Polyurethane foams with decreased aldehyde emissions, a process for preparing these foams and a method for decreasing aldehyde in polyurethane foams

Patent metadata

Field	Value
Publication number	US-10066047-B2
Application number	US-201213364385-A
Country	US
Kind code	B2
Filing date	Feb 2, 2012
Priority date	Feb 2, 2012
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

Abstract

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.

First claim

What is claimed is:

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.

Assignees

• George Emmanuel
• Koshute Mark A
• Neal Brian L
• Thompson Carl
• Marcum Adona
• Covestro Llc

Inventors

• George Emmanuel
• Koshute Mark A
• Neal Brian L
• Thompson Carl
• Marcum Adona

Classifications

• C08G18/4072

  Mixtures of compounds of group C08G18/63 with other macromolecular compounds · CPC title

• C08G18/4837 Primary

  and other oxyalkylene units · CPC title

• C08G18/0857

  the solvent being a polyol · CPC title

• C08G18/724

  Combination of aromatic polyisocyanates with (cyclo)aliphatic polyisocyanates · CPC title

• C08G18/7621

  being toluene diisocyanate including isomer mixtures · CPC title