Process for producing composite elements

Patent metadata

Field	Value
Publication number	US-9475220-B2
Application number	US-201414176366-A
Country	US
Kind code	B2
Filing date	Feb 10, 2014
Priority date	Feb 13, 2013
Publication date	Oct 25, 2016
Grant date	Oct 25, 2016

Abstract

The invention relates to an improved process for producing composite elements comprising at least one outer layer and at least one isocyanate-based rigid foam layer by means of a fixed applicator apparatus and in which the flowable starting material comprises the following components: A) at least one polyisocyanate, B) at least one compound which reacts with isocyanate groups to form urethane, C) at least one blowing agent, D) catalysts comprising at least one compound D1) which catalyzes isocyanurate formation and at least one compound D2) which catalyzes polyurethane formation, comprising at least one amino group, and E) optionally auxiliaries and additives, where the manner of use of component A) and of component B) is such that the isocyanate index is at least 180, and where the ratio by weight of the compound D2) to the compound D1) is from 0.75 to 8.

First claim

The invention claimed is:

1. A process for producing a composite element comprising:
at least one outer layer b); and
at least one isocyanate-based rigid foam layer a),

the process comprising applying the isocyanate-based rigid foam layer a) in the form of a flowable starting material a*) to the outer layer b), while the outer layer b) is moved continuously, such that the applying is carried out with a fixed applicator apparatus c),
wherein:
the flowable starting material a*) comprises:
A) at least one polyisocyanate;
B) at least one compound which reacts with isocyanate groups to form urethane;
C) at least one blowing agent;
D) catalysts comprising at least one compound D1) which catalyzes isocyanurate formation and at least one compound D2) which catalyzes polyurethane formation and which differs from the compound D1); and
E) optionally auxiliaries and additives;
the compound D2) comprises at least one amino group;
an isocyanate index of the component A) is at least 180; and
a ratio by weight of the compound D2) to the compound D1) is from 0.75 to 8.

2. The process according to claim 1 , wherein compound D1) is selected from the group consisting of an alkali metal carboxylate, an alkaline earth metal carboxylate and an ammonium carboxylate.

3. The process according to claim 1 , wherein compound D1) is a carboxylate of an alkali metal.

4. The process according to claim 3 , wherein the carboxylate is selected from the group consisting of formate, ethylhexanoate, and acetate.

5. The process according to claim 4 , wherein compound D1 is an alkali metal acetate.

6. The process according to claim 1 , wherein compound D2) is selected from the group consisting of an amidine, a tertiary amine, and an alkanolamine.

7. The process according to claim 1 , wherein component D2) comprises at least one compound D2-T) of the following structure:
NR 2 —CH 2 —CH 2 —X—CH 2 —CH 2 —Y,

wherein Y═NR 2 or OH and X═NR or O, such that each R independently represents an organic group having at least one carbon atom.

8. The process according to claim 7 , wherein Y═NR 2 and X═NR or O, and R═CH 3 .

9. The process according to claim 7 , wherein a proportion of the compound D2-T), based on the total weight of component D2), is at least 50%.

10. The process according to claim 1 , wherein the ratio by weight of component D2) to component D1) is at least 1.

11. The process according to claim 1 , wherein the ratio by weight of component D2) to component D1) is at most 5.

12. The process according to claim 1 , wherein the component B) comprises at least one polyester polyol B1) and at least one polyether polyol B2).

13. The process according to claim 1 , wherein a height at which a tube of the apparatus c) provided with apertures f) is attached above the outer layer b) is from 5 to 30 cm.

14. The process according to claim 1 , wherein the fixed applicator apparatus c) comprises at least one fixed tube c′) provided with apertures f) and attached parallel to the outer layer b) and at right angles to the direction of movement of the outer layer b).

15. The process according to claim 14 , wherein the design of the tube is such that the input of the flowable starting material a*) takes place in the middle of the tube c′), and the length of the apertures of the tube c′) decreases from the middle of the tube c′) toward the ends of same.

16. The process according to claim 1 , wherein the viscosity at 25° C. of said flowable starting material a*) for the isocyanate-based rigid foam is from 100 mPa*s to 3500 mPa*s.

Assignees

• Basf Se

Inventors

• Jacobmeier Olaf
• Kampf Gunnar

Classifications

• B29C44/461 Primary

  dispensing apparatus, e.g. dispensing foaming resin over the whole width of the moving surface · CPC title

• B32B2509/10

  Refrigerators or refrigerating equipment · CPC title

• B29C44/32 Primary

  Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements · CPC title

• B32B3/266

  characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12 · CPC title

• B32B2266/0278

  Polyurethane · CPC title