WO1997043326A1 - Mousse de polyurethane a ecumage mecanique preparee a partir d'une formulation de polyurethane comprenant un catalyseur organometallique et un catalyseur d'amine tertiaire - Google Patents

Mousse de polyurethane a ecumage mecanique preparee a partir d'une formulation de polyurethane comprenant un catalyseur organometallique et un catalyseur d'amine tertiaire Download PDF

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Publication number
WO1997043326A1
WO1997043326A1 PCT/US1997/007903 US9707903W WO9743326A1 WO 1997043326 A1 WO1997043326 A1 WO 1997043326A1 US 9707903 W US9707903 W US 9707903W WO 9743326 A1 WO9743326 A1 WO 9743326A1
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Prior art keywords
acid
blocked
catalyst
organo
dιazbιcyclo
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PCT/US1997/007903
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English (en)
Inventor
Thomas Heebner Perry, Jr.
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The Dow Chemical Company
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Priority to AU30627/97A priority Critical patent/AU3062797A/en
Priority to JP09540972A priority patent/JP2000510188A/ja
Priority to EP97925508A priority patent/EP0898587A1/fr
Priority to BR9709003A priority patent/BR9709003A/pt
Publication of WO1997043326A1 publication Critical patent/WO1997043326A1/fr

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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
    • C08J9/30—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof by mixing gases into liquid compositions or plastisols, e.g. frothing with air
    • 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
    • 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
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0086—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing characterised by the cushion backing, e.g. foamed polyurethane
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0089—Underlays
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0008—Foam properties flexible
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • 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

