JP2604952B2 - Method for producing modified polyisocyanurate foam - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001] The present invention relates to a method for producing a modified polyisocyanurate foam, and more particularly, to a modified polyisocyanurate suitable for continuous production of a laminate board or a side board, which does not require the use of an evaporative foaming agent such as chlorofluorocarbon. The present invention relates to a method for producing a nurate foam.

A method for producing a modified polyisocyanurate foam using an organic polyisocyanate and a polyol in combination with an isocyanuration catalyst and a carbodiimidation catalyst in the presence of a blowing agent is known (for example, JP-B-46-4).
No. 591). Further, a modified polyisocyanurate foam is produced by using an organic polyisocyanate and a polyol in the presence of a blowing agent in combination with methanol, furfuryl alcohol or fluorene oxide (carbodiimidization catalyst) and an alkali metal salt (trimerization catalyst). (See U.S. Pat. No. 4,166,164 and Japanese Patent Application Laid-Open No. 2-245013). Further, JP-A-50-95397 and JP-A-50-12499
7, JP-A-51-75799, JP-A-51-75799
-76395, JP-A-51-80393,
JP-A-51-102098 discloses a method of obtaining a modified polyisocyanate foam using a tertiary amine and an alcohol such as an amino alcohol as a cocatalyst, and a method of using a Mannich polyol or a phosphorus-containing polyol as a catalyst. ,
Methods using s-triazine and phenol have been reported.

In the production of these (modified) polyisocyanurate foams, it is common to use chlorofluorocarbon as a blowing agent. However, fluorocarbon has a problem of depletion of the ozone layer, and the use of fluorocarbon in the near future is not expected. There is a tendency to be totally banned. As an alternative to CFCs, a method using carbon dioxide gas generated by the reaction between water and isocyanate is conceivable. However, in order to reduce the density of the foam (to obtain a highly foamed one), it is necessary to increase the amount of water used. , Formed urea bond (-NC
O + H ₂ O → −NH ₂ + CO ₂ }, −NH ₂ + OCN− → −
There is a problem that the amount of NHCONH-) is large, the strength is low, the dimensional stability is poor, and only a foam having poor adhesion to the face material can be obtained. In addition, in the above-mentioned method in which a conventional isocyanuration catalyst and a carbodiimidation catalyst are used in combination, when water is used as a foaming agent, it is difficult to control the reaction, which is particularly required for a laminate board, a sideboard, and the like. It is not possible to produce cured high foams with densities below 30 kg / m ³ at economical rates.

The present inventors have developed a highly foamed modified polyisocyanurate foam having a density of 30 kg / m ³ or less from an organic polyisocyanate and a polyol without using an evaporating foaming agent represented by freon. As a result of intensive studies on the industrially applicable method that can be produced, it has been found that when a certain combination of a specific trimerization catalyst and a carbodiimidation catalyst is used together with water, the trimerization of polyisocyanate is performed. The reaction, the carbodiimidization reaction, the reaction between water and the polyisocyanate, etc., proceed rapidly in a well-balanced manner, and can be carried out without using an evaporating foaming agent such as Freon.
It has been found that a modified polyisocyanurate foam having a low density of 0 kg / m ³ or less can be obtained in a short time, and the present invention has been completed.

Thus, according to the present invention, an organic polyisocyanate, a polyol and water are converted into a compound represented by the formula (a)

[0006]

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In the formula, R ₁ , R ₂ and R ₃ each represent an alkyl group, and R ₄ and R ₅ each represent a hydrogen atom or an alkyl group. Catalyst and formula (b)

[0008]

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In the formula, R ₁ represents a substituted or unsubstituted alkyl, phenyl, naphthyl or benzyl group;
R ₂ , R ₃ , R ₄ , R ₅ , R ₆ and R ₇ each represent H, Cl or a C ₁ -C ₄ alkyl group in the presence of a carbodiimidization catalyst comprising There is provided a method for producing a modified polyisocyanurate foam characterized by reacting.

Hereinafter, the present invention will be described in more detail.

The organic polyisocyanate used as a raw material in the method of the present invention may be of any type such as aliphatic, alicyclic, aromatic and a mixture thereof. Those used in the production of polyurethane and polyisocyanurate can be similarly used. Specifically, for example, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate,
Aromatic diisocyanates such as crude tolylene diisocyanate, methylene diphenyl diisocyanate, and crude methylene diphenyl diisocyanate; aromatic triisocyanates such as 4,4 ', 4 "-triphenylmethane triisocyanate and 2,4,6-tolylene triisocyanate Isocyanate;
4,4'-dimethyldiphenylmethane-2,2'-5,5'-
Aromatic tetraisocyanates such as tetraisocyanate; aliphatic isocyanates such as hexamethylene-1,6-diisocyanate; alicyclic isocyanates such as hydrogenated methylene diphenyl diisocyanate;
-Phenylenediisocyanate, naphthylene-1,5-diisocyanate, 1-methoxyphenyl-2,4-diisocyanate, 4,4'-biphenylenediisocyanate,
3'-dimethoxy-4,4'-biphenyl diisocyanate, 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate, etc., among which 2,4-tolylene diisocyanate, 2,6-triisocyanate Range isocyanate, crude tolylene diisocyanate, methylene diphenyl diisocyanate, crude methylene diphenyl diisocyanate,
Hexamethylene-1,6-diisocyanate, hydrogenated methylene diphenyl diisocyanate and the like are preferred. The above organic polyisocyanates can be used alone or in combination of two or more.

Examples of the polyol include aliphatic, saccharide, and aromatic compounds having two or more hydroxyl groups in one molecule, such as polyether polyols, polyester polyols, and castor oil, and mixtures thereof. And those conventionally used in the production of polyurethane can be similarly used. Such polyols may be of either low molecular weight or high molecular weight. Specifically, for example, polyether polyols include polyhydric alcohols, polyphenols, amines, and alkylene active compounds such as polycarboxylic acids. Compounds having a structure to which an oxide is added can be given. As polyhydric alcohol,
For example, ethylene glycol, propylene glycol,
Dihydric alcohols such as 1,4-butanediol, 1,6-hexanediol, diethylene glycol and neopentyl glycol; and trihydric alcohols such as pentaerythritol and sucrose
And polyhydric alcohols having a valency or higher. Examples of the polyhydric phenol include polyphenols such as pyrogallol and hydroquinone, bisphenols such as bisphenol A, and condensates of phenol and formaldehyde. Amines include ammonia, mono-, di-
-, and triethanolamine, isopropanolamine, alkanolamines such as aminoethylethanolamine; alkylamines _{C 1 ~C 22, C 2 ~C} 6
Of alkylene diamine, polyalkylene polyamine, aniline, phenylenediamine, diaminotoluene, xylylenediamine, methylenedianiline, aromatic amines such as diphenyletherdiamine, alicyclic amines such as isophoronediaminecyclohexylenediamine, and complex And cyclic amines. Examples of polycarboxylic acids include aliphatic polycarboxylic acids such as succinic acid, adipic acid, sebacic acid, maleic acid, and dimer acid, and aromatic polycarboxylic acids such as phthalic acid, terephthalic acid, trimellitic acid, and pyromellitic acid. These active hydrogen-containing compounds may be used in combination of two or more.
Examples of the alkylene oxide added to the active hydrogen-containing compound include propylene oxide, ethylene oxide, butylene oxide, and tetrahydrofuran. These alkylene oxides may be used alone or in combination of two or more. In the latter case, the alkylene oxides may be added by block addition or random addition.
As the polyester polyol, for example, a polyhydric alcohol (the dihydric alcohol, trimethylolpropane, glycerin, etc.) and a carboxylic acid (the polycarboxylic acid, etc.)
And a condensation polyester polyol obtained by reacting
Examples include polyester polyols obtained by ring-opening polymerization of lactones, and those obtained by adding ethylene oxide adduct of nonylphenol to a recovered polyester. Among these, aliphatic, aromatic, aliphatic or aromatic amine-based, pentaerythritol-based, sucrose-based polyether polyols; aromatic or aliphatic carboxylic polyester polyols; lactone-based polyester polyols and the like are particularly preferable. It is. The above polyols can be used alone or in combination of two or more.

