CATALYSTS FOR THE FORMATION OF POLYURETHANES

Abstract

The invention relates to novel urethane or carbamate compounds which can act as a catalyst for the reaction of at least one isocyanate compound with at least one isocyanate-reactive compound, in particular for the manufacture of polyisocyanate polyaddition products, such as polyurethanes, in particular, for the manufacture of polyurethane (PU) foams, where they exhibit superior blowing performance.

Claims

1. A compound obtained by the reaction of an isocyanate compound with at least one isocyanate-reactive compound of the formula (I):
(R).sub.a—X  (I) wherein R is selected from R.sup.1 and R.sup.2, wherein R.sup.1 is selected from the group consisting of R.sup.3, R.sup.4, R.sup.5, R.sup.6, R.sup.14 and R.sup.16, where R.sup.3 is a hydrocarbyl group comprising at least two tertiary amino groups and at least one ether (—O—) group, R.sup.4 is a hydrocarbyl group comprising at least one monocyclic heterocyclic group, R.sup.5 is a group of the formula: ##STR00038## (the dotted line indicates the binding site to X) wherein R.sup.17 is an aliphatic hydrocarbyl group having at least three carbon atoms, and R.sup.7 and R.sup.8 each represent a linear or branched aliphatic hydrocarbyl residue, which optionally may be substituted by one or more tertiary amino groups, and may optionally contain one or more ether (—O—) groups, R.sup.6 is a group of the formula: ##STR00039## wherein R.sup.18 is an aliphatic hydrocarbyl group having at least two carbon atoms, R.sup.19 is an aliphatic hydrocarbyl group having at least three carbon atoms, and R.sup.9 to R.sup.11 are each independently selected from a linear or branched aliphatic hydrocarbyl residue, R.sup.14 is a group of the formula: ##STR00040## wherein each R.sup.15 independently is selected from a hydrocarbyl group, comprising at least one tertiary amino group, and optionally comprises one or more ether (—O—) groups, and R.sup.16 is an aromatic group substituted by at least two hydrocarbyl groups, each comprising at least one tertiary amino group, R.sup.2 is selected from a hydrocarbyl group or hydrogen, a is 2 or 3, and X is selected from the group consisting of O, S, or N, with the provisos that the compounds comprise at least one group R.sup.1 and at least one group R being R.sup.2 being hydrogen and that R.sup.1 can represent only one group R.sup.5, or salts thereof, and mixtures thereof.

2. The compound according to claim 1, wherein the isocyanate-reactive compound is selected from the group consisting of: ##STR00041## ##STR00042## ##STR00043## ##STR00044## ##STR00045## ##STR00046##

3. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.3.

4. The compound according claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.3 selected from the group consisting of saturated aliphatic hydrocarbyl groups having up to 20 carbon atoms, comprising at least two tertiary amino groups and at least one ether (—O—) group.

5. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.3 selected from the following formula: ##STR00047## wherein the groups R.sup.13 are independently selected from a divalent linear, branched or cyclic hydrocarbyl groups, and two of A, B, and C is selected from a tertiary amino group, (—N(R.sup.12)— for A and/or B, and —N(R.sup.12).sub.2 for C, where R.sup.12 is an organic group, and one of A, B, or C is an ether group (for A and B selected from —O— and for C selected from —OR.sup.12, wherein R.sup.12 is as defined before.

6. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.3 selected from the following formula: ##STR00048## wherein x, y, and z are integers of 2 to 6, and two of A, B, and C represent tertiary amino groups (for A and B selected from —N(R.sup.12)— and for C selected from —N(R.sup.12).sub.2 where R.sup.12 is an organic group) and one of A, B, or C is an ether group (for A and B selected from —O— and for C selected from —OR.sup.12, wherein R.sup.12 is as defined before.

7. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.3 and where the isocyanate-reactive compounds are selected from the consisting of: ##STR00049##

8. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.3 and where the isocyanate-reactive compounds are selected from the consisting of: ##STR00050##

9. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.4.

10. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.4 which is a saturated linear or branched hydrocarbyl group having up to 10 carbon atoms, which may contain up to three heteroatoms, such as N or O, which may be substituted by one or more hydroxy groups, and which hydrocarbyl group is substituted by at least one monocyclic heterocyclic group, selected from saturated or unsaturated or aromatic optionally substituted 5 to 6-membered heterocyclic rings having optionally one or two heteroatoms selected from N, O, and S.

11. The compound according to claim 1, wherein the monocyclic heterocyclic group in R.sup.4 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of pyrrolidinyl, piperidyl, 4-alkylpiperazin-1-yl, imidazolyl, and morpholin-4-yl.

12. The compound according to claim 1, wherein R.sup.1 in formula (I) in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.4 and where the isocyanate-reactive compounds are selected from the group consisting of: ##STR00051## ##STR00052## ##STR00053## ##STR00054##

13. The compound according to claim 1, wherein R.sup.1 in formula (I) in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.5 and R.sup.6.

14. The compound according to claim 1, wherein R.sup.1 in formula (I) in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.5 and R.sup.6, wherein R.sup.5 is a group of the formula: ##STR00055## wherein n is an integer of ≥3, and R.sup.7 and R.sup.8 each selected from a linear or branched aliphatic hydrocarbyl residue, which optionally may be substituted by one or more tertiary amino groups, and may optionally contain one or more ether (—O—) groups, and R.sup.6 is a group of the formula: ##STR00056## wherein o is an integer of ≥2, p is an integer of ≥3, and R.sup.9 to R.sup.11 each represent a linear or branched aliphatic hydrocarbyl residue.

15. The compound according to claim 1, wherein R.sup.1 in formula (I) in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.5 is a group of the formula: ##STR00057## wherein n is an integer of 3 to 6, and R.sup.7 and R.sup.8 each represent a linear or branched alkyl group with up to 6 carbon atoms, and R.sup.6 is a group of the formula: ##STR00058## wherein o is an integer of 2 to 6, p is an integer of 3 to 6, and R.sup.9 to R.sup.11 are each selected from a linear or branched alkyl group with up to 6 carbon atoms.

16. The compound according to claim 1, wherein R.sup.1 in formula (I) in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.5 and R.sup.6 and where the isocyanate-reactive compound is selected from the group consisting of: ##STR00059##

17. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.14 or R.sup.16.

18. The compound according to claim 1, wherein R.sup.1 in formula (I) of the isocyanate-reactive compounds is selected from the group consisting of R.sup.14 or R.sup.16 and where the isocyanate-reactive compound is selected from: ##STR00060##

19. The compound according to claim 1, wherein the at least one isocyanate-reactive compound is selected from the group of the formulas (Ia) and (Ib):
R.sup.1—OH  (Ia),
R.sup.1—NH—R.sup.2  (Ib), and
R.sup.1—NH—R.sup.1  (Ic), wherein R.sup.1 and R.sup.2 are each as defined above.

20. The compound according to claim 1, wherein the isocyanate compound is selected from mono- and polyisocyanate compounds.

21. The compound according to claim 1, wherein the isocyanate compound is a monoisocyanate.

22. The compound according to claim 1, wherein the isocyanate compound is a monoisocyanate selected from aliphatic or aromatic isocyanates selected from octadecylisocyanate; octylisocyanate; butyl and t-butylisocyanate; cyclohexyl isocyanate; adamantyl isocyanate; ethylisocyanatoacetate; ethoxycarbonylisocyanate; phenylisocyanate; alphamethylbenzyl isocyanate; 2-phenylcyclopropyl isocyanate; 2-ethylphenylisocyanate; benzylisocyanate; meta and para-tolylisocyanate; 2-, 3-, or 4-nitrophenylisocyanates; 2-ethoxyphenyl isocyanate; 3-methoxyphenyl isocyanate; 4-methoxyphenyl isocyanate; ethyl 4-isocyanatobenzoate; 2,6-dimethylphenylisocyanate; 1-naphythylisocyanate; and (naphthyl) ethylisocyanates.

