Cure rebond binder

• US 20060035990A1
• Filed: 08/11/2005
• Published: 02/16/2006
• Est. Priority Date: 08/11/2004
• Status: Active Grant

• Current Assignee: Huntsman Petrochemical LLC (Huntsman Corporation)
• Original Assignee: Huntsman Petrochemical LLC (Huntsman Corporation)
• Inventors: Grigsby, Robert A. Jr., Sawitski, Robert G. Jr., Ridgway, Donald H., Pratt, Jennifer K., Hennington, Roger
• Granted Patent: US 8,501,828 B2
• Time in Patent Office: Days
• US Class Current: 521/99
• CPC Class Codes: C08G 18/10 Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
• CPC Class Codes: C08G 18/2018 having one nitrogen atom in the ring
• CPC Class Codes: C08G 18/2081 containing at least two non-condensed heterocyclic rings
• CPC Class Codes: C08G 18/302 Water
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08G 2350/00 Acoustic or vibration damping material
• CPC Class Codes: C08J 2205/06 Flexible foams
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 2475/00 Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
• CPC Class Codes: C08J 9/35 Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments

Abstract

The present invention provides processes for producing re-bonded polyurethane foam constructs that are useful in applications such as carpet underlayments. According to the invention, a tertiary amine is employed as a catalyst either alone, or preferably in combination with other catalysts in a binder which comprises an organic isocyanate and a polyol. Inclusion of a tertiary amine as a catalyst dramatically increases production throughput.

Claims

1. ) A process for producing a cured polyurethane foam article that comprises particles of one or more polyurethane foams bonded together with a binder, which process comprises:

a) forming a mixture comprising;

i) a plurality of particles of polyurethane foam;

ii) a binder that comprises a prepolymer made from an organic isocyanate and a polyol; and

iii) an effective catalytic amount of a tertiary amine; and

b) curing said mixture by contacting it with steam.

2. ) A process according to claim 1 which is carried out at any temperature in the range of about 0°

C. to about 400°

C.

3. ) A process according to claim 1 which is carried out at any pressure in the range of about 0 psi to about 1000 psi.

4. ) A process according to claim 1 wherein the tertiary amine is present in any amount in the range of about 0.01% to about 2.00% by weight based on the total weight of the finished foam article.

5. ) A process according to claim 1 wherein the tertiary amine is 2,2′

-dimorpholinodiethylether.

6. ) A process according to claim 1 wherein the tertiary amine is a morpholine based amine selected from the group consisting of:

N-ethylmorpholine;

N-t-butylmorpholine;

N-methylmorpholine;

N-butylmorpholine;

hydroxyethylmorpholine;

4-(2-methoxyethyl-)morpholine; and

combinations thereof.

7. ) A process according to claim 1 wherein the tertiary amine is a non-morpholine based amine selected from the group consisting of:

Bis-(2-dimethylaminoethyl)ether;

triethylenediamine;

N-(3-dimethylaminopropyl)-N,N-diisopropanolamine;

N,N-bis (3-dimethylaminopropyl-N-isopropanolamine;

2-((2-(2-(dimethylamino)ethoxy)ethyl)methylamino)ethanol;

2,11-dimethyl-2,11-diaza-5,8-dioxa-dodecan;

benzyldimethylamine;

dimethylpiperzine;

pentamethyldiethylenetriamine;

pentamethyldipropylenetriamine;

N,N,N′

-trimethyl-N′

-hydroxyethylethanediamine-1,2;

1,3,5-tris-(3-dimethylaminopropyl-)hexahydro-s-triazine;

dimethylethanolamine;

tetramethyldipropylenetriamine;

N,N-dimethyl-2(2-aminoethoxy)ethanol; and

combinations thereof.

8. ) A process according to claim 1 wherein the tertiary amine is selected from the group consisting of:

2,2′

-dimorpholinodiethylether, at least one morpholine based amine, at least one non-morpholine based amine, and combinations thereof.

9. ) A process according to claim 1 wherein the average size of said particles is such that their average longest length diameter is any value in the range of about 0.5 cm to about 15 cm.

10. ) A process according to claim 1 wherein said mixture further comprises an extender oil, a carbonate ester, a solvent, an ester, a filler, another amine catalyst, a blowing agent, or combinations thereof.

11. ) A process according to claim 1 wherein said mixture comprises an acid-blocked catalyst.

12. ) A process according to claim 1 wherein said mixture further comprises at least one surfactant.

13. ) A process according to claim 1 wherein said mixture further comprises at least one silicone surfactant.

14. ) A flexible, cured polyurethane foam article which comprises particles of one or more polyurethane foams bonded together with a binder, which foam article comprises a tertiary amine in any amount in the range of about 0.01% to about 2.00% by weight based on the total weight of said foam article.

15. ) A foam article according to claim 14 where the tertiary amine is 2,2′

-dimorpholinodiethylether.

16. ) A re-bond composition comprising:

an organic isocyanate;

a polyol;

a diluent; and

a tertiary amine.

17. ) The composition according to claim 16 wherein the tertiary amine comprises 2,2′

-dimorpholinodiethylether.

18. ) The composition according to claim 16 wherein the tertiary amine is selected from the group consisting of:

2,2′

-dimorpholinodiethylether, N-ethylmorpholine;

N-t-butylmorpholine;

N-methylmorpholine;

N-butylmorpholine;

hydroxyethylmorpholine;

4-(2-methoxyethyl-)morpholine;

Bis-(2-dimethylaminoethyl)ether;

triethylenediamine;

N-(3-dimethylaminopropyl)-N,N-diisopropanolamine;

N,N-bis(3-dimethylaminopropyl-N-isopropanolamine;

2-((2-(2-(dimethylamino)ethoxy)ethyl)methylamino)ethanol;

2,11-dimethyl-2,11-diaza-5,8-dioxa-dodecan;

benzyldimethylamine;

dimethylpiperzine;

pentamethyldiethylenetriamine;

pentamethyldipropylenetriamine;

N,N,N′

-trimethyl-N′

-hydroxyethylethanediamine-1,2;

1,3,5-tris-(3-dimethylaminopropyl-)hexahydro-s-triazine;

dimethylethanolamine;

tetramethyldipropylenetriamine;

N,N-dimethyl-2(2-aminoethoxy)ethanol; and

combinations thereof.

19. ) The composition according to claim 16 further comprising an adhesive.

20. ) The composition according to claim 16 wherein said composition further comprises an acid-blocked catalyst, a surfactant, an extender oil, a carbonate ester, a solvent, an ester, a filler, another amine catalyst, a blowing agent, or combinations thereof.