EP4669686A1 - Inhibitory solid formation during CO2 polyurethane production - Google Patents
Inhibitory solid formation during CO2 polyurethane productionInfo
- Publication number
- EP4669686A1 EP4669686A1 EP24706986.7A EP24706986A EP4669686A1 EP 4669686 A1 EP4669686 A1 EP 4669686A1 EP 24706986 A EP24706986 A EP 24706986A EP 4669686 A1 EP4669686 A1 EP 4669686A1
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- European Patent Office
- Prior art keywords
- acid
- group
- polyol
- alkyl
- bis
- 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.)
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- 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
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- 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
- C08G18/161—Catalysts containing two or more components to be covered by at least two of the groups C08G18/166, C08G18/18 or C08G18/22
- C08G18/163—Catalysts containing two or more components to be covered by at least two of the groups C08G18/166, C08G18/18 or C08G18/22 covered by C08G18/18 and C08G18/22
- C08G18/165—Catalysts containing two or more components to be covered by at least two of the groups C08G18/166, C08G18/18 or C08G18/22 covered by C08G18/18 and C08G18/22 covered by C08G18/18 and C08G18/24
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- 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
- C08G18/18—Catalysts containing secondary or tertiary amines or salts thereof
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- 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
- C08G18/18—Catalysts containing secondary or tertiary amines or salts thereof
- C08G18/1825—Catalysts containing secondary or tertiary amines or salts thereof having hydroxy or primary amino groups
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- 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
- C08G18/246—Catalysts containing metal compounds of tin tin salts of carboxylic acids containing also tin-carbon bonds
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- 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
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- 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
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- 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
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- 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
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- 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
- C08G2110/005—< 50kg/m3
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- 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
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/06—CO2, N2 or noble gases
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/122—Hydrogen, oxygen, CO2, nitrogen or noble gases
Definitions
- compositions and methods for producing a polyurethane foam comprise contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition.
- BACKGROUND Tertiary amines are commonly used as catalysts for the preparation of polyurethane materials that are widely used in consumer durable goods (such as cars, home appliances, furniture, toys, among other products) as well as in insulation of commercial and residential areas.
- SUMMARY One embodiment described herein is a method for making a polyurethane foam, the method comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: MBF 024010-0029-US01 Foreign Filing Evonik 202100329 at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C 3–6 cycloalkyl–OH.
- At least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting of ,
- the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon.
- the blowing agent comprises carbon dioxide (CO2) and water.
- at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), a polymeric isocyanate or a combination thereof.
- At least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. In another aspect, the at least one polyol is new or recycled. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine.
- the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl-imidazole, N- methylmorpholine, N-ethylmorpholine, triethylamine, N,N′-dimethylpiperazine, 1,3,5- tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6-tris(dimethylaminomethyl)phenol, N- methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)- ethyl-piperazine, tributylamine, pentamethyl-diethylenetriamine, hexamethyl- triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylamino), 1,2-
- the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst.
- the metal catalyst is a metal carboxylate salt.
- the metal carboxylate salt comprises a metal and a MBF 024010-0029-US01 Foreign Filing Evonik 202100329 carboxylate anion.
- the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K).
- the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid.
- carboxylic acid selected from the group
- the metal catalyst is an organotin catalyst.
- the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt.
- the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp.
- the polyurethane foam has an isocyanate index between 80 and 120.
- the polyurethane foam has a density between 0.8 pounds per cubic foot (pcf) and 3.5 pcf.
- the monohydric alcohol is present in the catalyst composition at 5 mass percentage (wt%) to 15 wt%.
- the monohydric alcohol is present at less than 0.5 wt% of the foam formulation.
- the monohydric alcohol is tertiary amine is present at less than 1.0 wt% of the foam formulation.
- the monohydric alcohol comprises at least one alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2- pentanol, 3-pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 4- heptanol, cyclopentanol, and cyclohexanol.
- At least one tertiary amine is a tertiary amine of formula: , wherein: R 1 is hydrogen or –C1–4alkyl; R 2 is hydrogen, –C 1–6 alkyl, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 R 3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R 4 and R 5 are each independently hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C1–6alkyl–NH2.
- At least one tertiary amine is selected from the group consisting of: N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine, N,N,N′-trimethylaminopropyl ethanolamine, bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea, N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine.
- At least one tertiary amine is a tertiary amine of formula: , R 6 is hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, –C 1–6 alkyl–NH 2, –C 1–6 alkyl–N(CH 3 ) 2 ; R 7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or R 8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; MBF 024010-0029-US01 Foreign Filing Evonik 202100329 R 9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R 10 and R 11 are each independently hydrogen, –C 1–6 alkyl,
- At least one tertiary amine is selected from the group consisting of: N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol, N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis bis N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis ether, 1-(2-hydroxyethyl)piperazine.
- At least one tertiary amine is selected from the group consisting of: N-(2-hydroxypropyl)imidazole, and N-(2-hydroxyethyl) imidazole.
- the catalyst composition comprises at least two tertiary amines.
- the catalyst composition further comprises a tertiary amine that does not contain an isocyanate reactive group.
- the tertiary amine that does not contain an isocyanate reactive group is one or more selected from the group consisting of: MBF 024010-0029-US01 Foreign Filing Evonik 202100329 1,4-diazabicyclo[2.2.2]octane (DABCO), N,N-dimethylcyclohexyl amine, bis-dimethylaminoethyl ether, pentamethyldiethylenetriamine, hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine, and tris(dimethylaminopropyl)amine.
- DABCO Foreign Filing Evonik 202100329 1,4-diazabicyclo[2.2.2]octane
- Another embodiment described herein is a method of making a polyurethane foam, the method comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C 3–6 cycloalkyl–OH; wherein: the monohydric alcohol is present in the catalyst composition at 5 wt% to 15 wt%; and the polyurethane foam has an isocyanate index between 80 and 120.
- At least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting of , .
- the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl MBF 024010-0029-US01 Foreign Filing Evonik 202100329 formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon.
- at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), or a combination thereof.
- At least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. In another aspect, the at least one polyol is new or recycled. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine.
- the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl-imidazole, N- methylmorpholine, N-ethylmorpholine, triethylamine, N,N′-dimethylpiperazine, 1,3,5- tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6-tris(dimethylaminomethyl)phenol, N- methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)- ethyl-piperazine, tributylamine, pentamethyl-diethylenetriamine, hexamethyl- triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylamino), 1,2-
- the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst.
- the metal catalyst is a metal carboxylate salt.
- the metal carboxylate salt comprises a metal and a carboxylate anion.
- the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K).
- the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid.
- carboxylic acid selected from the group
- the metal catalyst is an organotin catalyst.
- the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), MBF 024010-0029-US01 Foreign Filing Evonik 202100329 dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononano
- the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp.
- at least one tertiary amine is a tertiary amine of formula: , wherein: R 1 is hydrogen or –C 1–4 alkyl; R 3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R 4 and R 5 are each independently hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C1–6alkyl–NH2.
- At least one tertiary amine is selected from the group consisting of: N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine, N,N,N′-trimethylaminopropyl ethanolamine, bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea, N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- isopropanolamine, and MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine.
- At least one tertiary amine is a tertiary amine of formula: , R 6 is hydrogen, –C1–4alkyl, –C1–4alkyl–OH, –C1–4alkyl–NH2, –C1–4alkyl–N(CH3)2; R 7 is hydrogen, –C 2–6 alkyl–OH, –C 2–6 alkyl–NH 2, –C 2–6 alkyl–N(CH 3 ) 2 , or R 8 is hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C 1–6 alkyl–NH 2 ; R 9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R 10 and R 11 are each independently hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C1–6 alky
- At least one tertiary amine is selected from the group consisting of: N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol, N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether, N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and and MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N,N′-trimethyl-N′-3-amino-2-(1- hydroxyethyl)propyl- bis(aminoethyl) ether,
- FIG. 1 shows comparative Fourier transform infrared spectroscopy (FTIR) spectra illustrating the carbonyl absorption band for carbamates potentially in 1600–1736 cm ⁇ 1 range (spectra A–D).
- FTIR Fourier transform infrared spectroscopy
- the methods of making polyurethane foams may comprise preparing a foam formulation by contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition comprising.
- the catalyst composition may comprise at least one tertiary amine comprising an isocyanate reactive group and a monohydric alcohol.
- the monohydric alcohol may comprise at least one alcohol selected from the group consisting of C 1–7 linear alkyl–OH, C 3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH.
- the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine.
- suitable organic isocyanates, polyols, blowing agents, tertiary amines, additional amines, metal catalysts, and other formulation components are described below. Definitions Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art.
- any MBF 024010-0029-US01 Foreign Filing Evonik 202100329 nomenclatures used in connection with, and techniques of chemistry, synthetic organic chemistry, and polymer chemistry described herein are well known and commonly used in the art. In case of conflict, the present disclosure, including definitions, will control. Exemplary methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the embodiments and aspects described herein.
- the terms such as “include,” “including,” “contain,” “containing,” “having,” and the like mean “comprising.”
- the present disclosure also contemplates other embodiments “comprising,” “consisting of,” and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.
- the term “a,” “an,” “the” and similar terms used in the context of the disclosure are to be construed to cover both the singular and plural unless otherwise indicated herein or clearly contradicted by the context.
- “a,” “an,” or “the” means “one or more” unless otherwise specified.
- the term “or” can be conjunctive or disjunctive.
- the term “substantially” means to a great or significant extent, but not completely.
- the term “about” or “approximately” as applied to one or more values of interest refers to a value that is similar to a stated reference value, or within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, such as the limitations of the measurement system.
- the term “about” refers to any values, including both integers and fractional components that are within a variation of up to ⁇ 10% of the value modified by the term “about.” Alternatively, “about” can mean within 3 or more standard deviations, per the practice in the art. Alternatively, such as with respect to biological systems or processes, the term “about” can mean within an order of magnitude, in some embodiments within 5-fold, and in some embodiments within 2-fold, of a value. As used herein, the symbol means “about” or “approximately.” All ranges disclosed herein include both end points as discrete values as well as all integers and fractions specified within the range. For example, a range of 0.1–2.0 includes 0.1, 0.2, 0.3, 0.4. . .
- control or “reference” are used herein interchangeably.
- a “reference” or “control” level may be a predetermined value or range, which is employed as a MBF 024010-0029-US01 Foreign Filing Evonik 202100329 baseline or benchmark against which to assess a measured result.
- Control also refers to control experiments.
- room temperature RT
- ambient temperature refer to the typical temperature in an indoor laboratory setting.
- the laboratory setting is climate controlled to maintain the temperature at a substantially uniform temperature or with a specific range of temperatures.
- “room temperature” refers a temperature of about 20– 30 °C, including all integers and endpoints within the specified range.
- “room temperature” refers a temperature of about 20–27 °C; about 22–25 °C; about 22–27 °C; about 25–27 °C; about 22 °C ⁇ 10%; about 25 °C ⁇ 10%; about 27 °C ⁇ 10%; ⁇ 20 °C, ⁇ 22 °C, ⁇ 25 °C, or ⁇ 27 °C, at standard atmospheric pressure. Definitions of specific functional groups and chemical terms are described in more detail below.
- alkoxy refers to a group –O–alkyl. Representative examples of alkoxy include, but are not limited to, methoxy, ethoxy, propoxy, 2-propoxy, butoxy and tert- butoxy.
- alkyl as used herein, means a straight or branched, saturated hydrocarbon chain.
- lower alkyl or “C 1–6 alkyl” means a straight or branched chain hydrocarbon containing from 1 to 6 carbon atoms.
- C1–4alkyl means a straight or branched chain hydrocarbon containing from 1 to 4 carbon atoms.
- alkyl include, but are not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl, n- pentyl, isopentyl, neopentyl, n-hexyl, 3-methylhexyl, 2,2-dimethylpentyl, 2,3-dimethylpentyl, n- heptyl, n-octyl, n-nonyl, and n-decyl.
- alkenyl means a straight or branched, hydrocarbon chain containing at least one carbon-carbon double bond. MBF 024010-0029-US01 Foreign Filing Evonik 202100329.
- alkoxyalkyl refers to an alkoxy group, as defined herein, appended to the parent molecular moiety through an alkyl group, as defined herein.
- alkoxyfluoroalkyl refers to an alkoxy group, as defined herein, appended to the parent molecular moiety through a fluoroalkyl group, as defined herein.
- alkylene refers to a divalent group derived from a straight or branched chain hydrocarbon of 1 to 10 carbon atoms, for example, of 2 to 5 carbon atoms.
- Representative examples of alkylene include, but are not limited to, –CH2–, –CD2–, –CH2CH2–, –CH2CH2CH2–, –CH2CH2CH2CH2–, and –CH2CH2CH2CH2CH2–.
- alkylamino as used herein, means at least one alkyl group, as defined herein, is appended to the parent molecular moiety through an amino group, as defined herein.
- amide means –C(O)NR– or –NRC(O)–, wherein R may be hydrogen, alkyl, cycloalkyl, aryl, heteroaryl, heterocycle, alkenyl, or heteroalkyl.
- aminoalkyl means at least one amino group, as defined herein, is appended to the parent molecular moiety through an alkylene group, as defined herein.
- amino means –NR x R y , wherein R x and R y may be hydrogen, alkyl, cycloalkyl, aryl, heteroaryl, heterocycle, alkenyl, or heteroalkyl.
- amino may be –NR x –, wherein Rx may be hydrogen, alkyl, cycloalkyl, aryl, heteroaryl, heterocycle, alkenyl, or heteroalkyl.
- aryl refers to a phenyl or a phenyl appended to the parent molecular moiety and fused to a cycloalkane group (e.g., the aryl may be indan-4-yl), fused to a 6-membered arene group (i.e., the aryl is naphthyl), or fused to a non-aromatic heterocycle (e.g., the aryl may be benzo[d][1,3]dioxol-5-yl).
- phenyl is used when referring to a substituent and the term 6-membered arene is used when referring to a fused ring.
- the 6- membered arene is monocyclic (e.g., benzene or benzo).
- the aryl may be monocyclic (phenyl) or bicyclic (e.g., a 9- to 12-membered fused bicyclic system).
- cyanoalkyl means at least one –CN group, is appended to the parent molecular moiety through an alkylene group, as defined herein.
- cyanofluoroalkyl means at least one –CN group, is appended to the parent molecular moiety through a fluoroalkyl group, as defined herein.
- cycloalkoxy refers to a cycloalkyl group, as defined herein, appended to the parent molecular moiety through an oxygen atom.
- cycloalkyl or “cycloalkane,” as used herein, refers to a saturated ring system containing all carbon atoms as ring members and zero double bonds.
- cycloalkyl is MBF 024010-0029-US01 Foreign Filing Evonik 202100329 used herein to refer to a cycloalkane when present as a substituent.
- a cycloalkyl may be a monocyclic cycloalkyl (e.g., cyclopropyl), a fused bicyclic cycloalkyl (e.g., decahydronaphthalenyl), or a bridged cycloalkyl in which two non-adjacent atoms of a ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms (e.g., bicyclo[2.2.1]heptanyl).
- a monocyclic cycloalkyl e.g., cyclopropyl
- a fused bicyclic cycloalkyl e.g., decahydronaphthalenyl
- a bridged cycloalkyl in which two non-adjacent atoms of a ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms (e.g., bicyclo[2.2.1]heptanyl).
- cycloalkyl include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, adamantyl, and bicyclo[1.1.1]pentanyl.
- cycloalkenyl or “cycloalkene,” as used herein, means a non-aromatic monocyclic or multicyclic ring system containing all carbon atoms as ring members and at least one carbon-carbon double bond and preferably having from 5-10 carbon atoms per ring.
- cycloalkenyl is used herein to refer to a cycloalkene when present as a substituent.
- a cycloalkenyl may be a monocyclic cycloalkenyl (e.g., cyclopentenyl), a fused bicyclic cycloalkenyl (e.g., octahydronaphthalenyl), or a bridged cycloalkenyl in which two non-adjacent atoms of a ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms (e.g., bicyclo[2.2.1]heptenyl).
- Exemplary monocyclic cycloalkenyl rings include cyclopentenyl, cyclohexenyl or cycloheptenyl.
- Exemplary monocyclic cycloalkenyl rings include cyclopentenyl, cyclohexenyl or cycloheptenyl.
- the term “carbocyclyl” means a “cycloalkyl” or a “cycloalkenyl.”
- the term “carbocycle” means a “cycloalkane” or a “cycloalkene.”
- the term “carbocyclyl” refers to a “carbocycle” when present as a substituent.
- cycloalkylene and heterocyclylene refer to divalent groups derived from the base ring, i.e., cycloalkane, heterocycle.
- examples of cycloalkylene and heterocyclylene include, respectively, .
- Cycloalkylene and heterocyclylene include a geminal divalent groups such as 1,1-C 3-6 cycloalkylene (i.e., ).
- a further example is 1,1-cyclopropylene (i.e.,
- fluoroalkyl means an alkyl group, as defined herein, in which one, two, three, four, five, six, seven or eight hydrogen atoms are replaced by fluorine.
- fluoroalkyl include, but are not limited to, 2-fluoroethyl, 2,2,2- trifluoroethyl, trifluoromethyl, difluoromethyl, pentafluoroethyl, and trifluoropropyl such as 3,3,3- trifluoropropyl.
- fluoroalkylene means an alkylene group, as defined herein, in which one, two, three, four, five, six, seven or eight hydrogen atoms are replaced by fluorine.
- fluoroalkyl include, but are not limited to –CF2–, –CH2CF2–, 1,2- difluoroethylene, 1,1,2,2-tetrafluoroethylene, 1,3,3,3-tetrafluoropropylene, 1,1,2,3,3- pentafluoropropylene, and perfluoropropylene such as 1,1,2,2,3,3-hexafluoropropylene.
- halogen or “halo,” as used herein, means Cl, Br, I, or F.
- haloalkyl means an alkyl group, as defined herein, in which one, two, three, four, five, six, seven or eight hydrogen atoms are replaced by a halogen.
- haloalkoxy means at least one haloalkyl group, as defined herein, is appended to the parent molecular moiety through an oxygen atom.
- halocycloalkyl means a cycloalkyl group, as defined herein, in which one or more hydrogen atoms are replaced by a halogen.