23. The compound according to claim 1, wherein the isocyanate compound is a polyisocyanate.

24. The compound according to claim 1, wherein the isocyanate compound is a polyisocyanate selected from aliphatic or aromatic polyisocyanates selected from the group consisting of isophorone diisocyanate (IPDI); toluene diisocyanate (TDI); diphenylmethane-2,4′-diisocyanate (2,4′-MDI); diphenylmethane-4,4′-diisocyanate (4,4′-MDI); hydrogenated diphenylmethane-4,4′-diisocyanate (H.12 MDI); tetra-methyl xylene diisocyanate (TMXDI); hexamethylene-1,6-diisocyanate (HDI); napthylene-1,5-diisocyanate; 3,3′-dimethoxy-4,4′-biphenyldiisocyanate; 3,3′-dimethyl-4,4′-bimethyl-4,4′-biphenyldiisocyanate; phenylene diisocyanate; 4,4′-biphenyldiisocyanate; trimethylhexamethylene diisocyanate; tetramethylene xylene diisocyanate; 4,4′-methylene-bis (2,6-diethylphenyl isocyanate); 1,12-diisocyanatododecane; 1,5-diisocyanato-2-methylpentane; 1,4-diisocyanatobutane; and cyclohexylene diisocyanate and its isomers or and derivatives thereof; trimethylolpropane trimer of TDI, isocyanurate trimers of TDI, HDI, IPDI; biuret trimers of TDI, HDI, or IPDI; and polyisocyanates, where the isocyanate groups are partially reacted with at least one isocyanate-reactive compound which does not have a group R.sup.1.

25. The compound according to claim 1, wherein the isocyanate compound is a polyisocyanate selected from isophorone diisocyanate (IPDI), hexamethylene diisocyanate (HDI), and derivatives derived from IPDI and/or HDI.

26. The compound according to claim 1, wherein the isocyanate compound is isophorone diisocyanate (IPDI) and R.sup.1 of the isocyanate-reactive compounds of the formula (I) is selected from R.sup.3.

27. The compound according to claim 1, wherein the isocyanate groups of the polyisocyanates are completely or partially reacted.

28. The compound according to claim 1, selected from compounds of the formula (II) and (III): ##STR00061## wherein R.sup.1 is as defined above, x is 1 to 6, and R.sup.20 is one- to six-valent optionally substituted hydrocarbyl group that optionally contains one or more heteroatoms and which is bound to the nitrogen atom of the urethane group by a carbon atom, ##STR00062## wherein one R is R.sup.1 as defined above, and the other R is selected from R.sup.1 or R.sup.2 as defined above, and x and R.sup.20 are as defined above, wherein R.sup.20 is bound to the nitrogen atom of the urea group by a carbon atom.

29. The compound according to claim 1, selected from ##STR00063##

30. A process for the manufacture of the compounds according to claim 1, which process comprises reacting the at least one isocyanate compound and the at least one at least one isocyanate-reactive compound of the formula (I).

31. The process according to claim 30, wherein the reaction is carried out at a temperature of about 20-140° C., optionally in the presence of one or more diluents and one or more catalysts.

32. A composition comprising one or more compounds according to claim 1, which further comprises (i) at least one diluent; and/or (ii) at least one conventional polyurethane formation catalyst; and/or (iii) comprises at least one carboxylic acid selected from the group consisting of monocarboxylic acid compounds, polycarboxylic acid compounds, such as dicarboxylic acid compounds, and hydroxyl-functional carboxylic acid compounds.

33. (canceled)

34. (canceled)

35. The composition according to claim 32, the at least one carboxylic acid is selected from the group consisting of salicyclic acid, benzoic acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, and citric acid.

36. (canceled)

37. (canceled)

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. A catalyst comprising the compounds or compositions according to claim 1.

43. The catalyst according to claim 42, comprising one more additional catalyst for the manufacture of polyisocyanate polyaddition products.

44. A process for the manufacture of an isocyanate addition product comprising reacting an isocyanate compound with an isocyanate-reactive compound in the presence of the compound according to claim 1.

45. A process for the manufacture of an isocyanate addition product comprising reacting an isocyanate compound with an isocyanate-reactive compound in the presence of the compounds according to claim 1 in the presence of water.

