Catalyst blends for producing low thermal desorption polyurethane foams
View Patent ↗A catalyst composition for catalyzing a polyurethane forming reaction includes a gelling catalyst and a blowing catalyst selected such that the resulting polyurethane foam has a low level of volatile and/or malodorous material in it. The gelling catalysts are selected from tertiary aminoalkyl substituted primary or secondary amines; and the blowing catalysts are selected from bis(aminoalkyl) ethers comprising alkanol moieties, primary amine moieties, or ureido moieties derived from such primary amine moieties.
1. A formulation for producing a polyurethane foam, the formulation comprising a polyol, a polyisocyanate, water, and a catalyst composition comprising:
1) a gelling catalyst represented by the general formula:
in which:
A represents CH or N,
R 1 represents hydrogen or the group
n represents an integer between 1 and 3, inclusive,
R 2 and R 3 each represent hydrogen or a C1-C6 alkyl group, and
R 6 represents H or 3-aminopropyl, provided that:
when A is N, R 4 and R 5 each represents a C1-C6 alkyl group or together represent a C2-C5 alkylene group which may contain a ring amine moiety —NR—, where R is hydrogen, a C1-C4 alkyl group,
and
when A is CH, R 4 and R 5 together represent a C2-C5 alkylene group containing a ring amine moiety —NR—, where R is a C1-C4 alkyl group or the group
and
2) a blowing catalyst according to the general formula:
wherein:
R 7 , R 8 , and R 9 each independently represents a C1-C4 alkyl group;
R 10 represents H, a C1-C4 alkyl group, a C6-C20 aryl group, or a C6-C20 aralkyl group;
m, p, and q each independently represents an integer between 1 and 4, inclusive; and Z represents —OH, —NH 2 , —NH—CO—NH 2 , or
2. The formulation of claim 1 , wherein R 4 and R 5 are each a methyl group, A is nitrogen, and R 2 and R 3 are each hydrogen.
3. The formulation of claim 1 , wherein R 7 , R 8 , and R 9 are each a methyl group, m and p are each equal to 2, and q is either 2 or 3.
4. The formulation of claim 1 , wherein A is CH, n is an integer between 1 and 3, inclusive, and R 4 and R 5 together constitute —CH 2 CH 2 N(CH 3 )CH 2 —.
5. The formulation of claim 1 , wherein the gelling catalyst comprises N,N,N″,N″-tetramethyldipropylenetriamine.
6. The formulation of claim 1 , wherein the gelling catalyst comprises 3-dimethylaminopropylamine.
7. The formulation of claim 1 , wherein the gelling catalyst comprises N,N-bis(3-dimethylaminopropyl)-1,3-propanediamine.
8. The formulation of claim 1 , wherein the blowing catalyst comprises N,N,N′-trimethyl-N′-2-hydroxyethylbis(aminoethyl) ether.
9. The formulation of claim 8 , wherein the gelling catalyst comprises N,N,N″,N″-tetramethyldipropylenetriamine.
10. The formulation of claim 8 , wherein the gelling catalyst comprises 3-dimethylaminopropylamine.
11. The formulation of claim 8 , wherein the gelling catalyst comprises N,N-bis(3-dimethylaminopropyl)-1,3-propanediamine.
12. The formulation of claim 1 , wherein the blowing catalyst comprises N,N,N′-trimethyl-N′-3-aminopropylbis(aminoethyl) ether.
13. The formulation of claim 1 , wherein the blowing catalyst comprises N,N,N′-trimethyl-N′-3-ureidopropylbis(aminoethyl) ether.
14. The formulation of claim 1 , further comprising a carboxylic acid that forms a salt with one or both of the gelling catalyst and the blowing catalyst.
15. A polyurethane foam comprising a product of a reaction between a polyol and a polyisocyanate, the reaction taking place in the presence of water and a catalyst composition comprising:
1) a gelling catalyst represented by the general formula:
in which:
A represents CH or N,
R 1 represents hydrogen or the group
n represents an integer between 1 and 3, inclusive,
R 2 and R 3 each represent hydrogen or a C1-C6 alkyl group, and
R 6 represents H or 3-aminopropyl, provided that:
when A is N, R 4 and R 5 each represents a C1-C6 alkyl group or together represent a C2-C5 alkylene group which may contain a ring amine moiety —NR—, where R is hydrogen, a C1-C4 alkyl group, or the group
and
when A is CH, R 4 and R 5 together represent a C2-C5 alkylene group containing a ring amine moiety —NR—, where R is a C1-C4 alkyl group or the group
and PS 2) a blowing catalyst according to the general formula:
wherein:
R 7 , R 8 , and R 9 each independently represents a C1-C4 alkyl group;
R 10 represents H, a C1-C4 alkyl group, a C6-C20 aryl group, or a C6-C20 aralkyl group;
m, p, and q each independently represents an integer between 1 and 4, inclusive; and Z represents —OH, —NH 2 , —NH—CO—NH 2 , or
16. A method of making a polyurethane foam, the method comprising mixing together a polyol, a polyisocyanate, water, and a catalyst composition comprising:
1) a gelling catalyst represented by the general formula:
in which:
A represents CH or N,
R 1 represents hydrogen or the group
n represents an integer between 1 and 3, inclusive,
R 2 and R 3 each represent hydrogen or a C1-C6 alkyl group, and
R 6 represents H or 3-aminopropyl, provided that
when A is N, R 4 and R 5 each represents a C1-C6 alkyl group or together represent a C2-C5 alkylene group which may chain a ring amine moiety —NR—, where R is hydrogen, a C1-C4 alkyl group, or the group
and
when A is CH, R 4 and R 5 together represent a C2-C5 alkylene group containing a ring amine moiety —NR—, where R is a C1-C4 alkyl group or the group
2) a blowing catalyst according to the general formula:
wherein:
R 7 , R 8 , and R 9 each independently represents a C1-C4 alkyl group;
R 10 represents H, a C1-C4 alkyl group, a C6-C20 aryl group, or a C6-C20 aralkyl group;
m, p, and q each independently represents an integer between 1 and 4, inclusive; and Z represents —OH, —NH 2 , —NH—CO—NH 2 , or
.
17. The method of claim 16 , wherein the blowing catalyst comprises N,N,N′-trimethyl-N′-2-hydroxyethylbis(aminoethyl) ether.
18. The method of claim 16 , wherein the blowing catalyst comprises N,N,N′-trimethyl-N′-3-aminopropylbis(aminoethyl) ether.
19. The method of claim 16 , wherein the blowing catalyst comprises N,N,N′-trimethyl-N′-3-ureidopropylbis(aminoethyl) ether.
20. The method of claim 16 , wherein the catalyst composition further comprises a carboxylic acid that forms a salt with one or both of the gelling catalyst and the blowing catalyst.