- heteroalkyl means an alkyl group, as defined herein, in which one or more of the carbon atoms has been replaced by a heteroatom selected from S, O, P and N.
- heteroalkyls include, but are not limited to, alkyl ethers, secondary and tertiary alkyl amines, amides, and alkyl sulfides.
- heteroaryl refers to an aromatic monocyclic heteroatom- containing ring (monocyclic heteroaryl) or a bicyclic ring system containing at least one monocyclic heteroaromatic ring (bicyclic heteroaryl).
- heteroaryl is used herein to refer to a heteroarene when present as a substituent.
- the monocyclic heteroaryl are five or six membered rings containing at least one heteroatom independently selected from the group consisting of N, O and S (e.g., 1, 2, 3, or 4 heteroatoms independently selected from O, S, and N).
- the five membered aromatic monocyclic rings have two double bonds, and the six membered aromatic monocyclic rings have three double bonds.
- the bicyclic heteroaryl is an 8- to 12- membered ring system and includes a fused bicyclic heteroaromatic ring system (i.e., 10 ⁇ electron system) such as a monocyclic heteroaryl ring fused to a 6-membered arene (e.g., quinolin-4-yl, indol-1-yl), a monocyclic heteroaryl ring fused to a monocyclic heteroarene (e.g., naphthyridinyl), and a phenyl fused to a monocyclic heteroarene (e.g., quinolin-5-yl, indol-4-yl).
- a fused bicyclic heteroaromatic ring system i.e., 10 ⁇ electron system
- a monocyclic heteroaryl ring fused to a 6-membered arene e.g., quinolin-4-yl, indol-1-yl
- a bicyclic heteroaryl/heteroarene group includes a 9-membered fused bicyclic heteroaromatic ring system having four double bonds and at least one heteroatom contributing a lone electron pair to a fully aromatic 10 ⁇ electron system, such as ring systems with a nitrogen atom at the ring junction (e.g., imidazopyridine) or a benzoxadiazolyl.
- a bicyclic heteroaryl also includes a fused bicyclic ring system composed of one heteroaromatic ring and one non-aromatic ring such as a monocyclic heteroaryl ring fused to a monocyclic carbocyclic ring (e.g., 6,7-dihydro-5H- MBF 024010-0029-US01 Foreign Filing Evonik 202100329 cyclopenta[b]pyridinyl), or a monocyclic heteroaryl ring fused to a monocyclic heterocycle (e.g., 2,3-dihydrofuro[3,2-b]pyridinyl).
- the bicyclic heteroaryl is attached to the parent molecular moiety at an aromatic ring atom.
- heteroaryl include, but are not limited to, indolyl (e.g., indol-1-yl, indol-2-yl, indol-4-yl), pyridinyl (including pyridin-2-yl, pyridin-3-yl, pyridin-4-yl), pyrimidinyl, pyrazinyl, pyridazinyl, pyrazolyl (e.g., pyrazol-4-yl), pyrrolyl, benzopyrazolyl, 1,2,3-triazolyl (e.g., triazol-4-yl), 1,3,4-thiadiazolyl, 1,2,4-thiadiazolyl, 1,3,4- oxadiazolyl, 1,2,4-oxadiazolyl, imidazolyl, thiazolyl (e.g., thiazol-4-yl), isothiazolyl, thienyl, benzimidazolyl
- heterocycle or “heterocyclic,” as used herein, means a monocyclic heterocycle, a bicyclic heterocycle, or a tricyclic heterocycle.
- heterocyclyl is used herein to refer to a heterocycle when present as a substituent.
- the monocyclic heterocycle is a three-, four-, five-, six-, seven-, or eight-membered ring containing at least one heteroatom independently selected from the group consisting of O, N, and S.
- the three- or four-membered ring contains zero or one double bond, and one heteroatom selected from the group consisting of O, N, and S.
- the five- membered ring contains zero or one double bond and one, two or three heteroatoms selected from the group consisting of O, N and S.
- the six-membered ring contains zero, one or two double bonds and one, two, or three heteroatoms selected from the group consisting of O, N, and S.
- the seven- and eight-membered rings contains zero, one, two, or three double bonds and one, two, or three heteroatoms selected from the group consisting of O, N, and S.
- monocyclic heterocyclyls include, but are not limited to, azetidinyl, azepanyl, aziridinyl, diazepanyl, 1,3-dioxanyl, 1,3-dioxolanyl, 1,3-dithiolanyl, 1,3-dithianyl, imidazolinyl, imidazolidinyl, isothiazolinyl, isothiazolidinyl, isoxazolinyl, isoxazolidinyl, morpholinyl, 2-oxo-3-piperidinyl, 2- oxoazepan-3-yl, oxadiazolinyl, oxadiazolidinyl, oxazolinyl, oxazolidinyl, oxetanyl, oxepanyl, oxocanyl, piperazinyl, piperidinyl, pyranyl, pyrazol
- the bicyclic heterocycle is a monocyclic heterocycle fused to a 6-membered arene, or a monocyclic heterocycle fused to a monocyclic cycloalkane, or a monocyclic heterocycle fused to a monocyclic cycloalkene, or a monocyclic heterocycle fused to a monocyclic heterocycle, or a monocyclic MBF 024010-0029-US01 Foreign Filing Evonik 202100329 heterocycle fused to a monocyclic heteroarene, or a spiro heterocycle group, or a bridged monocyclic heterocycle ring system in which two non-adjacent atoms of the ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms, or an alkenylene bridge of two, three, or four carbon atoms.
- bicyclic heterocyclyl is attached to the parent molecular moiety at a non-aromatic ring atom (e.g., indolin-1-yl).
- bicyclic heterocyclyls include, but are not limited to, chroman-4-yl, 2,3-dihydrobenzofuran-2-yl, 2,3-dihydrobenzothien-2-yl, 1,2,3,4- tetrahydroisoquinolin-2-yl, 2-azaspiro[3.3]heptan-2-yl, 2-oxa-6-azaspiro[3.3]heptan-6-yl, azabicyclo[2.2.1]heptyl (including 2-azabicyclo[2.2.1]hept-2-yl), azabicyclo[3.1.0]hexanyl (including 3-azabicyclo[3.1.0]hexan-3-yl), 2,3-dihydro-1H-indol-1-yl, isoindolin-2-yl, o
- Tricyclic heterocycles are exemplified by a bicyclic heterocycle fused to a 6-membered arene, or a bicyclic heterocycle fused to a monocyclic cycloalkane, or a bicyclic heterocycle fused to a monocyclic cycloalkene, or a bicyclic heterocycle fused to a monocyclic heterocycle, or a bicyclic heterocycle in which two non-adjacent atoms of the bicyclic ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms, or an alkenylene bridge of two, three, or four carbon atoms.
- tricyclic heterocycles include, but are not limited to, octahydro-2,5-epoxypentalene, hexahydro-2H-2,5- methanocyclopenta[b]furan, hexahydro-1H-1,4-methanocyclopenta[c]furan, aza-adamantane (1- azatricyclo[3.3.1.13,7]decane), and oxa-adamantane (2-oxatricyclo[3.3.1.13,7]decane).
- the monocyclic, bicyclic, and tricyclic heterocyclyls are connected to the parent molecular moiety at a non-aromatic ring atom.
- hydroxyl or “hydroxy,” as used herein, means an —OH group.
- hydroxyalkyl means at least one –OH group, is appended to the parent molecular moiety through an alkylene group, as defined herein.
- hydroxyfluoroalkyl means at least one –OH group, is appended to the parent molecular moiety through a fluoroalkyl group, as defined herein. Terms such as “alkyl,” “cycloalkyl,” “alkylene,” etc.
- C 3 alkyl is an alkyl group with three carbon atoms (i.e., n-propyl, isopropyl).
- C1–4 the members of the group that follows may have any number of carbon atoms falling within the recited MBF 024010-0029-US01 Foreign Filing Evonik 202100329 range.
- substituted refers to a group that may be further substituted with one or more non-hydrogen substituent groups.
- the term “pphp” refers to “parts per hundred parts polyol,” and is used to describe the amount of other foam components (such as an amine catalyst, for example) as a ratio of the polyol.
- the compositions and methods described herein provides processes for making amine compositions wherein a monohydric alcohol is included in an amine catalyst composition to mitigate solid carbamate formation. The approach is a cost-effective solution to prevent/reduce the formation of solid intermediate carbamates during the polyurethane foam production process.
- One aspect as described herein relates to a method for making polyurethane foams by using the inventive amine catalyst compositions, which comprise an amine catalyst and a monohydric alcohol.
- the composition comprises an amine catalyst and a monohydric alcohol, where the monohydric alcohol concentration in the composition is between 1–50 percent mass (wt%), 3–25 percent mass (wt%), or 3–20 percent mass (wt%).
- the amine catalyst composition can be obtained by thoroughly blending 1–20 percent mass (wt%) of a monohydric alcohol with a tertiary, secondary, or primary amine catalyst for at least several minutes (e.g., for about 5 minutes to about 60 minutes).
- Suitable amine catalysts may comprise a tertiary amine, a secondary amine, a primary amine, or a combination thereof.
- Exemplary amine catalysts may comprise a tertiary amine containing at least one isocyanate-reactive group.
- the amine catalyst e.g., a tertiary amine containing at least one isocyanate-reactive group, is present at less than 1 wt% of the total foam formulation.
- Isocyanate reactive groups generally comprise an amino/amine moiety (e.g., a primary amine or a secondary amine moiety), a hydroxyl group, an amide, or a urea moiety.
- at least one isocyanate reactive group may comprise at least one moiety selected from the group consisting of .
- At least one tertiary amine may be a tertiary amine of formula: , wherein: R 1 is hydrogen or –C 1–4 alkyl; R 3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R 4 and R 5 are each independently hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C1–6alkyl–NH2.
- At least one tertiary amine may be selected from the group consisting of at least one tertiary amine is selected from the group consisting of: N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine, N,N,N′-trimethylaminopropyl ethanolamine, N,N-dimethylaminopropyl urea, bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and N,N-dimethyl-N′,N′-2-hydroxy(propyI
- At least one tertiary amine may be a tertiary amine of formula:
- R 6 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, –C1–6alkyl–NH2, –C1–6alkyl–N(CH3)2;
- R 7 is hydrogen, –C 2–6 alkyl–OH, –C 2–6 alkyl–NH 2, –C 2–6 alkyl–N(CH 3 ) 2 , or
- R 8 is hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C 1–6 alkyl–NH 2 ;
- R 9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2;
- R 10 and R 11 are each independently hydrogen, —C 1–6 alkyl, –C 1–6 alkyl–OH, or
- At least one tertiary amine may be selected from the group consisting of: N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol, N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis(aminoethyl) ether, 1-(2-hydroxyethyl
- At least one tertiary amine may be selected from the group consisting of: N-(2-hydroxypropyl)imidazole, and N-(2-hydroxyethyl) imidazole.
- the catalyst composition may comprise at least two tertiary amines.
- the catalyst composition may further comprise a tertiary amine that does not contain an isocyanate reactive group.
- the tertiary amine that does not contain an isocyanate reactive group may be one or more selected from the group consisting of: 1,4-diazabicyclo[2.2.2]octane (DABCO), N,N-dimethylcyclohexyl amine, bis-dimethylaminoethyl ether, pentamethyldiethylenetriamine, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine, and tris(dimethylaminopropyl)amine.
- DABCO 1,4-diazabicyclo[2.2.2]octane
- N,N-dimethylcyclohexyl amine bis-dimethylaminoethyl ether
- pentamethyldiethylenetriamine MBF 024010-0029-US01
- Suitable tertiary amines containing at least one isocyanate reactive group include both gelling and blowing amine catalysts.
- Exemplary gelling amine catalysts include at least one member selected from the group consisting of N,N-bis(3-dimethylaminopropyl)-N- isopropanolamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine (DABCO® T, Evonik Corporation of Allentown, Pa.), N,N,N′-trimethylaminopropyl ethanolamine (POLYCAT® 17, by Evonik Corporation), N,N-dimethylethanolamine (DABCO® DMEA), N,N-dimethyl-N′,N′-2- hydroxy(propyl)-1,3-propylenediamine, dimethylaminopropylamine (DMAPA), (N,N- dimethylaminoethoxy)ethanol, methyl-hydroxy-ethyl-piperazine, bis(N,N-
- Exemplary blowing amine catalysts include at least one member selected from the group consisting of 2-[N-(dimethylaminoethoxyethyl)-N-methylamino]ethanol, N,N-dimethylaminoethyl- N′-methyl-N′-ethanol (DABCO®-T), dimethylaminoethoxyethanol and N,N,N′-trimethyl-N′-3- aminopropyl-bis(aminoethyl) ether (DABCO® NE300).
- Suitable amine catalyst compositions may further comprise gelling catalysts that are highly volatile and are not reactive with isocyanate groups, e.g., a volatile gelling catalyst.
- Suitable volatile gelling catalysts may include, for example, at least one member selected from the group consisting of diazabicyclooctane (triethylenediamine), supplied commercially as DABCO®33-LV catalyst, tris(hydroformylationyl)amine (Polycat® 9), dimethylaminocyclohexylamine (Polycat® 8) and bis(dimethylaminopropyl)-N-methylamine (Polycat® 77), N,N-dimethylcyclohexylamine (Polycat-8, Evonik Corporation of Allentown, Pa.), N-methyldicyclohexylamine (Polycat-12, Evonik Corporation of Allentown, Pa.).
- diazabicyclooctane triethylenediamine
- DABCO®33-LV catalyst tris(hydroformylationyl)amine
- Polycat® 9 dimethylaminocyclohexylamine
- Polycat® 78 bis(dimethylaminopropyl)-
- Suitable volatile blowing catalysts include, for example, at least one member selected from the group consisting of bis-dimethylaminoethyl ether, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 commercially supplied as DABCO® BL-11 catalyst by Evonik Corporation, as well as pentamethyldiethylenetriamine (POLYCAT® 5, Evonik Corporation), hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine and related compositions, higher permethylated polyamines, 2-[N-(dimethylaminoethoxyethyl)-N-methylamino]ethanol and related structures, alkoxylated polyamines, imidazole-boron compositions, or amino propyl- bis(amino-ethyl)ether compositions.
- the loading of non-fugitive amine for making foam as described herein will be in the range of about 0.1 to about 20 pphp, more typically about 0.1 to about 10 pphp, and most typically about 0.1 to about 5 pphp. However, any effective amount may be used.
- the amount of volatile amine in the foam formulation can range from about 0.05 to about 20 pphp.
- Monohydric Alcohols Exemplary monohydric alcohols contain less than 10 carbon atoms. In various instances, the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1– 7 linear alkyl–OH, C 3–6 branched alkyl–OH, and C 3–6 cycloalkyl–OH.
- the monohydric alcohol comprises at least one alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2-pentanol, 3- pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 4-heptanol, cyclopentanol, and cyclohexanol.
- the monohydric alcohol is present at no more than 0.5 wt% of the total foam formulation.
- Foams of any of the various types known in the art may be made using the methods as described herein, using typical polyurethane formulations.
- flexible polyurethane foams with excellent physical properties described herein will typically comprise the components shown below in Table 1, in the amounts indicated. The components shown in Table 1 will be discussed in detail below.
- the NCO index is defined as the number of equivalents of isocyanate, divided by the total number of equivalents of active hydrogen, multiplied by 100.
- the isocyanate index can range from about 80 to about 500 depending on the type of foam formulation. For example, flexible foams have typically an isocyanate index of 80 to 120 while rigid foams such as those typically used in appliances, lamination and spray foam application can have indexes in the range of 100 to 500 depending on the application. The higher indexes are commonly used with a trimerization catalyst to produce polyisocyanurate (PIR) foams.
- PIR polyisocyanurate
- PIR foams are typically used in foam laminates that require effective thermal insulation.
- exemplary polyurethane foams typically have a density between 0.8 pounds per cubic foot (pcf) and 3.5 pcf.
- Another embodiment relates to a method of making a polyurethane comprising contacting at least one organic isocyanate with at least one polyol in the presence of a catalytically effective amount of the amine catalyst composition.
- Polyurethanes are produced by the reaction of organic isocyanates with the hydroxyl groups in a polyol, typically a mixture of polyols.
- the least one polyol may be a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol.
- the at least one polyol may be new or recycled.
- Suitable organic isocyanate compounds include, but are not limited to, at least one member from the group consisting of hexamethylene diisocyanate (HDI), phenylene diisocyanate (PDI), toluene diisocyanate (TDI), and 4,4′-diphenylmethane diisocyanate (MDI).
- HDI hexamethylene diisocyanate
- PDI phenylene diisocyanate
- TDI toluene diisocyanate
- MDI 4,4′-diphenylmethane diisocyanate
- 2,4-TDI, 2,6-TDI, or any mixture thereof may be used to produce polyurethane foams.
- Suitable organic isocyanates include monomeric isocyanates, e.g., MDI, and polymeric isocyanates, e.g., polymeric 4,4′-methylenediphenyl diisocyanate (PMDI).
- Other suitable isocyanate compounds are diisocyanate mixtures known commercially as “crude MDI.”
- PAPI TM One example is marketed by Dow Chemical Company under the name PAPI TM and contains about MBF 024010-0029-US01 Foreign Filing Evonik 202100329 60% of 4,4′-diphenylmethane diisocyanate (MDI) along with other isomeric and analogous higher polyisocyanates.
- Polyols The polyol of the foam formulations described herein may comprise at least a main or “base” polyol.
- Base polyols suitable for use as described herein include, as non-limiting examples, at least one member selected from the group consisting of polyether polyols.
- Exemplary polyether polyols may have a molecular weight (MW) of 2000 g/mol to 4000 g/mol and a polyol functionality of 2.5 to 3.3.
- polyol functionality refers to the number of –OH” groups per molecule.
- Polyether polyols include poly(alkylene oxide) polymers such as poly(ethylene oxide) and poly(propylene oxide) polymers and copolymers with terminal hydroxyl groups derived from polyhydric compounds, including diols and triols.
- diols and triols for reaction with the ethylene oxide or propylene oxide include at least one member selected from the group consisting of ethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,6- hexanediol, neopentyl glycol, diethylene glycol, dipropylene glycol, pentaerythritol, glycerol, diglycerol, trimethylol propane, and similar low molecular weight polyols.
