Patent Application
20240368331
The invention is in the field of polyurethanes and relates to the production of PU foams using recycled polyols.
On account of their exceptional mechanical and physical properties, polyurethanes find use in a very wide variety of sectors. A particularly important market for a very wide variety of polyurethanes is the PU foams sector.
Polyurethanes (PU) are for the purposes of the present invention all reaction products derived from isocyanates, in particular from polyisocyanates, and appropriately isocyanate-reactive molecules, in particular polyols. They include inter alia polyisocyanurates, polyureas and isocyanate or polyisocyanate reaction products containing allophanates, biurets, uretdiones, uretonimines or carbodiimides.
Polyurethanes are now so widespread worldwide that recycling is becoming increasingly important for these materials too. According to the state of the art, there accordingly already exists various recycling processes for the recovery of polyurethane waste. The known chemical recycling processes, such as the hydrolysis described for example in U.S. Pat. No. 5,208,379, glycolysis, acidolysis, aminolysis, hydrogenolysis, solvolysis and similar processes are aimed at depolymerization on a molecular level and in each case lead to polyol mixtures that can also sometimes be reused for PU production. These polyol mixtures are referred to very generally as recycled polyols.
The basic aim is to reuse the recycled polyols for the production of polyurethanes. Against this background, it was the specific object of the present invention to make it possible to provide PU foams using recycled polyols without there being a deterioration in the quality of the resulting foams by comparison with PU foams produced using conventional polyols, including in particular when relatively large amounts of recycled polyols are used.
An important prerequisite for the use of recycled polyols is that they are adequately stabilized against oxidation processes.
Conventional polyols always contain antioxidants in order to (a) protect the polyols themselves against oxidative degradation during storage and transport and (b) to prevent thermal degradation of the foam during foam production. If there is inadequate oxidative stabilization of the polyols and thus of the foam, brown discolorations can arise through thermal stress of the PU during foam production. Moreover, since inadequate oxidative stabilization of the polyols used can lead to spontaneous combustion of the foam, adequate stabilization is also an important safety aspect in foam production.
Recycled polyols obtained directly from the recycling process may still contain proportions of antioxidants, but—as expected—generally in insufficient amounts.
In order for it to be possible for recycled polyols to be used in larger amounts or as a complete substitute for conventional polyols, they need to have appropriate thermal/oxidative stabilization.
The object of the present invention was to develop a process that makes it possible, even when using large amounts of recycled polyols, to produce PU foams with which only very minimal or no discoloration occurs, even under thermal stress.
The above object is achieved by the subject matter of the invention. The invention provides a process for producing PU foams by reacting
The subject matter of the invention makes it possible, even when using relatively large amounts of recycled polyol, to provide polyurethane foams that correspond to the quality of conventional polyurethane foams produced in the same way but using conventional polyols.
The proportion by mass of the antioxidant present in the recycled polyols is determined in the context of the present invention by HPLC. For this, 500 mg of the polyol of the invention is dissolved in 10 ml of ethanol. An aliquot of the solution is analysed by HPLC. The analysis is carried out using an HPLC system (LC Agilent 1260, column: Agilent Zorbax Eclipse XDB-C8 150 mm*4.6 mm; 5μ, column temperature: 40° C., sample injection volume: 3 μL, detector: DAD 280 nm). The procedure is described more precisely in the examples section.
Through the high proportion of recycled polyol that can be achieved, the subject matter of the invention enables a significant increase in the total proportion of recycled raw materials in the polyurethane foams generated according to the invention by comparison with foams obtained from conventional polyols or using predominantly conventionally generated polyols, which is an important advance in respect of the recyclability of polyurethane foams.
The thermal durability of recycled polyols can be estimated through thermogravimetric analyses (TGAs) in air. In thermogravimetric analyses, the change in mass of the polyol under investigation is monitored as a function of temperature at a preset constant heating rate or as a function of time at a constant temperature. In recycled polyols, the loss of mass essentially triggered by thermal degradation reactions commences at a constant temperature of 180° C., generally already at an earlier point than with corresponding conventional polyols. An advantage of the invention is accordingly the use of antioxidants to adjust the thermal durability of recycled polyols such that this at least corresponds to the thermal durability of conventional polyols and thus enables the production from recycled polyols of PU foams having a lower tendency to discoloration.
The invention also enables the use of high amounts of corresponding recycled polyol accompanied by only an insignificant reduction in foam quality or none at all. It therefore corresponds to a preferred embodiment of the invention when the process of the invention uses, based on the total employed polyol component, more than 30% by weight, preferably more than 50% by weight, preferably more than 70% by weight, further preferably more than 80% by weight, in particular more than 95% by weight, of recycled polyol, wherein this recycled polyol meets the criterion of the invention concerning the antioxidant content.
The employed recycled polyol is a polyol originating in particular from the recycling of polyurethane waste. Polyurethane waste includes any polyurethanes, in particular PU foams, that are no longer being used but are earmarked for disposal. It therefore corresponds to a preferred embodiment of the invention when the employed recycled polyol is a recycled polyol and/or recycled polymer polyol produced from polyurethane waste, preferably obtained from the depolymerization of PU foam, in particular of hot-cure flexible PU foam (standard PU foam), viscoelastic PU foam and/or HR PU foam, the recycled polyol and/or recycled polymer polyol having been obtained by solvolysis, preferably by hydrolysis, aminolysis, acidolysis or glycolysis, in particular by hydrolysis, as described for example in the as yet unpublished European patent applications under file references 20192354.7 or 20192364.6. The term “recycled polyol” encompasses for the purposes of the present invention also “recycled polymer polyol”.
Following the depolymerization process, the recycled polyol may, through classical separation methods, be freed of other recycled products, in particular of the primary aromatic amines that can likewise be formed and of the added reagents for the particular depolymerization process. Some examples of methods for the purification and recovery of the recycled polyol from the crude mixture of recycling products present after the respective depolymerization step are mentioned below. One option for removing water from the crude mixture of recycling products consists of its removal by distillation. Primary aromatic amines such as tolylene 2,4-diamine, tolylene 2,6-diamine or isomers of methylenediphenyldiamine can be removed from the respective recycled polyol by distillation, by extraction with aromatic solvents or by washing with acidic wash aqueous solutions or by other methods from the crude mixture of recycling products. Any solid components that occur, such as recycling catalysts, salts or residual polyurethane components, can be removed from the crude product mixture/removed from the recycled polyols by filtration using various filter types.
It corresponds to a particularly preferred embodiment of the invention when the antioxidants from the original PU foams sent for recycling or from the polyols used in these original PU foams are retained during the depolymerization process and can be recovered as subcomponents of the recycled polyol during its purification.
By adding to the recycled polyols one or more additional antioxidants of formula 3a and/or formula 1d, it is readily possible to adjust the antioxidant content to 0.001% to 10% by weight, preferably 0.002% to 8% by weight, further preferably 0.005% to 7.5% by weight, particularly preferably 0.01% to 5% by weight, based on the total recycled polyol. A further particularly preferred embodiment of the invention is when, in the process of the invention, at least 10%, further preferably at least 20%, particularly preferably at least 30%, of the content of antioxidants of formula 3a originates from the recycled polyol as arising from the PU recycling process.
It corresponds to a very particularly preferred embodiment of the invention when the recycled polyol is used without further addition of antioxidants.
The employed recycled polyol may in particular be obtained from a polyurethane hydrolysis comprising the reaction of the polyurethane with water in the presence of a base-catalyst combination (I) or (II),
The use of recycled polyol obtained from the described hydrolysis process in which the total concentration of antioxidants of formula 3a and/or formula 1d can be adjusted to 0.001% to 10% by weight, preferably 0.002% to 8% by weight, further preferably 0.005% to 7.5% by weight, particularly preferably 0.01% to 5% by weight, based on the total recycled polyol, corresponds to a preferred embodiment of the invention.
Corresponding and preferred hydrolysis processes of PU materials are for example described in the as yet unpublished European patent applications under file references 20192354.7 or 20192364.6.
A particularly preferred variant, referred to here as preferred variant 1, of depolymerization by hydrolysis is described below.
In particular, it is preferable when the depolymerization of the polyurethane in step a) is effected using a base having a pkb at 25° C. of 1 to 10, preferably 1 to 8, further preferably 1 to 7, in particular 1.5 to 6, and also a catalyst selected from the group consisting of (i) quaternary ammonium salts containing an ammonium cation comprising 6 to 30 carbon atoms and (ii) organic sulfonate containing at least 7 carbon atoms. This corresponds to a preferred embodiment of the invention.
Preferred bases comprise an alkali metal cation and/or an ammonium cation. Preferred bases are here alkali metal phosphates, alkali metal hydrogen phosphates, alkali metal carbonates, alkali metal silicates, alkali metal hydrogen carbonates, alkali metal acetates, alkali metal sulfites, ammonium hydroxides or mixtures of the above. Preferred alkali metals are Na, K or Li or mixtures of the above, in particular Na or K or mixtures thereof, preferred ammonium cation is NH4+.
Particularly preferred bases are K2CO3, Na2SiO3, NH4OH, K3PO4, or KOAc.
The base is preferably used in the form of a saturated alkaline solution in water, wherein the ratio by weight of saturated alkaline solution to PU is within a range preferably from 0.5 to 25, preferably 0.5 to 15, further preferably 1 to 10, in particular 2 to 7.
Preferred quaternary ammonium salts have the general structure: R1R2R3R4NX
Very particularly preferred quaternary ammonium salts are tributylmethylammonium chloride, tetrabutylammonium hydrogen sulfate, benzyltrimethylammonium chloride, tributylmethylammonium chloride and/or trioctylmethylammonium methylsulfate.
The organic sulfonate containing at least 7 carbon atoms that is likewise employable as catalyst preferably comprises alkyl aryl sulfonates, alpha-olefin sulfonates, petroleum sulfonates and/or naphthalene sulfonates.
Preferred temperatures for the depolymerization are 80° C. to 200° C., preferably 90° C. to 180° C., further preferably 95° C. to 170° C. and in particular 100°° C. to 160° C.
Preferred reaction times for the depolymerization are 1 minute to 14 h, preferably 10 minutes to 12 h, preferably 20 minutes to 11 h and in particular 30 minutes to 10 h.
Preference is given to using for the depolymerization at least 0.5% by weight of catalyst based on the weight of the polyurethane, preferably 0.5% to 15% by weight, further preferably 1% to 10% by weight, even further preferably 1% to 8% by weight, further preferably still 1% to 7% by weight and in particular 2% to 6% by weight.
A preferred weight ratio of base to polyurethane is within a range from 0.01 to 50, preferably 0.1 to 25, in particular 0.5 to 20.
This related to the preferred variant 1 of the depolymerization.
Another further particularly preferred variant, referred to here as preferred variant 2, of depolymerization by hydrolysis is described below.
When the depolymerization of the polyurethane in step a) is effected using a base having a pKb at 25° C. of <1, in particular 0.5 to −2, preferably 0.25 to −1.5, in particular 0 to −1, of a catalyst from the group of quaternary ammonium salts containing an ammonium cation having 6 to 14 carbon atoms in the case of an ammonium cation that does not contain a benzyl substituent, or else containing an ammonium cation having 6 to 12 carbon atoms in the case of an ammonium cation that contains a benzyl substituent, this is a further preferred embodiment of the invention.
Preferred bases are here alkali metal hydroxides, alkali metal oxides, alkaline earth metal hydroxides, alkali metal oxides or mixtures thereof. Preferred alkali metals are Na, K or Li or mixtures of the above, in particular Na or K or mixtures thereof; preferred alkaline earth metals are Be, Mg, Ca, Sr or Ba or mixtures thereof, preferably Mg or Ca or mixtures thereof. A very particularly preferred base is NaOH.
Preferred quaternary ammonium salts have the general structure: R1R2R3R4NX
Particularly preferred quaternary ammonium salts are here benzyltrimethylammonium chloride or tributylmethylammonium chloride.
Preferred temperatures for the depolymerization are 80° C. to 200° C., preferably 90° C. to 180° C., further preferably 95° C. to 170° C. and in particular 100° C. to 160° C.
Preferred reaction times for the depolymerization are 1 minute to 14 h, preferably 10 minutes to 12 h, preferably 20 minutes to 11 h and in particular 30 minutes to 10 h.
Preference is given to using for the depolymerization at least 0.5% by weight of catalyst based on the weight of the polyurethane, preferably 0.5% to 15% by weight, further preferably 1% to 10% by weight, even further preferably 1% to 8% by weight, further preferably still 1% to 7% by weight and in particular 2% to 6% by weight.
A preferred weight ratio of base to polyurethane is within a range from 0.01 to 25, preferably 0.1 to 15, preferably 0.2 to 10, in particular 0.5 to 5.
Preference is given to using an alkaline solution comprising base and water, wherein the base concentration is preferably greater than 5% by weight, preferably 5% to 70% by weight, preferably 5% to 60% by weight, further preferably 10% to 50% by weight, even further preferably 15% to 40% by weight, in particular 20% to 40% by weight, based on the weight of the alkaline solution.
This related to the preferred variant 2 of the depolymerization.
Recycled polyols that are for the purposes of the invention preferred preferably have a functionality (isocyanate-reactive groups per molecule) of 2 to 8. The number-average molecular weight of the recycled polyol is preferably within a range from 500 to 15 000 g/mol. The OH value of the recycled polyol is preferably 10 to 1200 mg KOH/g. The OH value can in particular be determined in accordance with DIN 53240:1971-12.
A preferred embodiment of the invention is when the employed recycled polyol is structurally a polyether polyol, it being possible to obtain such a recycled polyol preferably from the recycling of PU wastes, particularly PU foams, that had been obtained originally from conventional polyether polyols or from polyether polyols that had already been recycled one or more times.
In their original form prior to any recycling, polyether polyols may be produced by known processes, for example by anionic polymerization of alkylene oxides in the presence of alkali metal hydroxides, alkali metal alkoxides or amines as catalysts and with addition of at least one starter molecule, preferably containing 2 to 8 reactive hydrogen atoms in bonded form, or by cationic polymerization of alkylene oxides in the presence of Lewis acids, for example antimony pentachloride or boron trifluoride etherate, or by polymerization of alkylene oxides over double metal cyanide catalysis. Suitable alkylene oxides contain 2 to 4 carbon atoms in the alkylene radical. Examples are tetrahydrofuran, ethylene oxide, 1,3-propylene oxide, 1,2-propylene oxide and 1,2- or 2,3-butylene oxide; preference is given to using ethylene oxide and 1,2-propylene oxide. The alkylene oxides may be used individually, cumulatively, in blocks, in alternation or as mixtures. Starter molecules used are preferably di-, tri- or tetrahydric alcohols, such as ethylene glycol, propane-1,2- and -1,3-diol, diethylene glycol, dipropylene glycol, glycerol, trimethylolpropane, pentaerythritol, castor oil, higher polyfunctional polyols, in particular sugar compounds, for example glucose, sorbitol, mannitol and sucrose, polyhydric phenols, resols.
