In-situ formation of polyurethane catalysts

Patent metadata

Field	Value
Publication number	US-10640601-B2
Application number	US-201615579223-A
Country	US
Kind code	B2
Filing date	May 31, 2016
Priority date	Jun 18, 2015
Publication date	May 5, 2020
Grant date	May 5, 2020

Abstract

An in-situ formed polyurethane catalyst for catalyzing the formation of polyurethane in a reactive composition comprising polyisocyanate compounds and isocyanate reactive compounds, said catalyst formed by combining in said reactive composition:
At least one lithium halide compound, and At least one epoxide compound

wherein the amount of epoxide to be used is such that the number of epoxide equivalents per isocyanate equivalents is from larger than 0 up to 0.095 and the number of moles of lithium halide per isocyanate equivalent ranging of from 0.0001-0.06.

First claim

The invention claimed is:

1. A reactive system for catalyzing the formation of polyurethane said reactive system comprising:
at least one lithium halide compound,
at least one epoxide compound,
a polyisocyanate composition comprising polyisocyanate compounds, and
a monol or polyol composition,

wherein the at least one lithium halide and at least one epoxy compound form an in situ polyurethane catalyst, the isocyanate index is in the range of 80-150, the amount of epoxide to be used is such that the number of epoxide equivalents per isocyanate equivalents is from larger than 0 up to 0.095 and the number of moles of lithium halide per isocyanate equivalent ranging of from 0.0001-0.06; wherein the reactive system has a viscosity ranging from 50 cps to 200 cps for at least 35 seconds at a temperature of 90° C.

2. The reactive system according to claim 1 , wherein the polyisocyanate compounds are selected from a toluene diisocyanate, a methylene diphenyl diisocyanate or a polyisocyanate composition comprising a methylene diphenyl diisocyanate or a mixture of such polyisocyanate compounds.

3. The reactive system according to claim 1 , wherein the number of moles of lithium halide per isocyanate equivalent is ranging from 0.00015-0.025 moles per isocyanate equivalent.

4. The reactive system according to claim 1 wherein the number of epoxide equivalents per isocyanate equivalents is in the range 0.01 up to 0.095.

5. The reactive system according to claim 1 , wherein the isocyanate reactive compounds are selected from a polyester and/or polyether polyol having an average molecular weight of 32-6000 and an average nominal functionality of 1-8.

6. The reactive system according to claim 1 , wherein the lithium halide is selected from lithium chloride and lithium bromide.

7. The reactive system according to claim 1 , wherein the epoxide is liquid at room temperature.

8. The reactive system according to claim 1 , wherein the polyisocyanate composition has an average isocyanate value of 1 to 48% by weight.

9. The reactive system according to claim 1 , wherein the number of moles of lithium halide per isocyanate equivalent is ranging from 0.00015-0.025 moles per isocyanate equivalent.

10. The reactive system according to claim 1 , wherein the number of epoxide equivalents per isocyanate equivalents is in the range 0.01 up to 0.095.

11. The reactive system according to claim 1 , wherein the isocyanate index is in the range 80-130.

12. The reactive system according to claim 1 , further comprising additives selected from the group consisting of catalysts, blowing agents, surfactants, water scavengers, antimicrobial agents, fire retardants, smoke suppressants, UV-stabilizers, colorants, plasticizers, internal mould release agents, rheology modifiers, wetting agents, dispersing agents and fillers.

13. A process for making the reactive system according to claim 1 , which process comprises combining and dissolving the at least one lithium halide compound and the monool or polyol composition, the polyisocyanate composition, the at least one epoxide compound and optional further additives and/or fillers according to claim 1 .

14. A process for making a polyurethane comprising material by allowing the ingredients of the reactive system according to claim 1 to react at elevated temperature of at least 50° C.

15. The process according to claim 14 , further comprising before the step of heating said reactive system at elevated temperatures of at least 80° C. the step of adding and mixing additives and/or to be bonded material(s) to the reactive system such as wood chips, wood dust, wood flakes, wooden plates; paper and cardboard, both shredded or layered; sand, vermiculite, clay, cement and other silicates; ground rubber, ground thermoplastics, ground thermoset materials; honeycombs of any material, like cardboard, aluminium, wood and plastics; metal particles and plates; cork in particulate form or in layers; natural fibers, like flax, hemp and sisal fibers; synthetic fibers, like polyimide, polyolefin, polyaramide, polyester and carbon fibers; mineral fibers, like glass fibers and rock wool fibers; mineral fillers like BaSO 4 and CaCO 3 ; nanoparticles, like clays, inorganic oxides and carbons; glass beads, ground glass, hollow glass beads; expanded or expandable beads; untreated or treated waste, like milled, chopped, crushed or ground waste and in particular fly ash; woven and non-woven textiles; and combinations of two or more of these materials.

16. A polyurethane comprising material made by allowing the reactive composition according to claim 1 , to react at elevated temperature of at least 50° C.

Assignees

• Huntsman Int Llc

Inventors

• Verbeke Hugo
• Verbeke Hans Godelieve Guido
• Giannini Giacomo
• Esbelin Christian

Classifications

• C08G18/58 Primary

  Epoxy resins {(C08G18/42, C08G18/48 take precedence; reaction products of epoxy resins with at least equivalent amounts of compounds containing active hydrogen C08G18/6407, with at least equivalent amounts of amines C08G18/6415; polymeric products of isocyanates or isothiocyanates with epoxy compounds having no active hydrogen C08G18/003)} · CPC title

• C08G18/225 Primary

  of alkali or alkaline earth metals · CPC title

• C08G18/4808

  Mixtures of two or more polyetherdiols · CPC title

• C08G59/4028

  Isocyanates; Thioisocyanates · CPC title

• C08G18/78

  Nitrogen {(C08G18/775, C08G18/776 take precedence)} · CPC title