- base polyol examples known in the art include polyhydroxy-terminated acetal resins, hydroxyl-terminated amines, and hydroxyl-terminated polyamines. Examples of these and other suitable isocyanate- reactive materials may be found in U.S. Pat. No.4,394,491, which is incorporated by reference herein.
- Suitable polyols also include those containing tertiary amine groups than can catalyze the gelling and the blowing reaction of polyurethanes, for example those described in WO 2003/016373 A1, WO 2001/58976 A1; WO 2004/060956 A1; WO 2003/016372 A1; and WO 2003/055930 A1; the disclosures of the foregoing references are incorporated by reference herein.
- Other useful polyols may include polyalkylene carbonate-based polyols and polyphosphate-based polyols.
- the amount of polyether polyol can range from about 20 to about 100 parts per hundred parts polyol (pphp).
- a single high molecular weight polyether polyol may be used as the base polyol.
- a mixture of high molecular weight polyether polyols for example, mixtures of di- and tri-functional materials and/or different molecular weight or different chemical composition materials may be used.
- di- and tri-functional materials include but are not limited to at least one member selected from the group consisting of polyethylene glycol, polypropylene glycol, glycerol-based polyether triols, trimethylolpropane-based polyether triols, and other similar compounds or mixtures, provided that they are ester-free.
- At least about 50 percent mass (wt%) of the ester-free polyol component consists of one or more polyether polyols.
- materials commonly referred to as “copolymer polyols” may be included in a polyol component for use as described herein. Copolymer polyols may be used in polyurethane foams to increase the resistance of the foam to deformation, for example to improve the load-bearing properties of the foam.
- copolymer polyols may comprise from 0 to about 80 percent by weight of the total polyol content.
- copolymer polyols include, but are not limited to, graft polyols and polyurea modified polyols, both of which are known in the art and are commercially available. Graft polyols are prepared by copolymerizing vinyl monomers, typically styrene and acrylonitrile, in a starting polyol. The starting polyol is typically a glycerol-initiated triol and is typically end-capped with ethylene oxide (approximately 80–85% primary hydroxyl groups).
- the graft polyol also contains homopolymers of styrene and acrylonitrile and unaltered starting polyol.
- the styrene/acrylonitrile solids content of the graft polyol typically ranges from about 5 percent mass (wt%) to about 45 percent mass (wt%), but any kind of graft polyol known in the art may be used.
- Polyurea modified polyols are formed by the reaction of a diamine and a diisocyanate in the presence of a starting polyol, with the product containing polyurea dispersion.
- polyurea modified polyols are polyisocyanate polyaddition (PIPA) polyols, which are formed by the in situ reaction of an isocyanate and an alkanolamine in a polyol.
- PIPA polyisocyanate polyaddition
- Useful polyester polyols include those produced when a dicarboxylic acid is reacted with an excess of a diol for example adipic acid or phthalic acid or phthalic anhydride with ethylene glycol or butanediol or reacting a lactone with an excess of a diol such as caprolactone with propylene glycol.
- Mannich polyols are also typically used in spray formulations.
- Mannich polyols are made by the condensation of phenols with aldehydes and amines to give polyols containing multiple hydroxyl groups (2–8) and tertiary amine centers.
- Polyester polyols may be present in the range from about 0 pphp to about 100 pphp.
- Flexible foams typically use copolymer polyols as part of the overall polyol content in the foam composition, along with base polyols of about 3000–6000 weight average molecular weight and hydroxyl number of about 28–60.
- Natural Oil Polyol To minimize the depletion of fossil fuel and other non-sustainable resources, all or a portion of the polyols may be used to prepare polyurethane foams are from inexpensive and MBF 024010-0029-US01 Foreign Filing Evonik 202100329 renewable resources.
- Natural oils comprise triglycerides of saturated and unsaturated fatty acids.
- One natural oil polyol is castor oil, a natural triglyceride of ricinoleic acid which is commonly used to make polyurethane foam despite some of its limitations, e.g., low hydroxyl content.
- Other natural oils may be chemically modified to introduce sufficient hydroxyl content to make them useful in the production of polyurethane polymers.
- Unsaturated sites present in oil or fat may be hydroxylated via epoxidation/ring opening or hydroformylation/hydrogenation. Alternatively, trans-esterification may be utilized to introduce –OH groups in natural oil and fat.
- the chemical process for the preparation of natural polyols using epoxidation route involves a reaction mixture that requires epoxidized natural oil, a ring opening acid catalyst and a ring opener.
- Epoxidized natural oils include epoxidized plant-based oils (epoxidized vegetable oils) and epoxidized animal fats.
- the epoxidized natural oils may be fully or partially epoxidized and these oils include at least one member selected from the group consisting of soybean oil, corn oil, sunflower oil, olive oil, canola oil, sesame oil, palm oil, rapeseed oil, tung oil, cotton seed oil, safflower oil, peanut oil, linseed oil and combinations thereof.
- Animal fats include fish, tallow, and lard.
- These natural oils are triglycerides of fatty acids which may be saturated or unsaturated with various chain lengths from C12 to C24.
- These acids can be: (1) saturated: lauric, myristic, palmitic, steric, arachidic and lignoceric; (2) mono-unsaturated: palmitoleic, oleic, (3) poly-unsaturated: linoleic, linolenic, arachidonic.
- Partially or fully epoxidized natural oil may be prepared when reacting peroxyacid under suitable reaction conditions. Examples of peroxyacids utilized in the epoxidation of oils have been described in WO 2006/116456 A1; which is incorporated by reference herein. Ring opening of the epoxidized oils with alcohols, water and other compounds having one or multiple nucleophilic groups can be used.
- oligomerization of the epoxidized oil can also occur. Ring opening yields natural oil polyol that can be used for the manufacture of polyurethane products.
- the oil is hydroformylated in a reactor filled with a hydrogen/carbon monoxide mixture in the presence of a suitable catalyst (typically cobalt or rhodium) to form an aldehyde which is hydrogenated in the presence of cobalt or nickel catalyst to form a polyol.
- a suitable catalyst typically cobalt or rhodium
- polyol form natural oil and fats can be produced by trans-esterification with a suitable poly-hydroxyl containing substance using an alkali metal or alkali earth metal base or salt as a trans- esterification catalyst.
- Any natural oil or alternatively any partially hydrogenated oil can be used in the transesterification process.
- oils include but are not limited to at least one member selected from the group consisting of soybean, corn, cottonseed, peanut, castor, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 sunflower, canola, rapeseed, safflower, fish, seal, palm, tung, olive oil or any blend.
- Any multifunctional hydroxyl compound can also be used such as lactose, maltose, raffinose, sucrose, sorbitol, xylitol, erythritol, mannitol, or any combination.
- the amount of natural oil polyol can range from about 0 to about 40 pphp of the foam formulation.
- Blowing Agents Polyurethane foam production may be aided by the inclusion of a blowing agent to produce voids in the polyurethane matrix during polymerization. Any blowing agent known in the art may be used. Suitable blowing agents include compounds with low boiling points which are vaporized during the exothermic polymerization reaction. Such blowing agents are generally inert and therefore do not decompose or react during the polymerization reaction.
- inert blowing agents include, but are not limited to, at least one member selected from the group consisting of water, carbon dioxide, chlorofluorocarbons, hydrogenated fluorocarbons, hydrogenated chlorofluorocarbons, fluoroolefins, chlorofluoroolefins, hydrofluoroolefins, hydrochlorfluoroolefins, acetone, and low-boiling hydrocarbons such as cyclopentane, isopentane, n-pentane, and their mixtures.
- suitable blowing agents include compounds, for example, water, that react with isocyanate compounds to produce a gas.
- the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO 2 ), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon.
- the amount of blowing agent typically ranges from about 0 pphp to about 80 pphp.
- the amount of water may range from about 0 pphp to about 60 pphp. In various instances, the amount of water may range from about 1.0 pphp to about 10 pphp and, in some cases, from about 2.0 pphp to about 5 pphp.
- Optional Components A variety of other components or ingredients may be included in the foam formulations described herein.
- optional components include, but are not limited to, at least one member selected from the group consisting of cell stabilizers, crosslinking agents, chain extenders, pigments, dyes, fillers, flame retardants, flame lamination additives, auxiliary urethane gelling catalysts, auxiliary urethane blowing catalysts, metal catalysts, additional amines and combinations thereof.
- Cell stabilizers can used in an amount from about 0.1 to about 20 pphp and typically from about 0.1 to about 10 pphp and, in some cases, from about 0.1 to about 5.0 MBF 024010-0029-US01 Foreign Filing Evonik 202100329 pphp.
- Fire retardants can be used in an amount from about 0 to about 20 pphp and from about 0 to about 10 pphp and from about 0 to about 5 pphp.
- Cell stabilizers may include, for example, silicone surfactants or anionic surfactants.
- suitable silicone surfactants include, but are not limited to, at least one member from the group consisting of polyalkylsiloxanes, polyoxyalkylene polyol-modified dimethylpolysiloxanes, alkylene glycol-modified dimethylpolysiloxanes, or combinations thereof.
- Suitable anionic surfactants include, but are not limited to, salts of fatty acids, salts of sulfuric acid esters, salts of phosphoric acid esters, salts of sulfonic acids, and combinations of any of these.
- Crosslinking agents include, but are not limited to, at least one member selected from the group consisting of low-molecular weight compounds containing at least two moieties selected from hydroxyl groups, primary amino groups, secondary amino groups, and other active hydrogen-containing groups which are reactive with an isocyanate group.
- Crosslinking agents include, for example, at least one member selected from the group consisting of polyhydric alcohols (especially trihydric alcohols, such as glycerol and trimethylolpropane), polyamines, and combinations thereof.
- Non-limiting examples of polyamine crosslinking agents include diethyltoluenediamine, chlorodiaminobenzene, diethanolamine, diisopropanolamine, triethanolamine, tripropanolamine, 1,6-hexanediamine, and combinations thereof.
- Typical diamine crosslinking agents comprise twelve carbon atoms or fewer, more commonly seven or fewer.
- the amount of crosslinking agent typically ranges from about 0.1 pphp to about 20 pphp.
- Examples of chain extenders include, but are not limited to, compounds having hydroxyl or amino functional group, such as glycols, amines, diols, and water.
- chain extenders include at least one member selected from the group consisting of ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol, 1,3- butanediol, 1,5-pentanediol, neopentyl glycol, 1,6-hexanediol, 1,10-decanediol, 1,12- dodecanediol, ethoxylated hydroquinone, 1,4-cyclohexanediol, N-methylethanolamine, N- methylisopropanolamine, 4-aminocyclohexanol, 1,2-diaminoethane, 2,4-toluenediamine, or any mixture thereof.
- Pigments may be used to color code the polyurethane foams during manufacture, for example to identify product grade or to conceal yellowing.
- Pigments may include any suitable organic or inorganic pigments known in the polyurethane art.
- organic pigments or colorants include, but are not limited to, at least one member selected from the group consisting of azo/diazo dyes, phthalocyanines, dioxazines, and carbon black.
- inorganic pigments include, but are not limited to, titanium dioxide, iron oxides, or chromium oxide. The amount of any pigment typically ranges from about 0 pphp to about 15 pphp.
- MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Fillers may be used to increase the density and load bearing properties of polyurethane foams.
- Suitable fillers include, but are not limited to, barium sulfate or calcium carbonate. The amount of any filler typically ranges from about 0 pphp to about 30 pphp
- Flame retardants may be used to reduce the flammability of polyurethane foams.
- suitable flame retardants include, but are not limited to, chlorinated phosphate esters, chlorinated paraffins, or melamine powders.
- the contacting of at least one organic isocyanate with at least one polyol may occur in the presence of metal catalyst.
- the metal catalyst may be a metal carboxylate salt where the metal carboxylate salt comprises a metal and a carboxylate anion.
- the metal may be at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K).
- the carboxylate may be the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid.
- carboxylic acid selected from the
- the metal catalyst may be an organotin catalyst.
- the organotin catalyst may be at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2- ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt.
- the metal catalyst may be present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. In some instances, the metal catalyst may be present at about 0 pphp to about 10 pphp. In some instances, the contacting of at least one organic isocyanate with at least one polyol may occur in the presence of an additional amine.
- the additional amine may comprise at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl-imidazole, N-methylmorpholine (commercially available as DABCO ® NMM), N- ethylmorpholine (commercially available as DABCO ® NEM), triethylamine (commercially available as DABCO ® TETN), N,N′-dimethylpiperazine (commercially available as POLYCAT ® 41), 1,3,5- tris(dimethylaminopropyl)hexahydrotriazine (commercially available as DABCO TMR ® 30), 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine (commercially available as POLYCAT ® 12), pentamethyldipropylene triamine (commercially available as POLYCAT ® 77), N- MBF 024010-0029-US01 Foreign Filing Evonik 2021003
- compositions, formulations, methods, and processes described herein include all actual or potential combinations of embodiments, aspects, options, examples, and preferences herein described.
- the exemplary compositions and formulations described herein may omit any component, substitute any component disclosed herein, or include any component disclosed elsewhere herein.
- the ratios of the mass of any component of any of the compositions or formulations disclosed herein to the mass of any other component in the formulation or to the total mass of the other components in the formulation are hereby disclosed as if they were expressly disclosed; this can be expressed as a percentage of the total mass of all components of a formulation or as a ratio of components.
- a method for making a polyurethane foam comprising: MBF 024010-0029-US01 Foreign Filing Evonik 202100329 preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH. Clause 2.
- the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2- dimethyl-imidazole, N-methylmorpholine, N-ethylmorpholine, triethylamine, N,N′- MBF 024010-0029-US01 Foreign Filing Evonik 202100329 dimethylpiperazine, 1,3,5-tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)-ethyl-piperazine, tributylamine, pentamethyl- diethylenetriamine, hexamethyl-triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine,
- TDA triethylene
- Clause 12 The method of any one of clauses 1–11, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst.
- the metal catalyst is a metal carboxylate salt.
- the metal carboxylate salt comprises a metal and a carboxylate anion.
- the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K).
- the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid.
- carboxylic acid selected from the group
- the metal catalyst is an organotin catalyst.
- the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous octoate, stannous neodecanoate
- Clause 19 The method of any one of clauses 12–18, wherein the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp.
- Clause 20 The method of any one of clauses 1–19, wherein the polyurethane foam has an isocyanate index between 80 and 120. MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Clause 21.
- the method of any one of clauses 1–20, wherein the polyurethane foam has a density between 0.8 pounds per cubic foot (pcf) and 3.5 pcf. Clause 22.
- the monohydric alcohol comprises at least one alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2-pentanol, 3-pentanol, 1- hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 4-heptanol, cyclopentanol, and cyclohexanol.
- tertiary amine is selected from the group consisting of: N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl N,N,N′-trimethylaminopropyl ethanolamine, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N-dimethylaminopropyl urea, bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea, N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine.
- Clause 28 The method of any one of clauses 1–27, wherein at least one tertiary amine is a tertiary amine of formula: , R 6 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, –C1–6alkyl–NH2, –C1–6alkyl–N(CH3)2; R 7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or R 8 is hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C 1–6 alkyl–NH 2 ; R 9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R 10 and R 11 are each independently hydrogen, –C1–6alkyl, –C1–6alky
- Clause 29 The method of any one of clauses 1–28, wherein at least one tertiary amine is selected from the group consisting of: N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis bis N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis ether, 1-(2-hydroxyethyl)piperazine.
- Clause 30 The method of any one of clauses 1–29, wherein at least one tertiary amine is selected from the group consisting of: N-(2-hydroxypropyl)imidazole, and N-(2-hydroxyethyl) imidazole.
- Clause 31 The method of any one of clauses 1–30, wherein the catalyst composition comprises at least two tertiary amines.
- Clause 32 The method of any one of clauses 1–31, wherein the catalyst composition further comprises a tertiary amine that does not contain an isocyanate reactive group.
- the tertiary amine that does not contain an isocyanate reactive group is one or more selected from the group consisting of: 1,4-diazabicyclo[2.2.2]octane (DABCO), N,N-dimethylcyclohexyl amine, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 bis-dimethylaminoethyl ether, pentamethyldiethylenetriamine, hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine, and tris(dimethylaminopropyl)amine.
- DABCO 1,4-diazabicyclo[2.2.2]octane
- a method of making a polyurethane foam comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C 3–6 cycloalkyl–OH; wherein: the monohydric alcohol is present in the catalyst composition at 5 wt% to 15 wt%; and the polyurethane foam has an isocyanate index between 80 and 120.
- Clause 35 The method of clause 34, wherein at least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting Clause 36.
- Clause 37 The method of any one of clauses 34–36, wherein at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), or a combination thereof.
- TDI toluene diisocyanate
- MDI methylene diphenyl diisocyanate
- the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2- dimethyl-imidazole, N-methylmorpholine, N-ethylmorpholine, triethylamine, N,N′- dimethylpiperazine, 1,3,5-tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)-ethyl-piperazine, tributylamine, pentamethyl- diethylenetriamine, hexamethyl-triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl, N-methylimi
- Clause 44 The method of any one of clauses 34–43, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst.
- the metal catalyst is a metal carboxylate salt.
- the metal carboxylate salt comprises a metal and a carboxylate anion.
- the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K).
- the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic MBF 024010-0029-US01 Foreign Filing Evonik 202100329 acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptade
- the metal catalyst is an organotin catalyst.
- the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and
- Clause 51 The method of any one of clauses 34–50, wherein the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp.
- Clause 52 The method of any one of clauses 34–51, wherein at least one tertiary amine is a tertiary amine of formula: , wherein: R 1 is hydrogen or –C 1–4 alkyl; R 2 is hydrogen, R 3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R 4 and R 5 are each independently hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C1–6alkyl–NH2.
- Clause 53 The method of any one of clauses 34–52, wherein at least one tertiary amine is selected from the group consisting of: N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl N,N,N′-trimethylaminopropyl ethanolamine, N,N-dimethylaminopropyl urea, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea, N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- isopropanolamine, and N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine.