The polyol as described above is generally used in an amount of from 20 to 60.
0 mgKOH / g, preferably 25-500 mgKOH
/ G, more preferably in the range of 50 to 400 mg KOH / g.

According to the method of the present invention, a polyisocyanurate foam is produced by reacting the above-mentioned organic polyisocyanate with a polyol together with water as a foaming agent. In this reaction, the proportions of the organic polyisocyanate, polyol and water used are not strictly limited, and can be varied over a wide range depending on the physical properties and applications desired for the modified polyisocyanurate foam of the final product. However, in general, NCO / O
An isocyanate index represented by an H equivalent ratio of 1.8 or more;
It is preferable to mix and react the above components so as to be preferably in the range of 1.8 to 5.0, particularly 2.0 to 4.0.

The amount of water used as a foaming agent can be adjusted depending on the density and the like desired for the modified polyisocyanurate foam of the final product. In particular, the method of the present invention has a great feature in that a product having a high expansion ratio can be produced using only water without using an evaporative foaming agent such as chlorofluorocarbon. 0.3 to 1.8% by weight, preferably 0.8 to 1.5% by weight, based on the total weight of the organic polyisocyanate, polyol and water.
The free foaming density is generally 30 kg / m ³ or less, especially 20 to 28 kg / m ³
Thus, a foam having a high expansion ratio can be easily produced without using an evaporating foaming agent.

A feature of the method of the present invention is that the reaction for producing a modified polyisocyanurate foam from the above-mentioned organic polyisocyanate, polyol and water is represented by the following formula (a).

[0017]

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In the formula, R ₁ , R ₂ and R ₃ each represent an alkyl group, and R ₄ and R ₅ each represent a hydrogen atom or an alkyl group. Catalyst and formula (b)

[0019]

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In the formula, R ₁ represents a substituted or unsubstituted alkyl, phenyl, naphthyl or benzyl group;
R ₂ , R ₃ , R ₄ , R ₅ , R ₆ and R ₇ each represent H, Cl or a C ₁ -C ₄ alkyl group in the presence of a carbodiimidization catalyst comprising The point is to implement.

In the above formula (I), "alkyl group"
May be linear or branched, for example, methyl, ethyl, n-propyl, iso-propyl,
n-butyl, tert-butyl, n-pentyl, isoamyl, n-hexyl, n-heptyl, 1-ethylpentyl,
n-octyl, 2-ethylhexyl and the like. R ₁
Alkyl group represented by to R ₃ is 6 or less carbon atoms,
It is preferably a lower one of 4 or less, while R ₄
And the alkyl group represented by R ₅ may be not only a lower alkyl group but also a higher alkyl group having up to 18 carbon atoms.

Thus, the hydroxyalkyl quaternary ammonium compound of the formula (I) used as a trimerization catalyst in the process of the present invention can be used for producing polyurethane, polyisocyanurate, polyurethane-polyisocyanurate resin and the like. The catalyst is known per se (for example, see JP-B-61-23214), and specific examples thereof include the following:

[0023]

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[0024]

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[0025]

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[0026]

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[0027]

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[0028]

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[0029]

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[0030]

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[0031]

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[0032]

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Among these hydroxyalkyl quaternary ammonium compounds, the above and the above compounds are preferably used.