46. The process for the manufacture of an isocyanate addition product, according to claim 45, wherein the isocyanate is a polyisocyanate and the isocyanate-reactive compound is a polyol, and the process is for producing a polyurethane.

47. The process for the manufacture of an isocyanate addition product according to claim 46, wherein the isocyanate addition product is a polyurethane selected from cellular or non-cellular polyurethanes, and the process optionally comprises a blowing agent.

48. The process for the manufacture of an isocyanate addition product according to claim 45, wherein the process is for producing a polyurethane, and the process optionally comprises the addition of a surfactant, a fire retardant, a chain extender, a cross-linking agent, an adhesion promoter, an anti-static additive, a hydrolysis stabilizer, a UV stabilizer, a lubricant, an anti-microbial agent, or a combination of two or more thereof.

49. The process for the manufacture of an isocyanate addition product according to claim 45, wherein the compound is present in an amount of about 0.005 wt-% to about 5 wt-% based on the total weight of the total composition including all components.

50. An isocyanate addition product forming a foam obtainable from the process of the manufacture of an isocyanate addition product of claim 45.

51. The isocyanate addition product forming a foam according to claim 50 selected from the group consisting of slabstock, molded foams, flexible foams, rigid foams, semi-rigid foams, spray foams, thermoformable foams, microcellular foams, footwear foams, open-cell foams, closed-cell foams, adhesives.

Description

EXAMPLES

[0133] Catalyst Formation Examples

[0134] First an 80 weight % of aqueous solution of C1 from U.S. Pat. No. 6,423,756B1, (C1 is the reaction product of dimethylaminoethoxyethanol and isophorone diisocyanate) was prepared and further used as amine catalyst with predominantly gel characteristics. The 80% aqueous solution of C1 is named as C1.1.

Inventive Catalyst 1 (or IC1) [Reaction Product of 2 Mol of N,N,N′-trimethyl-N′-(2-hydroxyethyl)bis(2-aminoethyl) ether with 1 mol of isophorone diisocyanate]

[0135] Then, a four naked 250 mL round bottom flask was equipped with a thermometer, mechanical stirrer and reflux condenser. The flask was flushed with dry nitrogen. Under nitrogen atmosphere N,N,N′-trimethyl-N′-(2-hydroxyethyl)bis(2-aminoethyl) ether (96.09 g, 0.505 mol) was charged into the flask. Isophorone diisocyanate (55.58 g, 0.25 mmol) was added over 30 minutes while vigorously stirring the reaction mixture and by keeping the temperature of the reaction mixture bellow 80° C. After the complete addition of isophorone diisocyanate the reaction mixture was heated at 75° C. for 2.5 hours to provide clear, viscous product. 43.32 g of the product. .sup.13C and .sup.1H NMR data confirmed the formation of Inventive catalyst 1 (IC1, as shown below as reaction product). 43.32 g of IC1 was dissolved in 10.83 g water to obtain 80 weight % aqueous solution IC1.1, which was used for polyurethane foam production. Furthermore, 71.70 g of IC1 was dissolved in 10.43 g dipropylene glycol to obtain IC1.2 which was used for polyurethane foaming reactions.

##STR00036##

Inventive Catalyst 2 (or IC2) [Reaction Product of 2 Mol of 2-{2-[(3-aminopropyl)(methyl) amino]ethoxy}ethyl)dimethylamine (or N′-[2-[2-(dimethylamino)ethoxy]ethyl]-N′-methyl-propane-1,3-diamine) with 1 mol of isophorone diisocyanate]

[0136] ##STR00037##

[0137] Into a 10 mL glass vial equipped with a magnetic stirrer 2.03 g (10 mmol) 2-{2-[(3-aminopropyl)(methyl)amino]ethoxy}ethyl)dimethylamine was added under nitrogen atmosphere and the vial was sealed with a septum cap. 1.11 g isophorone diisocyanate (5.0 mmol) was added dropwise while vigorously stirring the reaction mixture. The mixture was vigorously stirred for ˜5 minutes and the vial was placed into the heating block at 75° C. After 2 hours the vial was taken out from the heating block and cooled down to room temperature. A transparent glassy, high viscous mass was obtained. .sup.13C and .sup.1H NMR data confirmed the formation of Inventive catalyst 2 (IC2, shown as reaction product in the scheme above)).