- Clause 54 The method of any one of clauses 34–53, wherein at least one tertiary amine is a tertiary amine of formula: , R 6 is hydrogen, –C 1–4 alkyl, –C 1–4 alkyl–OH, –C 1–4 alkyl–NH 2, –C 1–4 alkyl–N(CH 3 ) 2 ; R 7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or R 8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; R 9 is hydrogen, –C 1–6 alkyl, –C 1–6 alkyl–OH, or –C 1–6 alkyl–NH 2 ; and R 10 and R 11 are each independently hydrogen, –C1–6alkyl, –C1–
- Clause 55 The method of any one of clauses 34–54, wherein at least one tertiary amine is selected from the group consisting of: N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol, MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether, N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis(amino
- Example 2 The model tertiary amine N,N,N′-trimethyl-N′-3-aminopropyl-bis(aminoethyl) ether (DABCO® NE300 (amine catalyst) was selected for this study because this compound is widely MBF 024010-0029-US01 Foreign Filing Evonik 202100329 used as a blowing catalyst in many commercial applications.
- the catalyst is a blowing polyurethane catalyst commonly used in flexible molded and flexible slabstock applications where chemical emanation is of great concern. However, the catalyst is also employed in many other used such as rigid, semi-rigid, spray and any other application where water may be used to blow the polyurethane polymer.
- the formulation was mixed for about 20 seconds at about 6,000 RPM using an overhead stirrer fitted with a 5.1 cm (2-inch) diameter stirring paddle.
- the toluene diisocyanate (TDI) was then added, and the formulation was mixed well for about another 6 seconds at about 6,000 RPM using the same stirrer, after which it was poured into a 5-gallon plastic bucket at room temperature. Rise time and foam height are monitored for 5 minutes. The foam is allowed to fully cure overnight and removed from the bucket the next day. Foam samples were stored under constant temperature and humidity conditions for 48 hours before being cut and tested. Table 3.
- Table 4 shows physical properties of flexible slabstock polyurethane foam samples for the amine catalyst with two different monohydric alcohols (iso-propanol and 1-pentanol) in a low density slabstock formulation.
- the flexible slabstock samples were made using a single blowing agent of the amine catalyst to show the influence of each individual co-solvent on foam physical properties.
- the gelling amine catalyst was in each case was triethylene diamine (TEDA). Table 4.
- the formulation was mixed for about 20 seconds at about 6000 RPM using an overhead stirrer fitted with a 5.1 cm (2-inch) diameter stirring paddle.
- the toluene diisocyanate (TDI) was then added, and the formulation was mixed well for about another 6 seconds at about 6000 RPM using the same stirrer, after which it was poured into a 3.5-gallon plastic bucket at room temperature. Rise time and foam height are monitored for 5 minutes. The foam is allowed to fully cure overnight and removed from the bucket the next day. Foam samples were stored under constant temperature and humidity conditions for 48 hours before being cut and tested.
- Table 6 shows physical properties of flexible slabstock polyurethane foam samples for the amine catalyst composition with two different monohydric alcohols (iso-propanol and 1-pentanol) in a high density slabstock formulation.
- the flexible slabstock samples were made using a single blowing using the amine catalyst to show the influence of each individual co-solvent on foam physical properties.
- the gelling amine catalyst was in each case was triethylene diamine (TEDA). Table 6.
- the glass container of amine/alcohol catalyst was then transferred to a 28 °C (82 °F) warm water bath for approx. 20 minutes to dissolve the solid CO2.
- the glass container was then removed from the warm water bath and allowed to stand at 24 °C (75 °F) for 5 mins.
- the amine/alcohol catalyst liquid was visually observed for solid formation.
- the container was secured with a lid and placed in MBF 024010-0029-US01 Foreign Filing Evonik 202100329 controlled temperature environment, such as incubator, at 10 °C (50 °F) overnight.
- the amine/alcohol catalyst was visually observed periodically for solid formation. Four samples were individually analyzed by FTIR for carbamate content.
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Abstract
Described herein are compositions and methods for producing a polyurethane foam. Exemplary methods comprise contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition.
Description
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 INHIBITING SOLIDS FORMATION IN CO2 POLYURETHANE PRODUCTION TECHNICAL FIELD Described herein are compositions and methods for producing a polyurethane foam. Exemplary methods comprise contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition. BACKGROUND Tertiary amines are commonly used as catalysts for the preparation of polyurethane materials that are widely used in consumer durable goods (such as cars, home appliances, furniture, toys, among other products) as well as in insulation of commercial and residential areas. Minimization of chemical emissions in these applications is of key importance to eliminate potential exposure of workers and end users to the hazards associated by either adventitious contaminants or by-products produced by adventitious contaminants that may be present in some of the raw materials utilized in the preparation of polyurethane-based products. During the preparation of polyurethane foam, several components are used such as polyol, isocyanates, surfactants, blowing agents, crosslinkers, cell openers, pigments, fillers, fire retardants, metal catalysts and tertiary amine catalysts. In some cases, certain tertiary, secondary and primary amines are combined with auxiliary blowing agents, such as CO2, to achieve lower foam density. However, the combination of amine and CO2 preferentially and undesirably leads to the formation of a solid intermediate carbamate. Premature generation of any solid in polyurethane foam making equipment, especially when using specialized auxiliary blowing agents, typically causes accelerated pressure development within the equipment, leading to early shutdown and economic loss problems. There is a need for low emission amine catalyst compositions that minimize the formation solid intermediates carbamate during polyurethane foam production. SUMMARY One embodiment described herein is a method for making a polyurethane foam, the method comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises:
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH. In one aspect, at least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting of
,
In another aspect, the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon. In another aspect, the blowing agent comprises carbon dioxide (CO2) and water. In another aspect, at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), a polymeric isocyanate or a combination thereof. In another aspect, at least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. In another aspect, the at least one polyol is new or recycled. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine. In another aspect, the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl-imidazole, N- methylmorpholine, N-ethylmorpholine, triethylamine, N,N′-dimethylpiperazine, 1,3,5- tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6-tris(dimethylaminomethyl)phenol, N- methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)- ethyl-piperazine, tributylamine, pentamethyl-diethylenetriamine, hexamethyl- triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl)ether, tris(3- dimethylaminopropyl)amine, 1,8-diazabicyclo[5.4.0] undecane, and an acid blocked derivative of 1,8-diazabicyclo[5.4.0] undecane. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst. In another aspect, the metal catalyst is a metal carboxylate salt. In another aspect, the metal carboxylate salt comprises a metal and a
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 carboxylate anion. In another aspect, the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K). In another aspect, the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid. In another aspect, the metal catalyst is an organotin catalyst. In another aspect, the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt. In another aspect, the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. In another aspect, the polyurethane foam has an isocyanate index between 80 and 120. In another aspect, the polyurethane foam has a density between 0.8 pounds per cubic foot (pcf) and 3.5 pcf. In another aspect, the monohydric alcohol is present in the catalyst composition at 5 mass percentage (wt%) to 15 wt%. In another aspect, the monohydric alcohol is present at less than 0.5 wt% of the foam formulation. In another aspect, the monohydric alcohol is tertiary amine is present at less than 1.0 wt% of the foam formulation. In another aspect, the monohydric alcohol comprises at least one alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2- pentanol, 3-pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 4- heptanol, cyclopentanol, and cyclohexanol. In another aspect, at least one tertiary amine is a tertiary amine of formula:
, wherein: R1 is hydrogen or –C1–4alkyl; R2 is hydrogen, –C1–6alkyl,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 R3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R4 and R5 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. In another aspect, at least one tertiary amine is selected from the group consisting of:
N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine,
N,N,N′-trimethylaminopropyl ethanolamine,
bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea,
N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and
N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine. In another aspect, at least one tertiary amine is a tertiary amine of formula: ,
R6 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, –C1–6alkyl–NH2, –C1–6alkyl–N(CH3)2; R7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or
R8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2;
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 R9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R10 and R11 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. In another aspect, at least one tertiary amine is selected from the group consisting of:
N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol,
N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis bis
N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and
hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis ether,
1-(2-hydroxyethyl)piperazine. In another aspect, at least one tertiary amine is selected from the group consisting of:
N-(2-hydroxypropyl)imidazole, and
N-(2-hydroxyethyl) imidazole. In another aspect, the catalyst composition comprises at least two tertiary amines. In another aspect, the catalyst composition further comprises a tertiary amine that does not contain an isocyanate reactive group. In another aspect, the tertiary amine that does not contain an isocyanate reactive group is one or more selected from the group consisting of:
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
1,4-diazabicyclo[2.2.2]octane (DABCO),
N,N-dimethylcyclohexyl amine,
bis-dimethylaminoethyl ether, pentamethyldiethylenetriamine,
hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine, and
tris(dimethylaminopropyl)amine. Another embodiment described herein is a method of making a polyurethane foam, the method comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH; wherein: the monohydric alcohol is present in the catalyst composition at 5 wt% to 15 wt%; and the polyurethane foam has an isocyanate index between 80 and 120. In one aspect, at least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting of
,
. In another aspect, the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon. In another aspect, at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), or a combination thereof. In another aspect, at least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. In another aspect, the at least one polyol is new or recycled. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine. In another aspect, the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl-imidazole, N- methylmorpholine, N-ethylmorpholine, triethylamine, N,N′-dimethylpiperazine, 1,3,5- tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6-tris(dimethylaminomethyl)phenol, N- methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)- ethyl-piperazine, tributylamine, pentamethyl-diethylenetriamine, hexamethyl- triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl)ether, tris(3- dimethylaminopropyl)amine, 1,8-diazabicyclo[5.4.0] undecane, and an acid blocked derivative of 1,8-diazabicyclo[5.4.0] undecane. In another aspect, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst. In another aspect, the metal catalyst is a metal carboxylate salt. In another aspect, the metal carboxylate salt comprises a metal and a carboxylate anion. In another aspect, the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K). In another aspect, the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid. In another aspect, the metal catalyst is an organotin catalyst. In another aspect, the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate),
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt. In another aspect, the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. In another aspect, at least one tertiary amine is a tertiary amine of formula:
, wherein: R1 is hydrogen or –C1–4alkyl;
R3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R4 and R5 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. In another aspect, at least one tertiary amine is selected from the group consisting of:
N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine,
N,N,N′-trimethylaminopropyl ethanolamine,
bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea,
N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- isopropanolamine, and
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine. In another aspect, at least one tertiary amine is a tertiary amine of formula: ,
R6 is hydrogen, –C1–4alkyl, –C1–4alkyl–OH, –C1–4alkyl–NH2, –C1–4alkyl–N(CH3)2; R7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or
R8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; R9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R10 and R11 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. In another aspect, at least one tertiary amine is selected from the group consisting of:
N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol,
N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether,
N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and
and
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N,N′-trimethyl-N′-3-amino-2-(1- hydroxyethyl)propyl- bis(aminoethyl) ether,
1-(2-hydroxyethyl)piperazine. DESCRIPTION OF THE DRAWINGS FIG. 1 shows comparative Fourier transform infrared spectroscopy (FTIR) spectra illustrating the carbonyl absorption band for carbamates potentially in 1600–1736 cm−1 range (spectra A–D). The 1600–1700 cm−1 wave number range is indicated as dashed lines. The carbamate peak is at ~1674 cm−1 and is highlighted on each of spectra A–D. Spectrum A (blue) shows the NE300 control with no CO2 treatment and no carbamate peak. Spectrum B (green) shows NE300 with 10% isopropanol, treated with CO2, and no carbamate peak. Spectrum C (purple) shows NE300 with 5% isopropanol, treated with CO2, and a small but notable carbamate peak. Spectrum D (red) shows NE300 with no isopropanol, treated with CO2, and a significant carbamate peak. DETAILED DESCRIPTION Described herein are methods of making polyurethane foams. The methods of making polyurethane foams may comprise preparing a foam formulation by contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition comprising. The catalyst composition may comprise at least one tertiary amine comprising an isocyanate reactive group and a monohydric alcohol. The monohydric alcohol may comprise at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH. In various instances, the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine. Various aspects of suitable organic isocyanates, polyols, blowing agents, tertiary amines, additional amines, metal catalysts, and other formulation components are described below. Definitions Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. For example, any
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 nomenclatures used in connection with, and techniques of chemistry, synthetic organic chemistry, and polymer chemistry described herein are well known and commonly used in the art. In case of conflict, the present disclosure, including definitions, will control. Exemplary methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the embodiments and aspects described herein. As used herein, the terms such as “include,” “including,” “contain,” “containing,” “having,” and the like mean “comprising.” The present disclosure also contemplates other embodiments “comprising,” “consisting of,” and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not. As used herein, the term “a,” “an,” “the” and similar terms used in the context of the disclosure (especially in the context of the claims) are to be construed to cover both the singular and plural unless otherwise indicated herein or clearly contradicted by the context. In addition, “a,” “an,” or “the” means “one or more” unless otherwise specified. As used herein, the term “or” can be conjunctive or disjunctive. As used herein, the term “substantially” means to a great or significant extent, but not completely. As used herein, the term “about” or “approximately” as applied to one or more values of interest, refers to a value that is similar to a stated reference value, or within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, such as the limitations of the measurement system. In one aspect, the term “about” refers to any values, including both integers and fractional components that are within a variation of up to ± 10% of the value modified by the term “about.” Alternatively, “about” can mean within 3 or more standard deviations, per the practice in the art. Alternatively, such as with respect to biological systems or processes, the term “about” can mean within an order of magnitude, in some embodiments within 5-fold, and in some embodiments within 2-fold, of a value. As used herein, the symbol
means “about” or “approximately.” All ranges disclosed herein include both end points as discrete values as well as all integers and fractions specified within the range. For example, a range of 0.1–2.0 includes 0.1, 0.2, 0.3, 0.4. . . 2.0. If the end points are modified by the term “about,” the range specified is expanded by a variation of up to ±10% of any value within the range or within 3 or more standard deviations, including the end points. As used herein, the terms “control,” or “reference” are used herein interchangeably. A “reference” or “control” level may be a predetermined value or range, which is employed as a