On the other hand, the above formula (II) used in combination with the above hydroxyalkyl quaternary ammonium compound
Alternatively, in (III), the alkyl group represented by R ₁ may be linear or branched, and may be partially substituted by halogen or another functional group. Examples of such alkyl groups include methyl, ethyl, propyl, isopropyl, n-butyl,
t-butyl, 2-phenylethyl, 2-chloroethyl, 2-
A methoxyethyl group; Examples of the substituted or unsubstituted phenyl, naphthyl and benzyl groups include benzyl, phenyl, o-, p- or m-tolyl, xylyl, naphthyl, 4-diphenyl, o-, p- or m-chlorophenyl and the like. Can be R ₁ can preferably be a C ₁ -C ₄ alkyl, phenyl and benzyl group. Examples of R _{2 to} R ₇ in the formula (II) or (III) include hydrogen, chlorine, methyl, ethyl, propyl, isopropyl and butyl, and are preferably hydrogen and methyl.

The following are specific examples of the phosphene oxide of the formula (II) or (III).

1-methylphthalene oxide, 3-methyl-1-phenylphthalene oxide, 3-methyl-
1-benzyl phthalene oxide, 3-methyl-1-ethyl phthalene oxide, 3-methyl-1-ethyl phenyl phthalene oxide, 1-phenyl-3- (4-
Methyl-3-pentenyl) phosphorene oxide, 1-
Phenyl-3-chlorophosphorene oxide and the like. Among these phosphorene oxides, in particular, 3-methyl-1-
PHENYL-2-PHOSPHOLENE OXIDE AND 3-METHYL-1
-Phenyl-3-phosphofluorene oxide is preferably used. These phosphene oxides are known per se as a catalyst for accelerating a reaction for producing a carbodiimide compound from an organic isocyanate (for example, see Japanese Patent Publication No. 46-5991).

The present invention relates to a catalyst for producing a modified polyisocyanurate foam from an organic polyisocyanate, a polyol and water, wherein the hydroxyalkyl quaternary ammonium compound of the above formula (I) (trimerization catalyst) is used. It is characterized in that it uses a specific combination with a phosphorene oxide of formula (II) or (III) (carbodiimidization catalyst). As a result, a modified polyisocyanurate foam having a high expansion ratio can be produced by an industrially applicable method without using a problematic evaporative foaming agent such as chlorofluorocarbon.

A hydroxyalkyl quaternary ammonium compound of the formula (I) (trimerization catalyst) and a compound of the formula (II) or (I
The amount of each of the phosphorene oxides (II) (carbodiimidization catalyst) is not strictly limited, and can be changed depending on the reaction conditions and the like. However, the former is based on the weight of the organic polyisocyanate. It is preferred that the trimerization catalyst be used in a range of generally 0.1 to 10% by weight, particularly 0.5 to 5% by weight, and the latter carbodiimidation catalyst is generally used in a range of 0.05 to 5% by weight, particularly 0.5% by weight. It is appropriate to use within the range of 1 to 2% by weight.

The relative ratio between the trimerization catalyst and the carbodiimidation catalyst can be varied in a wide range depending on the physical properties desired for the final product, but usually the weight ratio of the trimerization catalyst / carbodiimidation catalyst is 0. It is preferably in the range of 0.5 to 20, especially 1 to 10.

Further, in the method of the present invention, if necessary, a urethanization catalyst (for example, triethylenediamine, dimethylethanolamine, triethylamine, trimethylaminoethylethanolamine, dimethylaminoethyl ether, pentamethyldiethylenetriamine, N-methyl Morpholine, dibutyltin dilaurate,
Tin octoate, lead octoate, etc.), foam stabilizer (for example,
Dimethylsiloxane-polyether block copolymer, etc.), crosslinking agents (eg, ethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol, diethylene glycol, triethanolamine, diethanolamine, ethylenediamine, toluenediamine, etc.), Flame retardants (for example, triphenyl phosphite, triethyl phosphite, trimethyl phosphite, cresyl diphenyl phosphite, triscresil phosphite, trischloroethyl phosphite, trisdichloropropyl phosphite,
Tris-β-chloropropyl phosphate, Tris-β-
Chloroethyl Phosphate, Tris (2,3-dibromopropyl) Phosphate, Tris (bromocresyl)
Phosphate, melamine, antimony trioxide, etc.),
Coloring agents and other additives can be used in commonly used amounts.

