Latent catalyst for the production of polyurethane foam

• US 10,464,056 B2
• Filed: 07/21/2015
• Issued: 11/05/2019
• Est. Priority Date: 09/12/2014
• Status: Active Grant

• Current Assignee: Momentive Performance Materials Incorporated (Momentive Performance Materials Holdings LLC)
• Original Assignee: Momentive Performance Materials Incorporated (Momentive Performance Materials Holdings LLC)
• Inventors: Stengel, Jason
• Primary Examiner(s): Cooney, John M
• Application Number:
  US15/502,306
• Publication Number:
  US 20170225158A1
• Time in Patent Office: 1,568 Days
• CPC Class Codes: B01J 2531/16 Copper
• CPC Class Codes: B01J 31/0237 Amines
• CPC Class Codes: B01J 31/2234 Beta-dicarbonyl ligands, e.g. acetylacetonates
• CPC Class Codes: B01J 31/26 containing in addition, inorganic metal compounds not provided for in groups B01J31/02 - B01J31/24
• CPC Class Codes: C08G 18/08 Processes
• CPC Class Codes: C08G 18/163 covered by C08G18/18 and C08G18/22
• CPC Class Codes: C08G 18/18 containing secondary or tertiary amines or salts thereof
• CPC Class Codes: C08G 18/22 containing metal compounds
• CPC Class Codes: C08G 18/222 metal compounds not provided for in groups C08G18/225 - C08G18/26
• CPC Class Codes: C08G 18/3206 aliphatic
• CPC Class Codes: C08G 18/4072 Mixtures of compounds of group C08G18/63 with other macromolecular compounds
• CPC Class Codes: C08G 18/4804 Two or more polyethers of different physical or chemical nature
• CPC Class Codes: C08G 18/65 Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen C08G18/2805 takes precedence
• CPC Class Codes: C08G 18/6674 with compounds of group C08G18/3203
• CPC Class Codes: C08G 18/7671 containing only one alkylene bisphenyl group
• CPC Class Codes: C08G 2101/00 Manufacture of cellular products

Abstract

The present technology provides a foam-forming composition comprising at least one polyol, at least one isocyanate, at least one copper catalyst composition, and at least one surfactant. The copper catalyst composition may comprise a copper (II) compound dissolved in a solvent. In one embodiment, the copper catalyst composition comprises (Cu(II)(acac)₂) dissolved in DMSO.

Claims

1. A method for forming a foam comprising:

(i) combining;

a) at least one polyol;

b) at least one isocyanate;

c) a catalyst composition comprising a copper (II) compound dissolved in a solvent chosen from a dialkyl sulfoxide, an N,N-dialkylalkanoamides, a phosphonate, an aromatic compound, an ether compound, or an organic carbonate;

d) at least one surfactant to form a mixture; and

(ii) curing the mixture of (i).

2. The method of claim 1, where the copper (II) compound comprises copper (II) coordinated to a ligand chosen from a carboxylate, a diketonate, a salicylate, an organic salt, a halide, or a combination of two or more thereof.

3. The method of claim 1, where the catalyst composition comprises (Cu(II)(acac)₂).

4. The method of claim 3, where the solvent comprises DMSO.

5. The method of claim 1, where the catalyst composition comprises a co-diluent chosen from a fatty acid, a vegetable oil, or a combination thereof.

6. The method of claim 1, wherein the catalyst composition comprises two or more Cu(II) salts.

7. The method of claim 1, wherein the catalyst composition comprises Cu(II)(acac)₂ and Cu(II)acetate₂.

8. The method of claim 1, where the mixture comprises a copper concentration of about 0.04 to about 10 parts per 100 parts polyol (pphr).

9. The method of claim 1, comprising a co-catalyst (c′

).

10. The method of claim 9, wherein the co-catalyst is chosen from a tertiary amine.

11. The method of claim 10, wherein the tertiary amine is chosen from triethylenediamine, 2-methyltriethylenediamine, N,N,N′

,N′

-tetramethylethylenediamine, N,N,N′

,N′

-tetramethylpropylenediamine, N,N,N′

,N″

,N″

-pentamethyldiethylenetriamine, N,N,N′

,N″

,N″

-pentamethyl-(3-aminopropyl)ethylenediamine, N,N,N′

,N″

,N″

-pentamethyldipropylenetriamine, N,N,N′

,N′

-tetramethylhexamethylenediamine, bis(2-dimethylaminoethyl)ether, dimethylethanolamine, dimethylisopropanolamine, dimethylaminoethoxyethanol, N,N-dimethyl-N′

-(2-hydroxyethyl)ethylenediamine, N,N-dimethyl-N′

-(2-hydroxyethyl)propanediamine, bis(dimethylaminopropyl)amine, bis(dimethyl aminopropyl)isopropanolamine, 3-quinuclidinol, N,N,N′

,N′

-tetramethylguanidine, 1,3,5-tris(N,N-dimethylaminopropyl)hexahydro-S-triazine, 1,8-diazabicyclo[5.4.0]undecene-7, N-methyl-N′

-(2-dimethylaminoethyl)piperazine, N,N′

-dimetylpiperazine, dimethylcyclohexylamine, N-methylmorpholine, N-ethylmorpholine, 1-methylimidazole, 1,2-dimethylimidazole, 1-isobutyl-2-methylimidazole, 1-dimethylaminopropylimidazole, N,N-dimethyhexanolamine, N-methyl-N′

-(2-hydroxyethyl)piperazine, 1-(2-hydroxyethyl)imidazole, 1-(2-hydroxypropyl)imidazole, 1-(2-hydroxyethyl)-2-methylimidazole, 1-(2-hydroxypropyl)-2-methylimidazole, quinuclidine, 2-methylquinuclidine, or a combination of two or more thereof.

12. The method of claim 9, wherein the catalyst composition and the co-catalyst are added separately in part (i).

13. The method of claim 9, wherein the catalyst composition and the co-catalyst are part of a single composition.

14. The method of claim 9, wherein the co-catalyst is present in an amount of from about 0.1 to about 10% by weight of the catalyst composition.

15. The method of claim 1, further comprising combining a component (e) with components (a)-(d), where component (e) is chosen from a blowing agent, a chain extender, a crosslinker, a filler, a reinforcement, a pigment, a tint, a dye, a colorant, a flame retardant, an antioxidant, an antiozonant, a UV stabilizer, an anti-static agent, a biocide, a biostat, or a combination or two or more thereof.

16. The method of claim 1, wherein step (i) comprises frothing components (a)-(d) to form a frothed mixture.