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 baseline or benchmark against which to assess a measured result. “Control” also refers to control experiments. As used herein, the terms “room temperature,” “RT,” or “ambient temperature” refer to the typical temperature in an indoor laboratory setting. In one aspect, the laboratory setting is climate controlled to maintain the temperature at a substantially uniform temperature or with a specific range of temperatures. In one aspect, “room temperature” refers a temperature of about 20– 30 °C, including all integers and endpoints within the specified range. In another aspect, “room temperature” refers a temperature of about 20–27 °C; about 22–25 °C; about 22–27 °C; about 25–27 °C; about 22 °C ± 10%; about 25 °C ± 10%; about 27 °C ± 10%; ~20 °C, ~22 °C, ~25 °C, or ~27 °C, at standard atmospheric pressure. Definitions of specific functional groups and chemical terms are described in more detail below. For purposes of this disclosure, the chemical elements are identified in accordance with the Periodic Table of the Elements, CAS version, Handbook of Chemistry and Physics, 75th Ed., inside cover, and specific functional groups are generally defined as described therein. Additionally, general principles of organic chemistry, as well as specific functional moieties and reactivity, are described in Organic Chemistry, Thomas Sorrell, University Science Books, Sausalito, 1999; Smith and March March’s Advanced Organic Chemistry, 5th Edition, John Wiley & Sons, Inc., New York, 2001; Larock, Comprehensive Organic Transformations, VCH Publishers, Inc., New York, 1989; Carruthers, Some Modern Methods of Organic Synthesis, 3rd Edition, Cambridge University Press, Cambridge, 1987; the entire contents of each of which are incorporated herein by reference. The term “alkoxy,” as used herein, refers to a group –O–alkyl. Representative examples of alkoxy include, but are not limited to, methoxy, ethoxy, propoxy, 2-propoxy, butoxy and tert- butoxy. The term “alkyl,” as used herein, means a straight or branched, saturated hydrocarbon chain. The term “lower alkyl” or “C1–6alkyl” means a straight or branched chain hydrocarbon containing from 1 to 6 carbon atoms. The term “C1–4alkyl” means a straight or branched chain hydrocarbon containing from 1 to 4 carbon atoms. Representative examples of alkyl include, but are not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl, n- pentyl, isopentyl, neopentyl, n-hexyl, 3-methylhexyl, 2,2-dimethylpentyl, 2,3-dimethylpentyl, n- heptyl, n-octyl, n-nonyl, and n-decyl. The term “alkenyl,” as used herein, means a straight or branched, hydrocarbon chain containing at least one carbon-carbon double bond.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 The term “alkoxyalkyl,” as used herein, refers to an alkoxy group, as defined herein, appended to the parent molecular moiety through an alkyl group, as defined herein. The term “alkoxyfluoroalkyl,” as used herein, refers to an alkoxy group, as defined herein, appended to the parent molecular moiety through a fluoroalkyl group, as defined herein. The term “alkylene,” as used herein, refers to a divalent group derived from a straight or branched chain hydrocarbon of 1 to 10 carbon atoms, for example, of 2 to 5 carbon atoms. Representative examples of alkylene include, but are not limited to, –CH2–, –CD2–, –CH2CH2–, –CH2CH2CH2–, –CH2CH2CH2CH2–, and –CH2CH2CH2CH2CH2–. The term “alkylamino,” as used herein, means at least one alkyl group, as defined herein, is appended to the parent molecular moiety through an amino group, as defined herein. The term “amide,” as used herein, means –C(O)NR– or –NRC(O)–, wherein R may be hydrogen, alkyl, cycloalkyl, aryl, heteroaryl, heterocycle, alkenyl, or heteroalkyl. The term “aminoalkyl,” as used herein, means at least one amino group, as defined herein, is appended to the parent molecular moiety through an alkylene group, as defined herein. The term “amino,” as used herein, means –NRxRy, wherein Rx and Ry may be hydrogen, alkyl, cycloalkyl, aryl, heteroaryl, heterocycle, alkenyl, or heteroalkyl. In the case of an aminoalkyl group or any other moiety where amino appends together two other moieties, amino may be –NRx–, wherein Rx may be hydrogen, alkyl, cycloalkyl, aryl, heteroaryl, heterocycle, alkenyl, or heteroalkyl. The term “aryl,” as used herein, refers to a phenyl or a phenyl appended to the parent molecular moiety and fused to a cycloalkane group (e.g., the aryl may be indan-4-yl), fused to a 6-membered arene group (i.e., the aryl is naphthyl), or fused to a non-aromatic heterocycle (e.g., the aryl may be benzo[d][1,3]dioxol-5-yl). The term “phenyl” is used when referring to a substituent and the term 6-membered arene is used when referring to a fused ring. The 6- membered arene is monocyclic (e.g., benzene or benzo). The aryl may be monocyclic (phenyl) or bicyclic (e.g., a 9- to 12-membered fused bicyclic system). The term “cyanoalkyl,” as used herein, means at least one –CN group, is appended to the parent molecular moiety through an alkylene group, as defined herein. The term “cyanofluoroalkyl,” as used herein, means at least one –CN group, is appended to the parent molecular moiety through a fluoroalkyl group, as defined herein. The term “cycloalkoxy,” as used herein, refers to a cycloalkyl group, as defined herein, appended to the parent molecular moiety through an oxygen atom. The term “cycloalkyl” or “cycloalkane,” as used herein, refers to a saturated ring system containing all carbon atoms as ring members and zero double bonds. The term “cycloalkyl” is
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 used herein to refer to a cycloalkane when present as a substituent. A cycloalkyl may be a monocyclic cycloalkyl (e.g., cyclopropyl), a fused bicyclic cycloalkyl (e.g., decahydronaphthalenyl), or a bridged cycloalkyl in which two non-adjacent atoms of a ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms (e.g., bicyclo[2.2.1]heptanyl). Representative examples of cycloalkyl include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, adamantyl, and bicyclo[1.1.1]pentanyl. The term “cycloalkenyl” or “cycloalkene,” as used herein, means a non-aromatic monocyclic or multicyclic ring system containing all carbon atoms as ring members and at least one carbon-carbon double bond and preferably having from 5-10 carbon atoms per ring. The term “cycloalkenyl” is used herein to refer to a cycloalkene when present as a substituent. A cycloalkenyl may be a monocyclic cycloalkenyl (e.g., cyclopentenyl), a fused bicyclic cycloalkenyl (e.g., octahydronaphthalenyl), or a bridged cycloalkenyl in which two non-adjacent atoms of a ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms (e.g., bicyclo[2.2.1]heptenyl). Exemplary monocyclic cycloalkenyl rings include cyclopentenyl, cyclohexenyl or cycloheptenyl. Exemplary monocyclic cycloalkenyl rings include cyclopentenyl, cyclohexenyl or cycloheptenyl. The term “carbocyclyl” means a “cycloalkyl” or a “cycloalkenyl.” The term “carbocycle” means a “cycloalkane” or a “cycloalkene.” The term “carbocyclyl” refers to a “carbocycle” when present as a substituent. The terms cycloalkylene and heterocyclylene refer to divalent groups derived from the base ring, i.e., cycloalkane, heterocycle. For purposes of illustration, examples of cycloalkylene and heterocyclylene include, respectively,
. Cycloalkylene and heterocyclylene include a geminal divalent groups such as 1,1-C3-6cycloalkylene (i.e.,
). A further example is 1,1-cyclopropylene (i.e.,
The term “fluoroalkyl,” as used herein, means an alkyl group, as defined herein, in which one, two, three, four, five, six, seven or eight hydrogen atoms are replaced by fluorine. Representative examples of fluoroalkyl include, but are not limited to, 2-fluoroethyl, 2,2,2- trifluoroethyl, trifluoromethyl, difluoromethyl, pentafluoroethyl, and trifluoropropyl such as 3,3,3- trifluoropropyl.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 The term “fluoroalkylene,” as used herein, means an alkylene group, as defined herein, in which one, two, three, four, five, six, seven or eight hydrogen atoms are replaced by fluorine. Representative examples of fluoroalkyl include, but are not limited to –CF2–, –CH2CF2–, 1,2- difluoroethylene, 1,1,2,2-tetrafluoroethylene, 1,3,3,3-tetrafluoropropylene, 1,1,2,3,3- pentafluoropropylene, and perfluoropropylene such as 1,1,2,2,3,3-hexafluoropropylene. The term “halogen” or “halo,” as used herein, means Cl, Br, I, or F. The term “haloalkyl,” as used herein, means an alkyl group, as defined herein, in which one, two, three, four, five, six, seven or eight hydrogen atoms are replaced by a halogen. The term “haloalkoxy,” as used herein, means at least one haloalkyl group, as defined herein, is appended to the parent molecular moiety through an oxygen atom. The term “halocycloalkyl,” as used herein, means a cycloalkyl group, as defined herein, in which one or more hydrogen atoms are replaced by a halogen. The term “heteroalkyl,” as used herein, means an alkyl group, as defined herein, in which one or more of the carbon atoms has been replaced by a heteroatom selected from S, O, P and N. Representative examples of heteroalkyls include, but are not limited to, alkyl ethers, secondary and tertiary alkyl amines, amides, and alkyl sulfides. The term “heteroaryl,” as used herein, refers to an aromatic monocyclic heteroatom- containing ring (monocyclic heteroaryl) or a bicyclic ring system containing at least one monocyclic heteroaromatic ring (bicyclic heteroaryl). The term “heteroaryl” is used herein to refer to a heteroarene when present as a substituent. The monocyclic heteroaryl are five or six membered rings containing at least one heteroatom independently selected from the group consisting of N, O and S (e.g., 1, 2, 3, or 4 heteroatoms independently selected from O, S, and N). The five membered aromatic monocyclic rings have two double bonds, and the six membered aromatic monocyclic rings have three double bonds. The bicyclic heteroaryl is an 8- to 12- membered ring system and includes a fused bicyclic heteroaromatic ring system (i.e., 10 ^ electron system) such as a monocyclic heteroaryl ring fused to a 6-membered arene (e.g., quinolin-4-yl, indol-1-yl), a monocyclic heteroaryl ring fused to a monocyclic heteroarene (e.g., naphthyridinyl), and a phenyl fused to a monocyclic heteroarene (e.g., quinolin-5-yl, indol-4-yl). A bicyclic heteroaryl/heteroarene group includes a 9-membered fused bicyclic heteroaromatic ring system having four double bonds and at least one heteroatom contributing a lone electron pair to a fully aromatic 10 ^ electron system, such as ring systems with a nitrogen atom at the ring junction (e.g., imidazopyridine) or a benzoxadiazolyl. A bicyclic heteroaryl also includes a fused bicyclic ring system composed of one heteroaromatic ring and one non-aromatic ring such as a monocyclic heteroaryl ring fused to a monocyclic carbocyclic ring (e.g., 6,7-dihydro-5H-
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 cyclopenta[b]pyridinyl), or a monocyclic heteroaryl ring fused to a monocyclic heterocycle (e.g., 2,3-dihydrofuro[3,2-b]pyridinyl). The bicyclic heteroaryl is attached to the parent molecular moiety at an aromatic ring atom. Other representative examples of heteroaryl include, but are not limited to, indolyl (e.g., indol-1-yl, indol-2-yl, indol-4-yl), pyridinyl (including pyridin-2-yl, pyridin-3-yl, pyridin-4-yl), pyrimidinyl, pyrazinyl, pyridazinyl, pyrazolyl (e.g., pyrazol-4-yl), pyrrolyl, benzopyrazolyl, 1,2,3-triazolyl (e.g., triazol-4-yl), 1,3,4-thiadiazolyl, 1,2,4-thiadiazolyl, 1,3,4- oxadiazolyl, 1,2,4-oxadiazolyl, imidazolyl, thiazolyl (e.g., thiazol-4-yl), isothiazolyl, thienyl, benzimidazolyl (e.g., benzimidazol-5-yl), benzothiazolyl, benzoxazolyl, benzoxadiazolyl, benzothienyl, benzofuranyl, isobenzofuranyl, furanyl, oxazolyl, isoxazolyl, purinyl, isoindolyl, quinoxalinyl, indazolyl (e.g., indazol-4-yl, indazol-5-yl), quinazolinyl, 1,2,4-triazinyl, 1,3,5-triazinyl, isoquinolinyl, quinolinyl, imidazo[1,2-a]pyridinyl (e.g., imidazo[1,2-a]pyridin-6-yl), naphthyridinyl, pyridoimidazolyl, thiazolo[5,4-b]pyridin-2-yl, and thiazolo[5,4-d]pyrimidin-2-yl. The term “heterocycle” or “heterocyclic,” as used herein, means a monocyclic heterocycle, a bicyclic heterocycle, or a tricyclic heterocycle. The term “heterocyclyl” is used herein to refer to a heterocycle when present as a substituent. The monocyclic heterocycle is a three-, four-, five-, six-, seven-, or eight-membered ring containing at least one heteroatom independently selected from the group consisting of O, N, and S. The three- or four-membered ring contains zero or one double bond, and one heteroatom selected from the group consisting of O, N, and S. The five- membered ring contains zero or one double bond and one, two or three heteroatoms selected from the group consisting of O, N and S. The six-membered ring contains zero, one or two double bonds and one, two, or three heteroatoms selected from the group consisting of O, N, and S. The seven- and eight-membered rings contains zero, one, two, or three double bonds and one, two, or three heteroatoms selected from the group consisting of O, N, and S. Representative examples of monocyclic heterocyclyls include, but are not limited to, azetidinyl, azepanyl, aziridinyl, diazepanyl, 1,3-dioxanyl, 1,3-dioxolanyl, 1,3-dithiolanyl, 1,3-dithianyl, imidazolinyl, imidazolidinyl, isothiazolinyl, isothiazolidinyl, isoxazolinyl, isoxazolidinyl, morpholinyl, 2-oxo-3-piperidinyl, 2- oxoazepan-3-yl, oxadiazolinyl, oxadiazolidinyl, oxazolinyl, oxazolidinyl, oxetanyl, oxepanyl, oxocanyl, piperazinyl, piperidinyl, pyranyl, pyrazolinyl, pyrazolidinyl, pyrrolinyl, pyrrolidinyl, tetrahydrofuranyl, tetrahydropyranyl, tetrahydropyridinyl, tetrahydrothienyl, thiadiazolinyl, thiadiazolidinyl, 1,2-thiazinanyl, 1,3-thiazinanyl, thiazolinyl, thiazolidinyl, thiomorpholinyl, 1,1- dioxidothiomorpholinyl (thiomorpholine sulfone), thiopyranyl, and trithianyl. The bicyclic heterocycle is a monocyclic heterocycle fused to a 6-membered arene, or a monocyclic heterocycle fused to a monocyclic cycloalkane, or a monocyclic heterocycle fused to a monocyclic cycloalkene, or a monocyclic heterocycle fused to a monocyclic heterocycle, or a monocyclic
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 heterocycle fused to a monocyclic heteroarene, or a spiro heterocycle group, or a bridged monocyclic heterocycle ring system in which two non-adjacent atoms of the ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms, or an alkenylene bridge of two, three, or four carbon atoms. The bicyclic heterocyclyl is attached to the parent molecular moiety at a non-aromatic ring atom (e.g., indolin-1-yl). Representative examples of bicyclic heterocyclyls include, but are not limited to, chroman-4-yl, 2,3-dihydrobenzofuran-2-yl, 2,3-dihydrobenzothien-2-yl, 1,2,3,4- tetrahydroisoquinolin-2-yl, 2-azaspiro[3.3]heptan-2-yl, 2-oxa-6-azaspiro[3.3]heptan-6-yl, azabicyclo[2.2.1]heptyl (including 2-azabicyclo[2.2.1]hept-2-yl), azabicyclo[3.1.0]hexanyl (including 3-azabicyclo[3.1.0]hexan-3-yl), 2,3-dihydro-1H-indol-1-yl, isoindolin-2-yl, octahydrocyclopenta[c]pyrrolyl, octahydropyrrolopyridinyl, tetrahydroisoquinolinyl, 7- oxabicyclo[2.2.1]heptanyl, hexahydro-2H-cyclopenta[b]furanyl, 2-oxaspiro[3.3]heptanyl, 3- oxaspiro[5.5]undecanyl, 6-oxaspiro[2.5]octan-1-yl, and 3-oxabicyclo[3.1.0]hexan-6-yl. Tricyclic heterocycles are exemplified by a bicyclic heterocycle fused to a 6-membered arene, or a bicyclic heterocycle fused to a monocyclic cycloalkane, or a bicyclic heterocycle fused to a monocyclic cycloalkene, or a bicyclic heterocycle fused to a monocyclic heterocycle, or a bicyclic heterocycle in which two non-adjacent atoms of the bicyclic ring are linked by an alkylene bridge of 1, 2, 3, or 4 carbon atoms, or an alkenylene bridge of two, three, or four carbon atoms. Examples of tricyclic heterocycles include, but are not limited to, octahydro-2,5-epoxypentalene, hexahydro-2H-2,5- methanocyclopenta[b]furan, hexahydro-1H-1,4-methanocyclopenta[c]furan, aza-adamantane (1- azatricyclo[3.3.1.13,7]decane), and oxa-adamantane (2-oxatricyclo[3.3.1.13,7]decane). The monocyclic, bicyclic, and tricyclic heterocyclyls are connected to the parent molecular moiety at a non-aromatic ring atom. The term “hydroxyl” or “hydroxy,” as used herein, means an –OH group. The term “hydroxyalkyl,” as used herein, means at least one –OH group, is appended to the parent molecular moiety through an alkylene group, as defined herein. The term “hydroxyfluoroalkyl,” as used herein, means at least one –OH group, is appended to the parent molecular moiety through a fluoroalkyl group, as defined herein. Terms such as “alkyl,” “cycloalkyl,” “alkylene,” etc. may be preceded by a designation indicating the number of atoms present in the group in a particular instance (e.g., “C1–4alkyl,” “C3–6cycloalkyl,” “C1–4alkylene”). These designations are used as generally understood by those skilled in the art. For example, the representation “C” followed by a subscripted number indicates the number of carbon atoms present in the group that follows. Thus, “C3alkyl” is an alkyl group with three carbon atoms (i.e., n-propyl, isopropyl). Where a range is given, as in “C1–4,” the members of the group that follows may have any number of carbon atoms falling within the recited
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 range. A “C1–4alkyl,” for example, is an alkyl group having from 1 to 4 carbon atoms, however arranged (i.e., straight chain or branched). The term “substituted” refers to a group that may be further substituted with one or more non-hydrogen substituent groups. Substituent groups include, but are not limited to, halogen, =O (oxo), =S (thioxo), cyano, nitro, fluoroalkyl, alkoxyfluoroalkyl, fluoroalkoxy, alkyl, alkenyl, alkynyl, haloalkyl, haloalkoxy, heteroalkyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl, heterocycle, cycloalkylalkyl, heteroarylalkyl, arylalkyl, hydroxy, hydroxyalkyl, alkoxy, alkoxyalkyl, alkylene, aryloxy, phenoxy, benzyloxy, amino, alkylamino, acylamino, aminoalkyl, arylamino, sulfonylamino, sulfinylamino, sulfonyl, alkylsulfonyl, arylsulfonyl, aminosulfonyl, sulfinyl, –COOH, ketone, amide, carbamate, and acyl. The term “pphp” refers to “parts per hundred parts polyol,” and is used to describe the amount of other foam components (such as an amine catalyst, for example) as a ratio of the polyol. The compositions and methods described herein provides processes for making amine compositions wherein a monohydric alcohol is included in an amine catalyst composition to mitigate solid carbamate formation. The approach is a cost-effective solution to prevent/reduce the formation of solid intermediate carbamates during the polyurethane foam production process. One aspect as described herein relates to a method for making polyurethane foams by using the inventive amine catalyst compositions, which comprise an amine catalyst and a monohydric alcohol. The composition comprises an amine catalyst and a monohydric alcohol, where the monohydric alcohol concentration in the composition is between 1–50 percent mass (wt%), 3–25 percent mass (wt%), or 3–20 percent mass (wt%). The amine catalyst composition can be obtained by thoroughly blending 1–20 percent mass (wt%) of a monohydric alcohol with a tertiary, secondary, or primary amine catalyst for at least several minutes (e.g., for about 5 minutes to about 60 minutes). Various aspects of exemplary amine catalysts and monohydric alcohols are described below. Amine Catalysts Suitable amine catalysts may comprise a tertiary amine, a secondary amine, a primary amine, or a combination thereof. Exemplary amine catalysts may comprise a tertiary amine containing at least one isocyanate-reactive group. Typically, the amine catalyst, e.g., a tertiary amine containing at least one isocyanate-reactive group, is present at less than 1 wt% of the total foam formulation. Isocyanate reactive groups generally comprise an amino/amine moiety (e.g., a primary amine or a secondary amine moiety), a hydroxyl group, an amide, or a urea moiety. In
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 various instances, at least one isocyanate reactive group may comprise at least one moiety selected from the group consisting of
. At least one tertiary amine may be a tertiary amine of formula:
, wherein: R1 is hydrogen or –C1–4alkyl;
R3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R4 and R5 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. For example, at least one tertiary amine may be selected from the group consisting of at least one tertiary amine is selected from the group consisting of:
N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine,
N,N,N′-trimethylaminopropyl ethanolamine,
N,N-dimethylaminopropyl urea,
bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and
N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine. In some instances, at least one tertiary amine may be a tertiary amine of formula:
R6 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, –C1–6alkyl–NH2, –C1–6alkyl–N(CH3)2; R7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or
R8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; R9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R10 and R11 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. For example, at least one tertiary amine may be selected from the group consisting of:
N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol,
N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and
hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis(aminoethyl) ether,
1-(2-hydroxyethyl)piperazine. In some instances, at least one tertiary amine may be selected from the group consisting of:
N-(2-hydroxypropyl)imidazole, and
N-(2-hydroxyethyl) imidazole. In some instances, the catalyst composition may comprise at least two tertiary amines. For example, the catalyst composition may further comprise a tertiary amine that does not contain an isocyanate reactive group. In some instances, the tertiary amine that does not contain an isocyanate reactive group may be one or more selected from the group consisting of:
1,4-diazabicyclo[2.2.2]octane (DABCO),
N,N-dimethylcyclohexyl amine,
bis-dimethylaminoethyl ether, pentamethyldiethylenetriamine,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine, and
