Catalysts useful in polyurethane foam
The invention provides amine catalyst composition useful in producing a polyurethane foam, which catalyst comprises a material described by the general structure: wherein R 1 and R 2 in each occurrence are independently selected from the group consisting of: methyl, ethyl, propyl, and butyl; m in each occurrence is any integer between 2 and about 10, including 2 and 10; and R 3 and R 4 are each independently selected from the group consisting of: hydrogen and C 1 to C 6 alkyl. flexible polyurethane foams produced using a catalyst according to the invention are low in odor, are not prone to discoloration, and have a low volatile organic chemical (VOC) content.
1 ) An amine catalyst composition useful in producing a polyurethane foam, which catalyst comprises a material described by the general structure:
wherein R 1 and R 2 in each occurrence are independently selected from the group consisting of: methyl, ethyl, propyl, and butyl; m in each occurrence is any integer between 2 and about 10, including 2 and 10; and R 3 and R 4 are each independently selected from the group consisting of: hydrogen and C 1 to C 6 alkyl.
2 ) An amine catalyst according to claim 1 wherein R 1 and R 2 in each occurrence are methyl, wherein m in each occurrence equals 3, and wherein n equals 2.
3 ) An catalyst according to claim 1 wherein the vapor pressure of said composition is less than about 5 mm Hg @ 25° C.
4 ) An catalyst according to claim 1 wherein the vapor pressure of said composition is less than about 2 mm Hg @ 25° C.
5 ) A process for producing a polyurethane foam which comprises the steps of:
a) providing a diisocyanate;
b) providing a polyol; and
c) contacting said polyol with said diisocyanate in the presence of a catalyst mixture which comprises a material described by the general structure:
wherein R 1 and R 2 in each occurrence are independently selected from the group consisting of: methyl, ethyl, propyl, and butyl; m in each occurrence is any integer between 2 and about 10, including 2 and 10; and R 3 and R 4 are each independently selected from the group consisting of hydrogen and C 1 to C 6 alkyl.
6 ) A process according to claim 5 in which said catalyst comprises 3-(bis-(dimethylaminopropyl)amino)-propionamide.
7 ) A process according to claim 5 wherein said polyol is a polyester polyol.
8 ) A process according to claim 5 wherein said diisocyanate is a diisocyanate selected from the group consisting of 4,4′ diphenylmethane di-isocyanate and toluene diisocyanate.
9 ) A cured polyurethane foam which comprises residual amounts of a catalyst, said catalyst comprising a material described by the general structure:
wherein R 1 and R 2 in each occurrence are independently selected from the group consisting of: methyl, ethyl, propyl, and butyl; m in each occurrence is any integer between 2 and about 10, including 2 and 10; and R 3 and R 4 are each independently selected from the group consisting of hydrogen and C 1 to C 6 alkyl, wherein the amount of residual catalyst present is any amount between 0.01 and 1.00% by weight based upon the total weight of said foam.
10 ) A foam according to claim 9 wherein said catalyst comprises 3-(bis-(dimethylaminopropyl)amino)-propionamide.
11 ) A composition from which a polyurethane polyester foam may be produced which comprises:
a) a polyol;
b) a catalyst that is described by the general structure:
wherein R 1 and R 2 in each occurrence are independently selected from the group consisting of: methyl, ethyl, propyl, and butyl; m in each occurrence is any integer between 2 and about 10, including 2 and 10; and R 3 and R 4 are each independently selected from the group consisting of: hydrogen and C 1 to C 6 alkyl, wherein the amount of residual catalyst present is any amount between 0.01 and 1.00% by weight based upon the total weight of said foam.
12 ) A composition according to claim 11 wherein the vapor pressure of said composition is less than about 2 mm Hg @ 25° C.