Melamine-polyol dispersions and uses thereof in manufacturing polyurethane

Patent metadata

Field	Value
Publication number	US-9884945-B2
Application number	US-201214370173-A
Country	US
Kind code	B2
Filing date	Jan 6, 2012
Priority date	Jan 6, 2012
Publication date	Feb 6, 2018
Grant date	Feb 6, 2018

Abstract

Melamine-polyol dispersions comprising ethoxylated alcohols of specific structures are disclosed. Such dispersions maintain their stability under stationary conditions for at least 24 hours and are useful in the manufacturing of polyurethane foams. The resulted polyurethane foams display more evenly-distributed flame retardant properties.

First claim

The invention claimed is:

1. A dispersion obtained by
contacting: at least one polyol,
melamine particles, and
at least one ethoxylated alcohol of the following formula:
RO(CH 2 CH 2 O) n H

wherein R is a C1-C31 linear alkyl group,
n is an integer equal to or greater than 18;
wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 15.7; and
wherein the at least one ethoxylated alcohol is present in an amount of about 0.5 to 2.0 parts by weight per hundred weight parts of the at least one polyol of the dispersion.

2. The dispersion of claim 1 , wherein the at least one ethoxylated alcohol is present in an amount effective for keeping said dispersion stable for at least 24 hours.

3. The dispersion of claim 1 , wherein the at least one polyol is selected from the group consisting of polyether polyols, polyester polyols, or polymer polyols.

4. The dispersion of claim 1 , wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value between 15.7 and 17.0.

5. The dispersion of claim 1 , wherein the at least one ethoxylated alcohol is in an aqueous solution.

6. The dispersion of claim 1 , wherein melamine particles are present in an amount of about 5 to about 80 parts by weight per hundred weight parts of the at least one polyol of the dispersion.

7. The dispersion of claim 1 , wherein melamine particles are present in an amount of about 30 to about 80 parts by weight per hundred weight parts of the at least one polyol of the dispersion.

8. The dispersion of claim 1 , further comprising fillers including CaCO 3 , BaSO 4 or any combination thereof.

9. The dispersion of claim 1 , further comprising a liquid flame retardant selected from the group consisting of halogenated flame retardants, non-halogenated flame retardants and any combination thereof.

10. The dispersion of claim 1 , wherein the dispersion is substantially free of thickening agents.

11. The dispersion of claim 1 , wherein the dispersion is substantially free of thickening agents selected from the group consisting of xanthan gums, carrageenans, polyacrylamide, chemically treated cellulose, clays and any combination thereof.

12. A dispersion consisting essentially of:
at least one polyol,
melamine, and
at least one ethoxylated alcohol of the following formula:
RO(CH 2 CH 2 O) n H,

wherein R is a C13 linear alkyl group and n is 40,
wherein melamine is present in an amount of about 30 to about 80 parts by weight per hundred weight parts of the at least one polyol of the dispersion,
wherein the at least one ethoxylated alcohol is present in an amount of about 0.7 to 2.0 parts by weight per hundred weight parts of the at least one polyol of the dispersion.

13. The dispersion of claim 12 , wherein the at least one ethoxylated alcohol is present in an amount effective for keeping said dispersion stable for at least 24 hours.

14. The dispersion of claim 12 , wherein the at least one ethoxylated alcohol is in an aqueous solution.

15. A method for making a dispersion, comprising:
a) combining to form a mixture at least one polyol, melamine particles and at least one ethoxylated alcohol of the following formula:
RO(CH 2 CH 2 O) n H,

wherein R is a C1-C31 linear alkyl group,
n is an integer equal to or greater than 18,
wherein melamine particles are present in an amount of greater than 0 to about 80 parts by weight per hundred weight parts of the at least one polyol of the dispersion,
wherein the at least one ethoxylated alcohol is in an aqueous solution, is present in an amount of about 0.7 to 2.0 parts by weight per hundred weight parts of the at least one polyol of the dispersion, is effective for keeping said dispersion stable for at least 24 hours, and has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 15.7; and
b) mixing the mixture of a) until a stable dispersion is formed.

16. A polyurethane foam formulation comprising
a) the dispersion of claim 1 ,
b) at least one polyisocyanate,
c) at least one blowing agent,
d) at least one amine catalyst,
e) at least one metal catalyst; and
f) at least one silicone surfactant.

17. A method for preparing a polyurethane foam comprising
a) forming a premix comprising
i) the dispersion of claim 1 ,
ii) at least one blowing agent,
iii) at least one amine catalyst,
iv) at least one metal catalyst,
v) at least one silicone surfactant; and
b) contacting the premix with at least one polyisocyanate at an isocyanate index from about 80 to about 150.

18. A polyurethane foam made with the polyurethane foam formulation of claim 16 .

19. The dispersion of claim 12 , wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value between 15.7 and 17.0.

20. The method of claim 15 , wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value between 15.7 and 17.0.

21. The dispersion of claim 1 , wherein n is an integer of 18 to 20.

Assignees

• Su Jackson
• Cao Jacky
• Yasue Tadao
• Cao Mark
• Evonik Degussa Gmbh

Inventors

• Su Jackson
• Cao Jacky
• Yasue Tadao
• Cao Mark

Classifications

• C08G2101/00

  Manufacture of cellular products · CPC title

• C08J9/0028

  containing nitrogen · CPC title

• C08J9/145

  only chlorine as halogen atoms · CPC title

• C08G18/3851

  containing three nitrogen atoms in the ring · CPC title

• C08J9/009 Primary

  Use of pretreated compounding ingredients · CPC title