Foam compositions
View Patent ↗Foam compositions are provided. The compositions are prepared from multi-functional acetoacetate esters and multi-functional amines or acrylates. The foam compositions can include one or more additives. The foam compositions can be used for home and commercial insulation, air sealing, sound proofing, structural improvement, and exterior roofing, among other applications. The foam compositions provide advantages of being isocyanate free and offer reduced exposure to isocyanate.
1. A foam comprising a compound of formula (I-a):
wherein A and B, at each occurrence, are each independently selected from a saturated or unsaturated, linear, branched, or cyclic hydrocarbon group, wherein each hydrocarbon group optionally includes one or more heteroatoms; an aromatic group; a heteroaromatic group; and a heterocyclic group; or any combination thereof; wherein said groups, at each occurrence, are independently unsubstituted or substituted with one or more suitable substituents.
2. The foam of claim 1 , wherein
A, at each occurrence, is derived from a compound independently selected from the group consisting of glycerol triacetoacetate, a sorbitol acetoacetate, an erythritol acetoacetate, a multi-functionalized acetoacetate ester of a monosaccharide, and a multi-functionalized acetoacetate ester of a disaccharide; and
B, at each occurrence, is derived from a compound independently selected from the group consisting of xylene diamine, and 2-methyl-1,5-diaminopentane.
3. The foam of claim 2 , wherein the disaccharide is sucrose.
4. The foam of claim 1 , wherein the foam comprises a compound of formula (I-b),
5. The foam of claim 1 , wherein the foam is a rigid foam or a semi-rigid foam.
6. A method of preparing a foam according to claim 1 , comprising reacting a compound of formula (a) with a compound of formula (b):
wherein
R 1 and R 2 , at each occurrence, are each independently selected from a saturated or unsaturated, linear, branched, or cyclic hydrocarbon group, wherein each hydrocarbon group optionally includes one or more heteroatoms; an aromatic group; a heteroaromatic group; and a heterocyclic group; or any combination thereof; wherein said groups, at each occurrence, are independently unsubstituted or substituted with one or more suitable substituents;
m is 2 to 200; and
n is 2 to 200.
7. The method of claim 6 , wherein the compound of formula (a) and the compound of formula (b) are pneumatically pumped from separate first and second containers to respective first and second conduits.
8. The method of claim 7 , wherein the compound of formula (a) and the compound of formula (b) are brought from their respective first and second conduits to a mixing chamber under pressure from an electric or hydraulic pump, the compound of formula (a) and the compound of formula (b) forming a reaction mixture.
9. The method of claim 8 , wherein the pressure is 500-2,000 psi.
10. The method of claim 8 , wherein the reaction mixture is pumped from the mixing chamber through a third conduit to a nozzle or orifice and expelled through the nozzle or orifice.
11. The method of claim 10 , wherein the third conduit is heated to a temperature of 70 ° F. to 200 ° F.
12. The method of claim 10 , wherein the expelled reaction mixture is directed to a mold or other surface.
13. The method of claim 6 , wherein water produced as a consequence of reaction between compound (a) and compound (b) acts as a chemical blowing agent.
14. The method of claim 6 , wherein the compound of formula (a), at each occurrence, is independently selected from the group consisting of glycerol triacetoacetate, a sorbitol acetoacetate, an erythritol acetoacetate, a multi-functionalized acetoacetate ester of a monosaccharide, and a multi-functionalized acetoacetate ester of a disaccharide.
15. The method of claim 14 , wherein the disaccharide is sucrose.
16. The method of claim 6 , wherein the compound of formula (b), at each occurrence, is independently selected from the group consisting of xylene diamine, and 2-methyl-1,5-diaminopentane.
17. The foam of claim 1 , wherein A, at each occurrence, is derived from a compound of formula (a),
wherein
R 1 , at each occurrence, is independently selected from a saturated or unsaturated, linear, branched, or cyclic hydrocarbon group, wherein each hydrocarbon group optionally includes one or more heteroatoms; an aromatic group; a heteroaromatic group; and a heterocyclic group; or any combination thereof; wherein said groups, at each occurrence, are independently unsubstituted or substituted with one or more suitable substituents; and
m is 2 to 200.
18. The foam of claim 17 , wherein m, at each occurrence, is independently 3, 7, or 8.
19. The foam of claim 1 , wherein A, at each occurrence, is derived from a compound independently selected from the group consisting of:
wherein R 4 , at each occurrence, is independently selected from —H and —C(O)CH 2 C(O)CH 3 , provided that at least two R 4 groups are —C(O)CH 2 C(O)CH 3 ; and R 5 is —H or —C(O)CH 2 C(O)CH 3 .
20. The foam of claim 1 , wherein A, at each occurrence, is derived from a compound independently selected from the group consisting of glycerol triacetoacetate, a sorbitol acetoacetate, an erythritol acetoacetate, a multi-functionalized acetoacetate ester of a monosaccharide, and a multi-functionalized acetoacetate ester of a disaccharide.
21. The foam of claim 1 , wherein B, at each occurrence, is derived from a compound of formula (b):
wherein
R 2 , at each occurrence, is independently selected from a saturated or unsaturated, linear, branched, or cyclic hydrocarbon group, wherein each hydrocarbon group optionally includes one or more heteroatoms; an aromatic group; a heteroaromatic group; and a heterocyclic group; or any combination thereof; wherein said groups, at each occurrence, are independently unsubstituted or substituted with one or more suitable substituents; and
n is 2 to 200.
22. The foam of claim 21 , wherein n=2.
23. The foam of claim 1 , wherein B, at each occurrence, is derived from a compound independently selected from the group consisting of: