Method for producing polyurethane rigid foams and polyisocyanurate rigid foams

Patent metadata

Field	Value
Publication number	US-10259906-B2
Application number	US-201515117960-A
Country	US
Kind code	B2
Filing date	Jan 27, 2015
Priority date	Feb 11, 2014
Publication date	Apr 16, 2019
Grant date	Apr 16, 2019

Abstract

The present invention relates to polyester polyols obtainable or obtained by esterification of 10 to 70 mol % of at least one compound from the group consisting of terephthalic acid (TPA), dimethyl terephthalate (DMT), polyethylene terephthalate (PET), phthalic anhydride (PA), phthalic acid and isophthalic acid, 0.1 to 30 mol % of one or more fatty acids and/or fatty acid derivatives, 10 to 70 mol % of one or more aliphatic or cycloaliphatic diols having 2 to 18 carbon atoms or alkoxylates thereof, 5 to 70 mol % of a polyether polyol prepared by alkoxylating an aromatic starter molecule having a functionality of not less than 2, and of 0 to 70 mol % of a tri- or polyol other than the polyether polyol, all based on the total amount of the components used, wherein the amounts used of the components add up to 100 mol %. The present invention further relates to a process for producing rigid polyurethane or polyisocyanurate foams which comprises reacting an isocyanate component with a polyol component (PK) comprising a polyester polyol of the present invention and further components, to the polyol component as such and also to the rigid polyurethane or polyisocyanurate foams obtainable or obtained by a process of the present invention. The present invention also relates to the method of using a polyester polyol (P1) of the present invention in the manufacture of rigid polyurethane foams or rigid polyisocyanurate foams.

First claim

We claim:

1. A polyester polyol (P1) obtained by esterification of components (i) to (v):
(i) 10 to 70 mol % of at least one compound from the group consisting of terephthalic acid (TPA), dimethyl terephthalate (DMT), polyethylene terephthalate (PET), phthalic anhydride (PA), phthalic acid and isophthalic acid,
(ii) 0.1 to 30 mol % of one or more fatty acids and/or fatty acid derivatives,
(iii) 10 to 70 mol % of one or more aliphatic or cycloaliphatic diols having 2 to 18 carbon atoms or alkoxylates thereof,
(iv) 5 to 70 mol % of a polyether polyol prepared by alkoxylating an aromatic starter molecule having a functionality of not less than 2,
(v) 0 to 70 mol % of a tri- or polyol other than component (iv),
all based on a total amount of components (i) to (v), wherein the amounts used of components (i) to (v) add up to 100 mol %.

2. The polyester polyol (P1) according to claim 1 , wherein said components (i) to (v) are used in the following amounts:
component (i) in an amount from 25 to 40 mol %,
component (ii) in an amount from 8 to 14 mol %,
component (iii) in an amount from 25 to 55 mol %,
component (iv) in an amount from 12 to 18 mol %, and
component (v) in an amount from 0 to 18 mol %,
all based on the total amount of components (i) to (v), wherein the amounts used of components (i) to (v) add up to 100 mol %.

3. The polyester polyol (P1) according to claim 1 , wherein said component (i) is selected from the group consisting of terephthalic acid and dimethyl terephthalate (DMT).

4. The polyester polyol (P1) according to claim 1 , wherein said component (ii) is selected from the group consisting of oleic acid, soya oil, rapeseed oil and tallow.

5. The polyester polyol (P1) according to claim 1 , wherein said component (iii) is selected from the group consisting of diethylene glycol (DEG) and monoethylene glycol (MEG).

6. The polyester polyol (P1) according to claim 1 , wherein said component (iv) is obtained by ethoxylating an aromatic polyol having a functionality of greater than 2.

7. The polyester polyol (P1) according to claim 1 , wherein said component (iv) is obtained by ethoxylating a composition consisting of tolylenediamine isomers and comprising not less than 90 wt % of tolylenediamine isomers having a vicinal position for the two amino groups.

8. The polyester polyol (P1) according to claim 1 , wherein said polyester polyol (P1) has a number average molecular weight in the range from 450 g/mol to 800 g/mol.

9. A process for producing rigid polyurethane foams or rigid polyisocyanurate foams, the process comprising:
reacting
A) a component (A) comprising at least one compound selected from the group consisting of organic diisocyanates, modified organic diisocyanates, organic polyisocyanates and modified organic polyisocyanates, with
B) a polyol component (PK), comprising:
(b1.1) at least one polyester polyol (P1) according to claim 1 ,
(b2) at least one flame retardant,
(b3) at least one blowing agent, and
(b4) at least one catalyst.

10. The process according to claim 9 , wherein said polyol component (PK) further comprises one or more of the following compounds:
(b1.2) at least one polyester polyol (P2) other than said polyester polyol (P1),
(b1.3) at least one compound selected from the group consisting of polyether polyols (P3), compounds having two or more isocyanate-reactive groups, chain-extending agents and crosslinking agents,
(b5) further auxiliaries and/or admixture agents.

11. The process according to claim 10 , wherein a mass ratio of a sum total of polyester polyols (P1) and (P2) to a sum total used of polyether polyols (P3) is not less than 0.1.

12. The process according to claim 10 , wherein said polyol component (PK) comprises no further polyester polyol (P2) in addition to said polyester polyol (P1).

13. The process according to claim 10 , wherein the polyether polyol component of (b1.3) comprises polyethylene glycol only and no further polyether polyols are used.

14. The process according to claim 9 , wherein the flame retardant component (b2) comprises tris(2-chloropropyl) phosphate (TCPP) only and no further flame retardants are used.

15. The process according to claim 9 , wherein the blowing agent (b3) comprises chemical and physical blowing agents, wherein the chemical blowing agent is selected from the group consisting of water, formic acid-water mixtures and formic acid and the physical blowing agent consists of one or more pentane isomers.

16. A polyol component (PK), comprising:
(b1.1) 50 to 90 wt % of polyester polyol (P1) according to claims 1 ,
(b1.2) 0 to 20 wt % of at least one polyester polyol (P2),
(b1.3) 2 to 9 wt % of at least one polyether polyol (P3),
(b2) 5 to 30 wt % of at least one flame retardant,
(b3) 1 to 30 wt % of at least one blowing agent,
(b4) 0.5 to 10 wt % of at least one catalyst, and
(b5) 0.5 to 20 wt % of further auxiliary and admixture agents,
all based on a total weight of polyol component (PK), wherein the weight percentages add up to 100 wt %, and wherein a mass ratio of a sum total of polyester polyols (P1) and (P2) to a sum total used of polyether polyols (P3) is not less than 2.

Assignees

• Basf Se

Inventors

• Kaluschke Tobias
• Kampf Gunnar

Classifications

• C08J2375/08

  from polyethers · CPC title

• C08G18/7671

  containing only one alkylene bisphenyl group · CPC title

• C08G18/14

  Manufacture of cellular products · CPC title

• C08G18/4219

  from aromatic dicarboxylic acids and dialcohols in combination with polycarboxylic acids and/or polyhydroxy compounds which are at least trifunctional · CPC title

• C08G18/4288

  modified by higher fatty oils or their acids or by resin acids · CPC title