tris(dimethylaminopropyl)amine. Suitable tertiary amines containing at least one isocyanate reactive group include both gelling and blowing amine catalysts. Exemplary gelling amine catalysts include at least one member selected from the group consisting of N,N-bis(3-dimethylaminopropyl)-N- isopropanolamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine (DABCO® T, Evonik Corporation of Allentown, Pa.), N,N,N′-trimethylaminopropyl ethanolamine (POLYCAT® 17, by Evonik Corporation), N,N-dimethylethanolamine (DABCO® DMEA), N,N-dimethyl-N′,N′-2- hydroxy(propyl)-1,3-propylenediamine, dimethylaminopropylamine (DMAPA), (N,N- dimethylaminoethoxy)ethanol, methyl-hydroxy-ethyl-piperazine, bis(N,N-dimethyl-3- aminopropyl)amine (POLYCAT® 15), N,N-dimethylaminopropyl urea (DABCO® NE1060, DABCO® NE1070), N,N′-bis(3-dimethylaminopropyl) urea (DABCO® NE1070, DABCO® NE1080), bis(dimethylamino)-2-propanol, N-(3-aminopropyl)imidazole, N-(2- hydroxypropyl)imidazole, and N-(2-hydroxyethyl) imidazole. Exemplary blowing amine catalysts include at least one member selected from the group consisting of 2-[N-(dimethylaminoethoxyethyl)-N-methylamino]ethanol, N,N-dimethylaminoethyl- N′-methyl-N′-ethanol (DABCO®-T), dimethylaminoethoxyethanol and N,N,N′-trimethyl-N′-3- aminopropyl-bis(aminoethyl) ether (DABCO® NE300). Suitable amine catalyst compositions may further comprise gelling catalysts that are highly volatile and are not reactive with isocyanate groups, e.g., a volatile gelling catalyst. Suitable volatile gelling catalysts may include, for example, at least one member selected from the group consisting of diazabicyclooctane (triethylenediamine), supplied commercially as DABCO®33-LV catalyst, tris(hydroformylationyl)amine (Polycat® 9), dimethylaminocyclohexylamine (Polycat® 8) and bis(dimethylaminopropyl)-N-methylamine (Polycat® 77), N,N-dimethylcyclohexylamine (Polycat-8, Evonik Corporation of Allentown, Pa.), N-methyldicyclohexylamine (Polycat-12, Evonik Corporation of Allentown, Pa.). Suitable volatile blowing catalysts include, for example, at least one member selected from the group consisting of bis-dimethylaminoethyl ether,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 commercially supplied as DABCO® BL-11 catalyst by Evonik Corporation, as well as pentamethyldiethylenetriamine (POLYCAT® 5, Evonik Corporation), hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine and related compositions, higher permethylated polyamines, 2-[N-(dimethylaminoethoxyethyl)-N-methylamino]ethanol and related structures, alkoxylated polyamines, imidazole-boron compositions, or amino propyl- bis(amino-ethyl)ether compositions. Typically, the loading of non-fugitive amine for making foam as described herein will be in the range of about 0.1 to about 20 pphp, more typically about 0.1 to about 10 pphp, and most typically about 0.1 to about 5 pphp. However, any effective amount may be used. The amount of volatile amine in the foam formulation can range from about 0.05 to about 20 pphp. Monohydric Alcohols Exemplary monohydric alcohols contain less than 10 carbon atoms. In various instances, the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1– 7 linear alkyl–OH, C3–6 branched alkyl–OH, and C3–6 cycloalkyl–OH. In various instances, the monohydric alcohol comprises at least one alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2-pentanol, 3- pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 4-heptanol, cyclopentanol, and cyclohexanol. Typically, the monohydric alcohol is present at no more than 0.5 wt% of the total foam formulation. Preparation of Foam Formulations Foams of any of the various types known in the art may be made using the methods as described herein, using typical polyurethane formulations. For example, flexible polyurethane foams with excellent physical properties described herein will typically comprise the components shown below in Table 1, in the amounts indicated. The components shown in Table 1 will be discussed in detail below. Table 1 Polyurethane Components Component pphp* Polyol 20–100 Polymer polyol 0–80 Natural oil polyol Varied Silicone surfactant 0.5–10 Blowing agent 2-4.5 Crosslinker 0.5–2.0
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Catalyst 0.25–10 Isocyanate index 70–115 * The term “pphp” means parts per hundred parts polyol. The amount of organic isocyanate used in polyurethane formulations as described herein is not limited, but it will typically be within those ranges known to those of skill in the art. An exemplary range is given above in Table 1, indicated by reference to “NCO Index” (isocyanate index). As is known in the art, the NCO index is defined as the number of equivalents of isocyanate, divided by the total number of equivalents of active hydrogen, multiplied by 100. The NCO index is represented by the following formula. NCO index = [NCO/(OH + NH)] × 100. The isocyanate index can range from about 80 to about 500 depending on the type of foam formulation. For example, flexible foams have typically an isocyanate index of 80 to 120 while rigid foams such as those typically used in appliances, lamination and spray foam application can have indexes in the range of 100 to 500 depending on the application. The higher indexes are commonly used with a trimerization catalyst to produce polyisocyanurate (PIR) foams. PIR foams are typically used in foam laminates that require effective thermal insulation. Regarding the foam density, exemplary polyurethane foams typically have a density between 0.8 pounds per cubic foot (pcf) and 3.5 pcf. Another embodiment relates to a method of making a polyurethane comprising contacting at least one organic isocyanate with at least one polyol in the presence of a catalytically effective amount of the amine catalyst composition. Polyurethanes are produced by the reaction of organic isocyanates with the hydroxyl groups in a polyol, typically a mixture of polyols. The least one polyol may be a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. The at least one polyol may be new or recycled. Various aspects of exemplary organic isocyanates and polyols are discussed below. Organic Isocyanates Suitable organic isocyanate compounds include, but are not limited to, at least one member from the group consisting of hexamethylene diisocyanate (HDI), phenylene diisocyanate (PDI), toluene diisocyanate (TDI), and 4,4′-diphenylmethane diisocyanate (MDI). In one aspect described herein, 2,4-TDI, 2,6-TDI, or any mixture thereof may be used to produce polyurethane foams. Suitable organic isocyanates include monomeric isocyanates, e.g., MDI, and polymeric isocyanates, e.g., polymeric 4,4′-methylenediphenyl diisocyanate (PMDI). Other suitable isocyanate compounds are diisocyanate mixtures known commercially as “crude MDI.” One example is marketed by Dow Chemical Company under the name PAPITM and contains about
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 60% of 4,4′-diphenylmethane diisocyanate (MDI) along with other isomeric and analogous higher polyisocyanates. Polyols The polyol of the foam formulations described herein may comprise at least a main or “base” polyol. Base polyols suitable for use as described herein include, as non-limiting examples, at least one member selected from the group consisting of polyether polyols. Exemplary polyether polyols may have a molecular weight (MW) of 2000 g/mol to 4000 g/mol and a polyol functionality of 2.5 to 3.3. As used herein “polyol functionality” refers to the number of –OH” groups per molecule. Polyether polyols include poly(alkylene oxide) polymers such as poly(ethylene oxide) and poly(propylene oxide) polymers and copolymers with terminal hydroxyl groups derived from polyhydric compounds, including diols and triols. Examples of diols and triols for reaction with the ethylene oxide or propylene oxide include at least one member selected from the group consisting of ethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,6- hexanediol, neopentyl glycol, diethylene glycol, dipropylene glycol, pentaerythritol, glycerol, diglycerol, trimethylol propane, and similar low molecular weight polyols. Other base polyol examples known in the art include polyhydroxy-terminated acetal resins, hydroxyl-terminated amines, and hydroxyl-terminated polyamines. Examples of these and other suitable isocyanate- reactive materials may be found in U.S. Pat. No.4,394,491, which is incorporated by reference herein. Suitable polyols also include those containing tertiary amine groups than can catalyze the gelling and the blowing reaction of polyurethanes, for example those described in WO 2003/016373 A1, WO 2001/58976 A1; WO 2004/060956 A1; WO 2003/016372 A1; and WO 2003/055930 A1; the disclosures of the foregoing references are incorporated by reference herein. Other useful polyols may include polyalkylene carbonate-based polyols and polyphosphate-based polyols. The amount of polyether polyol can range from about 20 to about 100 parts per hundred parts polyol (pphp). In one aspect, a single high molecular weight polyether polyol may be used as the base polyol. Alternatively, a mixture of high molecular weight polyether polyols, for example, mixtures of di- and tri-functional materials and/or different molecular weight or different chemical composition materials may be used. Such di- and tri-functional materials include but are not limited to at least one member selected from the group consisting of polyethylene glycol, polypropylene glycol, glycerol-based polyether triols, trimethylolpropane-based polyether triols, and other similar compounds or mixtures, provided that they are ester-free. In some
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 embodiments as described herein, at least about 50 percent mass (wt%) of the ester-free polyol component consists of one or more polyether polyols. In addition to the base polyols described above, or instead of them, materials commonly referred to as “copolymer polyols” may be included in a polyol component for use as described herein. Copolymer polyols may be used in polyurethane foams to increase the resistance of the foam to deformation, for example to improve the load-bearing properties of the foam. Depending upon the load-bearing requirements for the polyurethane foam, copolymer polyols may comprise from 0 to about 80 percent by weight of the total polyol content. Examples of copolymer polyols include, but are not limited to, graft polyols and polyurea modified polyols, both of which are known in the art and are commercially available. Graft polyols are prepared by copolymerizing vinyl monomers, typically styrene and acrylonitrile, in a starting polyol. The starting polyol is typically a glycerol-initiated triol and is typically end-capped with ethylene oxide (approximately 80–85% primary hydroxyl groups). Some of the copolymer grafts to some of the starting polyol. The graft polyol also contains homopolymers of styrene and acrylonitrile and unaltered starting polyol. The styrene/acrylonitrile solids content of the graft polyol typically ranges from about 5 percent mass (wt%) to about 45 percent mass (wt%), but any kind of graft polyol known in the art may be used. Polyurea modified polyols are formed by the reaction of a diamine and a diisocyanate in the presence of a starting polyol, with the product containing polyurea dispersion. A variant of polyurea modified polyols, also suitable for use, are polyisocyanate polyaddition (PIPA) polyols, which are formed by the in situ reaction of an isocyanate and an alkanolamine in a polyol. Useful polyester polyols include those produced when a dicarboxylic acid is reacted with an excess of a diol for example adipic acid or phthalic acid or phthalic anhydride with ethylene glycol or butanediol or reacting a lactone with an excess of a diol such as caprolactone with propylene glycol. Mannich polyols are also typically used in spray formulations. Mannich polyols are made by the condensation of phenols with aldehydes and amines to give polyols containing multiple hydroxyl groups (2–8) and tertiary amine centers. Polyester polyols may be present in the range from about 0 pphp to about 100 pphp. Flexible foams typically use copolymer polyols as part of the overall polyol content in the foam composition, along with base polyols of about 3000–6000 weight average molecular weight and hydroxyl number of about 28–60. Natural Oil Polyol To minimize the depletion of fossil fuel and other non-sustainable resources, all or a portion of the polyols may be used to prepare polyurethane foams are from inexpensive and
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 renewable resources. Natural oils comprise triglycerides of saturated and unsaturated fatty acids. One natural oil polyol is castor oil, a natural triglyceride of ricinoleic acid which is commonly used to make polyurethane foam despite some of its limitations, e.g., low hydroxyl content. Other natural oils may be chemically modified to introduce sufficient hydroxyl content to make them useful in the production of polyurethane polymers. When attempting to modify natural oil or fat into a useful polyol, there are two chemically reactive sites that can be considered: (1) the unsaturated sites (double bonds); (2) the ester functionality. Unsaturated sites present in oil or fat may be hydroxylated via epoxidation/ring opening or hydroformylation/hydrogenation. Alternatively, trans-esterification may be utilized to introduce –OH groups in natural oil and fat. The chemical process for the preparation of natural polyols using epoxidation route involves a reaction mixture that requires epoxidized natural oil, a ring opening acid catalyst and a ring opener. Epoxidized natural oils include epoxidized plant-based oils (epoxidized vegetable oils) and epoxidized animal fats. The epoxidized natural oils may be fully or partially epoxidized and these oils include at least one member selected from the group consisting of soybean oil, corn oil, sunflower oil, olive oil, canola oil, sesame oil, palm oil, rapeseed oil, tung oil, cotton seed oil, safflower oil, peanut oil, linseed oil and combinations thereof. Animal fats include fish, tallow, and lard. These natural oils are triglycerides of fatty acids which may be saturated or unsaturated with various chain lengths from C12 to C24. These acids can be: (1) saturated: lauric, myristic, palmitic, steric, arachidic and lignoceric; (2) mono-unsaturated: palmitoleic, oleic, (3) poly-unsaturated: linoleic, linolenic, arachidonic. Partially or fully epoxidized natural oil may be prepared when reacting peroxyacid under suitable reaction conditions. Examples of peroxyacids utilized in the epoxidation of oils have been described in WO 2006/116456 A1; which is incorporated by reference herein. Ring opening of the epoxidized oils with alcohols, water and other compounds having one or multiple nucleophilic groups can be used. Depending on the reaction conditions oligomerization of the epoxidized oil can also occur. Ring opening yields natural oil polyol that can be used for the manufacture of polyurethane products. In the hydroformylation/hydrogenation process, the oil is hydroformylated in a reactor filled with a hydrogen/carbon monoxide mixture in the presence of a suitable catalyst (typically cobalt or rhodium) to form an aldehyde which is hydrogenated in the presence of cobalt or nickel catalyst to form a polyol. Alternatively, polyol form natural oil and fats can be produced by trans-esterification with a suitable poly-hydroxyl containing substance using an alkali metal or alkali earth metal base or salt as a trans- esterification catalyst. Any natural oil or alternatively any partially hydrogenated oil can be used in the transesterification process. Examples of oils include but are not limited to at least one member selected from the group consisting of soybean, corn, cottonseed, peanut, castor,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 sunflower, canola, rapeseed, safflower, fish, seal, palm, tung, olive oil or any blend. Any multifunctional hydroxyl compound can also be used such as lactose, maltose, raffinose, sucrose, sorbitol, xylitol, erythritol, mannitol, or any combination. The amount of natural oil polyol can range from about 0 to about 40 pphp of the foam formulation. Blowing Agents Polyurethane foam production may be aided by the inclusion of a blowing agent to produce voids in the polyurethane matrix during polymerization. Any blowing agent known in the art may be used. Suitable blowing agents include compounds with low boiling points which are vaporized during the exothermic polymerization reaction. Such blowing agents are generally inert and therefore do not decompose or react during the polymerization reaction. Examples of inert blowing agents include, but are not limited to, at least one member selected from the group consisting of water, carbon dioxide, chlorofluorocarbons, hydrogenated fluorocarbons, hydrogenated chlorofluorocarbons, fluoroolefins, chlorofluoroolefins, hydrofluoroolefins, hydrochlorfluoroolefins, acetone, and low-boiling hydrocarbons such as cyclopentane, isopentane, n-pentane, and their mixtures. Other suitable blowing agents include compounds, for example, water, that react with isocyanate compounds to produce a gas. In various instances, the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon. The amount of blowing agent typically ranges from about 0 pphp to about 80 pphp. The amount of water may range from about 0 pphp to about 60 pphp. In various instances, the amount of water may range from about 1.0 pphp to about 10 pphp and, in some cases, from about 2.0 pphp to about 5 pphp. Optional Components A variety of other components or ingredients may be included in the foam formulations described herein. Examples of optional components include, but are not limited to, at least one member selected from the group consisting of cell stabilizers, crosslinking agents, chain extenders, pigments, dyes, fillers, flame retardants, flame lamination additives, auxiliary urethane gelling catalysts, auxiliary urethane blowing catalysts, metal catalysts, additional amines and combinations thereof. Cell stabilizers can used in an amount from about 0.1 to about 20 pphp and typically from about 0.1 to about 10 pphp and, in some cases, from about 0.1 to about 5.0
