Non isocyanate polyurethane foams

• US 10,450,416 B2
• Filed: 01/27/2017
• Issued: 10/22/2019
• Est. Priority Date: 01/29/2016
• Status: Active Grant

• Current Assignee: Faurecia Interieur Industrie (Stellantis NV), Faurecia Sieges D'Automobile (Stellantis NV)
• Original Assignee: Faurecia Interieur Industrie (Stellantis NV)
• Inventors: Lauth, Marc, Mulhaupt, Rolf, Blattmann, Hannes
• Primary Examiner(s): Cooney, John M
• Application Number:
  US15/418,555
• Publication Number:
  US 20170218124A1
• Time in Patent Office: 998 Days
• CPC Class Codes: C07D 317/36 Alkylene carbonates; Substituted alkylene carbonates
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/005 < 50kg/m3
• CPC Class Codes: C08G 71/04 Polyurethanes
• CPC Class Codes: C08J 2203/142 Halogenated saturated hydrocarbons, e.g. H3C-CF3
• CPC Class Codes: C08J 2205/044 Micropores, i.e. average diameter being between 0,1 micrometer and 0,1 millimeter
• CPC Class Codes: C08J 2205/06 Flexible foams
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/146 only fluorine as halogen atoms

Abstract

A curable isocyanate free formulation for preparing a polyurethane foam. The formulation includes a compound A chosen from multifunctional cyclic carbonates of a formula (I) or a mixture thereof, a compound B chosen from multifunctional cyclic carbonates containing oxyalkylene groups —OR3- of a formula (II) or a mixture thereof, a compound C chosen from multifunctional amines of a formula (III) or a mixture thereof and a compound D chosen from non-reactive blowing agents, as well as a process for preparing a non-isocyanate polyurethane foam, a foam obtainable by this process, compound B, a mixture of compounds A and B, the use of compound B for enhancing the solubility of a non-reactive blowing agent in a compound A and a foamable system having a first part A containing compound A and compound B and a second part B containing compound C, wherein part A and part B are preferably physically separated.

Claims

1. A curable isocyanate free formulation for preparing a polyurethane foam comprising the following compounds:

Compound A chosen from multifunctional cyclic carbonates of formula (I) or a mixture thereof;

2. The curable isocyanate free formulation according to claim 1, wherein R¹ and R^1′

, identical or different, are a linear or branched hydrocarbon chain having 3 to 10 carbon atoms.

3. The curable isocyanate free formulation according to claim 1, wherein i and i′

, identical or different, are integers from 2 to 6.

4. The curable isocyanate free formulation according to claim 1, wherein:

Compound A is chosen from a compound of formula (Ia);

5. The curable isocyanate free formulation according to claim 4, wherein:

Compound A is chosen from a compound of formula (Ia)

Compound B is chosen from a compound of formula (IIa) or a mixture thereof wherein q =2 and n, m, and p are 6 or 7.

6. The curable isocyanate free formulation according to claim 1, wherein the Compound C is chosen from 1,2-diamonethane, 1,3-diaminopropane, butane-1,4-diamine, pentane-1,5-diamine, 1,6-diaminohexane, 1,12 diaminododecane, isophorondiamine, polyethylene imine or dimeric fatty acid diamines.

7. The curable isocyanate free formulation according to claim 1, wherein compound D is chosen from liquids which boiling point is below 100°

C., hydrocarbons, ethers, halogenated hydrocarbons, nitriles, nitrogen or carbon dioxide, or mixtures thereof.

8. The curable isocyanate free formulation according to claim 1, further comprising a catalyst as compound E.

9. A process for preparing a flexible non-isocyanate polyurethane foam comprising the steps of:

reacting compounds A and B with compound C in the presence of compound D and a catalyst as compound E so as to form an expanded reaction mixture,

curing said expanded reaction mixture so as to form a flexible non-isocyanate polyurethane foam,

wherein compounds A, B, C, and D comprise the curable isocyanate free formulation defined in claim 1.

10. The process according to claim 9, wherein:

compounds A and B are first mixed with compound E and compound C, so as to form a reaction mixture and start the polymerization of said reaction mixture,

then compound D is added to this reaction mixture.

14. The curable isocyanate free formulation according to claim 8, wherein the catalyst as compound E is chosen from amine catalysts or organometallic catalysts or mixtures thereof.

11. A foamable system comprising:

a first part A containing;

Compound A which is chosen from multifunctional cyclic carbonates of formula (I) or a mixture thereof;

12. The foamable system according to claim 11, further comprising a catalyst as compound E either in part A or in part B, or in a third part C preferably physically separated from part A and part B.

13. The foamable system according to claim 11, further comprising a non-reactive blowing agent as compound D either in part A, in part B or in third part C, or in a fourth part D preferably physically separated from part A, part B and part C.

15. The foamable system of claim 11, wherein part A and part B are physically separated.