Definitions

  • This invention relates to polyurethane foam.
  • This invention particularly relates to mechanically frothed polyurethane foam useful for preparing attached cushion carpets and carpet underlays.
  • Cost is a very important property because of the highly competitive nature of the carpet industry. However, if a carpet does not properly install or rolls up after installation, the carpet is not desirable to purchasers.
  • Polyurethane foams are generally prepared by admixing an "A" component, a polyisocyanate, with a “B” component, an active hydrogen containing material, wherein a gas is either mechanically introduced or produced chemically, the gas forming bubbles which in turn form a cell-like structure in the cured polyurethane.
  • the process of introducing gas into a polyurethane formulation is known as "blowing" the formulation. The greater the amount of gas introduced into a polyurethane formulation, the lower the density of the resultant foam produced therewith.
  • the present invention is a process for preparing a polyurethane foam useful for preparing attached cushion carpets comprising admixing, with frothing, a polyurethane formulation including a polyisocyanate component, an active hydrogen containing component and a catalyst component, wherein the catalyst component includes at least two catalysts, at least one being an organo-metallic catalyst and at least one other being a tertiary amine catalyst.
  • the present invention is a polyurethane foam
  • a polyurethane foam comprising a polyurethane foam prepared by admixing, with frothing, a polyurethane formulation including a polyisocyanate component, an active hydrogen containing component and a catalyst component, wherein the catalyst component consists of at least two catalysts, at least one being an organo-metallic catalyst and at least one other being a tertiary amine catalyst.
  • the present invention is a textile having an attached cushion comprising a textile and a polyurethane foam adherent thereto wherein the polyurethane foam is prepared by admixing, with frothing, a polyurethane formulation including a polyisocyanate component, an active hydrogen containing component and a catalyst component, wherein the catalyst component consists of at least two catalysts, at least one being an organo-metallic catalyst and at least one other being a tertiary amine catalyst.
  • the present invention is a polyurethane foam pad integral to a polyurethane backed textile, known as an attached cushion carpet.
  • the polyurethane backed textile is a carpet or carpet tile having at least one polyurethane foam layer.
  • This application of a polyurethane layer in a carpet is disclosed in, for example, U.S. Patent No. 4,853,054, to Turner, et al., which is incorporated herein by reference, and U.S. Patent No. 5,104,693 to Jenkmes, et al., also incorporated herein by reference.
  • the present invention is a polyurethane foam for use as a carpet underlay.
  • Carpet underlays are prepared in a manner similar to attached cushion carpet except that the polyurethane foam is applied to a substrate, usually a woven substrate prepared from polypropylene. After the polyurethane foam has cured, the underlay can be used to supplement cushioning to attached cushion carpets or as a cushioning support for unpadded carpets.
  • the polyurethane foams of the present invention are similar to conventionally prepared foams except that they are prepared from formulations having both an organo-metallic and an amme catalyst.
  • the polyurethane foams so produced have sufficiently low densities to be less expensive to produce than conventional polyurethane foams for carpet applications, yet the foams have sufficient dimensional stability and roll set properties to be desirable for use in carpet applications.
  • foam formulations of the present invention can have improved foaming properties.
  • the desirable combination of good physical properties and low density of the present invention results from the use of the dual catalysts of the present invention.
  • the foam formulations used to prepare the polyurethane foams of the present invention have from 0.5 to 3 parts water per hundred parts polyol, from 0.02 to 0.25 parts organo-metallic and amine catalyst per hundred parts polyol, and from 0.4 to 2 parts surfactant per hundred parts polyol.
  • the resultant polyurethane foams have densities of from 8 to 13 pounds per cubic foot (lb. /ft 3 ) (from 128 to 208 kg/M 3 ) .
  • the foams of the present invention will have a density of about 9 lb. /ft 3 (144 kg/M 3 ) .
  • Conventional polyurethane foams useful for carpet applications when prepared under similar conditions to the polyurethane foams of the present invention can have densities of from 13 to 16 lb. /ft 3 (from 192 to 256 kg/M 3 ) .
  • the polyisocyanate can be any polyisocyanate in an amount to provide an isocyanate index of 90 to 130.
  • An isocyanate index is a value calculated by dividing the equivalents of isocyanate by the equivalents of isocyanate reactive components in a polyurethane formulation and then multiplying by 100. For example, in a formulation where both isocyanate and isocyanate reactive components are present in a stoichiometric amount, such a formulation would have an isocyanate index of 100.
  • a polyisocyanate can be used as is or it can be first combined with less than a stochiometric amount of a polyol to form a prepolymer.
  • the prepolymer is at least 30 percent by weight of the total polyisocyanate and is a soft segment prepolymer which is the reaction product of a stoichiometric excess of MDI or an MDI derivative and an isocyanate reactive organic polymer having an equivalent weight from 500 to 5,000, the prepolymer having an isocyanate group content of 10 to 30 percent by weight.