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 pphp. Fire retardants can be used in an amount from about 0 to about 20 pphp and from about 0 to about 10 pphp and from about 0 to about 5 pphp. Cell stabilizers may include, for example, silicone surfactants or anionic surfactants. Examples of suitable silicone surfactants include, but are not limited to, at least one member from the group consisting of polyalkylsiloxanes, polyoxyalkylene polyol-modified dimethylpolysiloxanes, alkylene glycol-modified dimethylpolysiloxanes, or combinations thereof. Suitable anionic surfactants include, but are not limited to, salts of fatty acids, salts of sulfuric acid esters, salts of phosphoric acid esters, salts of sulfonic acids, and combinations of any of these. Crosslinking agents include, but are not limited to, at least one member selected from the group consisting of low-molecular weight compounds containing at least two moieties selected from hydroxyl groups, primary amino groups, secondary amino groups, and other active hydrogen-containing groups which are reactive with an isocyanate group. Crosslinking agents include, for example, at least one member selected from the group consisting of polyhydric alcohols (especially trihydric alcohols, such as glycerol and trimethylolpropane), polyamines, and combinations thereof. Non-limiting examples of polyamine crosslinking agents include diethyltoluenediamine, chlorodiaminobenzene, diethanolamine, diisopropanolamine, triethanolamine, tripropanolamine, 1,6-hexanediamine, and combinations thereof. Typical diamine crosslinking agents comprise twelve carbon atoms or fewer, more commonly seven or fewer. The amount of crosslinking agent typically ranges from about 0.1 pphp to about 20 pphp. Examples of chain extenders include, but are not limited to, compounds having hydroxyl or amino functional group, such as glycols, amines, diols, and water. Specific non-limiting examples of chain extenders include at least one member selected from the group consisting of ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol, 1,3- butanediol, 1,5-pentanediol, neopentyl glycol, 1,6-hexanediol, 1,10-decanediol, 1,12- dodecanediol, ethoxylated hydroquinone, 1,4-cyclohexanediol, N-methylethanolamine, N- methylisopropanolamine, 4-aminocyclohexanol, 1,2-diaminoethane, 2,4-toluenediamine, or any mixture thereof. Pigments may be used to color code the polyurethane foams during manufacture, for example to identify product grade or to conceal yellowing. Pigments may include any suitable organic or inorganic pigments known in the polyurethane art. For example, organic pigments or colorants include, but are not limited to, at least one member selected from the group consisting of azo/diazo dyes, phthalocyanines, dioxazines, and carbon black. Examples of inorganic pigments include, but are not limited to, titanium dioxide, iron oxides, or chromium oxide. The amount of any pigment typically ranges from about 0 pphp to about 15 pphp.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Fillers may be used to increase the density and load bearing properties of polyurethane foams. Suitable fillers include, but are not limited to, barium sulfate or calcium carbonate. The amount of any filler typically ranges from about 0 pphp to about 30 pphp Flame retardants may be used to reduce the flammability of polyurethane foams. For example, suitable flame retardants include, but are not limited to, chlorinated phosphate esters, chlorinated paraffins, or melamine powders. In some instances, the contacting of at least one organic isocyanate with at least one polyol may occur in the presence of metal catalyst. The metal catalyst may be a metal carboxylate salt where the metal carboxylate salt comprises a metal and a carboxylate anion. The metal may be at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K). The carboxylate may be the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid. In some instances, the metal catalyst may be an organotin catalyst. The organotin catalyst may be at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2- ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt. The metal catalyst may be present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. In some instances, the metal catalyst may be present at about 0 pphp to about 10 pphp. In some instances, the contacting of at least one organic isocyanate with at least one polyol may occur in the presence of an additional amine. The additional amine may comprise at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl-imidazole, N-methylmorpholine (commercially available as DABCO® NMM), N- ethylmorpholine (commercially available as DABCO® NEM), triethylamine (commercially available as DABCO® TETN), N,N′-dimethylpiperazine (commercially available as POLYCAT® 41), 1,3,5- tris(dimethylaminopropyl)hexahydrotriazine (commercially available as DABCO TMR® 30), 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine (commercially available as POLYCAT® 12), pentamethyldipropylene triamine (commercially available as POLYCAT® 77), N-
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 methyl-N′-(2-dimethylamino)-ethyl-piperazine, tributylamine, pentamethyl-diethylenetriamine (commercially available as POLYCAT® 5), hexamethyl-triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine (commercially available as POLYCAT® 8), triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl)ether (commercially available as DABCO® BL19), tris(3-dimethylaminopropyl)amine (commercially available as POLYCAT® 9), 1,8-diazabicyclo[5.4.0] undecane, and an acid blocked derivative of 1,8-diazabicyclo[5.4.0] undecane. Examples are given below of TDI- and MDI-based polyurethane foam formulations which were used to evaluate the various inventive amine catalyst compositions. In the case of flexible molded foams, the pads were removed from the heated mold and allowed to cool down to room temperature to monitor dimensional stability (shrinkage) or mechanically crushed to evaluate their physical and mechanical properties. It will be apparent to one of ordinary skill in the relevant art that suitable modifications and adaptations to the compositions, formulations, methods, processes, and applications described herein can be made without departing from the scope of any embodiments or aspects thereof. The compositions and methods provided are exemplary and are not intended to limit the scope of any of the specified embodiments. All of the various embodiments, aspects, and options disclosed herein can be combined in any variations or iterations. The scope of the compositions, formulations, methods, and processes described herein include all actual or potential combinations of embodiments, aspects, options, examples, and preferences herein described. The exemplary compositions and formulations described herein may omit any component, substitute any component disclosed herein, or include any component disclosed elsewhere herein. The ratios of the mass of any component of any of the compositions or formulations disclosed herein to the mass of any other component in the formulation or to the total mass of the other components in the formulation are hereby disclosed as if they were expressly disclosed; this can be expressed as a percentage of the total mass of all components of a formulation or as a ratio of components. Should the meaning of any terms in any of the patents or publications incorporated by reference conflict with the meaning of the terms used in this disclosure, the meanings of the terms or phrases in this disclosure are controlling. Furthermore, the foregoing discussion discloses and describes merely exemplary embodiments. All patents and publications cited herein are incorporated by reference herein for the specific teachings thereof. Various embodiments and aspects of the inventions described herein are summarized by the following clauses: Clause 1. A method for making a polyurethane foam, the method comprising:
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH. Clause 2. The method of clause 1, wherein at least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group
Clause 3. The method of clause 1 or 2, wherein the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon. Clause 4. The method of any one of clauses 1–3, wherein the blowing agent comprises carbon dioxide (CO2) and water. Clause 5. The method of any one of clauses 1–4, wherein at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), a polymeric isocyanate or a combination thereof. Clause 6. The method of any one of clauses 1–5, wherein at least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. Clause 7. The method of any one of clauses 1–6, wherein the at least one polyol is new or recycled. Clause 8. The method of any one of clauses 1–7, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. Clause 9. The method of any one of clauses 1–8, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. Clause 10. The method of any one of clauses 1–9, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine. Clause 11. The method of clause 10, wherein the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2- dimethyl-imidazole, N-methylmorpholine, N-ethylmorpholine, triethylamine, N,N′-
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 dimethylpiperazine, 1,3,5-tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)-ethyl-piperazine, tributylamine, pentamethyl- diethylenetriamine, hexamethyl-triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl)ether, tris(3-dimethylaminopropyl)amine, 1,8-diazabicyclo[5.4.0] undecane, and an acid blocked derivative of 1,8- diazabicyclo[5.4.0] undecane. Clause 12. The method of any one of clauses 1–11, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst. Clause 13. The method of clause 12, wherein the metal catalyst is a metal carboxylate salt. Clause 14. The method of clause 13, wherein the metal carboxylate salt comprises a metal and a carboxylate anion. Clause 15. The method of clause 14, wherein the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K). Clause 16. The method of clause 14, wherein the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid. Clause 17. The method of clause 12, wherein the metal catalyst is an organotin catalyst. Clause 18. The method of clause 17, wherein the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt. Clause 19. The method of any one of clauses 12–18, wherein the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. Clause 20. The method of any one of clauses 1–19, wherein the polyurethane foam has an isocyanate index between 80 and 120.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Clause 21. The method of any one of clauses 1–20, wherein the polyurethane foam has a density between 0.8 pounds per cubic foot (pcf) and 3.5 pcf. Clause 22. The method of any one of clauses 1–21, wherein the monohydric alcohol is present in the catalyst composition at 5 mass percentage (wt%) to 15 wt%. Clause 23. The method of any one of clauses 1–22, wherein the monohydric alcohol is present at less than 0.5 wt% of the foam formulation. Clause 24. The method of any one of clauses 1–23, wherein the monohydric alcohol is tertiary amine is present at less than 1.0 wt% of the foam formulation. Clause 25. The method of any one of clauses 1–24, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2-pentanol, 3-pentanol, 1- hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 4-heptanol, cyclopentanol, and cyclohexanol. Clause 26. The method of any one of clauses 1–25, wherein at least one tertiary amine is a tertiary amine of formula:
, wherein: R1 is hydrogen or –C1–4alkyl; R2 is hydrogen, –C1–6alkyl,
R3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R4 and R5 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. Clause 27. The method of any one of clauses 1–26, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl
N,N,N′-trimethylaminopropyl ethanolamine,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 N,N-dimethylaminopropyl urea,
bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea,
N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and
N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine. Clause 28. The method of any one of clauses 1–27, wherein at least one tertiary amine is a tertiary amine of formula: ,
R6 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, –C1–6alkyl–NH2, –C1–6alkyl–N(CH3)2; R7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or
R8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; R9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R10 and R11 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. Clause 29. The method of any one of clauses 1–28, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis bis
N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and
hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis ether,
1-(2-hydroxyethyl)piperazine. Clause 30. The method of any one of clauses 1–29, wherein at least one tertiary amine is selected from the group consisting of:
N-(2-hydroxypropyl)imidazole, and
N-(2-hydroxyethyl) imidazole. Clause 31. The method of any one of clauses 1–30, wherein the catalyst composition comprises at least two tertiary amines. Clause 32. The method of any one of clauses 1–31, wherein the catalyst composition further comprises a tertiary amine that does not contain an isocyanate reactive group. Clause 33. The method of clause 32, wherein the tertiary amine that does not contain an isocyanate reactive group is one or more selected from the group consisting of:
1,4-diazabicyclo[2.2.2]octane (DABCO),
N,N-dimethylcyclohexyl amine,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
bis-dimethylaminoethyl ether, pentamethyldiethylenetriamine,
hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine, and
tris(dimethylaminopropyl)amine. Clause 34. A method of making a polyurethane foam, the method comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH; wherein: the monohydric alcohol is present in the catalyst composition at 5 wt% to 15 wt%; and the polyurethane foam has an isocyanate index between 80 and 120. Clause 35. The method of clause 34, wherein at least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting
Clause 36. The method of clause 34 or 35, wherein the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon. Clause 37. The method of any one of clauses 34–36, wherein at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), or a combination thereof.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Clause 38. The method of any one of clauses 34–37, wherein at least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. Clause 39. The method of any one of clauses 34–38, wherein the at least one polyol is new or recycled. Clause 40. The method of any one of clauses 34–39, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. Clause 41. The method of any one of clauses 34–40, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. Clause 42. The method of any one of clauses 34–41, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine. Clause 43. The method of clause 42, wherein the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2- dimethyl-imidazole, N-methylmorpholine, N-ethylmorpholine, triethylamine, N,N′- dimethylpiperazine, 1,3,5-tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)-ethyl-piperazine, tributylamine, pentamethyl- diethylenetriamine, hexamethyl-triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl)ether, tris(3-dimethylaminopropyl)amine, 1,8-diazabicyclo[5.4.0] undecane, and an acid blocked derivative of 1,8- diazabicyclo[5.4.0] undecane. Clause 44. The method of any one of clauses 34–43, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst. Clause 45. The method of clause 44, wherein the metal catalyst is a metal carboxylate salt. Clause 46. The method of clause 45, wherein the metal carboxylate salt comprises a metal and a carboxylate anion. Clause 47. The method of clause 46, wherein the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K). Clause 48. The method of clause 46, wherein the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid. Clause 49. The method of clause 44, wherein the metal catalyst is an organotin catalyst. Clause 50. The method of clause 49, wherein the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt. Clause 51. The method of any one of clauses 34–50, wherein the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. Clause 52. The method of any one of clauses 34–51, wherein at least one tertiary amine is a tertiary amine of formula:
, wherein: R1 is hydrogen or –C1–4alkyl; R2 is hydrogen,
R3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R4 and R5 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. Clause 53. The method of any one of clauses 34–52, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl
N,N,N′-trimethylaminopropyl ethanolamine,
N,N-dimethylaminopropyl urea,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea,
N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- isopropanolamine, and
N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine. Clause 54. The method of any one of clauses 34–53, wherein at least one tertiary amine is a tertiary amine of formula: ,
R6 is hydrogen, –C1–4alkyl, –C1–4alkyl–OH, –C1–4alkyl–NH2, –C1–4alkyl–N(CH3)2; R7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or
R8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; R9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R10 and R11 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. Clause 55. The method of any one of clauses 34–54, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether,
N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and
hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis(aminoethyl) ether,
1-(2-hydroxyethyl)piperazine. EXAMPLES Example 1 Hand Mix Evaluations Hand mix experiments were conducted using the following procedure. Formulations were blended together for approximately 10 minutes using a mechanical mixer equipped with a 7.6 cm diameter high shear mixing blade, rotating at 5000 RPM. Premixed formulations were maintained at 23 °C using a low temperature incubator. Mondur TD-80 (an 80/202,4/2,6 isomer blend of toluene diisocyanate) or modified MDI was added to the premix at the correct stoichiometric amount for the reported index of each foam. The mixture was blended together with a Premier Mill Corporation Series 2000, Model 89, and dispersed for approximately five seconds. The foaming mixture was transferred to an Imperial Bondware #GDR-170 paper bucket and allowed to free rise while data was recorded. Example 2 The model tertiary amine N,N,N′-trimethyl-N′-3-aminopropyl-bis(aminoethyl) ether (DABCO® NE300 (amine catalyst) was selected for this study because this compound is widely
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 used as a blowing catalyst in many commercial applications. The catalyst is a blowing polyurethane catalyst commonly used in flexible molded and flexible slabstock applications where chemical emanation is of great concern. However, the catalyst is also employed in many other used such as rigid, semi-rigid, spray and any other application where water may be used to blow the polyurethane polymer. Solid Carbamate Formation Evaluations at Ambient Conditions Approximately 20 g of amine catalyst was blended with approximately 12 g of solid CO2 in an open glass container, immersed briefly in a 2 °C (35 °F) cold water bath. The glass container of amine catalyst was then transferred to a 28 °C (82 °F) warm water bath for approx.20 minutes to dissolve the solid CO2. The glass container was then removed from the warm water bath and allowed to stand at 24 °C (75 °F) for 5 mins. The amine catalyst liquid was visually observed for solid formation. The container was secured with a lid and placed in controlled temperature environment, such as incubator, at 10 °C (50 °F) overnight. The amine catalyst was visually observed periodically for solid formation. Various alcohols at various ratios were added to mitigate the formation of the solid carbamate intermediate. Table 2 shows the results. Table 2. Solid Carbamate Formation Evaluations at Ambient Conditions NE300 interaction with CO2 NE300 100% 99% 95% 90% solid NE300 blends Alcohols CAS 1% 5% 10% Methyl 1,3 propanediol 2163-42-0 solid Cyclohexanol 108-93-0 solid solid N-propanol, 1-propanol 71-23-8 solid N-butanol, 1-butanol 71-36-3 solid no solid Iso-propanol 67-63-0 slow solid no solid Methanol 67-56-1 slow solid no solid 1-pentanol 71-41-0 solid no solid Ethanol 64-17-5 solid no solid Water 7732-18-5 no solid no solid Dipropylene glycol 25265-71-8 solid Polyethylene glycol, 400 MW 25322-68-3 solid Acetone 67-64-1 no solid, dark Propylene carbonate 108-32-7 solid no solid Triethylene glycol 112-27-6 solid solid solid
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 200 MW C11-C14 branched,
