METHOD FOR PRODUCING POLYURETHANE SOFT FOAMS

Abstract

The invention relates to a method for producing polyurethane soft foams, in particular open-cell polyurethane soft foams based on polyether carbonate polyol and toluylene diisocyanate, wherein the resulting polyurethane soft foams have similar properties to the already known polyurethane soft foams and they are simpler and more sustainable in terms of their production.

Claims

1. A process for the production of flexible polyurethane foams comprising reacting component A) polyether carbonate polyol A1 and optionally one or more polyether polyols A2, with the polyether polyols A2 being free of carbonate units, component B) comprising: B1) catalysts, and optionally B2) auxiliaries and additives, C) water and/or physical blowing agents, with D) di- and/or polyisocyanates comprising tolylene 2,4-diisocyanate and tolylene 2,6-diisocyanate; wherein the production is carried out at an index of 90 to 125, wherein the production is performed in the presence of at least one compound E having the formula (I) below: ##STR00006## where R.sup.1 is an aromatic hydrocarbon radical having at least 5 carbon atoms or is a linear, branched, substituted or unsubstituted aliphatic hydrocarbon radical having at least 2 or, if branched, at least 3 carbon atoms; R.sup.2 is a linear, branched, substituted or unsubstituted aliphatic hydrocarbon radical; and n is 1 to 3.

2. The process as claimed in claim 1, wherein in the formula (I) R.sup.1 is an aromatic hydrocarbon radical having at least 6 carbon atoms or is a linear, branched, substituted or unsubstituted aliphatic hydrocarbon radical having at least 3 carbon atoms; R.sup.2 is a linear, branched, substituted or unsubstituted aliphatic hydrocarbon radical having at least 3 carbon atoms; and n is 1 to 3.

3. The process as claimed in claim 1, wherein component A comprises: A1 40 to 100 parts by weight of one or more polyether carbonate polyols having a hydroxyl number in accordance with DIN 53240-1:2013-06 of from 20 mg KOH/g to 120 mg KOH/g, A2 0 to 60 parts by weight of one or more polyether polyols having a hydroxyl number in accordance with DIN 53240-1:2013-06 of from 20 mg KOH/g to 250 mg KOH/g and a content of ethylene oxide of from 0.1% to 59% by weight, with the polyether polyols A2 being free of carbonate units, A3 0 to 20 parts by weight, based on a sum of the parts by weight of components A1 and A2, of one or more polyether polyols having a hydroxyl number in accordance with DIN 53240-1:2013-06 of from 20 mg KOH/g to 250 mg KOH/g and a content of ethylene oxide of at least 60% by weight, with the polyether polyols A3 being free of carbonate units, A4 0 to 40 parts by weight, based on the sum of the parts by weight of components A1 and A2, of one or more polymer polyols, PUD polyols, PIPA polyols, or a combination thereof, and A5 0 to 40 parts by weight, based on the sum of the parts by weight of components A1 and A2, of polyols different from components A1 to A4, wherein all stated parts by weight of components A1, A2, A3, A4, A5 are normalized so that the sum of the parts by weight A1+A2 in the composition is 100.

4. The process as claimed in claim 1, wherein the at least one compound E is used in an amount of 1.0 to 15.0 parts by weight, wherein all stated parts by weight of compound E are based on a sum of the parts by weight of components A1+A2=100 parts by weight.

5. The process as claimed in claim 1, wherein component B comprises: B1 catalysts comprisinq a) aliphatic tertiary amines, cycloaliphatic tertiary amines, aliphatic amino ethers, cycloaliphatic amino ethers, aliphatic amidines, cycloaliphatic amidines, urea or derivatives of urea, or a combination thereof, and/or b) tin(II) salts of carboxylic acids, and B2 optionally auxiliaries and additives.

6. The process as claimed in claim 1, wherein component A comprises: A1 65 to 75 parts by weight of one or more polyether carbonate polyols having a hydroxyl number in accordance with DIN 53240-1:2013-06 of from 20 mg KOH/g to 120 mg KOH/g and A2 35 to 25 parts by weight of one or more polyether polyols having a hydroxyl number in accordance with DIN 53240 of from 20 mg KOH/g to 250 mg KOH/g and a content of ethylene oxide of from 0.1% to 59% by weight, with the polyether polyols A2 being free of carbonate units.

7. The process as claimed in claim 1, wherein component A1 comprises a polyether carbonate polyol obtained by copolymerization of carbon dioxide and one or more alkylene oxides in the presence of one or more H-functional starter molecules.

8. The process as claimed in claim 1, wherein component D comprises at least 50% by weight of tolylene 2,4-diisocyanate and tolylene 2,6-diisocyanate.

9. The process as claimed in claim 1, wherein component D comprises not more than 21.5% by weight of tolylene 2,6-diisocyanate, based on the total weight of component D.

