Mixtures of polyether carbonate polyols and polyether polyols for producing polyurethane soft foams

Patent metadata

Field	Value
Publication number	US-10106641-B2
Application number	US-201415038486-A
Country	US
Kind code	B2
Filing date	Nov 24, 2014
Priority date	Nov 27, 2013
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

The invention relates to a method for producing polyurethane soft foam by reacting an isocyanate component with a component which is reactive towards isocyanates. The component which is reactive towards isocyanates comprises a mixture of at least one polyether carbonate polyol and a polyether polyol as the constituents. In the component which is reactive towards isocyanates, the total proportion of polyether carbonate polyols is =20 wt. % to =80 wt. % and the total proportion of polyether polyol is =20 wt. % to =80 wt. %, based on the total weight of the provided polyols. The invention further relates to a polyurethane soft foam produced using said method.

First claim

The invention claimed is:

1. A process for producing flexible polyurethane foams which comprises reacting an isocyanate component with a component reactive toward isocyanates, wherein the component reactive toward isocyanates comprises the following constituents:
A) ≥50 to ≤80% by weight of a polyether carbonate polyol having a hydroxyl number to DIN 53240 of ≥20 mg KOH/g to ≤250 mg KOH/g, obtained by copolymerization of
≥2% by weight to ≤30% by weight of carbon dioxide and ≥70 by weight to ≤98% by weight of one or more alkylene oxides,
in the presence of one or more H-functional starter molecules having an average functionality of ≥2 to ≤6,
where the polyether carbonate polyol is free of terminal alkylene oxide blocks, and

B) ≤50 to ≥20% by weight of a polyether polyol having a hydroxyl number to DIN 53240 of ≥20 mg KOH/g to ≤250 mg KOH/g, the polyether polyol being free of carbonate units.

2. The process as claimed in claim 1 , wherein the component reactive toward isocyanates comprises the following constituents:
A) ≥50 to ≤80% by weight of a polyether carbonate polyol having a hydroxyl number to DIN 53240 of ≥20 mg KOH/g to ≤250 mg KOH/g, obtained by copolymerization of
≥2% by weight to ≤30% by weight of carbon dioxide and ≥70% by weight to ≤98% by weight of one or more alkylene oxides,
in the presence of one or more H-functional starter molecules having an average functionality of ≥2 to ≤4,
where the polyether carbonate polyol is free of terminal alkylene oxide blocks, and

B) ≤50 to ≥20% by weight of a polyether polyol having a hydroxyl number to DIN 53240 of ≥20 mg KOH/g to ≤250 mg KOH/g, the polyether polyol being free of carbonate units.

3. The process as claimed in claim 1 , wherein the component reactive toward isocyanates comprises the following constituents:
A) ≥55 to ≤80% by weight of a polyether carbonate polyol having a hydroxyl number to DIN 53240 of ≥20 mg KOH/g to ≤250 mg KOH/g, obtained by copolymerization of
≥2% by weight to ≤30% by weight of carbon dioxide and ≥70% by weight to ≤98% by weight of one or more alkylene oxides,
in the presence of one or more H-functional starter molecules having an average functionality of ≥2 to ≤3,
where the polyether carbonate polyol is free of terminal alkylene oxide blocks, and

B) ≤45 to ≥20% by weight of a polyether polyol having a hydroxyl number to DIN 53240 of ≥20 mg KOH/g to ≤250 mg KOH/g, the polyether polyol being free of carbonate units.

4. The process as claimed in claim 1 , wherein component A) is obtained by
(α) an H-functional starter substance or a mixture of at least two H-functional starter substances is initially charged and any water and/or other volatile compounds are removed by elevated temperature and/or reduced pressure, with addition of the DMC catalyst to the H-functional starter substance or to the mixture of at least two H-functional starter substances before or after any water and/or other volatile compounds are removed by elevated temperature and/or reduced pressure,
(β) activation is accomplished by adding a portion, based on the total amount of alkylene oxides used in the activation and copolymerization, of one or more alkylene oxides to the mixture resulting from step (α), where this portion of alkylene oxide may optionally be added in the presence of CO 2 and where the temperature spike which then occurs due to the exothermic chemical reaction that follows and/or a pressure drop in the reactor is awaited in each case, and where step (β) for activation may also be repeated,
(γ) one or more of the alkylene oxides and carbon dioxide are added to the mixture resulting from step (β), where the alkylene oxides used in step (γ) may be the same as or different than the alkylene oxides used in step (β),
and where no further alkoxylation step follows on after step (γ).

5. The process as claimed in claim 1 , wherein one or more alkylene oxides in component A) is ethylene oxide, propylene oxide and/or 1,2-butylene oxide.

6. The process as claimed in claim 5 , wherein component B) includes ≥0% to ≤40% by weight of ethylene oxide units.

7. The process as claimed in claim 1 , wherein the component reactive toward isocyanates includes ≥50 to ≤80% by weight of A) and ≤50 to ≥20% by weight of B).

8. The process as claimed in claim 1 , wherein in the component reactive toward isocyanates includes ≥55 to ≤80% by weight of A) and ≤45 to ≥20% by weight of B).

9. The process as claimed in claim 1 , wherein, in the component reactive toward isocyanates, the total proportion of units originating from carbon dioxide in the polyols present is ≥5.0% by weight to ≤25.0% by weight, based on the total weight of the polyols present.

10. The process as claimed in claim 1 , wherein the polyether carbonate polyol A) has a hydroxyl number to DIN 53240 of ≥25 mg KOH/g to ≤90 mg KOH/g.

11. The process as claimed in claim 1 , wherein the polyether polyol B) has a hydroxyl number to DIN 53240 of ≥20 mg KOH/g to ≤80 mg KOH/g.

12. The process as claimed in claim 1 , wherein the reaction takes place in the presence of water as a blowing agent.

13. The process as claimed in claim 1 , wherein the isocyanate component comprises tolylene 2,4-, 2,6-diisocyanate (TDI), diphenylmethane 4,4′-, 2,4′-, 2,2′-diisocyanate (MDI) and/or polyphenyl polymethylene polyisocyanate (“polycyclic MDI”).

14. The process as claimed in claim 1 , wherein the polyether carbonate polyol (A) includes blocks of formula (VIII) having an e/f ratio of 2:1 to 1:20,

wherein
R is an organic radical which optionally contains at least one heteroatom
e is an integer and
f is an integer.

15. The process as claimed in claim 14 , wherein R is an alkyl, alkylaryl or aryl, which optionally contains O, S or Si and the ratio of e/f is from 1.5:1 to 1:10.

Assignees

• Covestro Deutschland Ag

Inventors

• Klesczewski Bert
• Laemmerhold Kai
• Hofmann Jörg

Classifications

• C08J2375/08

  from polyethers · CPC title

• C08G18/4866 Primary

  having a low unsaturation value · CPC title

• C08J9/00

  Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof (mechanical aspects of shaping of plastics or substances in a plastic state for the production of porous or cellular articles B29C) · CPC title

• C08G18/14

  Manufacture of cellular products · CPC title

• C08J2205/06

  Flexible foams · CPC title