In a preferred embodiment of the invention, especially in the production of hot-cure flexible foams, it is possible to use di- or trifunctional polyether polyols in which the proportion of end groups formed through propoxylation (PO end groups) is preferably over 50%, more preferably over 80%, in particular those having a propylene oxide block or random propylene oxide and ethylene oxide block at the chain end, or those based solely on propylene oxide blocks. Such polyether polyols preferably have a functionality from 2 to 8, more preferably from 2 to 4, number-average molecular weights within a range from 500 to 8000, preferably 800 to 5000, more preferably 2500 to 4500 g/mol, and usually OH values within a range from 10 to 100, preferably 20 to 60, mg KOH/g.
According to a preferred embodiment of the invention, especially for production of moulded and highly resilient flexible PU foams, it is possible to use di- and/or trifunctional polyether polyols having preferably at least 50%, further preferably at least 80%, primary hydroxyl groups. Especially polyether polyols having an ethylene oxide end block —CH2—CH2—O—H may be used. Polyols for cold-cure polyurethane foams (known as HR polyols) can come under this category when the number-average molar mass is at the same time preferably over 4000 g/mol.
In a further preferred embodiment of the invention, it is possible to use for production of hypersoft PU foams optionally also further polyether polyols consisting largely of ethylene oxide, preferably ones containing more than 70% of ethylene oxide blocks, further preferably more than 90% of ethylene oxide blocks (hypersoft polyols). All polyether polyols described in the context of this preferred embodiment preferably have a functionality of 2 to 8 hydroxy groups, preferably 2 to 5 hydroxy groups, per molecule, preferably a number-average molecular weight of 500 to 8000 g/mol, preferably 800 to 7000 g/mol, and preferably OH values within a range from 5 to 100 mg KOH/g, preferably 20 to 60 mg KOH/g. Polyols having primary hydroxyl functions are in the case of hot-cure flexible foams preferably used not on their own, but preferably together with polyols having secondary hydroxyl groups.
In a further preferred embodiment of the invention, especially for the production of viscoelastic polyurethane foams, preference is given to using mixtures of different, preferably two to three, polyfunctional polyether polyols. The polyol combinations used consist preferably of a crosslinker polyol having a high functionality (>3) and having a low molecular weight, preferably having an OH value of 100 to 400 mg KOH/g, and/or a conventional flexible slabstock foam polyol and/or a HR polyol and/or a “hypersoft” polyether polyol, preferably having an OH value of between 20 to 40 mg KOH/g, having a high proportion of ethylene oxide and cell-opening properties. When HR polyols are used within a viscoelastic foam formulation, the proportion thereof in the polyol mixture is preferably always less than 50%.
Independently of the recycled polyol of the invention, it is in the context of the present invention additionally possible to also optionally use other polyols, in particular conventional polyols. Conventional polyols are polyols that do not originate from a recycling process.
It therefore corresponds to a preferred embodiment of the invention when the total employed polyol component comprises both recycled polyol of the invention and also additionally one or more further polyols.
Antioxidants that may be employed in association with polyols are known per se to those skilled in the art.
It corresponds to a preferred embodiment of the invention when the antioxidant present in the recycled polyol comprises at least one antioxidant of formula 1d and/or 3a,
It corresponds to a further preferred embodiment of the invention when the antioxidants of formula 3a and/or formula 1d are selected from 4,4′-dioctyldiphenylamine, 4,4′-dibutyldiphenylamine, 4-butyl-4′-octyldiphenylamine (e.g. Irganox® 5057), heptyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate, octyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate, nonyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate (e.g. Irganox® 1135 containing (C7-C9 alkyl) 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate), tridecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate, tetradecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate, pentadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate (e.g. Anox® 1315 containing (C13-C15 alkyl) 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate), octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate (e.g. Irganox® 1076) and/or pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxy-phenyl)propanoate) (e.g. Anox® 20).
It corresponds to a further preferred embodiment of the invention when it is possible for the recycled polyol to optionally comprise further antioxidants selected from the following group:
The process of the invention makes it possible to provide all known PU foam types. According to a preferred embodiment of the invention, the resulting PU foam is a rigid PU foam, a flexible PU foam, a hot-cure flexible PU foam (standard foam), a viscoelastic PU foam, an HR PU foam, a hypersoft PU foam, a semirigid PU foam, a thermoformable PU foam or an integral PU foam, preferably a hot-cure flexible PU foam, HR PU foam, hypersoft PU foam or viscoelastic PU foam. Hot-cure flexible PU foam is most preferred.
The production of the PU foams may in principle be carried out in the customary manner and as described in the prior art. It is well known to those skilled in the art. A comprehensive overview is found in, for example, G. Oertel, Polyurethane Handbook, 2nd edition, Hanser/Gardner Publications Inc., Cincinnati, Ohio, 1994, pp. 177-247. Further details of the starting materials, catalysts and auxiliaries and additives that may be used can be found for example in Kunststoffhandbuch [Plastics Handbook], volume 7, Polyurethane [Polyurethanes], Carl-Hanser-Verlag Munich, 1st edition 1966, 2nd edition 1983 and 3rd edition 1993.