10. The process as claimed in claim 9, wherein tolylene 2,4-diisocyanate and tolylene 2,6-diisocyanate are used in a form of a mixture of at least two mutually dissimilar batches, wherein a first batch comprises tolylene 2,4-diisocyanate and tolylene 2,6-diisocyanate in a ratio of 80% by weight to 20% by weight and a second batch comprises tolylene 2,4-diisocyanate and tolylene 2,6-diisocyanate in a ratio of 67% by weight to 33% by weight, wherein a proportion of the second batch is not more than 25% by weight, based on a total weight of the first and the second batch.

11. A flexible polyurethane foams obtained by the process as claimed in claim 1.

12. The flexible polyurethane foams as claimed in claim 11, wherein the flexible polyurethane foam is an open-cell flexible polyurethane foams.

13. The flexible polyurethane foams as claimed in claim 11, wherein the flexible polyurethane foam has a foam density in accordance with DIN EN ISO 845:2009-10 of from 45.5 to 60.0 kg/m.sup.3.

14. (canceled)

15. A two-component system for producing flexible polyurethane foams, comprising a first component K1 comprising or consisting of: component A) comprising A1) polyether carbonate polyol and optionally A2) one or more polyether polyols, with the polyether polyols A2 being free of carbonate units, B) optionally B1) catalysts, and/or B2) auxiliaries and additives, C) water and/or physical blowing agents, and E) a compound having the formula (I) below: ##STR00007## where R.sup.1 is an aromatic hydrocarbon radical having at least 5 carbon atoms or is a linear, branched, substituted or unsubstituted aliphatic hydrocarbon radical having at least 2 carbon atoms; R.sup.2 is a linear, branched, substituted or unsubstituted aliphatic hydrocarbon radical; and n is 1 to 3, and a second component K2 comprising: D) di- and/or polyisocyanates which comprise tolylene 2,4-diisocyanate and tolylene 2,6-diisocyanate, and at least one catalyst, wherein component K1 and component K2 are present in a relative ratio of an isocyanate index of 90 to 125.

Description

EXAMPLES

Component A:

[0199] A1-1 CARDYON LC05 is a polyol mixture consisting of 70% by weight of DESMOPHEN 95LC04 and 30% by weight of ARCOL POLYOL 1108 having an OH number of 54 mg KOH/g; CO.sub.2 content approx. 14%; DESMOPHEN 95LC04: polyether carbonate polyol, glycerol-started; propylene oxide-based; prepared by means of DMC catalysis, OH number: 56 mg KOH/g. ARCOL POLYOL 1108: propylene oxide/ethylene oxide-based polyol; prepared by means of DMC catalysis; starter: glycerol; OH number: 48 mg KOH/g [0200] A1-2 DESMOPHEN 41WB01 is a commercially available ethylene oxide/propylene oxide-based polyol (Covestro AG) having a very high proportion of ethylene oxide groups; starter: glycerol; KOH catalysis; OH number of 37 mg KOH/g

Component B:

[0201] B1-1 Bis[(2-dimethylamino)ethyl]ether (70% by weight) in dipropylene glycol (30% by weight) (Niax catalyst A-1, Momentive Performance Chemicals, Leverkusen, Germany). [0202] B1-2 1,4-Diazabicyclo[2.2.2]octane (33% by weight) in dipropylene glycol (67% by weight) (Dabco 33 LV, Evonik, Essen, Germany). [0203] B2-1 Tegostab B 8244 polyether siloxane-based foam stabilizer (Evonik, Essen, Germany). [0204] B2-2 Tegostab B 8002 polyether siloxane-based foam stabilizer (Evonik, Essen, Germany).

Component C: Water

Component D:

[0205] D-1: Mixture of 2,4- and 2,6-TDI in a weight ratio of 80:20 and having an NCO content of from 48% to 48.2% by weight, commercially available as Desmodur T 80 (Covestro AG). [0206] D-2: Mixture of 2,4- and 2,6-TDI in a weight ratio of 67:33 and with an NCO content of 48-48.2% by weight, commercially available as Desmodur T 65 (Covestro AG).

Component E:

[0207] E-1: Diisodecyl sebacate, commercially available as Uniplex DIDS [0208] E-2: Tris(2-ethylhexyl) 0-acetylcitrate, commercially available as Citrofol AHII [0209] E-3: Bis(2-ethylhexyl) adipate, commercially available as Oxsoft DOA

Production of the Flexible Polyurethane Foams

[0210] The starting components are processed in a single-stage process by slabstock foaming under the processing conditions customary for the production of flexible polyurethane foams.

[0211] The foam density was determined in accordance with DIN EN ISO 845:2009-10.

[0212] The compression hardness (CLD 40%) was determined in accordance with DIN EN ISO 3386-1:2015-10

at a deformation of 40%, 1st and 4th cycle.