  • the underlay is prepared by frothing the reactants with air.
  • Foam formulations of the present invention include a polyol component .
  • the polyol component of the foam formulation can be any polyol or polyol mixture which can be used to prepare a foam which can withstand the rigorous physical property and handling requirements of foams used in carpet applications.
  • the polyol component can preferably be a polyol mixture having as one part of the mixture a polyol based on a C 3 -C 8 alkylene oxide, which has an equivalent weight of 1000 to 5000, and an internal poly(ethylene oxide) block or a terminal ethylene oxide cap constituting 15 to 30 percent of the weight of the polyol, or mixture of such polyols wherein the polyol or mixture thereof has an average functionality of 1.8 to 2.2
  • the other portion of the polyol mixture is preferably a minor amount of a low equivalent weight compound having about 2 active hydrogen containing groups per molecule.
  • the polyurethane foams of the present invention are prepared with at least two catalysts.
  • One catalyst is an organo-metallic catalyst, preferably an organo-tm such as: dimethyltm dilaurate, dibutyltin dilaurate, dioctyltin dilaurate, stannous octoate, dibutyl tin sulfide, dibutyltin dnsooctylmercaptoacetate, dioctyltin dnsoctylmercaptoacetate.
  • Other cations besides tin can also be used with the present invention. For example, ferric acetylacetonate and nickel acetylacetonate can be used.
  • At least one other catalyst besides an organo-metallic catalyst is used to prepare the urethane foams of the present invention.
  • the second catalyst is a tertiary amme catalyst such as triethylenediamine, acid blocked pentamethyldipropylenetnamine, 1,8- d ⁇ azab ⁇ cyclo-5,4, 0-undecene-7 unblocked or blocked with phenolic acid or 2-ethylhexano ⁇ c acid or oleic acid or formic acid, N-methyl morpholine, N-ethyl morpholine, diethyl ethanolamine, N-cocoa morpholine, l-methyl-4-d ⁇ methylam ⁇ noethyl piperazine, bis (dimethylammoethyl) ether, 3-methoxy-N-d ⁇ methylpropylam ⁇ ne, N,N- d ⁇ ethyl-3-d ⁇ ethyl aminopropylamine, dimethylbenzyl amine.
  • the foams of the present invention are prepared using blowing agents.
  • the blowing agent is preferably air, however, other gases, such as carbon dioxide, nitrogen can be used.
  • the blowing agent is most preferably introduced into the polymer by frothing.
  • a frother is a device which injects the blowing agent, usually compressed air, into an admixture as it agitates the admixture. Frothing a polyurethane formulation is often facilitated by using a surfactant to stabilize the foam, that is, to enhance the ability of the foam to retain blowing gasses, and to improve cell structure.
  • foams of the present invention can have an inherently finer, more uniform cell structure. Therefore, surfactants which have maximum frothing efficiency can be used with the formulations of the present invention, regardless of their impact on the ability of the formulation to retain cell structure, so long as the surfactants are not foam destabilizers.
  • the foams of the present invention are prepared from formulations including fillers.
  • the fillers are preferably aluminum oxide trihydrate (alumina), calcium carbonate, barium sulfate or mixtures thereof. Other fillers can be used instead of or in addition to the preferred fillers.
  • the formulations used to prepare the polyurethane foams of the present invention include fillers at a level of from about 40 parts per hundred parts of polyol to about 250 parts per hundred parts of polyol.
  • polyisocyanates, fillers, and polyols are examples of useful materials which can be included in the formulations of the present invention, other materials can also be used.
  • the polyisocyanate component of the formulations of the present invention can be advantageously selected from organic polyisocyanates, modified polyisocyanates, isocyanate-based prepolymers, and mixtures thereof. These can include aliphatic and cycloaliphatic isocyanates, but aromatic and especially multifunctional aromatic isocyanates are preferred.
  • Preferred polyisocyanates are 2,4- and 2,6- toluenednsocyanate and the corresponding isome ⁇ c mixtures; 4,4'-, 2,4'- and 2,2' -diphenyl-methanednsocyanate and the corresponding isomeric mixtures; mixtures of 4,4'-, 2,4'- and 2,2'- diphenylmethanednsocyanates and polyphenyl polymethylene polyisocyanates PMDI; and mixtures of PMDI and toluene dnsocyanates.
  • aliphatic and cycloaliphatic isocyanate compounds such as 1,6- hexamethylene-dnsocyanate; l- ⁇ socyanato-3, 5, 5-tr ⁇ methyl-l-3- lsocyanatomethyl-cyclohexane; 2, 4- and 2, 6-hexahydrotoluene- dnsocyanate, as well as the corresponding isomeric mixtures; 4,4'-, 2,2'- and 2, 4 '-dicyclohexylmethanednsocyanate, as well as the corresponding isomeric mixtures.
  • modified multifunctional isocyanates that is, products which are obtained through chemical reactions of the above dnsocyanates and/or polyisocyanates.
  • modified multifunctional isocyanates that is, products which are obtained through chemical reactions of the above dnsocyanates and/or polyisocyanates.
  • exemplary are polyisocyanates containing esters, ureas, biurets, allophanates and preferably carbodiimides and/or uretonimmes; isocyanurate and/or urethane group containing dnsocyanates or polyisocyanates.
  • NCO isocyanate groups
