.5 to 15, more preferably 1 to 10, in particular 2 to 7.
  • Preferred quaternary ammonium salts have the general structure: Ri R2 R3 R4 NX with R1.R2.R3 and R4 identical or different hydrocarbon groups selected from alkyl, aryl and/or arylalkyl, where Ri to R4 are preferably selected such that the sum of the carbon atoms of the quaternary ammonium cation is 6-14, preferably 7-14, more preferably 8-13.
  • X is selected from halide, preferably chloride and/or bromide, bisulfate, alkyl sulfate, preferably methyl sulfate or ethyl sulfate, carbonate, bicarbonate or carboxylate, preferably acetate or hydroxide.
  • Very particularly preferred quaternary ammonium salts are tributylmethylammonium chloride, tetrabutylammonium hydrogen sulfate, benzyltrimethylammonium chloride, tributylmethylammonium chloride and/or trioctylmethylammonium methyl sulfate.
  • the organic sulfonate containing at least 7 carbon atoms which can also be used as a catalyst preferably includes alkylaryl sulfonates, alpha-olefin sulfonates, petroleum sulfonates and/or naphthalene sulfonates.
  • Preferred temperatures for the depolymerization are 80°C to 200°C, preferably 90°C to 180°C, more preferably 95°C to 170°C and in particular 100°C to 160°C.
  • Preferred reaction times for the depolymerization are 1 minute to 14 hours, preferably 10 minutes to 12 hours, preferably 20 minutes to 11 hours and in particular 30 minutes to 10 hours. Preference is given to using at least 0.5% by weight of catalyst in the depolymerization, based on the weight of the polyurethane, preferably 0.5 to 15% by weight, more preferably 1 to 10% by weight, even more preferably 1 to 8 % by weight, again more preferably 1 to 7% by weight and in particular 2 to 6% by weight.
  • a preferred weight ratio of base to polyurethane is in the range from 0.01 to 50, preferably from 0.1 to 25, in particular from 0.5 to 20.
  • a catalyst from the group of quaternary ammonium salts containing an ammonium cation with 6 to 14 carbon atoms if the ammonium cation does not contain a benzyl radical, or containing an ammonium cation with 6 to 12 carbon atoms if the ammonium cation contains a benzyl radical includes, takes place, there is a further preferred embodiment of the invention.
  • Preferred bases here are alkali metal hydroxides, alkali metal oxides, alkaline earth metal hydroxides, alkali metal oxides or mixtures thereof.
  • Preferred alkali metals are Na, K or Li or mixtures of the aforementioned, in particular Na or K or mixtures thereof;
  • preferred alkaline earth metals are Be, Mg, Ca, Sr or Ba or mixtures thereof, preferably Mg or Ca or mixtures thereof.
  • a very particularly preferred base is NaOH.
  • Preferred quaternary ammonium salts have the general structure: R 1 R 2 R 3 R 4 NX where R 1 , R 2 , R 3 and R 4 are the same or different hydrocarbyl groups selected from alkyl, aryl and arylalkyl.
  • X is selected from halide, preferably chloride and/or bromide, bisulfate, alkyl sulfate, preferably methyl sulfate or ethyl sulfate, carbonate, bicarbonate, carboxylate, preferably acetate or hydroxide.
  • Particularly preferred quaternary ammonium salts are benzyltrimethylammonium chloride or tributylmethylammonium chloride.
  • Preferred temperatures for the depolymerization are 80°C to 200°C, preferably 90°C to 180°C, more preferably 95°C to 170°C and in particular 100°C to 160°C.
  • Preferred reaction times for the depolymerization are 1 minute to 14 hours, preferably 10 minutes to 12 hours, preferably 20 minutes to 11 hours and in particular 30 minutes to 10 hours.
  • a preferred weight ratio of base to polyurethane is in the range from 0.01 to 25, preferably 0.1 to 15, preferably 0.2 to 10, in particular 0.5 to 5.
  • An alkaline solution comprising base and water, the concentration of the base preferably being greater than 5% by weight, preferably 5 to 70% by weight, preferably 5 to 60% by weight, more preferably 10 to 50% by weight %, more preferably 15 to 40%, especially 20 to 40% by weight based on the weight of the alkaline solution.
  • the recycling polyol used was obtained from recycling, preferably by hydrolysis of polyurethane and the polydispersity of the resulting recycling polyol is at most 0.5, preferably at most 0.3, in particular at most is 0.2 higher than the polydispersity of the original polyols of the original polyurethane from which the recycling polyol is obtained.
  • Recycling polyols which are preferred for the purposes of the invention preferably have a functionality (groups per molecule which are reactive towards isocyanate) of 2 to 8.
  • the number average molecular weight of the recycle polyol is preferably in the range of 500 to 15000 g/mol.
  • the OH number of the recycling polyols is preferably from 10 to 1200 mg KOH/g. The OH number can be determined in particular on the basis of DIN 53240:1971-12.
  • recycled polyols with the above-mentioned specification for the polydispersity are used together with preferably a maximum of 50%, more preferably a maximum of 30%, particularly preferably a maximum of 20% recycled polymer polyols based on the total polyol component. Because of their proportion of high molecular weight copolymer fillers, recycling polymer polyols do not meet the requirement of polydispersity mentioned above and in claim 1. Recycled polymer polyols are available from the depolymerization of PU from polymer polyols.
  • Polymer polyols are known to those skilled in the art, their preparation is described in Ron Herrington, Kathy Fock Flexible Polyurethane Foams, published by Dow Chemical Company, Chapter 2, 2nd Edition, Midland, 1997. They contain up to 50% by weight of finely dispersed, solid fillers made from polyurea (PHD polyols), from polyurethanes (PIPA polyols) or from solid copolymer aggregates in which styrene-acrylonitrile copolymers are covalently linked to polyol molecules (SAN polyols).