When, in the process of the invention for the production of PU foams, the reaction is carried out using
A further preferred embodiment of the invention is when, in the process of the invention, the addition of antioxidant to the employed recycled polyol to adjust the total concentration of antioxidant of formula 3a and/or formula 1d in the recycled polyol to from 0.001% to 10% by weight, preferably 0.002% to 8% by weight, further preferably 0.005% to 7.5% by weight, particularly preferably 0.01% to 5% by weight, based on the total recycled polyol, takes place not more than 150 hours before the reaction to form the PU foam.
Another further preferred embodiment of the invention is when, in the process of the invention, the addition of antioxidant to the employed recycled polyol to adjust the total concentration of antioxidant of formula 3a and/or formula 1d in the recycled polyol to from 0.001% to 10% by weight, preferably 0.002% to 8% by weight, further preferably 0.005% to 7.5% by weight, particularly preferably 0.01% to 5% by weight, based on the total recycled polyol, took place not more than 150 hours after production of the polyol.
A further particularly preferred embodiment of the invention is when, in the process of the invention, at least 10%, further preferably at least 20%, particularly preferably at least 30%, of the antioxidant content originates from the recycled polyol as arising from the PU recycling process.
The present invention further provides a composition suitable for production of polyurethane foam, comprising at least one polyol component, at least one isocyanate component, catalyst, foam stabilizer, blowing agent, optionally auxiliaries, wherein the polyol component comprises recycled polyol, characterized in that the total concentration of antioxidants of formula 3a and/or formula 1d in the recycled polyol is 0.001% to 10% by weight, preferably 0.002% to 8% by weight, further preferably 0.005% to 7.5% by weight, particularly preferably 0.01% to 5% by weight, based on the total recycled polyol. Preferred optional auxiliaries comprise surfactants, biocides, dyes, pigments, fillers, antistatic additives, crosslinkers, chain extenders, cell openers, as described for example in EP 2998333A1, fragrances, cell expanders, as described for example in EP 2986661B1, plasticizers, hardening promoters, additives for preventing cold flow, as described for example in DE 2507161C3, WO 2017029054A1, aldehyde scavengers, as described for example in WO 2021/013607A1, additives for resistance of PU foams to hydrolysis, as described for example in US 2015/0148438A1, compatibilizers (emulsifiers), adhesion promoters, hydrophobization additives, flame-lamination additives, as described for example in EP 2292677A1, additives that reduce compression set, additives for adjusting the glass transition temperature, temperature-controlling additives and/or odour-reducers.
According to a preferred embodiment of the invention, the composition of the invention has the feature that, based on the total polyol component, more than 30% by weight, preferably more than 50% by weight, preferably more than 70% by weight, further preferably more than 80% by weight, in particular more than 95% by weight, of recycled polyol is used, the total concentration of antioxidants of formula 3a and/or formula 1d in the recycled polyol being 0.001% to 10% by weight, preferably 0.002% to 8% by weight, further preferably 0.005% to 7.5% by weight, particularly preferably 0.01% to 5% by weight, based on the total recycled polyol.
The compounds employed according to the invention, the production thereof, the use of the compounds for producing the PU foams and the PU foams themselves are hereinbelow described by way of example without any intention to limit the invention to these exemplary embodiments. Where ranges, general formulas or compound classes are specified below, these are intended to include not only the corresponding ranges or groups of compounds that are explicitly mentioned but also all subranges and subgroups of compounds that can be obtained by removing individual values (ranges) or compounds. Where documents are cited in the context of the present description, their content shall fully form part of the disclosure content of the present invention, particularly in respect of the matters referred to. Where figures are hereinbelow stated in per cent, these are percentages by weight unless otherwise stated. Average values specified hereinbelow are number averages unless otherwise stated. Where properties of a material are referred to hereinbelow, for example viscosities or the like, these are the properties of the material at 25° C. unless otherwise stated. Where chemical (empirical) formulas are used in the present invention, the stated indices may be not only absolute numbers but also average values. For polymeric compounds, the indices preferably represent average values.
The process of the invention enables access to all PU foams. Preferred PU foams are for the purposes of the present invention flexible PU foams and rigid PU foams. Flexible PU foams and rigid PU foams are fixed technical terms. The known and fundamental difference between flexible foams and rigid foams is that flexible foam shows elastic behaviour and hence deformation is reversible. By contrast, rigid foam undergoes permanent deformation. Various foam subgroups that are in the context of the invention preferred are described in more detail hereinbelow.
In the context of the present invention, rigid polyurethane foam is in particular understood as meaning a foam to DIN 7726:1982-05 that has a compressive strength to DIN 53421:1984-06 of advantageously ≥20 kPa, preferably ≥80 kPa, more preferably ≥100 kPa, further preferably ≥150 kPa, particularly preferably ≥180 kPa. In addition, the rigid polyurethane foam to DIN EN ISO 4590:2016-12 advantageously has a closed-cell content of greater than 50%, preferably greater than 80% and more preferably greater than 90%. Rigid PU foams are used mostly for insulation purposes.
