Rigid Polyurethane Foam Based on Toluene Diamine-Initiated Polyols

• US 20070208095A1
• Filed: 10/28/2004
• Published: 09/06/2007
• Est. Priority Date: 11/03/2003
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Inventors: Martin, Charles, Dean, Geoffrey, Moore, Stanley, Kind, Christiaan, Cosman, James
• Granted Patent: US 7,691,913 B2
• Time in Patent Office: Days
• US Class Current: 521/131
• CPC Class Codes: C08G 18/4018 Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48
• CPC Class Codes: C08G 18/4208 containing aromatic groups
• CPC Class Codes: C08G 18/482 Mixtures of polyethers containing at least one polyether containing nitrogen
• CPC Class Codes: C08G 18/4845 containing oxypropylene or higher oxyalkylene end groups
• CPC Class Codes: C08G 18/4883 containing cyclic groups having at least one oxygen atom in the ring
• CPC Class Codes: C08G 18/5024 containing primary and/or secondary amino groups
• CPC Class Codes: C08G 18/5033 containing carbocyclic groups C08G18/5024 takes precedence
• CPC Class Codes: C08G 18/7664 containing alkylene polyphenyl groups
• CPC Class Codes: C08G 2110/0025 rigid
• CPC Class Codes: C08G 2110/005 < 50kg/m3
• CPC Class Codes: C08G 65/2627 containing aromatic or arylaliphatic amine groups
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/146 only fluorine as halogen atoms
• CPC Class Codes: C08L 83/00 Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers

Abstract

Rigid polyurethane foams are made using a polyol component that includes toluene diamine-initiated polyols containing specified levels of oxyethylene groups. Foams made from these polyols have low k-factors and excellent demold expansion values.

Claims

1. A method of malting a polyurethane foam, comprising (1) forming a reaction mixture by mixing, under reaction conditions,

(a) an isocyanate-reactive component containing a polyol or mixture thereof having an average hydroxyl number of from 300 to 600 and an average of at least 3 hydroxyl groups/molecule with

(b) an isocyanate-component containing a polyisocyanate that is reactive with the polyol or mixture thereof,

in the presence of an effective amount of physical blowing agent selected from the group consisting of hydrofluorocarbons having from 2 to 4 carbon atoms and from 0.1 to 4 parts by weight water per 100 parts by weight of the polyol or mixture thereof, and (2) subjecting the reaction mixture to conditions such that it reacts, expands and cures within an enclosed space to form a rigid polyurethane foam within said enclosed space,

wherein at least 10 percent by weight of said polyol or mixture thereof is one or more hydroxyl group containing, toluene diamine-initiated polyethers, wherein the toluene diamine-initiated polyether(s) have an average hydroxyl number of from 300 to 600, and further wherein oxyethylene (—

CH₂—

CH₂—

O—

) groups constitute 2 to 25 percent of the total weight of the toluene diamine initiated polyether(s).

2. The method of claim 1, wherein the physical blowing agent is selected from HFC 134A, HFC 245fa, HFC 365mfc and mixtures thereof.

4. The method of claim 1 or 3, wherein the toluene diamine-initiated polyether(s) have an average oxyethylene group content of 3 to 20 percent by weight.

5. The method of claim 4, wherein the toluene diamine is at least 50 percent by weight the 2-3-isomer.

6. The method of claim 1 or 3, wherein the toluene diamine-initiated polyether(s) constitute at least 50 percent by weight of the polyol or mixture thereof.

7. The method of claim 6, wherein the toluene diamine-initiated polyether(s) have an average oxyethylene group content of 6 to 15 percent by weight.

8. The method of claim 7, wherein the toluene diamine-initiated polyether(s) constitute at least 80 percent by weight of the polyol or mixture thereof.

10. The method of claim 1 or 3, wherein the isocyanate-reactive component and the isocyanate component are mixed in the presence of a surfactant and a catalyst.

11. The method of claim 1 or 3, wherein the enclosed space is a wall of a freezer, refrigerator or cooler.

3. A method of making a polyurethane foam, comprising (1) forming a reaction mixture by mixing, under reaction conditions,

(a) an isocyanate-reactive component containing a polyol or mixture thereof having an average hydroxyl number of from 300 to 600 and an average of at least 3 hydroxyl groups/molecule with

(b) an isocyanate-component containing a polyisocyanate that is reactive with the polyol or mixture thereof,

in the presence of an effective amount of physical blowing agent selected from the group consisting of alkanes having 3-6 carbon atoms and cycloalkanes having 5-6 carbon atoms and from 0.1 to 4 parts by weight water per 100 parts by weight of the polyol or mixture thereof, and (2) subjecting the reaction mixture to conditions such that it reacts, expands and cures within an enclosed space to form a rigid polyurethane foam within said enclosed space,

wherein at least 10 percent by weight of said polyol or mixture thereof is one or more hydroxyl group containing, toluene diamine-initiated polyethers, wherein the toluene diamine-initiated polyether(s) have an average hydroxyl number of from 300 to 600, and further wherein oxyethylene (—

CH₂—

CH₂—

O—

) groups constitute 2 to 25 percent of the total weight of the toluene diamine initiated polyether(s).