  • PLD polyols polyurea
  • PIPA polyurethanes polyurethanes
  • SAN polyols solid copolymer aggregates in which styrene-acrylonitrile copolymers are covalently linked to polyol molecules
  • a preferred embodiment of the invention is when the recycled polyol employed is structurally a polyether polyol, such recycled polyol preferably being obtainable from the recycling of PU waste, particularly PU foams, originally derived from conventional polyether Polyols or polyether polyols that have already been recycled once or several times were obtained.
  • polyether polyols can be prepared by known processes, for example by anionic polymerization of alkylene oxides in the presence of alkali metal hydroxides, alkali metal alcoholates or amines as catalysts and with the addition of at least one starter molecule that preferably contains 2 to 8 reactive hydrogen atoms or by cationic polymerization of alkylene oxides in the presence of Lewis acids such as antimony pentachloride or boron trifluoride etherate or by polymerization of alkylene oxides via double metal cyanide catalysis.
  • Suitable alkylene oxides contain 2 to 4 carbon atoms in the alkylene radical.
  • Examples are tetrahydrofuran, ethylene oxide, 1,3-propylene oxide, 1,2-propylene oxide, 1,2- or 2,3-butylene oxide; ethylene oxide and 1,2-propylene oxide are preferably used.
  • the alkylene oxides can be used individually, cumulatively, in blocks, alternately one after the other, or as mixtures.
  • Preferred starting molecules are dihydric, trihydric or tetrahydric alcohols such as ethylene glycol, 1,2- and 1,3-propanediol, diethylene glycol, dipropylene glycol, glycerol, trimethylolpropane, pentaerythritol, castor oil, higher polyfunctional polyols, in particular sugar compounds such as glucose, Sorbitol, mannitol and sucrose, polyvalent phenols, resols are used.
  • dihydric, trihydric or tetrahydric alcohols such as ethylene glycol, 1,2- and 1,3-propanediol, diethylene glycol, dipropylene glycol, glycerol, trimethylolpropane, pentaerythritol, castor oil, higher polyfunctional polyols, in particular sugar compounds such as glucose, Sorbitol, mannitol and sucrose, polyvalent phenols, resols are used.
  • di- or trifunctional polyether polyols in particular in the production of hot flexible foams, di- or trifunctional polyether polyols can be used which have a proportion of end groups (PO end groups) resulting from propoxylation of preferably over 50%, more preferably over 80%, in particular those with a propylene oxide block or random propylene and ethylene oxide block at the chain end or those based solely on propylene oxide blocks.
  • PO end groups end groups
  • Such polyether polyols preferably have a functionality of 2 to 8, particularly preferably 2 to 4, number-average molecular weights in the range from 500 to 8000, preferably 800 to 5000, particularly preferably 2500 to 4500 g/mol and usually OH numbers in the range of 10 to 100, preferably 20 to 60 mg KOH/g.
  • difunctional and/or trifunctional polyether polyols with preferably at least 50%, more preferably at least 80%, primary hydroxyl groups can be used.
  • polyether polyols with an ethylene oxide endblock -CH2-CH2-O-H can be used.
  • Polyols for polyurethane cold foams can be part of this category if the average number-average molar mass simultaneously is preferably above 4000 g/mol.
  • polyether polyols which consist largely of ethylene oxide, preferably those with ethylene oxide blocks of more than 70%, more preferably of more than 90%
  • Hypersoft polyols can be used. All polyether polyols described in the context of this preferred embodiment preferably have a functionality of 2 to 8 hydroxy groups, preferably 2 to 5 hydroxy groups per molecule, preferably an average number average molecular weight of 500 to 8000 g/mol, preferably 800 to 7000 g/mol, and preferably OH numbers in the range 5 to 100 mg KOH/g, preferably 20 to 60 mg KOH /G.
  • polyols with primary hydroxyl functions are preferably used not alone, but preferably together with polyols with secondary hydroxyl groups.
  • polyfunctional polyether polyols preference is given to using mixtures of different, preferably two to three, polyfunctional polyether polyols.
  • the polyol combinations used consist preferably of a crosslinker polyol with a high functionality (>3) and a low molecular weight, preferably with an OH number of 100 to 400 mg KOH/g and/or a conventional flexible block foam polyol and/or or an HR polyol and/or a "hypersoft" polyether polyol, preferably with an OH number between 20 and 40 mg KOH/g with a high proportion of ethylene oxide and cell-opening properties.
  • HR polyols are used within a viscoelastic foam formulation, their proportion in the polyol mixture is preferably always less than 50%.
  • the recycling polyol according to the invention which has a polydispersity ⁇ 2, preferably ⁇ 1.5, in particular ⁇ 1.2
  • other polyols in particular conventional polyols
  • Conventional polyols are polyols that do not come from recycling processes.
  • the total polyol component used comprises both recycling polyol according to the invention and one or more other polyols
  • the polydispersity of the one or more other polyols if they are at least 5% by weight, preferably at least 10% by weight, particularly preferably at least 15% by weight, in particular at least 20% by weight, of the proportion of the total polyol is also ⁇ 2, preferably ⁇ 1.5, in particular ⁇ 1.2, with the proviso that the polydispersity of the recycling polyol is at most 0.3, preferably at most 0.2, in particular at most 0.1 higher than the polydispersity of the one or more other polyols.
  • the PU foam is a PU rigid foam, a PU flexible foam, a PU hot flexible foam (standard foam), a viscoelastic PU foam, an HR PU foam, a PU hypersoft foam semi-rigid PU foam, a thermoformable PU foam or a PU integral foam, preferably a PU hot flexible foam, HR PU foam, PU hypersoft foam or viscoelastic PU foam.
  • PU hot flexible foam is most preferred.
  • the PU foams can be produced in the usual manner and as described in the prior art. It is well known to those skilled in the art. A basic overview can be found e.g.