  • Suitable prepolymers also useful with the present invention are prepolymers having NCO contents of from 5 to 40 weight percent, more preferably from 15 to 30 weight percent. These prepolymers are prepared by reaction of the di- and/or poly-isocyanates with materials including lower molecular weight diols, triols, but also they can be prepared with multivalent active hydrogen compounds such as di- and t ⁇ -amines and di- and tri-thiols.
  • aromatic polyisocyanates containing urethane groups preferably having NCO contents of from 5 to 40 weight percent, more preferably 20 to 35 weight percent, obtained by reaction of dnsocyanates and/or polyisocyanates with, for example, lower molecular weight diols, triols, oxyalkylene glycols, dioxyalkylene glycols or polyoxyalkylene glycols having molecular weights up to about 800.
  • These polyols can be employed individually or in mixtures as di- and/or polyoxyalkylene glycols.
  • diethylene glycols, dipropylene glycols, polyoxyethylene glycols, polyoxypropylene glycols and polyoxypropylenepolyoxyethylene glycols can be used.
  • PMDI in any of its forms can also be used and is preferred. In this case it preferably has an equivalent weight between 125 and 300, more preferably from 130 to 175, and an average functionality of greater than about 2. More preferred is an average functionality of from 2.5 to 3.5.
  • the viscosity of the polyisocyanate component is preferably from 25 to 5,000 centipoise (cps) (0.025 to about 5 Pa's), but values from 100 to 1,000 cps at 25°C (0.1 to 1 Pa's) are preferred for ease of processing. Similar viscosities are preferred where alternative polyisocyanate components are selected. Still, preferably, the polyisocyanate component of the formulations of the present invention is selected from the group consisting of MDI, PMDI, an MDI prepolymer, a PMDI prepolymer, a modified MDI and mixtures thereof.
  • Polyfunctional active hydrogen containing materials useful with the present invention can include materials other than those already described hereinabove.
  • Active hydrogen containing compounds most commonly used in polyurethane production are those compounds having at least two hydroxyl groups. Those compounds are referred to herein as polyols. Representatives of suitable polyols are generally known and are described in such publications as High Polymers, Vol. XVI,
  • Such materials include those selected from the following classes of compositions, alone or in admixture: (a) alkylene oxide adducts of polyhydroxyalkanes; (b) alkylene oxide adducts of non-reducing sugars and sugar derivatives; (c) alkylene oxide adducts of phosphorus and polyphosphorus acids; and (d) alkylene oxide adducts of polyphenols.
  • compositions alone or in admixture: (a) alkylene oxide adducts of polyhydroxyalkanes; (b) alkylene oxide adducts of non-reducing sugars and sugar derivatives; (c) alkylene oxide adducts of phosphorus and polyphosphorus acids; and (d) alkylene oxide adducts of polyphenols.
  • base polyols polyols of these types are referred to herein as "base polyols”.
  • alkylene oxide adducts of polyhydroxyalkanes useful herein are adducts of ethylene glycol, propylene glycol, 1,3- dihydroxypropane, 1, 4-dihydroxybutane, and 1, 6-dihydroxyhexane, glycerol, 1, 2, 4-trihydroxybutane, 1, 2, 6-trihydroxyhexane, 1,1,1- trimethylolethane, 1, 1, 1-trimethylolpropane, pentaerythritol, polycaprolactone, xylitol, arabitol, sorbitol, mannitol.
  • alkylene oxide adducts of polyhydroxyalkanes are the ethylene oxide adducts of trihydroxyalkanes.
  • Other useful adducts include ethylene diamine, glycerin, ammonia, 1, 2, 3, 4-tetrahydroxy butane, fructose, and sucrose.
  • poly(oxypropylene) glycols are also preferred.
  • triols are also preferred.
  • tetrols are also preferred.
  • hexols are also preferred.
  • polyols also include poly (oxypropyleneoxyethylene)polyols.
  • the oxyethylene content should preferably comprise less than about 80 weight percent of the total polyol weight and more preferably less than about 40 weight percent.
  • the ethylene oxide, when used, can be incorporated in any way along the polymer chain, for example, as internal blocks, terminal blocks, or randomly distributed blocks, or any combination thereof.
  • Polyamines, amine-terminated polyols, polymercaptans and other isocyanate-reactive compounds are also suitable in the present invention.
  • Polyisocyanate polyaddition active hydrogen containing compounds are particularly preferred for use with the present invention.
  • PIPA compounds are typically the reaction products of TDI and triethanolamine.
  • a method for preparing PIPA compounds can be found in, for example, United States Patent 4,374,209, issued to Rowlands.
  • copolymer polyols are base polyols containing stablely dispersed polymers such as acrylonitrile-styrene copolymers. Production of these copolymer polyols can be from reaction mixtures comprising a variety of other materials, including, for example, catalysts such as azobisisobutyro- nitrile; copolymer polyol stabilizers; and chain transfer agents such as isopropanol.
  • the polyisocyanate and the B component are admixed and then the blowing agent gas is blended into the admixture using, for example, an OAKES FROTHER* (*OAKES FROTHER is a trade designation of the E.T. Oakes Corporation) .
  • OAKES FROTHER* is a trade designation of the E.T. Oakes Corporation.
  • the composition is preferably applied to a textile or other substrate prior to any significant level of curing using equipment such as a doctor knife, air knife, or extruder to apply and gauge the layer.
  • the polyurethane formulation can be applied by forming it into a layer using a moving belt, allowing it to partially cure, and then marrying it to the textile using equipment such as a double belt laminator. After application of the foam layer, the polyurethane is cured by applying heat by means of an infrared oven, open flame forced draft convection impingement oven, heated plates or the like.