slow tridec alcohol solid 250 MW C16 dimer alcohol 2425-77-6 solid solid C14-C15 branched alcohols 68333-80-2 solid solid Amines Tertiary and secondary amine structure amine solid solid Hydroxy functionalized tertiary amine structure amine solid solid Amide functionalized tertiary amine structure amine solid solid Example 3 The Amine Catalyst Composition can be Used as a Blowing Catalyst to Make Polyurethane Foam in Various Polyurethane Foam Densities Foam pads were prepared by adding the amine catalyst to about 320 g of a premix (prepared as in Table 3) in a 951 mL (32 oz) paper cup. The formulation was mixed for about 20 seconds at about 6,000 RPM using an overhead stirrer fitted with a 5.1 cm (2-inch) diameter stirring paddle. The toluene diisocyanate (TDI) was then added, and the formulation was mixed well for about another 6 seconds at about 6,000 RPM using the same stirrer, after which it was poured into a 5-gallon plastic bucket at room temperature. Rise time and foam height are monitored for 5 minutes. The foam is allowed to fully cure overnight and removed from the bucket the next day. Foam samples were stored under constant temperature and humidity conditions for 48 hours before being cut and tested. Table 3. Premix Components #1 Component PPHP CARPOL ® GP-30081 100 Water 5.3 TEGOSTAB ® B-82292 1.50 Amine Catalyst Composition- Varied KOSMOS ® T-93 0.30 Methylene Chloride 10.00 Toluene diisocyanate to provide NCO index = 111.5 1Conventional slabstock polyether polyol of 3000 molecular weight triol, glycerin initiated with all internal EO, available from Carpenter Company, Richmond, VA. 2Silicone surfactant is available from Evonik Corporation. 3Stannous octoate organotin catalyst is available from Evonik Corporation.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Table 4 shows physical properties of flexible slabstock polyurethane foam samples for the amine catalyst with two different monohydric alcohols (iso-propanol and 1-pentanol) in a low density slabstock formulation. The flexible slabstock samples were made using a single blowing agent of the amine catalyst to show the influence of each individual co-solvent on foam physical properties. The gelling amine catalyst was in each case was triethylene diamine (TEDA). Table 4. Physical Properties at Ambient Conditions DABCO NE300 DABCO NE300 DABCO NE300 Monohydric Alcohol iso-propanol 1-pentanol Height (mm) Density (pcf) 0.88 0.84 0.88 Airflow (scfm) 1.14 1.75 1.24 ILD (lb-ft) – 25% 36.4 34.2 35.8 – 65% 64.9 62.5 63.8 – 25% R 20.8 19.8 20.6 Support Factor 1.78 1.83 1.78 Tensile (psi) 9.8 10.2 10.3 Elongation (%) 108.7 115.1 113.9 Tear (lbs) 1.35 1.41 1.39 Example 4 Foam pads were prepared by adding the amine catalyst to about 320 g of a premix (prepared as in Table 4) in a 951 mL (32 oz) paper cup. The formulation was mixed for about 20 seconds at about 6000 RPM using an overhead stirrer fitted with a 5.1 cm (2-inch) diameter stirring paddle. The toluene diisocyanate (TDI) was then added, and the formulation was mixed well for about another 6 seconds at about 6000 RPM using the same stirrer, after which it was poured into a 3.5-gallon plastic bucket at room temperature. Rise time and foam height are monitored for 5 minutes. The foam is allowed to fully cure overnight and removed from the bucket the next day. Foam samples were stored under constant temperature and humidity conditions for 48 hours before being cut and tested.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Table 5 Premix Components #1 Component PPHP CARPOL ® GP-30081 100 Water 2.7 TEGOSTAB ® B-82442 1.25 Amine Catalyst Composition- Varied KOSMOS ® T-93 0.18 Toluene diisocyanate to provide NCO index = 111.5 1Conventional slabstock polyether polyol of 3000 molecular weight triol, glycerin initiated with all internal EO, available from Carpenter Company, Richmond, VA. 2Silicone surfactant is available from Evonik Corporation. 3Stannous octoate organotin catalyst is available from Evonik Corporation. Table 6 shows physical properties of flexible slabstock polyurethane foam samples for the amine catalyst composition with two different monohydric alcohols (iso-propanol and 1-pentanol) in a high density slabstock formulation. The flexible slabstock samples were made using a single blowing using the amine catalyst to show the influence of each individual co-solvent on foam physical properties. The gelling amine catalyst was in each case was triethylene diamine (TEDA). Table 6. Physical Properties at Ambient Conditions DABCO NE300 DABCO NE300 DABCO NE300 Monohydric Alcohol iso-propanol 1-pentanol Height (mm) Density (pcf) 2.02 2.01 2.03 Airflow (scfm) 1.31 1.22 1.22 ILD (lb-ft) – 25% 39.6 40.6 40.3 – 65% 79.1 80.4 79.6 – 25% R 30.9 31.6 31.5 Support Factor 2.00 1.98 1.97 Tensile (psi) 11.44 10.9 10.8 Elongation (%) 111.5 106.3 106.0 Tear (lbs) 1.34 1.20 1.22 Example 5 As previously described in example 2, approximately 20 g of amine catalyst alone or with addition of 1–2 g of isopropyl alcohol was blended with approximately 12 g of solid CO2 in an open glass container, immersed briefly in a 2 °C (35 °F) cold water bath. The glass container of amine/alcohol catalyst was then transferred to a 28 °C (82 °F) warm water bath for approx. 20 minutes to dissolve the solid CO2. The glass container was then removed from the warm water bath and allowed to stand at 24 °C (75 °F) for 5 mins. The amine/alcohol catalyst liquid was visually observed for solid formation. The container was secured with a lid and placed in
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 controlled temperature environment, such as incubator, at 10 °C (50 °F) overnight. The amine/alcohol catalyst was visually observed periodically for solid formation. Four samples were individually analyzed by FTIR for carbamate content. A droplet of each sample was placed on a Thermo Scientific FTIR window for analysis. The four samples included (1) NE300 without solid CO2 exposure (control, Spectrum A), (2) NE300 with solid CO2 exposure (Spectrum D), (3) NE300 with 5% isopropyl alcohol blend with solid CO2 exposure (Spectrum C) and (4) NE300 with 10% CO2 exposure (Spectrum B). Carbamate growth is evident by the presence of a peak near 1674 cm−1 wavenumber for the samples corresponding to spectra C and D. Example 6 Table 7 and Table 8 show physical properties of flexible slabstock polyurethane foam samples for the amine catalyst composition with 3 linear monohydric alcohols, as well as cyclic and branched alcohols. It also shows physical properties for a non-alcohol amine catalyst composition. The flexible slabstock samples were made using a single blowing agent of the amine catalyst to show the influence of each individual co-solvent on the foam physical properties. The control gelling amine catalysts, triethylene diamine (TEDA) and DABCO NE1082 were used in the comparisons. Table 7. Physical Properties at Ambient Conditions Foam Type Control Control Control Control Gel Amine 33LV NE1082 NE1082 NE1082 NE1082 NE1082 NE1082 NE300/ NE300/ NE300/ Blow Linear Linear Linear Amine NE300 NE300 alcohol A1 NE300 alcohol A2 NE300 alcohol A3 blend blend blend range range range Density pcf 0.874 0.874 0.874- 0. 0.905- 0.918 886 0.911 0.874 0.880 Airflow scfm 3.27 4.16 3.85-4.56 4.76 4.34-4.59 4.74 4.45-4.66 ILD 25% ft-lb 29.70 28.35 27.43- 29.00 29.68 29.45- 30.35 26.10 26.08-26.98 ILD 65% ft-lb 54.77 57.08 54.63- 58.00 57.62 57.10- 58.23 50.47 50.36-52.61 ILD 25% R ft-lb 16.77 15.92 15.51- 16.86 16.88 16.86- 17.31 14.84 14.84-15.51 Support 65/25 Factor ratio 1.84 2.01 2.0-2.0 1.94 1.9-1.9 1.93 1.9-2.0 Resilience % 37 41 37-41 40 38-41 39 38-41 90% Dry C Set % 75.5 9.9 8.5-9.4 15.6 12.9-15.3 17 16-22 Tensile psi 10.14 8.40 8.12-8.41 8.12 7.98-8.27 8.98 8.12-8.85 Elongation % 102.4 123 106-123 91.3 86-91 112 99-110 Tear lbs/in 1.56 1.28 0.98-1.31 1.14 1.05-1.17 1.28 1.13-1.30
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 Table 8. Physical Properties at Ambient Conditions Foam Type Control Control Control Control Gel Amine 33LV NE1082 NE1082 NE1082 NE1082 NE1082 NE1082 NE300/ NE300/ NE300/ Blow Cyclic Branched Non- Amine NE300 NE300 alcohol NE300 alcohol NE300 alcohol blend blend blend range range range Density pcf 0.874 0.880 0.880- 0.868 0.861- 0. 0.855- 0.905 0.880 874 0.868 Airflow scfm 3.27 4.13 3.85-4.27 4.16 4.17-4.48 3.71 3.85-4.34 ILD 25% ft-lb 29.70 30.89 29.45- 2 23.83- 23.61- 31.03 3.70 25.40 25.02 25.18 ILD 65% ft-lb 54.77 59.29 57.33- 46.54- 46.31- 60.48 47.01 49.46 49.33 49.91 ILD 25% R ft-lb 16.77 17.60 16.64- 13.49- 13.26- 17.76 13.42 14.39 14.28 14.39 Support 65/25 Factor ratio 1.84 1.92 1.9-1.9 1.98 1.95-1.98 1.97 1.97-1.99 Resilience % 37 37 39-40 38 38-39 40 36-38 90% Dry C Set % 75.5 10.9 7.7-9.7 46.5 12-23 37 27-33 Tensile psi 10.14 7.41 7.40-8.12 9.22 8.99-9.43 8.66 8.12-8.27 Elongation % 102.4 100.1 102-112 153 132-152 122 113-137 Tear lbs/in 1.56 0.94 0.92-1.08 1.66 1.46-1.63 1.53 1.27-1.44
Claims
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 CLAIMS What is claimed: 1. A method for making a polyurethane foam, the method comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH. 2. The method of claim 1, wherein at least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting of
3. The method of claim 1, wherein the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon. 4. The method of claim 3, wherein the blowing agent comprises carbon dioxide (CO2) and water. 5. The method of claim 1, wherein at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), a polymeric isocyanate or a combination thereof. 6. The method of claim 1, wherein at least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. 7. The method of claim 6, wherein the at least one polyol is new or recycled.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 8. The method of claim 1, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. 9. The method of claim 1, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. 10. The method of claim 1, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine. 11. The method of claim 10, wherein the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl- imidazole, N-methylmorpholine, N-ethylmorpholine, triethylamine, N,N′- dimethylpiperazine, 1,3,5-tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)-ethyl-piperazine, tributylamine, pentamethyl- diethylenetriamine, hexamethyl-triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl)ether, tris(3-dimethylaminopropyl)amine, 1,8-diazabicyclo[5.4.0] undecane, and an acid blocked derivative of 1,8- diazabicyclo[5.4.0] undecane. 12. The method of claim 1, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst. 13. The method of claim 12, wherein the metal catalyst is a metal carboxylate salt. 14. The method of claim 13, wherein the metal carboxylate salt comprises a metal and a carboxylate anion. 15. The method of claim 14, wherein the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K).
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 16. The method of claim 14, wherein the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid. 17. The method of claim 12, wherein the metal catalyst is an organotin catalyst. 18. The method of claim 17, wherein the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt. 19. The method of claim 12, wherein the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. 20. The method of claim 1, wherein the polyurethane foam has an isocyanate index between 80 and 120. 21. The method of claim 1, wherein the polyurethane foam has a density between 0.8 pounds per cubic foot (pcf) and 3.5 pcf. 22. The method of claim 1, wherein the monohydric alcohol is present in the catalyst composition at 5 mass percentage (wt%) to 15 wt%. 23. The method of claim 1, wherein the monohydric alcohol is present at less than 0.5 wt% of the foam formulation.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 24. The method of claim 1, wherein the monohydric alcohol is tertiary amine is present at less than 1.0 wt% of the foam formulation. 25. The method of claim 1, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1- butanol, 2-butanol, 1-pentanol, 2-pentanol, 3-pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 4-heptanol, cyclopentanol, and cyclohexanol. 26. The method of claim 1, wherein at least one tertiary amine is a tertiary amine of formula:
, wherein: R1 is hydrogen or –C1–4alkyl;
R3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R4 and R5 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. 27. The method of claim 1, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine,
N,N,N′-trimethylaminopropyl ethanolamine, N,N-dimethylaminopropyl urea,
bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and
N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine. 28. The method of claim 1, wherein at least one tertiary amine is a tertiary amine of formula: ,
R6 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, –C1–6alkyl–NH2, –C1–6alkyl–N(CH3)2; R7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or
R8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; R9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R10 and R11 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. 29. The method of claim 1, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol,
N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and
hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis ether,
1-(2-hydroxyethyl)piperazine. 30. The method of claim 1, wherein at least one tertiary amine is selected from the group consisting of:
N-(2-hydroxypropyl)imidazole, and
N-(2-hydroxyethyl) imidazole. 31. The method of claim 1, wherein the catalyst composition comprises at least two tertiary amines. 32. The method of claim 1, wherein the catalyst composition further comprises a tertiary amine that does not contain an isocyanate reactive group. 33. The method of claim 32, wherein the tertiary amine that does not contain an isocyanate reactive group is one or more selected from the group consisting of:
1,4-diazabicyclo[2.2.2]octane (DABCO),
N,N-dimethylcyclohexyl amine,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
bis-dimethylaminoethyl ether, pentamethyldiethylenetriamine,
hexamethyltriethylenetetramine, heptamethyltetraethylenepentamine, and
tris(dimethylaminopropyl)amine. 34. A method of making a polyurethane foam, the method comprising: preparing a foam formulation by: contacting at least one organic isocyanate with at least one polyol in the presence of a blowing agent and a catalyst composition, wherein the catalyst composition comprises: at least one tertiary amine comprising an isocyanate reactive group; and a monohydric alcohol, wherein the monohydric alcohol comprises at least one alcohol selected from the group consisting of C1–7 linear alkyl–OH, C3–6 branched alkyl-OH, and C3–6 cycloalkyl–OH; wherein: the monohydric alcohol is present in the catalyst composition at 5 wt% to 15 wt%; and the polyurethane foam has an isocyanate index between 80 and 120. 35. The method of claim 34, wherein at least one tertiary amine comprising an isocyanate reactive group comprises at least one moiety selected from the group consisting of
36. The method of claim 34, wherein the blowing agent comprises at least one selected from the group consisting of carbon dioxide (CO2), water, acetone, methyl formate, a hydrofluorocarbon (HFC), a hydrofluoroolefin (HFO), and a hydrocarbon.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 37. The method of claim 34, wherein at least one organic isocyanate is toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), or a combination thereof. 38. The method of claim 34, wherein at least one polyol is a polyether polyol, a polyester polyol, a copolymer polyol, or a natural oil polyol. 39. The method of claim 34, wherein the at least one polyol is new or recycled. 40. The method of claim 34, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a crosslinking agent. 41. The method of claim 34, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a silicone surfactant. 42. The method of claim 34, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of an additional amine. 43. The method of claim 42, wherein the additional amine comprises at least one selected from the group consisting of triethylenediamine (TEDA), N-methylimidazole, 1,2-dimethyl- imidazole, N-methylmorpholine, N-ethylmorpholine, triethylamine, N,N′- dimethylpiperazine, 1,3,5-tris(dimethylaminopropyl)hexahydrotriazine, 2,4,6- tris(dimethylaminomethyl)phenol, N-methyldicyclohexylamine, pentamethyldipropylene triamine, N-methyl-N′-(2-dimethylamino)-ethyl-piperazine, tributylamine, pentamethyl- diethylenetriamine, hexamethyl-triethylenetetramine, heptamethyltetraethylenepentamine, dimethylaminocyclohexyl-amine, triethanolamine, dimethylethanolamine, bis(dimethylaminoethyl)ether, tris(3-dimethylaminopropyl)amine, 1,8-diazabicyclo[5.4.0] undecane, and an acid blocked derivative of 1,8- diazabicyclo[5.4.0] undecane. 44. The method of claim 34, wherein the contacting of at least one organic isocyanate with at least one polyol occurs in the presence of a metal catalyst. 45. The method of claim 44, wherein the metal catalyst is a metal carboxylate salt.
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 46. The method of claim 45, wherein the metal carboxylate salt comprises a metal and a carboxylate anion. 47. The method of claim 46, wherein the metal is at least one selected from the group consisting of tin (Sn), bismuth (Bi), lead (Pb), iron (Fe), zinc (Zn), and potassium (K). 48. The method of claim 46, wherein the carboxylate is the carboxylate anion of at least one carboxylic acid selected from the group consisting of acetic acid, propanoic acid, butanoic acid, pentanoic acid, neopentanoic acid, hexanoic acid, 2-ethylhexyl carboxylic acid, neohexanoic acid, octanoic acid, neooctanoic acid, heptanoic acid, neoheptanoic acid, nonanoic acid, neononanoic acid, decanoic acid, neodecanoic acid, undecanoic acid, neoundecanoic acid, dodecanoic acid, neododecanoic acid, myristic acid, pentadecanoic acid, hexadecanoic acid, heptadecanoic acid, and octadecanoic acid. 49. The method of claim 44, wherein the metal catalyst is an organotin catalyst. 50. The method of claim 49, wherein the organotin catalyst is at least one selected from the group consisting of dibutyltin diacetate, dimethyltin dilaurylmercaptide, dibutyltin dilaurylmercaptide, dimethyltin diisooctylmaleate, dibutyltin diisooctylmaleate, dimethyltin bi(2-ethylhexyl mercaptoacetate), dibutyltin bi(2-ethylhexyl mercaptoacetate), dimethyltin neodecanoate, dibutyltin neodecanoate, dimethyltin isononanoate, dibutyltin isononanoate, stannous octoate, stannous neodecanoate, stannous isononanoate, and a stannous carboxylate salt. 51. The method of claim 44, wherein the metal catalyst is present at about 0 parts per hundred parts of polyol (pphp) to about 20 pphp. 52. The method of claim 32, wherein at least one tertiary amine is a tertiary amine of formula:
, wherein: R1 is hydrogen or –C1–4alkyl;
MBF 024010-0029-US01 Foreign Filing Evonik 202100329
R3 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R4 and R5 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. 53. The method of claim 32, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylaminopropylamine, N,N-dimethylaminoethyl-N′-methyl ethanolamine,
N,N,N′-trimethylaminopropyl ethanolamine,
bis(N,N-dimethyl-3-aminopropyl)amine, N,N′-bis(3-dimethylaminopropyl) urea,
N,N-bis(3-dimethylaminopropyl)-N′- N,N-bis(3-dimethylaminopropyl)-N′- ethanolamine, isopropanolamine, and
N,N-dimethyl-N′,N′-2-hydroxy(propyI)-1,3- propylenediamine. 54. The method of claim 32, wherein at least one tertiary amine is a tertiary amine of formula: ,
MBF 024010-0029-US01 Foreign Filing Evonik 202100329 R6 is hydrogen, –C1–4alkyl, –C1–4alkyl–OH, –C1–4alkyl–NH2, –C1–4alkyl–N(CH3)2; R7 is hydrogen, –C2–6alkyl–OH, –C2–6alkyl–NH2, –C2–6alkyl–N(CH3)2, or
R8 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; R9 is hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2; and R10 and R11 are each independently hydrogen, –C1–6alkyl, –C1–6alkyl–OH, or –C1–6alkyl–NH2. 55. The method of claim 32, wherein at least one tertiary amine is selected from the group consisting of:
N,N-dimethylethanolamine, (N,N-dimethylaminoethoxy)ethanol,
N,N,N′-Trimethyl-N′-(2-hydroxyethyl)- N,N,N′-trimethyl-N′-3-aminopropyl- bis(2-aminoethyl) ether, bis(aminoethyl) ether,
N,N,N′-Trimethyl-N′-3-amino-1- 2- (aminomethyl)propyl-bis(2- (1-hydroxyethyl)propyl- aminoethyl) ether, bis(aminoethyl) ether, and
hydroxyethyl)propyl- bis(dimethylamino)-2-propanol, and bis(aminoethyl) ether,
1-(2-hydroxyethyl)piperazine.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202363448126P | 2023-02-24 | 2023-02-24 | |
| PCT/EP2024/054359 WO2024175628A1 (en) | 2023-02-24 | 2024-02-21 | Inhibiting solids formation in co2 polyurethane production |
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| EP4669686A1 true EP4669686A1 (en) | 2025-12-31 |
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| EP24706986.7A Pending EP4669686A1 (en) | 2023-02-24 | 2024-02-21 | Inhibitory solid formation during CO2 polyurethane production |
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| Country | Link |
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| EP (1) | EP4669686A1 (en) |
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| US4394491A (en) | 1980-10-08 | 1983-07-19 | The Dow Chemical Company | Addition polymerizable adduct of a polymeric monoahl and an unsaturated isocyanate |
| EP1268598B1 (en) | 2000-02-10 | 2008-06-11 | Dow Global Technologies Inc. | Low emission polyurethane flexible foam made with autocatalytic polyols |
| TWI315730B (en) | 2001-08-15 | 2009-10-11 | Dow Global Technologies Inc | Process to manufacture polyurethane products |
| TW592813B (en) | 2001-08-15 | 2004-06-21 | Dow Global Technologies Inc | Process to manufacture polyurethane products |
| US20060217516A1 (en) | 2001-12-21 | 2006-09-28 | Casati Francois M | Tertiary amine modified polyurethane products made therefrom |
| WO2004060956A1 (en) | 2002-12-17 | 2004-07-22 | Dow Global Technologies Inc. | Amine-epoxy autocatalytic polymers and polyurethane products made therefrom |
| BRPI0610831B1 (en) | 2005-04-25 | 2018-04-10 | Cargill, Incorporated | Polyurethane Foams Understanding Oligomeric Polyols and Methods of Manufacturing Polyurethane Molded Foam Article and SLABSTOCK Polyurethane Foam Article |
| US10023683B2 (en) * | 2006-06-12 | 2018-07-17 | Evonik Degussa Gmbh | Catalyst compositions for improving polyurethane foam performance |
| EP3078696A1 (en) * | 2015-04-08 | 2016-10-12 | Evonik Degussa GmbH | Production of low-emission polyurethanes |
| CN108290994B (en) * | 2015-11-30 | 2021-10-22 | 东曹株式会社 | Catalyst composition for producing polyurethane foam, and method for producing flexible polyurethane foam using the same |
| CN109153762B (en) * | 2016-05-17 | 2021-04-02 | 东曹株式会社 | Amine catalyst composition for the manufacture of halogenated olefin foamed polyurethane |
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- 2024-02-21 EP EP24706986.7A patent/EP4669686A1/en active Pending
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