Polyurethane foams with decreased aldehyde emissions, a process for preparing these foams and a method for decreasing aldehyde in polyurethane foams
This invention relates to polyurethane foams which exhibit decreased aldehyde emission, to a process of preparing these polyurethane foams, and to a method of decreasing aldehyde emissions in foams. The polyurethane foams herein additionally comprise a small quantity of a polyhydrazodicarbonamide dispersion polyol to the isocyanate-reactive component, or a trimerized hexamethylene diisocyanate to the polyisocyanate component.
1. A polyurethane foam comprising the reaction product of:
(1) a polyisocyanate component,
with
(2) an isocyanate-reactive component comprising:
(a) at least one polyether polyol having a functionality of from 2 to 6, an OH number of from 18 to 238, and a number average molecular weight of from 160 to 8000;
and
(b) at least one filled polyol having an OH number of 18 to 32, a number average molecular weight of 2000 to 8000, and containing from 5 to 60% by weight of solids, which is selected from the group consisting of (i) styrene-acrylonitrile polymer polyols, (ii) polyisocyanate polyaddition (PIPA) polyols and (iii) mixtures thereof;
in the presence of
(3) at least one blowing gent;
(4) at least one catalyst;
and
(5) at least one surfactant;
wherein (1) said polyisocyanate component additionally comprises (6) from 0.5 to 8 parts of trimerized hexamethylene diisocyanate per 100 parts of polyisocyanate, or (2) said isocyanate-reactive component additionally comprises (7) from 2 to 5.5 parts of at least one polyhydrazodicarbonamide dispersion polyol per 100 parts of isocyanate-reactive component.
2. The foam of claim 1 , wherein (1) said polyisocyanate component comprises toluene diisocyanate.
3. The foam of claim 1 , wherein (2)(a) said polyether polyols have a functionality of 2.5 to 3.5, and an OH number of about 28 to about 42.
4. The foam of claim 1 , wherein (2)(b) said filled polyols have solids contents of from 10 to 50% by weight.
5. The foam of claim 1 , wherein (1) said polyisocyanate component additionally comprises (6) from 0.5 to 3 parts by weight of trimerized hexamethylene dilsocyanate per 100 parts of said polyisocyanate component, or (2) said isocyanate-reactive component additionally comprises (7) from 2 to 5 parts of at least one polyhydrazodicarbonamide dispersion polyol per 100 parts of said isocyanate-reactive component.
6. A process for preparing a polyurethane foam comprising:
(A) reacting:
(1) a polyisocyanate component,
with
(2) an isocyanate reactive component comprising:
(a) at least one polyether polyol having a functionality of from 2 to 6, an OH number of from 18 to 238,and a number average molecular weight of from 160 to 8000,
and
(b) at least one filled polyol having an OH number of 18 to 32, a number average molecular weight of 2000 to 8000, and containing from 5 to 60% by weight of solids, which is selected from the group consisting of (i) styrene-acrylonitrile polymer polyols, (ii) polyisocyanate polyaddition (PIPA) polyols and (iii) mixtures thereof;
in the presence of
(3) at least one blowing agent;
(4) at least one catalyst;
and
(5) at least one surfactant;
wherein (1) said polyisocyanate component additionally comprises (6) from 0.5 to 8 parts of trimerized hexamethylene diisocyanate per 100 parts of polyisocyanate, or (2) said isocyanate-reactive component additionally comprises (7) from 2 to 5.5 parts of at least one polyhydrazoclicarbonamide dispersion polyol per 100 parts of isocyanate-reactive component.
7. The process of claim 6 , wherein (1) aid polyisocyanate component comprises toluene diisocyanate.
8. The process of claim 6 , wherein (2)(a) said polyether polyols have a functionality of 2.5 to 3.5, and an OH number of about 28 to about 42.
9. The process of claim 6 , wherein (2)(b) said filled polyols have solids contents of from 10 to 50% by weight.
10. The process of claim 6 , wherein (1) said polyisocyanate component additionally comprises (6) from 0.5 to 3 parts by weight of trimerized hexamethylene diisocyanate per 100 parts of said polyisocyanate component, or (2) said isocyanate-reactive component additionally comprises (7) from 2 to 5 parts of at least one polyhydrazodicarbonamide dispersion polyol per 100 parts of said isocyanate-reactive component.
11. A method of decreasing formaldehyde emissions in a foam comprising:
(A) reacting:
(1) a polyisocyanate component,
with
(2) an isocyanate-reactive component comprising:
(a) one or more polyoxyalkylene polyols having a functionality of from 2 to 6, an OH number of from 18 to 238, a number average molecular weight of from 160 to 8000,
and
(b) one or more filled polyols having an OH number of 18 to 32, a number average molecular weight of 2000 to 8000 and containing from 5 to 60% by weight of solids;
in the presence of
(3) at least one blowing agent;
(4) at least one catalyst;
and
(5) at least one surfactant;
wherein (1) said polyisocyanate component additionally comprises (6) from 0.5 to 8 parts of trimerized hexamethylene diisocyanate per 100 parts of polyisocyanate, or (2) said isocyanate-reactive component additionally comprises (7)from 2 to 5.5 parts of at least one polyhydrazodicarbonamide dispersion polyol per 100 parts of isocyanate-reactive component.
12. The method of claim 11 , wherein (1) said polyisocyanate component comprises toluene diisocyanate.
13. The method of claim 11 , wherein (2)(a) said polyether polyols have a functionality of 2.5 to 3.5, and an OH number of about 28 to about 42.
14. The method of claim 11 , wherein (2)(b) said filled polyols have solids contents of from 10 to 50% by weight.
15. The method of claim 11 , wherein (1) said polyisocyanate component additionally comprises (6) from 0.5 to 3 parts by weight of trimerized hexamethylene diisocyanate per 100 parts of said polyisocyanate component, or (2) said isocyanate-reactive component additionally comprises (7) from 2 to 5 parts of at least one polyhydrazodicarbonamide dispersion polyol per 100 parts of said isocyanate-reactive component.