  • the production of the PU foams according to the invention using f) water, g) one or more organic solvents, h) one or more stabilizers against oxidative degradation, in particular antioxidants, i) one or more flame retardants, and / or j) one or several other additives, preferably selected from the group of surfactants, biocides, dyes, pigments, fillers, antistatic additives, crosslinkers,
  • Chain extenders cell openers, fragrances, cell coarseners, plasticizers, hardeners, aldehyde scavengers, additives for resistance of PU foams to hydrolysis, compatibilizers (emulsifiers), adhesion promoters, hydrophobing additives, flame lamination additives, additives for preventing cold flow, additives to reduce compression set , additives for adjusting the glass transition temperature, temperature-controlling additives and/or odor reducers, a further preferred embodiment of the invention is present.
  • Another object of the present invention is a composition suitable for the production of polyurethane foam, comprising at least one polyol component, at least one isocyanate component, catalyst, foam stabilizer, blowing agent, optional auxiliary, wherein the polyol component comprises recycling polyol, the polydispersity of this recycling polyol is ⁇ 2, preferably ⁇ 1.5, in particular ⁇ 1.2.
  • Preferred optional auxiliaries include surfactants, biocides, dyes, pigments, fillers, antistatic additives, crosslinkers, chain extenders, cell openers such as described in EP2998333A1, fragrances, cell coarsening agents such as described in EP 2986661 B1, plasticizers, hardeners, additives for preventing cold Flow as e.g.
  • the composition according to the invention is characterized in that, based on the total polyol component, more than 30 % by weight, preferably more than 50% by weight, preferably more than 70% by weight, more preferably more than 80% by weight, in particular more than 95% by weight, recycling polyol having a polydispersity ⁇ 2, preferably ⁇ 1.5, in particular ⁇ 1.2.
  • the method according to the invention allows access to all PU foams.
  • Preferred PU foams for the purposes of this invention are flexible PU foams and rigid PU foams.
  • PU flexible foams and PU rigid foams are established technical terms.
  • the well-known and fundamental difference between flexible foams and rigid foams is that flexible foam shows elastic behavior and the deformation is therefore reversible.
  • the hard foam on the other hand, is permanently deformed.
  • foams are preferred within the scope of the invention are described in more detail below, with the term “foam” being used synonymously for “foam” within the scope of this invention for the sake of simplicity.
  • rigid polyurethane foam is understood in particular as meaning a foam according to DIN 7726:1982-05 which has a compressive strength according to DIN 53421:1984-06 of advantageously >20 kPa, preferably >80 kPa, preferably >100 kPa >150 kPa, particularly preferably >180 kPa.
  • the rigid polyurethane foam advantageously has a closed cell content of more than 50%, preferably more than 80% and particularly preferably more than 90%.
  • PU rigid foam is mostly used for insulation purposes.
  • PU flexible foams are elastic, reversibly deformable and mostly open-celled. This allows the air to escape easily when compressed.
  • PU flexible foam includes in particular the following types of foam known to those skilled in the art, namely PU hot flexible foam (standard foam), PU cold foam (also highly elastic or high resilient foam), hypersoft PU foam, viscoelastic PU flexible foam and PU ester foams ( from polyester polyols).
  • PU hot flexible foam standard foam
  • PU cold foam also highly elastic or high resilient foam
  • hypersoft PU foam viscoelastic PU flexible foam
  • PU ester foams from polyester polyols
  • PU hot flexible foam The crucial difference between a PU hot flexible foam and a PU cold flexible foam is the different mechanical properties.
  • the differentiation between PU hot flexible foams and PU cold flexible foams can be made in particular by the rebound elasticity, also known as "ball rebound” (BR) or "resilience".
  • BR rebound elasticity
  • a method for determining the rebound resilience is described, for example, in DIN EN ISO 8307:2008-03.
  • a steel ball with a specified mass is dropped onto the specimen from a certain height and the height of the rebound is then measured as a percentage of the dropping height.
  • PU hot flexible foams have rebound values of preferably 1% to a maximum of 50%. In the case of PU cold flexible foams, the level of rebound is preferably in the range >50%.
  • PU hot flexible foams have a comfort factor of preferably ⁇ 2.5.
  • the comfort factor is preferably > 2.5.
  • polyether polyols which are particularly reactive towards isocyanates and have a high proportion of primary hydroxyl groups and number-average molar masses >4000 g/mol are used.
  • hypersoft PU foams which represent a subcategory of flexible PU foams.
  • Hypersoft PU foams have compressive stresses determined according to DIN EN ISO 3386-1:1997 + A1:2010 of preferably ⁇ 2.0 kPa and have indentation hardnesses determined according to DIN EN ISO 2439:2009-05 of preferably ⁇ 80 N.
  • Hypersoft PU foams can be manufactured using a variety of known methods: by using a so-called hypersoft polyol in combination with so-called standard polyols and/or by using a special manufacturing method in which carbon dioxide is metered in during the foaming process.
  • Hypersoft PU foams Due to a pronounced open cell structure, Hypersoft PU foams have a high level of air permeability, promote the transport of moisture in application products and help to prevent heat build-up.
  • the Hypersoft polyols used to manufacture Hypersoft PU foams are characterized in particular by a very high proportion of primary OH groups of more than 60%.
  • a special class of flexible PU foams is that of viscoelastic PU foams (PU viscose foams), which are likewise preferred according to the invention. These are also known under the name of memory foam and are characterized both by a low rebound resilience according to DIN EN ISO 8307:2008-03 of preferably ⁇ 15% and by a slow, gradual recovery a completed compression (recovery time preferably 2-13 s).
  • PU viscose foams viscose foams
  • these are also known under the name of memory foam and are characterized both by a low rebound resilience according to DIN EN ISO 8307:2008-03 of preferably ⁇ 15% and by a slow, gradual recovery a completed compression (recovery time preferably 2-13 s).
  • the glass transition temperature for viscoelastic PU foams is preferably shifted to a range from -20 to +15°C.
  • a pneumatic effect must be distinguished from such "structural viscoelasticity" in open-cell viscoelastic PU foams, which is essentially based on the glass transition temperature of the polymer (also known as chemical viscoelastic foams). In the latter case, the cell structure is relatively closed (low porosity). Due to the low air permeability, the air only flows back in slowly after compression, which results in slower recovery (also called pneumatic visco-foams). In many cases, both effects are combined in one visco-foam. PU visco-foams are used because of their energy - and sound-absorbing properties.