Flexible PU foams are elastic and reversibly deformable and usually have open cells. This means that the air can escape easily on compression. The umbrella term “flexible PU foam” here includes in particular the following foam types known to those skilled in the art, namely hot-cure flexible PU foam (standard PU foam), cold-cure PU foam, (also highly elastic or high-resilience foam), hypersoft PU foam, viscoelastic flexible PU foam and ester-type PU foams (from polyester polyols). The different flexible PU foam types are explained in more detail again and differentiated from one another hereinbelow.
The crucial difference between a hot-cure flexible PU foam and a cold-cure PU foam lies in the different mechanical properties. The distinction between hot-cure flexible PU foams and cold-cure flexible PU foams can be made in particular through the rebound resilience, also known as “ball rebound” (BR) or “resilience”. A method for determining the rebound resilience is described for example in DIN EN ISO 8307:2008-03. In this method, a steel ball having a fixed mass is allowed to fall from a defined height onto the test specimen and the height of the rebound as a % of the drop height is then measured. Hot-cure flexible PU foams have rebound values of preferably 1% to not more than 50%. The height of the rebound in the case of cold-cure flexible PU foams is preferably within the range>50% The high rebound resilience of cold-cure flexible PU foams results from a relatively irregular cell size distribution. A further mechanical criterion is the sag or comfort factor. Here, a foam specimen is compressed in accordance with DIN EN ISO 2439:2009-05 and the ratio of compressive stress at 65% and 25% compression is measured. Hot-cure flexible PU foams have a comfort factor of preferably <2.5. In the case of cold-cure flexible PU foams, the comfort factor is preferably >2.5. The production of cold-cure flexible PU foams employs in particular polyether polyols that are highly reactive towards isocyanates and have a high proportion of primary hydroxyl groups and number-average molar masses>4000 g/mol. In the case of hot-cure flexible PU foams, on the other hand, less reactive polyols having secondary OH groups and a number-average molar mass of <4000 g/mol are predominantly used. As well as cold-cure slabstock PU foams, moulded cold-cure PU foams, which are used for example in automotive seat cushioning, represent a core use of cold-cure PU foams.
Preference is according to the invention likewise given to hypersoft PU foams, which represent a subcategory of flexible PU foams. Hypersoft PU foams have compressive stresses determined to DIN EN ISO 3386-1:1997+A1:2010 of preferably <2.0 kPa and exhibit indentation hardnesses determined to DIN EN ISO 2439:2009-05 of preferably <80 N. Hypersoft PU foams can be produced by various known processes: through use of a so-called hypersoft polyol in combination with so-called standard polyols and/or through a special production process in which carbon dioxide is metered in during the foaming process. A pronounced open-cell structure of hypersoft PU foams gives them high air permeability, promotes moisture transfer in application products and helps avoid heat buildup. A particular feature of the hypersoft polyols employed for production of hypersoft PU foams is a very high proportion of primary OH groups of more than 60%.
A special class of flexible PU foams is that of viscoelastic PU foams (visco foams), which are likewise preferred according to the invention. These are also known as “memory foam” and are notable both for a low rebound resilience to DIN EN ISO 8307:2008-03 of preferably <15% and for a slow, gradual recovery after compression (recovery time preferably 2-13 s). In contrast to hot-cure flexible PU foams and cold-cure flexible PU foams, which have a glass transition temperature of less than −32° C., for viscoelastic PU foams the glass transition temperature is preferably shifted to within a range from −20 to +15° C. Such “structural viscoelasticity” in the case of open-cell viscoelastic flexible PU foams, which is based essentially on the glass transition temperature of the polymer (also referred to as chemical visco foams), should be distinguished from a pneumatic effect. In the latter case, there is a relatively closed cell structure (low porosity). The low air permeability means that the air flows back in only gradually after compression, which results in slowed recovery (also referred to as pneumatic visco foams). In many cases the two effects are combined in a visco foam. PU visco foams are highly prized on account of their energy- and sound-absorbing properties.
A class of PU foams that is particularly important for applications in the automotive sector and has properties in between those of rigid and flexible foams is that of semirigid (semiflexible) PU foams. These too are preferred according to the invention. Like most PU foam systems, semiflexible foam systems also make use of the isocyanate/water reaction and of the CO2 evolved as a blowing agent for foam formation. The rebound resilience is generally lower than that of classical flexible foams, especially cold-cure foams. Semiflexible foams have higher hardness than conventional flexible foams. A characteristic feature of semiflexible foams is their high open-cell content (preferably >90% of cells). The densities of semiflexible foams can be significantly greater than those of flexible and rigid foams.
The polyol components employed are preferably one or more polyols having two or more OH groups.
It is obligatory for the polyol component according to the invention to comprise recycled polyol, the total concentration of antioxidants of formula 3a and/or formula 1d in the recycled polyol being 0.001% to 10% by weight, preferably 0.002% to 8% by weight, further preferably 0.005% to 7.5% by weight, particularly preferably 0.01% to 5% by weight, based on the total recycled polyol.
It is in addition optionally possible for further polyols also to be used.