[0138] Foaming Experiments:

[0139] The polyurethane foams were prepared according to the following procedure. A premix P1 of 4950.00 g reactive polyether polyol (Hyperlite® (or HP) 1629; hydroxyl number of 29.5-33.5 mg KOH/g), 49.50 g EO-rich cell opener (Voranol™ CP 1421; hydroxyl number of 33 mg KOH/g), 32.67 g 90 wt-% aqueous solution of diethanolamine (DEOA 90% in water), 29.70 g silicone stabilizer (Niax® Silicone L-3639S), 148.50 g water and 39.60 g predominantly gel catalyst C1.1 (for polyurethanes foams presented in Table 1) was prepared by mixing the mixture thoroughly in a plastic bucket for 20 minutes using propeller stirrer with ring at 800 rpm. From the premix, single batches each of 291.67 g were weighed to an appropriate mixing plastic container, the additional water amounts and corresponding catalysts (for instance C1.1, IC1.1) were added to obtain adjusted final polyol blends according to proportions given in Table 1.

[0140] For foam systems presented in Table 2 the premix P2 was prepared without addition of water and any catalyst by mixing the mixture thoroughly in a plastic bucket for 20 minutes using propeller stirrer with ring at 800 rpm. For those foam compositions after preparing the premix, single batches each of 281.22 g were weighed to an appropriate mixing plastic container.

[0141] The required water amounts and corresponding catalysts (for instance C1.1, IC1.1) were added to obtain the final polyol blends according to proportions given in Table 2.

[0142] To produce a foam pad the polyol blend was mixed thoroughly in the plastic container for 30 seconds using propeller stirrer with ring at 3000 rpm. Defined amount of Suprasec 2447 isocyanate (MDI, with NCO content of 32.6%) was added according to proportions given in Table 1 or 2 and the reactive mixture was mixed for 4-6 seconds. The reactive mixture was immediately poured into a 30×30×10 cm aluminum mold and the mold was immediately closed and clamped. The mold lid had four vent openings with a diameter of 0.4 mm at the four corners. The mold temperature was controlled at 55° C. via a hot water circulating thermostat. Release agent Chem-Trend® PU-1705M was used to coat the mold. Foams were demolded after 4 minutes. The processing and physical characteristics of the foam were evaluated as follows:

TABLE-US-00001 Physical Characteristic Test Method Density ASTM D 3574-05 Exit Time Exit time is the time elapsed, in seconds, from the addition of the isocyanate to the reaction mixture to the first appearance of foam extrusion from the four vents of the mold. The exit time is an appropriate relative measure of generation of the blowing agent CO.sub.2 resulting from the reaction of water and isocyanate during foaming of water blown polyurethane systems. The lower the exit time value, the higher the blowing efficiency of the system. Force-to-Crush ASTM 3574-05. Force-to-crush (FTC) is the peak force required to deflect a FTC, N foam pad with the standard 323 cm.sup.2 (50 sq. in.) indentor, 1 minute after demold, to 50% of its original thickness. It is measured with a load-testing machine using the same setup as that used for measuring foam hardness. A load tester crosshead speed of 50.8 cm/minute is used. The FTC value is a good relative measure of the degree of cell openness characteristic of a foam, i.e. the lower the value, the more open the foam. Hot ILD ASTM 3574-05. The indentation load deflection (hot ILD) is measured on the same pad used for the FTC measurement 3 minutes after demold. Following the FTC measurement, the foam pad is completely crushed by a mechanical crusher before the measurement of ILD at 50% compression is taken. The hot ILD value is a good relative measure of the curing degree of a foam 3 minutes after demold. The higher the hot ILD value, the higher the curing degree of the foam. ILD ASTM 3574-05. The indentation load deflection (ILD) is measured on the same pad used for the FTC and hot ILD measurements at least 48 hours after demold. Following the FTC and hot ILD measurements, the foam pad is completely crushed by a mechanical crusher before the measurement of ILD at 50% compression is taken. The ILD value is a good relative measure of the curing degree of a foam at least 48 hours after demold. The higher the ILD value, the higher the curing degree of the foam.