  • a class of PU foams that is particularly important for applications in the automotive sector and that can be classified between those of rigid and flexible foams in terms of properties consists of semi-rigid PU foams (also semi-flexible PU foams). These are also preferred according to the invention. Like most PU foam systems, semi-flexible foam systems also use the diisocyanate/water reaction and the resulting CO2 as a foaming agent. The rebound resilience is generally lower than that of classic flexible foams, especially cold foams. Semi-flexible foams are harder than conventional flexible foams. A characteristic feature of semi-flexible foams is their high number of open cells (preferably >90% of the cells). The densities of semi-flexible foams can be significantly higher than those of flexible and rigid foams.
  • polyols which have two or more OH groups are preferably used as polyol components, the polyol component according to the invention necessarily containing recycling polyol, the polydispersity of the recycling polyol being ⁇ 2, preferably ⁇ 1.5, in particular ⁇ 1.2 is. This has already been described above.
  • polyols which are in principle suitable as polyol components are all organic substances having a plurality of groups which are reactive toward isocyanates, preferably having two or more OH groups, and preparations thereof.
  • the polyol component according to the invention necessarily contains recycling polyol, the polydispersity of the recycling polyol is ⁇ 2, preferably ⁇ 1.5, in particular ⁇ 1.2. Recycled polyol has already been described above. In addition, further polyols can optionally be used.
  • Preferred additional polyols that can optionally be used are all of the polyether polyols and polyester polyols customarily used for the production of polyurethane systems, in particular polyurethane foams.
  • Polyether polyols can, for. B. be obtained by reacting polyhydric alcohols or amines with alkylene oxides.
  • Polyester polyols are preferably based on esters of polybasic carboxylic acids with polyhydric alcohols (mostly glycols).
  • the polybasic carboxylic acids can be either aliphatic (e.g. adipic acid) or aromatic (e.g. phthalic acid or terephthalic acid).
  • NOPs natural oil-based polyols
  • PU foams in view of the long-term limited availability of fossil resources, namely oil, coal and gas, and against the background of rising crude oil prices and have already been described many times in the production of polyurethane foams (WO 2005/033167 US 2006/0293400, WO 2006/094227, WO 2004/096882, US 2002/0103091, WO 2006/116456 and EP 1678232).
  • polyols from various manufacturers are now available on the market (WO2004/020497, US2006/0229375, WO2009/058367).
  • basic raw material e.g. soybean oil, palm oil or castor oil
  • polyols with different properties result.
  • the production of polyurethane foams from recycled polyols of the polydispersity described according to the invention together with NOPs represents a preferred application of the invention.
  • a further class of polyols which can optionally be used are those which are obtained as prepolymers by reacting polyol with isocyanate in a molar ratio of 100:1 to 5:1, preferably 50:1 to 10:1.
  • filler polyols represent yet another class of optionally usable polyols. These are characterized in that they contain solid organic fillers up to a solids content of 40% by weight or more in disperse distribution.
  • SAN polyols These are highly reactive polyols containing a dispersed styrene/acrylonitrile (SAN)-based copolymer.
  • PHD Polyols These are highly reactive polyols containing polyurea particles in a dispersed form.
  • PIPA Polyols These are highly reactive polyols containing polyurethane particles in dispersed form, prepared, for example, by the in situ reaction of an isocyanate with an alkanolamine in a conventional polyol.
  • the proportion of solids in the optional filler polyols which depending on the application can preferably be between 5 and 40% by weight, based on the polyol, is responsible for improved cell opening, so that the polyol can be foamed in a controlled manner, especially with TDI, and the foams do not shrink occurs.
  • the solid thus acts as an essential process aid.
  • Another function is to control the hardness via the solids content, since higher solids content causes the foam to be harder.
  • formulations with polyols containing solids are significantly less inherently stable and therefore require physical stabilization in addition to chemical stabilization through the crosslinking reaction.
  • polystyrene resin examples include polyethylene oxide resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polystyrene resin, polysulfate, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polystyrene foam, polys
  • a preferred ratio of isocyanate component to polyol component within the scope of this invention is in the range from 10 to 1000, preferably 40 to 350.
  • This index describes the ratio of the amount of isocyanate actually used to the amount of isocyanate theoretically required, corresponding to a stoichiometric ratio of isocyanate - Groups to isocyanate-reactive groups (eg OH groups, NH groups), multiplied by 100.
  • An index of 100 stands for a molar ratio of the reactive groups of 1 to 1.
  • One or more isocyanates are preferably used as isocyanate components have two or more isocyanate functions.
  • isocyanates in particular the known aliphatic, cycloaliphatic, araliphatic and preferably aromatic polyfunctional isocyanates, can be used as the isocyanate component in the process according to the invention.
  • Suitable isocyanates for the purposes of this invention have two or more isocyanate functions.
  • Suitable isocyanates for the purposes of this invention are preferably all polyfunctional organic isocyanates, such as diphenylmethane diisocyanate (MDI), toluene diisocyanate (TDI), hexamethylene diisocyanate (HMDI) and/or isophorone diisocyanate (IPDI).
  • MDI diphenylmethane diisocyanate
  • TDI toluene diisocyanate
  • HMDI hexamethylene diisocyanate
  • IPDI isophorone diisocyanate
  • MDI prepolymers are also particularly suitable.
  • isocyanates are listed, for example, in EP 1712578, EP 1161474, WO 00/58383, US 2007/0072951, EP 1678232 and WO 2005/085310, to which reference is made here in its entirety.
  • the isocyanates used preferably diphenylmethane diisocyanate (MDI) and toluene diisocyanate (TDI), preferably consist of at least 20%, more preferably at least 40%, particularly preferably at least 60% recycled isocyanates.
