Polyurethane foams based on polyethercarbonate polyols

Patent metadata

Field	Value
Publication number	US-10907007-B2
Application number	US-201916975769-A
Country	US
Kind code	B2
Filing date	Mar 4, 2019
Priority date	Mar 7, 2018
Publication date	Feb 2, 2021
Grant date	Feb 2, 2021

Abstract

The invention relates to a method for producing polyurethane foams by reacting the following components A a polyol component containing A1 40 to 100 parts by weight of polyether carbonate polyol with a hydroxyl number according to DIN 53240-1 June 2013 of 20 mg KOH/g to 120 mg KOH/g, A2 0 to 60 parts by weight of polyether polyol with a hydroxyl number according to DIN 53240-1 June 2013 of 20 mg KOH/g to 250 mg KOH/g and an ethylene oxide content of 0 to 60 wt. %, wherein polyether polyol A2 is free from carbonate units, B B1 a catalyst and B2 optionally auxiliary and additional materials, C water and/or physical blowing agents with D di- and/or polyisocyanates, wherein the production occurs at a characteristic value of 90 to 120, characterised in that the component A contains a component A5 of 0.05 to 10.00 parts by weight of polyester polyol, in relation to the sum of the parts by weight of the components A1+A2=100 parts by weight, said polyester polyol containing units derived from malonic acid.

First claim

The invention claimed is:

1. A process for producing polyurethane foams by reaction of the components
A polyol component comprising
A1 from 40 to 100 parts by weight of polyether carbonate polyol having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 20 mg KOH/g to 120 mg KOH/g,
A2 from 0 to 60 parts by weight of polyether polyol having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 20 mg KOH/g to 250 mg KOH/g and a content of ethylene oxide of from 0 to 60% by weight, with polyether polyol A2 being free of carbonate units,

B
B1 catalysts, and
B2 optionally auxiliaries and additives,

C water and/or physical blowing agents,
with
D diisocyanates and/or polyisocyanates,
where the production reaction is carried out at an index of from 90 to 120, wherein component A comprises a component
A5 from 0.05 to 10.00 parts by weight, based on a sum of the parts by weight of the components A1+A2=100 parts by weight, of polyester polyol containing structural units derived from malonic acid.

2. The process as claimed in claim 1 , wherein component A has the following composition:
A1 from 40 to 100 parts by weight of polyether carbonate polyol having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 20 mg KOH/g to 120 mg KOH/g,
A2 from 0 to 60 parts by weight of polyether polyol having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 20 mg KOH/g to 250 mg KOH/g and a content of ethylene oxide of from 0 to 60% by weight, with polyether polyol A2 being free of carbonate units,
A3 from 0 to 20 parts by weight, based on the sum of the parts by weight of the components A1 and A2, of polyether polyol having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 20 mg KOH/g to 250 mg KOH/g and a content of ethylene oxide of 60% by weight, with polyether polyol A3 being free of carbonate units,
A4 from 0 to 40 parts by weight, based on the sum of the parts by weight of the components A1 and A2, of polymer polyol, PUD polyol, PIPA polyol, or a combination thereof, and
A6 from 0 to 40 parts by weight, based on the sum of the parts by weight of the components A1 and A2, of polyol which is different from components A1 to A5,
where the parts by weight figures for the components A3, A4 and A6 are in each case based on the sum of the parts by weight of components A1+A2=100 parts by weight.

3. The process as claimed in claim 1 , wherein component A is free of components A3 and/or A4.

4. The process as claimed in claim 1 , wherein component A comprises:
A1 from 65 to 75 parts by weight of polyether carbonate polyol having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 20 mg KOH/g to 120 mg KOH/g, and
A2 from 25 to 35 parts by weight of polyether polyol having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 20 mg KOH/g to 250 mg KOH/g and a content of ethylene oxide of from 0 to 60% by weight, where polyether polyol A2 is free of carbonate units.

5. The process as claimed in claim 1 , wherein component A1 comprises a polyether carbonate polyol obtained by copolymerization of carbon dioxide and alkylene oxide in the presence of H-functional starter molecules, wherein the polyether carbonate polyol has a CO 2 content of from 15 to 25% by weight.

6. The process as claimed in claim 1 , wherein component B comprises:
B1 catalyst comprises one or more of the following compounds
a) aliphatic tertiary amines, cycloaliphatic tertiary amines, aliphatic amino ethers, cycloaliphatic amino ethers, aliphatic amidines, cycloaliphatic amidines, urea and derivatives of urea, and/or
b) tin(II) salts of carboxylic acids, and

B2 optionally auxiliaries and additives.

7. The process as claimed in claim 1 , wherein component B comprises:
B1 catalysts, and
B2 optionally auxiliaries and additives,
wherein component B1 comprises:
B1.1 from 0.05 to 1.50 parts by weight, based on the sum of the parts by weight of the components A1 and A2, of urea and/or derivatives of urea and
B1.2 from 0.03 to 1.50 parts by weight, based on the sum of the parts by weight of the components A1 and A2, of catalyst other than those of the components B1.1, with the content of amine catalyst in the component B1.2 being not more than 50% by weight based on components B1.

8. The process as claimed in claim 1 , wherein component D comprises 2,4- and/or 2,6-TDI.

9. The process as claimed in claim 1 , wherein the component A5 has been prepared by reaction of malonic acid and/or low molecular weight malonic esters with an alcohol component.

10. The process as claimed in claim 9 , wherein the reaction is carried out with at least one diol as alcohol component, the diol comprising ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, butanediol or a mixture of at least two of the compounds mentioned.

11. The process as claimed in claim 1 , wherein the component A5 contains a polyester polyol containing structural units derived from malonic acid and having a hydroxyl number in accordance with DIN 53240-1 of June 2013 of from 25 mg KOH/g to 300 mg KOH/g.

12. The process as claimed in claim 1 , wherein component A5 is used in an amount of from 0.5 to 6.0 parts by weight, based on the sum of the parts by weight of the components A1+A2=100 parts by weight.

13. A polyurethane foam obtained by a process as claimed in claim 1 .

14. The polyurethane foam as claimed in claim 13 , wherein the polyurethane foam is a flexible polyurethane foam.

Assignees

• Covestro Intellectual Property Gmbh & Co Kg

Inventors

• Hilken Persefoni
• Lindner Stefan
• Schedler Michael
• Nefzger Hartmut
• Baecker Michael

Classifications

• C08J9/125

  Water, e.g. hydrated salts · CPC title

• C08G18/4238

  derived from dicarboxylic acids and dialcohols · CPC title

• C08G18/7614 Primary

  containing only one aromatic ring · CPC title

• C08G18/44 Primary

  Polycarbonates · CPC title

• C08G18/4202

  Two or more polyesters of different physical or chemical nature (C08G18/44 takes precedence) · CPC title