Reduction of Aldehydes in Amine Catalysts

Patent metadata

Field	Value
Publication number	US-2016159966-A1
Application number	US-201414767930-A
Country	US
Kind code	A1
Filing date	Aug 26, 2014
Priority date	Aug 26, 2013
Publication date	Jun 9, 2016
Grant date	—

Abstract

The present disclosure provides a method for reducing the aldehyde content in an amine catalyst by treating the amine catalyst with an organic acid. The organic acid-treated amine catalyst may then be used in the production of polyurethane materials which exhibit reduced aldehyde emissions.

First claim

What is claimed is:

1 . A method for reducing the aldehyde content in an amine catalyst comprising (i) mixing an organic acid selected from a polymer acid, a carboxylic monoacid and a mixture thereof with an amine catalyst containing one or more aldehyde impurities to form a catalyst mixture and (ii) subjecting the catalyst mixture to conditions such that the level of aldehyde impurities in the catalyst mixture are reduced.

2 . The method of claim 1 wherein the conditions include maintaining the catalyst mixture at approximately room temperature for at least about 6 hours.

3 . The method of claim 1 wherein the organic acid is a polymer acid containing at least three or more of the same repeating monomers selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, maleic anhydride, furoic acid, fumaric acid, sorbic acid, tiglic acid, linoleic acid, linolenic aid and licanic acid.

4 . The method of claim 1 wherein the organic acid is a polymer acid containing at least two repeating monomers wherein the first monomer is an unsaturated carboxylic acid and the second monomer is a different unsaturated carboxylic acid, an anhydride or other monomer.

5 . The method of claim 4 wherein the unsaturated carboxylic acid is selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, furoic acid, fumaric acid, sorbic acid, tiglic acid, linoleic acid, linolenic aid and licanic acid.

6 . The method of claim 1 wherein the organic acid is a polymer acid containing at least two repeating monomers wherein the first monomer is an anhydride and the second monomer is a unsaturated carboxylic acid or other monomer.

7 . The method of claim 6 wherein the anhydride is maleic anhydride.

8 . The method of claim 1 wherein the organic acid is a carboxylic monoacid represented by the formula R—COOH where R is a saturated or unsaturated C1 to C40 hydrocarbon chain.

9 . The method of claim 8 wherein the carboxylic monoacid is selected from 2-ethylhexanoic acid, formic acid and lactic acid.

10 . A method for reducing aldehyde emissions from a polyurethane material comprising (i) mixing an organic acid selected from a polymer acid, a carboxylic monoacid and a mixture thereof with an amine catalyst containing one or more aldehyde impurities to form a catalyst mixture and subjecting the catalyst mixture to conditions such that the level of aldehyde impurities in the catalyst mixture are reduced and (ii) reacting a polyol with a polyisocyanate in the presence of the catalyst mixture from step (i) to form a polyurethane material.

11 . The method of claim 10 wherein the polyol and polyisocyanate are reacted in the presence of one more additives.

12 . The method of claim 11 wherein the one or more additives are selected from a blowing agent; a crosslinking agent, a flame retardant; a plasticizer; an internal mold release agent; a surfactant; an acid scavenger; a water scavenger; a cell regulator; a pigment; a dye; a UV stabilizer; a fungistatic or bacteriostatic substance; a filler; and a mixture thereof.

13 . A packaged product comprising (i) a container having an outlet and (ii) a catalyst mixture within the container comprising an organic acid selected from a polymer acid, a carboxylic monoacid and a mixture thereof and an amine catalyst containing one or more aldehyde impurities wherein the catalyst mixture is subjected to conditions such that the level of aldehyde impurities in the amine catalyst are reduced.

14 . The packaged product of claim 13 wherein the conditions include maintaining the catalyst mixture at room temperature for at least about 6 hours.

15 . The packaged product of claim 13 wherein the conditions include maintaining the catalyst mixture at a temperature of between about 25°-75° C. for at least about 6 hours.

16 . The packaged product of claim 13 wherein the container is a sealed container comprising a lid, a cover, a cap, or a plug and a nozzle or a pour spout.

17 . The packaged product of claim 13 wherein the sealed container has the shape of a cylinder, oval, round, rectangle, canister, tub, square or jug.

18 . The packaged product of claim 17 wherein the container is padded with an inert gas.

Assignees

• Huntsman Petrochemical Llc

Inventors

• Rodriguez Frank
• Grigsby Jr Robert A
• Wiltz Jr Eugene P
• Rister Jr Ernest L
• Barman Bhajendra N

Classifications

• C08L75/04 Primary

  Polyurethanes · CPC title

• B01J2219/1947

  oval or ellipsoidal · CPC title

• B01J2219/24

  Stationary reactors without moving elements inside · CPC title

• B01J19/24

  Stationary reactors without moving elements inside (B01J19/08, B01J19/26 take precedence; with stationary particles B01J8/02) · CPC title

• C08G18/18 Primary

  containing secondary or tertiary amines or salts thereof · CPC title