  • the recycling isocyanates are produced from the reaction of aromatic amine mixtures consisting of toluenediamine (TDA) and/or methylenediphenylamine (MDA), the amine mixtures preferably being at least 20%, more preferably at least 35%, particularly preferably at least 50% were obtained from the recycling of polyurethanes, preferably polyurethane foams.
  • Suitable catalysts which can be used in the process according to the invention for producing PU foam are preferably substances which catalyze the gel reaction (isocyanate-polyol), the blowing reaction (isocyanate-water) or the dimerization or trimerization of the isocyanate. Such are known to those skilled in the art. It corresponds to a preferred embodiment of the invention when the catalyst used is selected from
  • X includes oxygen, nitrogen, hydroxyl, amines of structure (NR m or NR m R lv ) or urea groups (N(R V )C(O)N
  • Y includes amines NR VIII R IX or ethers OR lx
  • R UI include identical or different linear or cyclic, aliphatic or aromatic hydrocarbons with 1-8 carbon atoms which are optionally functionalized with an OH group; and/or comprise hydrogen
  • R x includes identical or different radicals consisting of hydrogen and/or linear, branched or cyclic aliphatic or aromatic hydrocarbons with 1-18 carbon atoms, which can be substituted with 0-1 hydroxyl groups and 0-1 NH 2 groups.
  • Z includes oxygen, NRx or CH2.
  • organometallic or organometallic compounds includes, in particular, the use of metal-containing compounds that have a direct carbon-metal bond, here also as organometallic compounds (eg organyl tin) or organometallic or organometallic compounds (eg organotin compounds ) designated.
  • organometallic or organometallic salts includes in particular the use of organometallic or organometallic compounds with a salt character, i.e. ionic compounds in which either the anion or cation is of an organometallic nature (e.g. organotin oxides, organotin chlorides or organotin -carboxylates).
  • organometallic salts includes in particular the use of metal-containing compounds that do not have a direct carbon-metal bond and are at the same time metal salts in which either the anion or the cation is an organic compound (e.g. tin(II )-carboxylates).
  • inorganic metal salts includes in particular the use of metal-containing compounds or metal salts in which neither anion nor cation is an organic compound, eg metal chlorides (eg tin(II) chloride).
  • Suitable organic and organometallic metal salts that can be used preferably contain alcoholate, mercaptate or carboxylate anions such as acetate, 2-ethylhexanoate, octanoate, isononanoate, decanoate, neodecanoate, ricinoleate, laurate and/or oleate, particularly preferably 2-ethylhexanoate, ricinoleate, neodecanoate or isononanoate.
  • alcoholate, mercaptate or carboxylate anions such as acetate, 2-ethylhexanoate, octanoate, isononanoate, decanoate, neodecanoate, ricinoleate, laurate and/or oleate, particularly preferably 2-ethylhexanoate, ricinoleate, neodecanoate or isononanoate.
  • Suitable metal-containing catalysts that can be used are generally preferably selected such that they have no objectionable intrinsic odor, are essentially toxicologically harmless and that the resulting polyurethane systems, in particular polyurethane foams, have the lowest possible catalyst-related emissions.
  • organometallic salts such as dibutyltin dilaurate.
  • Suitable water contents in the process according to the invention depend on whether or not physical blowing agents are used in addition to the water. In the case of purely water-blown foams, the values are preferably from 1 to 20 pphp; if other blowing agents are also used, the amount used is reduced to typically, for example, 0 or, for example, 0.1 to 5 pphp. To the In order to achieve high foam density, preferably neither water nor other blowing agents are used.
  • Suitable physical blowing agents that can optionally be used in the context of this invention are gases, for example liquefied CO2, and volatile liquids, for example hydrocarbons with 4 or 5 carbon atoms, preferably cyclo-, iso- and n-pentane, fluorocarbons, preferably HFC 245fa, HFC 134a and HFC 365mfc, but also olefinic fluorocarbons such as HHO 1233zd or HH01336mzzZ, chlorofluorocarbons, preferably HCFC 141b, oxygen-containing compounds such as methyl formate and dimethoxymethane, or chlorinated hydrocarbons, preferably dichloromethane and 1,2-dichloroethane.
  • ketones e.g. acetone
  • aldehydes e.g. methylal
  • compositions according to the invention can advantageously contain one or more stabilizers.
  • stabilizers are in particular silicon compounds having carbon atoms, preferably selected from the polysiloxanes, polydimethylsiloxanes, organomodified polysiloxanes, polyether-modified polysiloxanes and polyether-polysiloxane copolymers. Preferred silicon compounds are described by formula (1c):
  • G independently the same or different radicals (Oiss)n SiR 1 m - CH 2 CHR 5 - R 4 - CR ⁇ CR ⁇ CHs
  • R 4 independently the same or different divalent organic radicals, preferably double organic radicals of 1 to 50 carbon atoms, optionally interrupted by ether, ester or amide groups and optionally functionalized with OH groups, or (- SiR 1 2 0 -) x SiR 1 2 - groups, particularly preferably the same or different divalent organic radicals, preferably double organic radicals of 1 to 50 carbon atoms, optionally interrupted by ether, ester or amide groups and optionally functionalized with OH groups, or (- SiR 1 2 0 -) x SiR 1 2 - groups, particularly preferably the same or different divalent organic radicals, preferably double organic radicals of 1 to 50 carbon atoms, optionally interrupted by ether, ester or amide groups and optionally functionalized with OH groups, or (- SiR 1 2 0 -) x SiR 1 2 - groups, particularly preferably the same or different divalent organic radicals, preferably double organic radicals of 1 to 50 carbon atoms, optionally interrupted by ether,
  • R 5 independently the same or different alkyl radicals consisting of 1 to 16 carbon atoms, aryl radicals having 6 to 16 carbon atoms or hydrogen, preferably from the
  • R 1 identical or different radicals selected from the group of saturated or unsaturated alkyl radicals having 1 to 16 carbon atoms or aryl radicals having 6 to 16 carbon atoms or hydrogen or -OR 6 , preferably methyl, ethyl, octyl, dodecyl, phenyl or hydrogen, particularly preferred methyl or phenyl.