Preferred further polyols that are optionally additionally employable are all polyether polyols and polyester polyols used for production of polyurethane systems, in particular polyurethane foam systems.
Polyether polyols are obtainable for example by reacting polyfunctional alcohols or amines with alkylene oxides. Polyester polyols are based preferably on esters of polybasic carboxylic acids with polyhydric alcohols (usually glycols). The polybasic carboxylic acids can either be aliphatic (for example adipic acid) or aromatic (for example phthalic acid or terephthalic acid).
An important class of optionally employable polyols obtainable from natural oils such as palm oil or soybean oil are known as “natural oil-based polyols” (NOPs) and can be obtained on the basis of renewable raw materials. NOPs are of increasing interest for more sustainable production of PU foams in view of the long-term limits on the availability of fossil resources—oil, coal and gas—and against the background of rising crude oil prices and have already been described many times in the production of polyurethane foams (WO 2005/033167; US 2006/0293400, WO 2006/094227, WO 2004/096882, US 2002/0103091, WO 2006/116456 and EP 1678232). A number of these polyols are now commercially available from various manufacturers (WO 2004/020497, US 2006/0229375, WO 2009/058367). Depending on the base raw material (e.g. soybean oil, palm oil or castor oil) and subsequent processing, polyols having a varying property profile are obtained It is possible here to distinguish essentially between two groups a) polyols based on renewable raw materials that are modified such that they can be used to an extent of 100% for production of polyurethanes (WO 2004/020497, US 2006/0229375); b) polyols based on renewable raw materials that, because of the processing and properties thereof, are able to replace the petrochemical-based polyol only up to a certain proportion (WO 2009/058367). The production of polyurethane foams from recycled polyols together with NOPs represents a preferred type of application of the invention.
A further class of optionally employable polyols comprises polyols obtained as prepolymers by reaction of polyol with isocyanate in a molar ratio of 100:1 to 5:1, preferably 50:1 to 10:1.
Yet another class of optionally employable polyols comprises what are known as filled polyols (polymer polyols). These contain dispersed solid organic fillers up to a solids content of 40% by weight or more. Employable polyols include for example inter alia:
The solids content in the optional filled polyols, which depending on the application may preferably be between 5% and >40% by weight based on the polyol, is responsible for improved cell opening, with the result that the polyol becomes controllably foamable, especially with TDI, and no shrinkage of the foams occurs. The solids content thus acts as an essential processing aid. A further function is to control the hardness via the solids content, since higher solids contents result in a higher hardness of the foam.
Formulations comprising polyols that contain solids have markedly reduced inherent stability and therefore tend to require not only chemical stabilization through the crosslinking reaction but also additional physical stabilization.
Other optionally employable polyols are those known as cell-opener polyols. These are polyether polyols having a high ethylene oxide content, specifically a content preferably of at least 40% by weight, in particular of 50% to 100% by weight, based on the content of alkylene oxide.
A ratio of isocyanate component to polyol component that is preferred in the context of the present invention, and is expressed as an index, is within a range from 10 to 1000, preferably 40 to 350. This index describes the ratio of the amount of isocyanate actually used to the amount of isocyanate theoretically required for a stoichiometric ratio of isocyanate groups to isocyanate-reactive groups (e.g. OH groups, NH groups), multiplied by 100. An index of 100 represents a molar ratio of reactive groups of 1:1.
The isocyanate components used are preferably one or more isocyanates having two or more isocyanate functions. Any isocyanate may be used as isocyanate component in the process of the invention, in particular the aliphatic, cycloaliphatic, araliphatic and preferably aromatic polyfunctional isocyanates known per se. Suitable isocyanates for the purposes of the present invention have two or more isocyanate functions.
Suitable isocyanates for the purposes of the present invention are preferably any polyfunctional organic isocyanates, for example diphenylmethane diisocyanate (MDI), toluene diisocyanate (TDI), hexamethylene diisocyanate (HMDI) and/or isophorone diisocyanate (IPDI). Preference is likewise given to using the mixture known as “polymeric MDI” (“crude MDI” or polyphenyl polymethylene polyisocyanate), composed of MDI and analogues with a higher level of condensation having an average functionality of 2 to 4.
Particular preference is given to using diphenylmethane 2,4′-diisocyanate and/or diphenylmethane 2,2′-diisocyanate and/or polyphenyl polymethylene polyisocyanate (crude MDI) and/or toluene 2,4-diisocyanate and/or toluene 2,6-diisocyanate or mixtures thereof.
MDI prepolymers are preferably also particularly suitable. Examples of particularly suitable isocyanates are detailed for example in EP 1712578, EP 1161474, WO 00/58383, US 2007/0072951, EP 1678232 and WO 2005/085310, which are hereby fully incorporated by reference.
It corresponds to a preferred embodiment of the invention when the isocyanate used, preferably diphenylmethane diisocyanate (MDI) and toluene diisocyanate (TDI), consists preferably to an extent of at least 20%, further preferably to an extent of at least 40%, particularly preferably to an extent of at least 60%, of recycled isocyanates.