As a method for producing a modified polyisocyanurate foam from each of the components described above, for example, an isocyanate component comprising the above-mentioned organic polyisocyanate or an isocyanate prepolymer obtained by previously reacting an organic polyisocyanate with a polyol Component and a polyol component obtained by adding a polyol, water, trimerization catalyst and carbodiimidization catalyst, and further, if necessary, a urethane conversion catalyst, a foam stabilizer, a cross-linking agent, a flame retardant, a colorant and other additives. There is a method of preparing, combining both components at the time of use, rapidly stirring and mixing, and then foam-curing.

The reaction temperature is usually sufficient at room temperature, but may be increased to a temperature up to about 90 ° C. in some cases.

Hereinafter, the present invention will be described more specifically with reference to examples.

[0044]

【Example】

Examples 1 to 14 and Comparative Examples 1 to 6 25 g of a polyol component prepared by mixing predetermined amounts of polyol, water, catalyst, foam stabilizer and flame retardant shown in Table 1 below (however, in the case of Example 14) Is 50g)
75 g of crude MDI (diphenylmethane diisocyanate)
(However, in the case of Example 14, 50 g) was mixed, and stirred with a hand drill (2200 rpm, stirring blade 30 mmφ) for 5 seconds. 80 g of the mixture is 150 × 150 × 15
The mixture was poured into a 0 mm wooden box, and the cream time and rise time were measured. The time from liquid to the start of foaming was defined as cream time, and the time at which foaming was completed was defined as rise time. After 1 minute, the foam was touched to determine the cured state of the surface. Approximately 1 center of the cured form
It was cut into 00 × 100 × 100 mm, and the free foam density was calculated from its volume and weight.

The results are shown in Table 1 below.

[0046]

[Table 1]

[0047]

[Table 2]

[0048]

[Table 3]

Note (1): Polyol Polyol A: phthalic ester polyol, hydroxyl value = 315 (APP-315 manufactured by Union Carbide) Polyol B: pentaerythritol polyol, hydroxyl value = 410 (410NE manufactured by Asahi Glass Co., Ltd.) Polyol C: Sugar aromatic amine polyol, hydroxyl value = 410 (manufactured by Sanyo Chemical Co., RX-403) Polyol D: aliphatic polyol, hydroxyl value = 400 (manufactured by Sanyo Chemical Co., GP-400) Polyol E: aliphatic System polyol, hydroxyl value = 28.
5 (manufactured by Sanyo Chemical Industries, FA-718) Note (2): Catalyst DABCO TMR:

[0050]

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DABCO TMR2:

[0052]

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DMEA:

[0054]

Embedded image (CH ₃ ) ₂ NCH ₂ CH ₂ OH (urethane-forming catalyst) TEDA:

[0055]

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KAO No. 1:

[0057]

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3-Methyl-1-phenyl-2-phthalene oxide:

[0059]

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3-Methyl-1-phenyl-3-phosphofluorene oxide:

[0061]

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KYURISEN 52:

[0063]

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DMP-30:

[0065]

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TAP:

[0067]

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[0068] Note (3): Foam stabilizer dimethylsiloxane - Porie Te le block copolymer (manufactured by Nippon Unicar Co., SZ-1627) Note (4): a flame retardant tris (beta-chloropropyl) phosphates (Stowe Sulfur Chemical Co., Fuairoru PCF) The results of measuring the physical properties of the modified polyisocyanurate foam obtained in Example 1 were as shown in Table 2 below.