  • the polyurethane foam carpet underlays of the present invention can be prepared in a single step or in two or more steps.
  • the A and B polyurethane components are all admixed in a frother at the same time and applied to a textile or other substrate.
  • some or all of the water, catalyst, and optionally other components of the polyurethane formulation are added to the formulation after it has been frothed. Preferably, this is done using a static mixer, but any means of adding and mixing the components which does not substantially remove or reduce the level of entrapped gasses added by frothing can be used.
  • Textiles useful with the present invention include broadloom carpet, automotive carpet, fabrics for automotive trim and automotive trunk liners.
  • the textiles useful with the present invention can include synthetic playing surfaces, woven polymeric scrim, non woven polymeric scrim, wall coverings, sheet polymers, furniture covers.
  • One preferred embodiment of the present invention is carpet tile prepared by incorporating the catalysts of the present invention into a carpet tile production process such as that disclosed in U.S. Patent No. 4,657,790 to Wing, et al. The '790 Wing, et al . patent is incorporated herein by reference.
  • the admixture was then mixed and heated to 120°F (48.9°C) and then allowed to cool to about 60°F (15.5°C) and was hereinafter referred to as the master batch.
  • the master batch and a 2.3 functional PMDI having an NCO content of about 32% and an average molecular weight of 290 were pumped to a 2 inch (5.1 cm) OAKES FROTHER* (*OAKES FROTHER was a trade designation of the E.T. Oakes Corporation) and frothed using compressed air.
  • the Master batch was fed to the frother at a rate of 181 7 g/minute and the PMDI was fed at a rate of 42.5 g/minute
  • the resulting froth had a density of about 284g/l.
  • the froth was applied using a knife with a gap of 0.25 inches (0.64 cm) onto one side of a 2 8 oz/yd ⁇ (95 g/m 2 ) woven polypropylene carrier material.
  • the resultant polyurethane foam backed textile was cured at 270°F (132°C) for about 6 minutes trimmed and rolled and cut for testing. Upon examination, the foam backed textile had satisfactory foam appearance and tactile properties.
  • a second master batch was prepared as follows. 100 parts of a 46:46:8 mixture of a 2,000 molecular weight poly(propylene oxide) diol having about 10 percent ethylene oxide end capping, a 3,000 molecular weight 8 weight percent ethylene oxide poly(propylene oxide ethylene oxide) hetero-t ⁇ ol, and diethylene glycol were admixed with 190 parts of calcium carbonate, heated to 120°F (48.9°C) and cooled to 72°F (22.2°C) .
  • 290 parts of the second master batch was mixed with: 1.8 parts of a of 1.25 percent solution of UL-6* (* UL-6 was a trade designation the Witco Chemical Corp. and was dibutyltin dnsooctylmercaptoacetate) in the diol described above, 9 parts of a 20 percent mixture of water and the diol described above, 7.5 parts of a 20 percent mixture of L5614* silicone surfactant in the diol described above, and 73.0 parts of a prepolymer having a percent NCO content of 27.5 percent, prepared by reacting a 1:1 a prepolymer having an NCO content of 23 percent made by reacting a 45:55 mixture of dipropylene glycol and tripropylene glycol with MDI and a 2.3 functional PMDI having about 14 percent of the 0',P' isomer.
  • UL-6 was a trade designation the Witco Chemical Corp. and was dibutyltin dnsooctyl
  • the materials were fed into an OAKES FROTHER and frothed therein with compressed air and applied by knife with a gap of 0.48cm (190 mils) onto one side of a polypropylene carrier material.
  • the resultant carrier and polyurethane foam were heated 177°C (350°F) until the foam was cured (about 8 minutes) .
  • the resulting carpet underlay was trimmed, cut and rolled.
  • the underlay had a density of 12.1 lb./ft 3 (194 g/1), excellent surface appearance and fine cell structure.
  • Examples 3-7 and Comparative Examples 8-9 were prepared substantially identically to Examples 1 except that the components listed in the table were used.
  • the resulting carpet underlay was trimmed, cut, and rolled.
  • the samples were subjected to physical testing, including the bend split test, the results of which were reported in the Table.
  • the Bend Split test was done by taking a 1 inch by 2 inch (2.5 cm x 5.1 cm ) foam sample and bending it over a 0.25 inch (0.64 cm) plastic dowel and securing the foam to the dowel with a binder clip.
  • the foam was then submerged in a 97°F (36.1°C) water bath observed to determine the length of time required for the foam to split completely across the 1 inch diameter (2.5 cm) down to the primary backing with the maximum reportable time being 3 minutes.
  • VORANOL 9420 was a trade designation of The Dow Chemical Company and was a
  • ⁇ VORANOL 9800 was a trade designation of The Dow Chemical Company and was a
  • Propoxylated ammo a ⁇ unoethylethanolamine having a nominal functionality of 4 and an OH number of 812.
  • ° POLYCAT SA-102 was a trade designation of Air Products and Chemicals, Inc., and was a 53 percent solution of 1,8 diaza-bicyclo- 5, 4, O-undecene-7, blocked with 2-ethylehexanoc ⁇ acid, in water.
  • PAPI-7940 was a trade designation of The Dow Chemical Company and was s a PMDI having an NCO content of 32 percent and an average molecular weight of 290.
  • the isocyanate index of a formulation was calculated by dividing the number of isocyanate equivalents by the number of isocyanate reactive equivalents and multiplying by 100. 9 ASTM D-3676-78

