PUR/PIR rigid foams made of polyaddition oligoesters

Patent metadata

Field	Value
Publication number	US-10982039-B2
Application number	US-201615777693-A
Country	US
Kind code	B2
Filing date	Nov 23, 2016
Priority date	Nov 26, 2015
Publication date	Apr 20, 2021
Grant date	Apr 20, 2021

Abstract

The invention relates to a method for producing PUR/PIR rigid foam materials, having the steps of reacting at least one polyester polyol (a), which can be obtained by reacting a. I.) at least one cyclic carboxylic acid anhydride; a.2.) at least one low-molecular dial with a molecular mass of 62 to 450 Da; and a.3.) at least one alkylene oxide; by esterifying the components a.I.) and a.2.) and subsequently oxalkylating the resulting carboxylic acid half-ester using component a.3.); wherein at least the oxalkylation is carried out using a.4.) at least one amine catalyst in which (the) nitrogen atom(s) is/are part of an aromatic ring system, with (b) at least one polyisocyanate-containing component, (c) at least one propellant, (d) at least one or more catalysts, (e) optionally at one flameproofing agent and/or other auxiliary agents, and (f) optionally at least one additional compound with at least two groups which are reactive towards isocyanates and which differ from polyester polyol (a). The invention also relates to a PUR/PIR rigid foam material which can be obtained using a method according to the invention, to a composite element comprising the PUR/PIR rigid foam material according to the invention, at least one cover layer selected from concrete, wood, press board, aluminum, copper, steel, stainless steel, paper, non-wovens, and plastic, and multilayer composites or a combination thereof. The invention also relates to the use of the PUR/PIR rigid foam materials according to the invention or the composite element according to the invention for heat damping.

First claim

What is claimed is:

1. A process for the production of rigid PUR/PIR foams, comprising reacting
(a) at least one polyester polyol obtainable via reaction of
a.1.) at least one cyclic carboxylic anhydride;
a.2.) at least one low-molecular weight diol with molecular weight from 62 to 450 daltons;
and
a.3.) at least one alkylene oxide;
by esterifying components a.1.) and a.2.), followed by alkoxylating the resultant carboxylic hemiester by means of component a.3.); wherein the alkoxylation reaction occurs in the presence of
a.4.) at least one aminic catalyst in which the nitrogen atom(s) is (are) part of an aromatic ring system,

with
(b) at least one polyisocyanate-containing component,
(c) at least one blowing agent,
(d) at least one catalyst,
(e) optionally, at least one flame retardant and/or other auxiliaries
and/or additional substances,

(f) optionally at least one compound having at least two groups which are reactive toward isocyanates and differ from the polyester polyol (a);
wherein a.3.) is selected from ethylene oxide or from a mixture of ethylene oxide and propylene oxide;
wherein ethylene oxide is added in an amount of from 90 to 100% by weight, based on the total weight of the alkylene oxide a.3.);
and
wherein the equivalents ratio of a.3.) to a.1.) is from 1.7:1 to 3:1.

2. The process as claimed in claim 1 , wherein the OH number of (a) said polyester polyol is from 100 to 280 mg KOH/g.

3. The process as claimed in claim 1 , wherein a.4.) is selected from the group of imidazole and imidazole derivatives.

4. The process as claimed in claim 1 , wherein a.1.) comprises maleic anhydride, itaconic anhydride, citraconic anhydride, succinic anhydride, glutaric anhydride, phthalic anhydride and tetrahydrophthalic anhydride, or mixtures thereof.

5. The process as claimed in claim 1 , wherein a.2.) comprises ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, or mixtures thereof.

6. The process as claimed in claim 1 , wherein (b) comprises tolylene 2,4-diisocyanate, tolylene-2,6-diisocyanate, diphenylmethane 4,4′-diisocyanate, diphenylmethane-2,4′-diisocyanate, derivatives thereof, or mixtures thereof.

7. The process as claimed in claim 1 , wherein (c) comprises n-pentane, cyclopentane, isopentane, water, carboxylic acids, or mixtures thereof.

8. The process as claimed in claim 1 , wherein (e) comprises a flame retardant, filler, cell regulator, foam stabilizer, surface-active compound, oxidative stabilizer, thermal stabilizer, microbial degradation stabilizer, ageing stabilizer, or a mixture thereof.

9. The process as claimed in claim 1 , wherein (f) comprises at least one polyether polyol, a polyester polyol which is different than said polyester polyol (a), or a mixture thereof.

10. The process as claimed in claim 1 , wherein
(a) is present in an amount of from 10 to 24% by weight;
(b) is present in an amount of from 43 to 89% by weight;
(c) is present in an amount of from 0.1 to 30% by weight;
(d) is present in an amount of from 0.05 to 3% by weight;
(e) is present in an amount of from 0.5 to 12% by weight;
(f) is present in an amount of from 0.1 to 9% by weight;
wherein the sum of components (a) to (f) totals 100% by weight.

11. A rigid PUR/PIR foam obtainable by a process as claimed in claim 1 .

12. A composite element comprising (i) a foam core comprising a rigid PUR/PIR foam as claimed in claim 11 and (ii) at least one outer layer comprising concrete, wood, pressboard, aluminum, copper, stainless steel, other types of steel, paper, nonwoven fabric, or plastic, wherein the surface of said foam core is attached to the surface of said outer layer.

13. A thermal insulation composite element comprising (i) a foam core comprising the rigid PUR/PIR foam as claimed in claim 11 and (ii) at least one outer layer comprising concrete, wood, pressboard, aluminum, copper, stainless steel, other types of steel, paper, nonwoven fabric, or plastic, wherein the surface of said foam core is attached to the surface of said outer layer.

14. The process as claimed in claim 1 , wherein
(a) is present in an amount of from 12 to 22% by weight;
(b) is present in an amount of from 48 to 83% by weight;
(c) is present in an amount of from 0.5 to 20% by weight;
(d) is present in an amount of from 0.06 to 2% by weight;
(e) is present in an amount of from 3 to 9% by weight;
(f) is present in an amount of from 1.4 to 7.5% by weight;
wherein the sum of components (a) to (f) totals 100% by weight.

15. The process of claim 3 , wherein a.4.) comprises N-methylimidazole.

16. The process as claimed in claim 1 , wherein the molar ratio of said cyclic carboxylic anhydride a.1) to said low molecular weight diol a.2) ranges from 1:0.3 to 1:1.5.

Assignees

• Covestro Deutschland Ag

Inventors

• Nefzger Hartmut
• Hagen Torsten
• Lorenz Klaus
• Abels Rene

Classifications

• C08J2203/14

  Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons · CPC title

• B32B27/08

  of synthetic resin · CPC title

• B32B13/08

  of paper or cardboard · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title

• B32B29/002

  as the main or only constituent of a layer, which is next to another layer of the same or of a different material (next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10) · CPC title