[0143] The summary table of the PU foam composition and PU foam properties is shown in the following Table 1 for reactive mixture 1 to 4 (the composition of the chemical components is given in parts per weight or pbw)

TABLE-US-00002 TABLE 1 Foam composition 1 2 3 4 HP-1629 100.00 CP-1421 1.00 DEOA (90% in water) 0.66 Niax Silicone L-3639S 0.60 Inventive catalyst solution IC1.1 — 0.25 0.75 Catalyst solution C1.1 1.05 1.55 0.80 Water added 3.75 3.65 3.75 3.65 Water total 4.03 MDI Suprasec 2447 67.4 67.1 67.1 67.1 Exit time, sec 78 52 60 40 FTC, N 379 1233 409 559 hot ILD, N 288 348 334 399 ILD, N 833 765 829 801 Density of the pad, kg/m.sup.3 46 46 46 45

[0144] It was found that the addition of the Inventive Catalyst solution IC1.1 to the catalyst solution C1.1 significantly improves the blowing efficiency of the catalyst blend. Thus, the exit time of the reactive mixture 1 is 78 seconds, whereas the exit time of the reactive mixture 3 is 60 seconds although the total weight amounts of active catalysts are the same (0.80+0.25=1.05 pbw) in those comparative experiments 1 and 3. In the same manner the comparison of exit time from the experiment 2 (52 seconds) with experiment 4 clearly demonstrates the higher blowing efficiency of the Inventive Catalyst solution IC1.1. In addition, it was found that ILD values for PU foams prepared by using Inventive Catalyst solution IC1.1 tend to be beneficially higher compared to PU foams made by using only the state-of-the-art catalyst solution C1.1. This tendency is demonstrated by comparison of ILD values of foams 2 and 4 made at higher use level of catalysts (0.80+0.75=1.55 pbw). In particularly, the catalyst composition of 0.80 pbw C1.1 and 0.75 pbw of IC1.1 (reactive mixture 4) provided PU foams with higher ILD values compared to the PU foams obtained from the reactive mixture 2 where C1.1 was used as sole catalyst at a use level of 1.55 pbw.

[0145] The summary of the experiments shown in the following Table 2 presents the comparison where only a single catalyst is used and where the Inventive catalyst in solution IC1.1 is compared with state-of-the-art catalyst in solution C1.1.

TABLE-US-00003 TABLE 2 Foam composition A1 A2 A3 A4 HP-1629 100.00 CP-1421 1.00 DEOA (90% in water) 0.66 Niax Silicone L-3639S 0.60 Inventive catalyst IC1.1 0.50 1.10 Comparative catalyst C1.1   0.50 1.10 Water added 3.86 3.74   3.86 3.74 Water total 4.03 MDI Suprasec ® 2447 67.1 Exit time, sec 83 44 143  82 FTC, N 222 460  107* 341 hot ILD, N 193 375  109* 292 ILD, N 818 864  828* 828 Density of the pad, kg/m.sup.3 48 47  49 48 *the foam was very soft, sticky and vulnerable after demolding indicating incomplete curing which is apparent also from the lower FTC and hot ILD values. The skin of the foam became wrinkly after demolding. Thus, the ILD values for this foam are not recommended to be used in further argumentation.

[0146] It was found that the blowing efficiency of the Inventive catalyst IC1.1 is significantly higher compared to state-of-the-art catalyst C1.1. Thus, the exit time of the reactive mixture A1 catalyzed by IC1.1 is 83 seconds, whereas the exit time of the reactive mixture A3 catalyzed by state-of-the-art catalyst C1.1 is significantly longer and is 143 seconds. Furthermore, in comparison to the PU foam A1, the foam A3 was very soft, sticky and vulnerable after demolding which is apparent from the lower FTC and hot ILD values. The skin of the PU foam A3 became wrinkly after demolding confirming incomplete polymerization. In the same manner the comparison of exit times from the experiment A2 (44 seconds) with experiment A4 clearly demonstrates the better blowing efficiency of the invented catalyst IC1. Furthermore, in addition to faster exit times the beneficial higher hot ILD and ILD values of A2 PU foam compared to A4 PU foam demonstrates the better curing efficiency of the Inventive catalyst IC1.1.