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Materials Engineering (AREA)
  • Polyurethanes Or Polyureas (AREA)

Abstract

L'invention concerne une mousse que l'on a fait écumer mécaniquement et qui est préparée à partir d'une formulation de polyuréthane qui comprend à la fois un catalyseur organométallique et un catalyseur d'amine tertiaire. Les mousses de la présente invention ont une faible densité et de bonnes propriétés physiques, ce qui les rend utiles pour la fabrication de tapis.
PCT/US1997/007903 1996-05-15 1997-05-08 Mousse de polyurethane a ecumage mecanique preparee a partir d'une formulation de polyurethane comprenant un catalyseur organometallique et un catalyseur d'amine tertiaire WO1997043326A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
AU30627/97A AU3062797A (en) 1996-05-15 1997-05-08 Mechanically frothed polyurethane foam prepared from a polyurethane formulation including an organo-metallic catalyst and a tertiary amine catalyst
JP09540972A JP2000510188A (ja) 1996-05-15 1997-05-08 有機金属触媒及び３級アミン触媒を含むポリウレタン組成物より製造された、機械的に起泡されたポリウレタンフォーム
EP97925508A EP0898587A1 (fr) 1996-05-15 1997-05-08 Mousse de polyurethane a ecumage mecanique preparee a partir d'une formulation de polyurethane comprenant un catalyseur organometallique et un catalyseur d'amine tertiaire
BR9709003A BR9709003A (pt) 1996-05-15 1997-05-08 Processo para preparar uma espuma de poliuretano espuma de poliuretano processo para preparar um carpete com substrato ou substrato de carpete de poliuretano e carpete com substrato ou substrato de carpete de espuma de poliuretano

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US1777096P 1996-05-15 1996-05-15
US60/017,770 1996-05-15

Publications (1)

Publication Number Publication Date
WO1997043326A1 true WO1997043326A1 (fr) 1997-11-20

Family

ID=21784444

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1997/007903 WO1997043326A1 (fr) 1996-05-15 1997-05-08 Mousse de polyurethane a ecumage mecanique preparee a partir d'une formulation de polyurethane comprenant un catalyseur organometallique et un catalyseur d'amine tertiaire

Country Status (6)

Country Link
EP (1) EP0898587A1 (fr)
JP (1) JP2000510188A (fr)
AU (1) AU3062797A (fr)
BR (1) BR9709003A (fr)
CA (1) CA2252796A1 (fr)
WO (1) WO1997043326A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000039178A1 (fr) * 1998-12-29 2000-07-06 The Dow Chemical Company Mousses polyurethanes preparees a partir de dispersions polyurethanes mecaniquement ecumees
WO2004053223A2 (fr) * 2002-12-09 2004-06-24 Dow Global Technologies Inc. Procede d'application d'une mousse a base d'une dispersion de polyurethane sur un article
EP1927466A1 (fr) * 2006-11-30 2008-06-04 Benecke-Kaliko AG Formation composite dotée d'une couche de polyuréthane, son procédé de fabrication et d'utilisation
DE102010028583B4 (de) * 2009-05-11 2015-04-23 Frank Prissok Abbau von Polyurethanen in Gegenwart spezieller ionischer Flüssigkeiten und einem geringen Wasseranteil