[0213] Tensile strength and elongation at break were determined in accordance with DIN EN ISO 1798:2008-04.

[0214] The compression set (CS 90%) was determined in accordance with DIN EN ISO 1856:2008-01 at 90% deformation.

[0215] The compression set (CS 50%) was determined in accordance with DIN EN ISO 1856:2008-01 (22 h, 70 C.) at 50% deformation.

[0216] In the table below, comparative examples are indicated as CE and examples according to the invention as IE.

TABLE-US-00001 TABLE 1 CE 1 and IE 1 to 6, table continued on next page for IE 7-12; pphp = parts per 100 parts polyol Unit CE 1 IE 1 IE 2 IE 3 IE 4 IE 5 IE 6 CARDYON LC05 [pphp] 90.00 90.00 90.00 90.00 100.00 90.00 90.00 DESMOPHEN 41WB01 [pphp] 10.00 10.00 10.00 10.00 10.00 10.00 water (added) [pphp] 1.90 1.90 1.90 1.90 1.90 1.90 1.90 Tegostab B 8244 [pphp] 1.20 1.20 1.20 1.20 1.20 Tegostab B 8002 [pphp] 1.20 1.20 Uniplex DIDS [pphp] 5.00 8.00 8.00 8.00 Citrofol AHII [pphp] 5.00 8.00 Oxsoft DOA [pphp] Dabco 33 LV [pphp] 0.10 0.10 0.10 0.10 0.10 0.10 0.10 Niax catalyst A-1 [pphp] 0.12 0.12 0.12 0.12 0.12 0.12 0.12 Dabco T-9 [pphp] 0.12 0.12 0.10 0.08 0.10 0.12 0.10 (tin octoate) DESMODUR T 80 [pphp] 13.16 19.74 26.32 23.82 26.73 19.74 26.32 DESMODUR T 65 [pphp] 13.16 6.58 2.65 6.58 Water, total [pphp] 1.90 1.90 1.90 1.90 1.90 1.90 1.90 INDEX [] 99.0 99.0 99.0 99.0 99.0 99.0 99.0 Mechanical properties Foam density [kg/m.sup.3] 45.1 47.7 50.5 55.5 54.60 46.8 49.1 Compression [kPa] 3.5 3.2 3.38 3.69 4.55 3.36 3.76 hardness 40%; 1st compression Compression [kPa] 2.54 2.38 2.62 2.82 3.35 2.59 2.96 hardness 40%; 4th compression Compression set 50% [%] 4.7 5.5 2.3 4.6 4.2 4.3 2.6 Compression set 90% [%] 61 37.9 6.3 6.7 11.3 8.6 4.9 Tensile strength [kPa] 76 68 67 76 65 66 61 Elongation at break [%] 197 199 175 149 153 193 172 Unit IE 7 IE 8 IE 9 IE 10 IE 11 IE 12 CARDYON LC05 [pphp] 90.00 100.00 90.00 90.00 90.00 100.00 DESMOPHEN 41WB01 [pphp] 10.00 10.00 10.00 10.00 water (added) [pphp] 1.90 1.90 1.90 1.90 1.90 1.90 Tegostab B 8244 [pphp] 1.20 1.20 Tegostab B 8002 [pphp] 1.20 1.20 1.20 1.20 Uniplex DIDS [pphp] Citrofol AHII [pphp] 8.00 8.00 Oxsoft DOA [pphp] 5.00 8.00 8.00 8.00 Dabco 33 LV [pphp] 0.10 0.10 0.10 0.10 0.10 0.10 Niax catalyst A-1 [pphp] 0.12 0.12 0.12 0.12 0.12 0.12 Dabco T-9 [pphp] 0.08 0.10 0.12 0.10 0.08 0.10 (tin octoate) DESMODUR T 80 [pphp] 23.82 26.73 19.74 26.32 23.82 26.73 DESMODUR T 65 [pphp] 2.65 6.58 2.65 Water, total [pphp] 1.90 1.90 1.90 1.90 1.90 1.90 INDEX [] 99.0 99.0 99.0 99.0 99.0 99.0 Mechanical properties Foam density [kg/m.sup.3] 57.3 52 46.8 48.7 53.5 54.6 Compression [kPa] 5.14 4.55 3.41 3.19 4.14 4.78 hardness 40%; 1st compression Compression [kPa] 3.96 3.41 2.68 2.5 3.17 3.63 hardness 40%; 4th compression Compression set 50% [%] 2.2 2.4 2.5 3.2 1.9 2.7 Compression set 90% [%] 3.7 3.4 4.8 5.7 3.8 13.3 Tensile strength [kPa] 83 78 58 64 72 77 Elongation at break [%] 159 166 171 179 149 168