  • R 2 independently identical or different polyethers obtainable by the polymerization of ethylene oxide and/or propylene oxide and/or other alkylene oxides such as butylene oxide or styrene oxide with the general formula (2) or an organic radical corresponding to the formula (3) (2) - (R 7 ) h - O - [C 2 H 4 0]i - [C 3 H 6 0]j - [CR 8 2 CR 8 20]k - R 9
  • R 7 divalent organic radical, preferably divalent organic alkyl or aryl radical optionally substituted with -OR 6 , more preferably a divalent organic radical of the type C P H2 .
  • R 3 identical or different radicals selected from the group of saturated or unsaturated alkyl radicals potentially substituted with heteroatoms, preferably identical or different radicals selected from the group of saturated or unsaturated alkyl radicals with 1 to 16 Carbon atoms or aryl radicals of 6-16 carbon atoms potentially substituted with halogen atoms, most preferably methyl, vinyl, chloropropyl or phenyl.
  • R 6 identical or different radicals selected from the group of saturated or unsaturated alkyl radicals having 1 to 16 carbon atoms or aryl radicals having 6 to 16 carbon atoms or hydrogen, preferably saturated or unsaturated alkyl radicals having 1 to 8 carbon atoms or hydrogen, methyl, ethyl being particularly preferred , isopropyl or hydrogen.
  • R 8 identical or different radicals selected from the group of alkyl radicals with 1 to 18 carbon atoms, potentially substituted with ether functions and potentially substituted with heteroatoms such as halogen atoms, aryl radicals with 6 - 18 carbon atoms, potentially substituted with ether functions, or hydrogen, preferably alkyl radicals with 1 to 12 carbon atoms potentially substituted with ether functions and potentially substituted with heteroatoms such as halogen atoms or aryl radicals having 6 to 12 carbon atoms potentially substituted with ether functions, or hydrogen, more preferably methyl, ethyl, benzyl or hydrogen.
  • R 9 same or different radicals selected from the group hydrogen, alkyl, -C(0)-R 11 , -C(0)0-R 11 or -C(0)NHR 11 , saturated or unsaturated, optionally substituted with Heteroatoms, preferably hydrogen or alkyl radicals having 1 to 8 carbon atoms or acetyl, particularly preferably hydrogen, acetyl, methyl or butyl.
  • R 10 identical or different radicals selected from the group of saturated or unsaturated alkyl radicals or aryl radicals, potentially substituted with one or more OH,
  • Ether, epoxide, ester, amine and/or halogen substituents preferably saturated or unsaturated alkyl radicals with 1 to 18 carbon atoms or aryl radicals with 6 - 18 carbon atoms, optionally substituted with one or more OH, ether, epoxide, ester, amine and/or Halogen substituents, particularly preferably saturated or unsaturated alkyl radicals having 1 to 18 carbon atoms or aryl radicals having 6 - 18 carbon atoms substituted with at least one OH, ether, epoxide, ester, amine and/or halogen substituent.
  • R 11 identical or different radicals selected from the group of alkyl radicals having 1 to 16 carbon atoms or aryl radicals having 6 - 16 carbon atoms, preferably saturated or unsaturated alkyl radicals having 1 - 8 carbon atoms or aryl radicals having 6 - 12 carbon atoms, particularly preferably methyl, ethyl, butyl or phenyl.
  • the foam stabilizers of the formula (1c) can be used in PU systems, preferably mixed in organic solvents such as, for example, dipropylene glycol, polyether alcohols or polyether diols.
  • a compatibilizer can preferably also be used. This can be selected from the group of aliphatic or aromatic hydrocarbons, particularly preferably aliphatic polyethers or polyesters.
  • the substances mentioned in the prior art can preferably be used as silicon compounds having one or more carbon atoms.
  • Si compounds used which are particularly suitable for the respective foam types.
  • Suitable siloxanes are described, for example, in the following documents: EP 0839852, EP 1544235, DE 102004001408, WO 2005/118668, US 2007/0072951, DE 2533074, EP 1537159 EP 533202, US 3933695, EP 0724239, DE 0724239, DE 429044 867465.
  • the Si compounds can be produced as described in the prior art. Suitable examples are e.g. e.g. in US 4147847, EP 0493836 and US 4855379.
  • foam stabilizers in particular silicon compounds
  • polyol components Preferably, from 0.00001 to 20 parts by mass of foam stabilizers, in particular silicon compounds, can be used per 100 parts by mass of polyol components.
  • blowing agents preferably water to form CO2 and, if necessary, other physical blowing agents
  • Flame retardants such as described in EP2998333A1, nucleating agents, thickeners, fragrances, cell coarsening agents such as described in EP 2986661 B1, plasticizers, hardeners, additives for the prevention of cold flow as described, for example, in DE 2507161C3, WO2017029054A1, aldehyde scavengers, as described, for example, in WO2021/013607A1, additives for the resistance of PU foams to hydrolysis, as described, for example, in US 2015/0148438A1, compatibilizers (emulsifiers), adhesion promoters, hydrophobing
  • Crosslinkers that can be used as an option and chain extenders that can be used as an option are low molecular weight, polyfunctional compounds that are reactive toward isocyanates.
  • hydroxyl- or amine-terminated substances such as glycerol, neopentyl glycol, dipropylene glycol, sugar compounds, 2-methyl-1,3-propanediol, triethanolamine (TEOA), diethanolamine (DEOA) and trimethylolpropane are suitable.
  • Crosslinkers that can also be used are polyethoxylated and/or polypropoxylated glycerol or sugar compounds whose number-average molecular weight is below 1500 g/mol.
  • the optional use concentration is preferably between 0.1 and 5 parts, based on 100 parts of polyol, but can also deviate from this depending on the formulation.
  • crude MDI for foam molding, this also takes on a crosslinking function.
  • the content of low-molecular crosslinkers can therefore be correspondingly reduced as the amount of crude MDI increases.