[0147] The following polyurethane foams based on TDI were prepared according to the following procedure. A premix P3 of 1425.00 g reactive polyether polyol (Hyperlite® polyol 1629; hydroxyl number of 29.5-33.5 mg KOH/g), 1425.00 g styrene-acrylonitrile (SAN) polymer modified reactive polyether polyol with 43% SAN content (Hyperlite® polyol 1639; hydroxyl number of 20 mg KOH/g), 34.20 g 90 wt-% aqueous solution of diethanolamine (DEOA 90% in water), 28.50 g silicone stabilizer (Niax® Silicone L-3555) and 85.50 g water was prepared by mixing the mixture thoroughly in a plastic bucket for 20 minutes using propeller stirrer with ring at 800 rpm. From the premix P3, single batches each of 315.60 g were weighed to an appropriate mixing plastic container, the additional water amounts and corresponding catalysts in solution (for instance C1.1, IC1.1) were added to obtain final polyol blends according to proportions given in Table 3. To produce a PU foam pad the polyol blend was mixed thoroughly in the plastic container for 30 seconds using propeller stirrer with ring at 3000 rpm. Defined amount of Scuranate T80 isocyanate (TDI, with NCO content of 48.1%) was added according to proportions given in Table 3 and the reactive mixture was mixed for 4-6 seconds. The reactive mixture was immediately poured into a 30×30×10 cm aluminum mold and the mold was immediately closed and clamped. The mold lid had 4 vent openings with a diameter of 0.4 mm at the four corners. The mold temperature was controlled at 65° C. via a hot water circulating thermostat. Release agent Chem-Trend® PU-1705M was used for coating the mold. Foams were demolded after 5 minutes. The processing and physical characteristics of the foam were evaluated as described above.

[0148] Table 3 describes reactive mixtures B1 to B4 of the PU foam compositions in pbw and the physical properties of corresponding PU foams.

TABLE-US-00004 TABLE 3 Foam composition B1 B2 B3 B4 HP-1629 50.00 HP-1639 50.00 DEOA (90% in water) 1.20 Niax Silicone L-3555 1.00 Inventive catalyst IC1.1    0.375 0.625 Comparative catalyst    0.375 0.625 C1.1 Water added   3.66 3.61   3.66 3.61 Water total 3.86 TDI Scuranate ® T80 44.10 Exit time, sec  49 33  68 53 FTC, N  140* 441  121* 467 hot ILD, N  129* 166   89* 147 ILD, N 618  552  606* 527 Density of the pad,  40 40  41 41 kg/m.sup.3 *the foam was very soft, sticky and vulnerable after demolding indicating incomplete curing which is apparent also from the lower FTC and hot ILD values. The skin of the foam became wrinkly after demolding. Thus, the ILD values for this foam are not recommended to be used in further argumentation.

[0149] It was found that the blowing efficiency of the Inventive catalyst IC1.1 is significantly higher compared to state-of-the-art catalyst C1.1. Thus, the exit time of the reactive mixture B1 catalyzed by IC1.1 is 49 seconds, whereas the exit time of the reactive mixture B3 catalyzed by state-of-the-art catalyst C1.1 is significantly longer and is 68 seconds. Furthermore, in comparison to the foam B1 the foam B3 was very much softer and stickier and more vulnerable after demolding which is apparent from the lower FTC and hot ILD values. The skin of the foam B3 became very wrinkly after demolding confirming incomplete polymerization. In the same manner the comparison of exit times from the experiment B2 (33 seconds) with experiment B4 clearly demonstrates the better blowing efficiency of the invented catalyst. Furthermore, in addition to faster exit times the tendency of beneficial higher hot ILD and ILD values of B2 foams compared to B4 foams demonstrates the better curing efficiency of the Invented catalyst IC1.1.