9. The method of claim 3, wherein the physical blowing agent is selected from alkanes having 3-6 carbon atoms and cycloalkanes having 5-6 carbons atoms, or a mixture of two ore more of said blowing agents.

12. An isocyanate-reactive composition comprising

(a) an isocyanate-reactive component containing a polyol or mixture thereof having an average hydroxyl number of from 300 to 600 and an average of at least 3 hydroxyl groups/molecule, (b) an effective amount of a physical blowing agent selected from the group consisting of hydrofluorocarbons having from 2 to 4 carbon atoms and (c) from 0.1 to 4 parts by weight water per 100 parts by weight of the polyol or mixture thereof, wherein at least 10 percent by weight of said polyol or mixture thereof is one or more hydroxyl group containing toluene diamine-initiated polyethers, the toluene diamine-initiated polyether(s) have an average hydroxyl number of from 300 to 600, and oxyethylene groups constitute 2 to 25 percent of the total weight of the toluene diamine initiated polyether(s).

13. The composition of claim 12, wherein the physical blowing agent is selected from HFC 134A, HFC 245fa, HFC 365mfc and mixtures thereof.

15. The composition of claim 12 or 14, wherein the toluene diamine-initiated polyether(s) have an average oxyethylene group content of 3 to 20 percent by weight.

16. The composition of claim 15, wherein the toluene diamine is at least 50 percent by weight the 2-3-isomer.

17. The composition of claim 16, wherein the toluene diamine-initiated polyether(s) constitute at least 50 percent by weight of the polyol or mixture thereof.

18. The composition of claim 17, wherein the toluene diamine-initiated polyether(s) have an average oxyethylene group content of 6 to 12 percent by weight.

19. The composition of claim 18, wherein the toluene diamine-initiated polyether(s) constitute at least 80 percent by weight of the polyol or mixture thereof.

21. The composition of claim 12 or 14, wherein the isocyanate-reactive component and the isocyanate component are mixed in the presence of a surfactant and a catalyst.

14. An isocyanate-reactive composition comprising

(a) an isocyanate-reactive component containing a polyol or mixture thereof having an average hydroxyl number of from 300 to 600 and an average of at least 3 hydroxyl groups/molecule, (b) an effective amount of a physical blowing agent selected from the group consisting of alkanes having 3-6 carbon atoms and cycloalkanes having 5-6 carbon atoms, or a mixture of any two or more of the foregoing physical blowing agents and (c) from 0.1 to 4 parts by weight water per 100 parts by weight of the polyol or mixture thereof,

wherein at least 10 percent by weight of said polyol or mixture thereof is one or more hydroxyl group containing toluene diamine-initiated polyethers, the toluene diamine-initiated polyether(s) have an average hydroxyl number of from 300 to 600, and oxyethylene groups constitute 2 to 25 percent of the total weight of the toluene diamine initiated polyether(s).

20. The composition of claim 14, wherein the physical blowing agent is selected from alkanes having 3-6 carbon atoms and cycloalkanes having 5-6 carbons atoms, or a mixture of two ore more of said blowing agents.

22. A method of making a polyurethane foam, comprising (1) forming a reaction mixture by mixing, under reaction conditions,

(a) an isocyanate-reactive component containing a polyol or mixture thereof having an average hydroxyl number of from 300 to 600 and an average of at least 3 hydroxyl groups/molecule with

(b) an isocyanate-component containing a polyisocyanate that is reactive with the polyol or mixture thereof,

in the presence of an effective amount of physical blowing agent selected from the group consisting of hydrofluorocarbons having from 2 to 4 carbon atoms, alkanes having 3-6 carbon atoms and cycloalkanes having 5-6 carbon atoms, or a mixture of any two or more of the foregoing physical blowing agents, and from 0.1 to 4 parts by weight water per 100 parts by weight of the polyol or mixture thereof, and (2) subjecting the reaction mixture to conditions such that it reacts, expands and cures within an enclosed space to form a rigid polyurethane foam within said enclosed space, wherein at least 10 percent by weight of said polyol or mixture thereof is one or more hydroxyl group containing, toluene diamine-initiated polyethers, wherein the toluene diamine-initiated polyether(s) have an average hydroxyl number of from 300 to 600, and further wherein oxyethylene (—

CH₂−

CH₂—

O—

) groups constitute 2 to 25 percent of the total weight of the toluene diamine initiated polyether(s).