  • Suitable optional stabilizers against oxidative degradation, so-called antioxidants are preferably all common free-radical scavengers, peroxide scavengers, UV absorbers, light stabilizers, complexing agents for metal ion impurities (metal deactivators).
  • Compounds of the following substance classes or substance classes containing the following functional groups can preferably be used: 2-(2'-hydroxyphenyl)benzotriazoles, 2-hydroxybenzophenones, benzoic acids and benzoates, phenols, in particular containing tert-butyl and/or methyl substituents on the aromatic compound, benzofuranones, diarylamines , triazines, 2,2,6,6-tetramethylpiperidines, hydroxylamines, alkyl and aryl phosphites, sulfides, zinc carboxylates, diketones.
  • Suitable optional flame retardants for the purposes of this invention are all substances which are considered suitable according to the prior art.
  • Preferred flame retardants are, for example, liquid organic phosphorus compounds, such as halogen-free organic phosphates, e.g. triethyl phosphate (TEP), halogenated phosphates, e.g. tris(1-chloro-2-propyl) phosphate (TCPP), tris(1,3-dichloroisopropyl) phosphate ( TDCPP) and tris(2-chloroethyl) phosphate (TCEP) and organic phosphonates, e.g.
  • TEP triethyl phosphate
  • TDP triethyl phosphate
  • TCPP tris(1-chloro-2-propyl) phosphate
  • TDCPP tris(1,3-dichloroisopropyl) phosphate
  • TCEP tris(2-chloroethyl) phosphat
  • DMMP dimethyl methane phosphonate
  • DMPP dimethyl propane phosphonate
  • oligomers ethyl ethylene phosphates or solids such as ammonium polyphosphate (APP) and red phosphorus.
  • halogenated compounds for example halogenated polyols, and solids such as expandable graphite and melamine are also suitable as flame retardants.
  • polyurethane foams with particularly high proportions of recycling polyols.
  • polyurethane is to be understood in particular as a generic term for a polymer made from di- or polyisocyanates and polyols or other species that are reactive towards isocyanate, such as amines, for example, where the urethane bond does not have to be the exclusive or predominant type of bond.
  • polyisocyanurates and polyureas are also expressly included.
  • polyurethane foams according to the invention can be carried out by any method familiar to the person skilled in the art, for example by hand mixing or preferably with the aid of high-pressure or low-pressure foaming machines.
  • the process according to the invention can be carried out continuously or batchwise.
  • a discontinuous implementation of the method is preferred in the production of molded foams, refrigerators, shoe soles or panels.
  • a continuous procedure is preferred in the production of insulating panels, metal composite elements, blocks or spray processes.
  • Another object of the present invention is a polyurethane foam, preferably PU rigid foam, PU flexible foam, PU hot flexible foam (standard foam), viscoelastic PU foam, HR PU foam, PU hypersoft foam, semi-rigid PU foam, thermoformable PU foam or PU integral foam, preferably PU hot flexible foam, HR PU foam, PU Hypersoft foam or viscoelastic PU foam, most preferably hot flexible PU foam, produced according to a method according to the invention as described above.
  • a very particularly preferred flexible polyurethane foam for the purposes of this invention has the following composition in particular:
  • Polyol comprising Recycled Polyol 100
  • Tin catalyst 0 to 5, preferably 0.001 to 2
  • blowing agents 0 to 130 Flame retardants 0 to 70 Fillers 0 to 150
  • Other additives 0 to 20 Isocyanate index: greater than 50
  • the polyurethane foams according to the invention can, for. B. as refrigerator insulation, insulating board, sandwich element, pipe insulation, spray foam, 1 & 1.5 component can foam (a 1.5 component can foam is a foam that is produced by destroying a container in the can), imitation wood, model foam , packaging foam, mattress, furniture pad, automotive seat pad, headrest, instrument panel, automotive interior trim, automotive headliner, sound absorbing material, steering wheel, shoe sole, carpet backing foam, filter foam, sealing foam, sealant, adhesive, binder, paint or as a coating or to manufacture related products be used.
  • a 1.5 component can foam is a foam that is produced by destroying a container in the can
  • imitation wood, model foam packaging foam, mattress, furniture pad, automotive seat pad, headrest, instrument panel, automotive interior trim, automotive headliner, sound absorbing material, steering wheel, shoe sole, carpet backing foam, filter foam, sealing foam, sealant, adhesive, binder, paint or as a coating or to manufacture related products be used.
  • 1.0 part (1.0 pphp) of a component means 1 g of this substance per 100 g of polyol.
  • Table 1 Formulation for the production of PU hot-cure flexible foams. Formulation 1 Parts by mass (pphp) Polyol 1) 100 pphp
  • Polyol standard polyether polyol Arcol® 1104 available from Covestro, this is a glycerol-based polyether polyol with an OH number of 56 mg KOH/g and a number-average molar mass of 3000 g/mol or recycling according to the invention Polyols or recycled polyol not according to the invention. The recycled polyols are processed via a chemical
  • KOSMOS® T9 available from Evonik Industries: tin(II) salt of 2-ethylhexanoic acid.
  • DABCO® DMEA dimethylethanolamine, available from Evonik Industries.
  • the polydispersity and the average molecular masses M n and M of the recycling polyols were determined using gel permeation chromatography based on ISO 13885-1:2020 under the following conditions: Separation column combination SDV 1000/10000 ⁇ with pre-column (length 65 cm, column temperature 30 °C) THF as mobile phase, flow rate 1 ml/min, sample concentration 10 g/l, injection volume 20 ml, refractive index detector engl. Rl detector) at 30 °C, calibration with polystyrene (162 - 2520000 g/mol). The values obtained are polystyrene mass equivalents.
  • the non-inventive recycling polyol 1 was produced in accordance with a regulation from H&S Anlagentechnik from 2012: https://www.dbu.de/OPAC/ab/DBU- Final Report-AZ-29395.pdf
  • a reactor from the Parr company Parr Instrumental Company
  • the polyurethane foam used was prepared according to Formulation 1, in which the conventional polyol Arcol® 1104 is used.
