ISOCYANATE TRIMERIZATION CATALYST FOR MAKING POLYISOCYANURATE COMPRISING FOAMS

• US 20170198082A1
• Filed: 03/31/2015
• Published: 07/13/2017
• Est. Priority Date: 04/03/2014
• Status: Active Grant

• Current Assignee: Huntsman International LLC (Huntsman Corporation)
• Original Assignee: Huntsman International LLC (Huntsman Corporation)
• Inventors: VERBEKE, Hugo, VANHALLE, Anja Anneke
• Granted Patent: US 11,548,973 B2
• Time in Patent Office: Days
• CPC Class Codes: C08G 18/092 oligomerisation to isocyanurate groups
• CPC Class Codes: C08G 18/14 Manufacture of cellular products
• CPC Class Codes: C08G 18/163 covered by C08G18/18 and C08G18/22
• CPC Class Codes: C08G 18/1808 having alkylene polyamine groups
• CPC Class Codes: C08G 18/1875 containing ammonium salts or mixtures of secondary of tertiary amines and acids
• CPC Class Codes: C08G 18/225 of alkali or alkaline earth metals
• CPC Class Codes: C08G 18/3853 containing cyanurate and/or isocyanurate groups
• CPC Class Codes: C08G 18/4829 Polyethers containing at least three hydroxy groups C08G18/4833 - C08G18/5096 take precedence
• CPC Class Codes: C08G 18/61 Polysiloxanes
• CPC Class Codes: C08G 18/7664 containing alkylene polyphenyl groups
• CPC Class Codes: C08G 2110/0025 rigid
• CPC Class Codes: C08G 2110/0058 ≥50 and <150kg/m3
• CPC Class Codes: C08G 2115/02 to isocyanurate groups
• CPC Class Codes: C08G 2330/00 Thermal insulation material
• CPC Class Codes: C08J 2203/182 of physical blowing agents, e.g. acetone and butane
• CPC Class Codes: C08J 2205/052 Closed cells, i.e. more than 50% of the pores are closed
• CPC Class Codes: C08J 2205/10 Rigid foams
• CPC Class Codes: C08J 2375/08 from polyethers
• CPC Class Codes: C08J 9/127 Mixtures of organic and inorganic blowing agents
• CPC Class Codes: C08K 5/521 Esters of phosphoric acids, e.g. of H3PO4
• CPC Class Codes: C09K 21/12 : containing phosphorus

Abstract

A trimerization catalyst composition suitable for making a polyisocyanurate comprising (insulation) foam, said composition comprising at least a trimerization catalyst compound selected from one or more organic salts from alkoxides wherein said organic salt is selected from alkali metal, earth alkali metal, a transition metal such as Ti and/or quaternary ammonium organic salts.

Claims

1. A process for making a polyisocyanurate-polyurethane comprising rigid foam (PIR-PUR), having a density <

60 kg/m³, said process comprising combining and mixing at an isocyanate index of at least more than 100, preferably 180 or higher, more preferably higher than 250;

a) a polyisocyanate composition comprising one or more polyisocyanate compounds;

b) an isocyanate-reactive composition comprising one or more isocyanate reactive compounds;

c) a trimerization catalyst composition comprising at least one trimerization catalyst compound selected from one or more organic alkoxides corresponding to the formula (I);

(R—

O⁻

)_xM^+x 

 

(I)

Wherein

R is an organic group which is selected from an hydrocarbyl group wherein the hydrocarbyl groups has 1-4 carbon atoms,

x is a number being defined by the oxidation state of M

M is selected from an alkali metal ion, an earth alkali metal ion, a transition metal ion such as Ti or a quaternary ammonium ion

d) optionally one or more surfactants, one or more flame retardants, water, one or more antioxidants, one or more auxiliary blowing agents, one or more urethane catalysts, one or more auxiliary trimerisation catalysts, or combinations thereof

2. The process according to claim 1 wherein the trimerization catalyst compound is selected from potassium ethoxide, sodium ethoxide, potassium methoxide, sodium methoxide, potassium tert-butoxide, titanium isopropoxide and mixtures thereof.

3. The process according to claim 1 wherein the trimerization catalyst compound is present in a solvent.

4. The process according to claim 1 wherein the trimerization catalyst composition further comprises a monool/polyol composition.

5. The process according to claim 4 wherein the polyol/monool composition is an isocyanate reactive agent which comprises polyester and/or polyether polyols having an average molecular weight of 32-6000 and an average nominal functionality of 1-8.

6. The process according to claim 1 wherein the trimerization catalyst compound is present in an amount such that the number of catalyst equivalents over the number of isocyanate equivalents ranges from 0.001 to 0.4, preferably in an amount from 0.01 to 0.26, or from 0.01 to 0.24, or from 0.02 to 0.2.

7. The process according to claim 1 wherein the polyisocyanate compounds are selected from a toluene diisocyanate, a methylene diphenyl diisocyanate or a polyisocyanate composition comprising a methylene diphenyl diisocyanate or a mixture of such polyisocyanates.

8. The process according to claim 1 wherein the one or more isocyanate reactive compounds are selected from monools and/or polyols such as glycols, polyether polyols and polyester polyols, mercaptans, carboxylic acids such as polybasic acids, amines, polyamines, components comprising at least one alcohol group and at least one amine group such as polyaminepolyols, urea and amides.

9. The process according to claim 1 wherein the isocyanate reactive compounds are selected from monools or polyols which have an average nominal hydroxy functionality of 1-8 and an average molecular weight of 32-8000 and mixtures of said monools and/or polyols.

10. The process according to claim 1 wherein the isocyanate reactive compounds are selected from monools selected from methanol, ethanol, propanol, butanol, phenol, cyclohexanol and hydrocarbon monools having an average molecular weight of 200-5000 like aliphatic and polyether monools and/or polyols selected from ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, trimethylol propane, sorbitol, sucrose, glycerol, ethanediol, propanediol, butanediol, pentanediol, hexanediol, aromatic and/or aliphatic polyols having a molecular weight of up to 8000, preferably 200-6000 polyester polyols having an average molecular weight of 200-8000, preferably 200-6000, polyether polyester polyols having an average molecular weight of 200-8000, preferably 200-6000 and polyether polyols having an average molecular weight of 200-8000, preferably 200-6000.

11. The process according to claim 1 wherein the blowing agent is selected from isobutene, dimethyl ether, water, methylene chloride, acetone, chlorofluorocarbons (CFCs), hydrofluorocarbons (HFCs), hydrochlorofluorocarbons (HCFCs), and/or hydrocarbons and is present in an amount of 1 to 80 pbw parts by weight (pbw), preferably from 5 to 60 pbw calculated per hundred weight parts of the one or more isocyanate reactive compounds (including the weight contribution of the catalyst system diluent).

14. A polyisocyanurate comprising material obtainable by the process according to claim 1.

12. (canceled)

15. The polyisocyanurate-polyurethane comprising rigid foam according to claim 12 having a free rise density (measured according to ISO 845) in the range of between 25 kg/m³ up to 60 kg/m³, preferably in the range 30 kg/m³ up to 55 kg/m³, a thermal conductivity in the range 20 up to 30 mW/mK, preferably 20 up to 25 mW/mK and having a closed cell content higher than 75% calculated on the total amount of closed and open cells being present in the material.

13. (canceled)

16. (canceled)