[0069]

[Table 4]

[0070] was applied to the procedure of Example 15 Example 1 to the actual Saide I Ngubodo continuous production line.

Foaming machine: low pressure foaming machine (forced stirring system), G
-05 type (manufactured by our company), discharge rate 2.0kg / min.

Double conveyor: conveyor length 18 m, conveyor speed 10 m / min.

Cutter: Traveling circular saw cutter, cut 2 minutes and 20 seconds after injection.

Molded product: face material (table) aluminum decorative board 0.32
mmt, (back) aluminum kraft paper.

Molded product (width) 350 mm, (thickness) 18 m
m.

Temperature conditions: polyol component 25 ° C., isocyanate component 40 ° C., face material temperature 20 ° C., conveyor temperature 7
5 ° C.

When continuous molding was carried out under the above conditions, there was no problem with the filling property, curability, and cutting property, and there was no particular problem with the molded product, such as warpage, shrinkage, and adhesion to paper and aluminum.

Main physical properties of serially produced product: Form density 3
2 kg / m ³ Peel strength (paper) 2.4 kg / 10 cm Oxygen index 24 Compressive strength 1.4 kg / cm ²

Continuation of the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location C08G 101: 00) C08L 75:04 (56) References JP-A-2-245013 (JP, A) JP-A Sho 53-46400 (JP, A) JP-A-60-99120 (JP, A) JP-A-64-60621 (JP, A) JP-A-47-30796 (JP, A) JP-A-51-74096 (JP, A) A) JP-A-52-27703 (JP, A) JP-A-52-100600 (JP, A) JP-A-61-235414 (JP, A) JP-A-61-235415 (JP, A) JP-A-157528 (JP, A) JP-A-49-75535 (JP, A) JP-B-46-4591 (JP, B1)

Claims (9)

(57) [Claims] 1. An organic polyisocyanate, a polyol and water are reacted with a compound represented by the formula (a): In the formula, R ₁ , R ₂ and R ₃ each represent an alkyl group, and R ₄ and R ₅ each represent a hydrogen atom or an alkyl group, and a trimerization catalyst comprising a hydroxyalkyl quaternary ammonium compound represented by the formula: b) Formula: In the formula, R ₁ represents a substituted or unsubstituted alkyl, phenyl, naphthyl or benzyl group, and R ₂ , R ₃ , R ₄ , R ₅ , R ₆ and R ₇ are each H, Cl or C ₁ -C ₄ A method for producing a modified polyisocyanurate foam, characterized in that the reaction is carried out in the presence of a carbodiimidization catalyst comprising a phosphofluorene oxide represented by the following formula: 2. The method of claim 1, wherein the hydroxyalkyl quaternary ammonium compound is The method of claim 1, wherein 3. The method of claim 1 wherein the phosphorene oxide is 3-methyl-1
The method according to claim 1, which is -phenylphosphorene oxide. 4. The method according to claim 1, wherein the polyol is 20 to 600 mg KOH /
The method according to claim 1, which is at least one polyol having a hydroxyl value in the range of g. 5. The method according to claim 1, wherein the compounding ratio of the organic polyisocyanate, polyol and water is 1.8 or more in an isocyanate index represented by an NCO / OH equivalent ratio. 6. The process according to claim 1, wherein the water is used in an amount of from 0.3 to 1.8% by weight, based on the total weight of the organic polyisocyanate, polyol and water. 7. The resulting modified polyisocyanurate foam has a free foam density of 30 kg / m ³ or less.
The described method. 8. A hydroxyalkyl quaternary ammonium compound represented by the formula (I) according to claim 1, and a compound represented by the formula (I)
A catalyst system for isocyanate polymerization comprising the phosphorene oxide represented by I) or (III). 9. A polyol composition comprising a polyol, water and the catalyst system according to claim 8.