  • the recycling polyol 2 according to the invention was obtained by the hydrolysis of polyurethane in the presence of a saturated K 2 CO 3 solution and tetrabutylammonium hydrogen sulfate as a catalyst:
  • a Parr reactor (Parr Instrumental Company) equipped with a PTFE inner vessel and a mechanical stirrer was charged with 25 g of compressed foam pieces (ca. 1 cm ⁇ 1 cm).
  • the polyurethane foam used was prepared according to Formulation 1 in which the conventional polyol Arcol® 1104 was used. Then 75 g of saturated K 2 CO 3 solution (pKb value 3.67 at 25°C) were added. The catalyst tetrabutylammonium hydrogen sulfate was then added at 5% by weight, based on the mass of the reaction mixture.
  • the reactor was sealed and the reaction mixture was heated to an internal temperature of 150°C for 14 hours. Upon completion of the 14 hours, heating was discontinued and the reaction mixture was cooled to room temperature.
  • reaction mixture was transferred to a round bottom flask.
  • the water was removed via rotary evaporation and the remaining reaction mixture was washed with cyclohexane extracted.
  • the cycle hexane solution was washed with 1N aqueous HCl solution and then dried over magnesium sulfate.
  • the recycling Pclycl 2 was obtained with a Pclydispersity of 1.07 in the form of a liquid. The hydrolysis process was repeated to provide a sufficient amount of recycled plastic for the foaming experiments.
  • the recycling Pclycl 3 according to the invention was obtained by the hydrolysis of polyurethane in the presence of a 20% sodium hydroxide solution and tributylmethylammonium chloride as a catalyst:
  • a Parr reactor (Parr Instrumental Company) equipped with a PTFE inner vessel and a mechanical stirrer was charged with 25 g of compressed foam pieces (ca. 1 cm ⁇ 1 cm).
  • the polyurethane foam used was prepared according to Formulation 1 in which the conventional polyol Arcol® 1104 was used. Then 75 g of sodium hydroxide solution (20% by weight in water) were added.
  • the catalyst tributylmethylammonium chloride was then added at 2.5% by weight based on the mass of the reaction mixture.
  • the reactor was sealed and the reaction mixture was heated to an internal temperature of 130°C for 14 hours. Upon completion of the 14 hours, heating was discontinued and the reaction mixture was cooled to room temperature. After opening the reactor, the reaction mixture was transferred to a round bottom flask. The water was removed via rotary evaporation and the remaining reaction mixture was extracted with cyclohexane. The cyclohexane phase was washed with 1N aqueous HCl solution and then dried over magnesium sulfate.
  • the recycling polyol 3 with a polydispersity of 1.06 was obtained in the form of a liquid and used for foaming experiments.
  • the hydrolysis process was repeated to provide a sufficient amount of recycled polyol for the foaming experiments.
  • the polyurethane foams were produced in the laboratory as so-called hand foams.
  • the foams were produced according to the following information at 22° C. and 762 mm Hg air pressure.
  • To produce the polyurethane foams according to formulation I either 300 or 400 g of polyol were used in each case.
  • the other formulation components were converted accordingly.
  • 1.0 part (1.0 pphp) of a component meant 1 g of this substance per 100 g of polyol.
  • the tin catalyst tin(II) 2-ethylhexanoate, polyol, the water, the amine catalysts and the respective foam stabilizer were placed in a paper cup and mixed for 60 s with a disc stirrer at 1000 rpm. After the first stir the isocyanate was added and incorporated with the same stirrer for 7 s at 2500 rpm and immediately transferred to a paper-lined box (30 cm ⁇ 30 cm base and 30 cm height). After pouring, the foam rose in the foaming box. Ideally, the foam blew off when the maximum rise height was reached and then sagged back slightly. The cell membranes of the foam bubbles opened up and an open-pored cell structure of the foam was obtained.
  • Foam height is the height of the free-rising foam formed after 3 minutes. Foam height is reported in centimeters (cm). c) rise time
  • the air permeability of the foam was determined based on DIN EN ISO 4638:1993-07 by measuring the dynamic pressure on the foam.
  • the back pressure measured was given in mm of water column, with the lower back pressure values then characterizing the more open foam. The values were measured in the range from 0 to 300 mm water column.
  • the dynamic pressure was measured using an apparatus comprising a nitrogen source, reducing valve with manometer, flow control screw, washing bottle, flow meter, T-piece, support nozzle and a scaled glass tube filled with water.
  • the support nozzle has an edge length of 100 ⁇ 100 mm, a weight of 800 g, a clear width of the outlet opening of 5 mm, a clear width of the lower support ring of 20 mm and an outer diameter of the lower support ring of 30 mm.
  • the measurement is carried out by setting the nitrogen pre-pressure to 1 bar using the reducing valve and adjusting the flow rate to 480 l/h.
  • the amount of water is set in the graduated glass tube in such a way that no pressure difference can be built up and read.
  • the contact nozzle is placed on the corners of the test specimen edges congruently and once on the (estimated) center of the test specimen (each on the side with the largest surface). is read when a constant dynamic pressure has been established.
  • the evaluation is carried out by averaging over the five measured values obtained.

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Abstract

L'invention concerne un procédé de production de mousses de PU en faisant réagir (a) au moins un constituant polyol qui contient un polyol recyclé avec (b) au moins un constituant isocyanate en présence de (c) un ou plusieurs catalyseurs qui catalysent les réactions d'isocyanate-polyol et/ou d'isocyanate-eau et/ou la réaction de trimérisation d'isocyanate, (d) au moins un stabilisant de mousse et (e) éventuellement un ou plusieurs agents de gonflement chimique ou physique, et la polydispersité du polyol recyclé respectif est < 2, de préférence < 1,5, plus particulièrement ≤ 1,2.
EP22738450.0A 2021-07-02 2022-06-28 Production de mousses de pu à l'aide de polyols recyclés Pending EP4363476A1 (fr)

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