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4492787B2 (ja) * 2003-03-18 2010-06-30 東ソー株式会社 ポリウレタン樹脂製造用触媒組成物及びポリウレタン樹脂の製造方法
ATE449117T1 (de) * 2006-04-07 2009-12-15 Dow Global Technologies Inc Heissverarbeitung von polyurethan- teppichträgersystemen mit doppelt verzögertem aktionskatalysator
JP2007308547A (ja) * 2006-05-17 2007-11-29 Emulsion Technology Co Ltd バッキング剤用組成物
JP5591272B2 (ja) * 2011-03-31 2014-09-17 三洋化成工業株式会社 ポリウレタンインテグラルスキンフォームの製造方法
TWI480187B (zh) * 2012-03-23 2015-04-11 Formosa Saint Jose Corp Car foot pad construction
WO2015092988A1 (fr) * 2013-12-17 2015-06-25 ニチアス株式会社 Composition de solution-mère de mousse d'uréthane rigide et procédé d'isolation

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3755212A (en) * 1971-05-13 1973-08-28 Dow Chemical Co Air blown polyurethane foams
US4006124A (en) * 1974-07-16 1977-02-01 Bayer Aktiengesellschaft Amidine-metal complexes and their use as catalysts for isocyanate polyaddition reactions
US4275172A (en) * 1980-01-28 1981-06-23 Union Carbide Corporation Frothable polyurethane composition and a cellular foam produced therefrom suitable for use in joints between wallboards
US4515846A (en) * 1984-04-09 1985-05-07 The Dow Chemical Company Polyurethane backed carpet formed with two catalysts
EP0482682A1 (fr) * 1990-09-14 1992-04-29 Recticel Méthode pour la préparation de mousse flexible de polyuréthane
WO1994009047A1 (fr) * 1992-10-09 1994-04-28 The Dow Chemical Company Nouveaux catalyseurs pour la preparation de polyurethanes

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3755212A (en) * 1971-05-13 1973-08-28 Dow Chemical Co Air blown polyurethane foams
US4006124A (en) * 1974-07-16 1977-02-01 Bayer Aktiengesellschaft Amidine-metal complexes and their use as catalysts for isocyanate polyaddition reactions
US4275172A (en) * 1980-01-28 1981-06-23 Union Carbide Corporation Frothable polyurethane composition and a cellular foam produced therefrom suitable for use in joints between wallboards
US4515846A (en) * 1984-04-09 1985-05-07 The Dow Chemical Company Polyurethane backed carpet formed with two catalysts
EP0482682A1 (fr) * 1990-09-14 1992-04-29 Recticel Méthode pour la préparation de mousse flexible de polyuréthane
WO1994009047A1 (fr) * 1992-10-09 1994-04-28 The Dow Chemical Company Nouveaux catalyseurs pour la preparation de polyurethanes

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000039178A1 (fr) * 1998-12-29 2000-07-06 The Dow Chemical Company Mousses polyurethanes preparees a partir de dispersions polyurethanes mecaniquement ecumees
AU760247B2 (en) * 1998-12-29 2003-05-08 Dow Global Technologies Inc. Polyurethane foams prepared from mechanically frothed polyurethane dispersions
WO2004053223A2 (fr) * 2002-12-09 2004-06-24 Dow Global Technologies Inc. Procede d'application d'une mousse a base d'une dispersion de polyurethane sur un article
WO2004053223A3 (fr) * 2002-12-09 2005-01-27 Dow Global Technologies Inc Procede d'application d'une mousse a base d'une dispersion de polyurethane sur un article
EP1927466A1 (fr) * 2006-11-30 2008-06-04 Benecke-Kaliko AG Formation composite dotée d'une couche de polyuréthane, son procédé de fabrication et d'utilisation
EP1927466B1 (fr) 2006-11-30 2016-01-06 Benecke-Kaliko AG Formation composite dotée d'une couche de polyuréthane, son procédé de fabrication et d'utilisation
DE102010028583B4 (de) * 2009-05-11 2015-04-23 Frank Prissok Abbau von Polyurethanen in Gegenwart spezieller ionischer Flüssigkeiten und einem geringen Wasseranteil

Also Published As

Publication number Publication date
EP0898587A1 (fr) 1999-03-03
JP2000510188A (ja) 2000-08-08
AU3062797A (en) 1997-12-05
BR9709003A (pt) 1999-08-03
CA2252796A1 (fr) 1997-11-20

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