In a preferred embodiment of the invention, the recycled isocyanates are produced from the reaction of aromatic amine mixtures consisting of toluene diisocyanate (TDI) and/or methylenediphenylamine (MDA), the amine mixtures having been obtained preferably to an extent of at least 20%, further preferably to an extent of at least 35%, particularly preferably to an extent of at least 50%, from the recycling of polyurethanes, preferably polyurethane foams.
Suitable catalysts for possible use in the process of the invention for producing PU foams are preferably substances that catalyse the gel reaction (isocyanate-polyol), the blowing reaction (isocyanate-water) or the di- or trimerization of the isocyanate.
It corresponds to a preferred embodiment of the invention when the catalyst used is selected from
A further class of suitable catalysts that may be used with preference in the process of the invention are metal compounds of the metals Sn, Bi, Zn, Al or K, in particular Sn, Zn or Bi. The metal compounds can be divided into the subgroups of organometallic compounds, organometallic salts, organic metal salts and inorganic metal salts, which are explained hereinbelow.
The expression “metalorganic or organometallic compounds” encompasses for the purposes of the present invention in particular the use of metal compounds having a direct carbon-metal bond, here also referred to as metal organyls (e.g. tin organyls) or organometallic/organometal compounds (e.g. organotin compounds). The expression “organometallic or metalorganic salts” encompasses for the purposes of the present invention in particular the use of metalorganic or organometallic compounds having salt character, i.e. ionic compounds in which either the anion or cation is organometallic in nature (e.g. organotin oxides, organotin chlorides or organotin carboxylates). The expression “organic metal salts” encompasses for the purposes of the present invention in particular the use of metal compounds that do not have any direct carbon-metal bond and are at the same time metal salts in which either the anion or the cation is an organic compound (e.g. tin(II) carboxylates). The expression “inorganic metal salts” encompasses for the purposes of the present invention in particular the use of metal compounds or of metal salts in which neither the anion nor the cation is an organic compound, e.g. metal chlorides (e.g. tin(II) chloride).
Organic and organometallic metal salts that are suitable for use contain preferably alkoxide, mercaptate or carboxylate anions, such as acetate, 2-ethylhexanoate, octanoate, isononanoate, decanoate, neodecanoate, ricinoleate, laurate and/or oleate, particularly preferably 2-ethylhexanoate, ricinoleate, neodecanoate or isononanoate.
As a general rule, metal-containing catalysts that are suitable for use are preferably selected such that they do not have any troublesome intrinsic odour and are essentially toxicologically safe, and such that the resulting polyurethane systems, especially polyurethane foams, have the lowest possible degree of catalyst-related emissions.
It may be preferable to combine one or more metal compounds with one or more amine catalysts of formula (1a) and/or (1b).
In the production according to the invention of polyurethane foams, it may be preferable to exclude the use of organometallic salts, for example of dibutyltin dilaurate.
Suitable amounts in which these catalysts are used for the production of PU foam in the process of the invention depend on the type of catalyst and are preferably within a range from 0.01 to 5 pphp (=parts by weight based on 100 parts by weight of polyol) or from 0.1 to 10 pphp in the case of potassium salts.
Suitable amounts of water in the process of the invention depend on whether or not physical blowing agents are used in addition to water. In the case of purely water-blown foams, values range from preferably 1 to 20 pphp; when other blowing agents are additionally used, the amount of water used is reduced to usually e.g. 0 or e.g. 0.1 to 5 pphp. To achieve high foam densities, it is preferable that neither water nor any other blowing agent is used.
Physical blowing agents that are suitable for use for the purposes of the present invention are gases, for example liquefied CO2, and volatile liquids, for example hydrocarbons having 4 or 5 carbon atoms, preferably cyclo-, iso- and n-pentane, hydrofluorocarbons, preferably HFC 245fa, HFC 134a and HFC 365mfc, but also olefinic hydrofluorocarbons such as HHO 1233zd or HHO1336mzzZ, hydrochlorofluorocarbons, preferably HCFC 141b, oxygen-containing compounds such as methyl formate and dimethoxymethane, or chlorinated hydrocarbons, preferably dichloromethane and 1,2-dichloroethane. Suitable blowing agents further include ketones (e.g. acetone) or aldehydes (e.g. methylal).
In addition to or in place of water and any physical blowing agents, the additive composition of the invention may also include other chemical blowing agents that react with isocyanates with gas evolution, examples being formic acid, carbamates or carbonates.
Foam stabilizers (referred to as stabilizers for the purposes of the invention) that can be used include the substances mentioned in the prior art. The compositions of the invention may advantageously contain one or more stabilizers. They are in particular silicon compounds containing carbon atoms, preferably selected from polysiloxanes, polydimethylsiloxanes, organomodified polysiloxanes, polyether-modified polysiloxanes and polyether-polysiloxane copolymers. Preferred silicon compounds are described by formula (1c)
[R12R2SiO1/2]a[R13SiO1/2]b[R12SiO2/2]c[R1R2SiO2/2]d[R3SiO3/2]e[SiO4/2]fGg Formula (1c)
where
(O1/2)nSiR1m—CH2CHR5—R4—CHR5CH2—SiR1m(O1/2)n,
(O1/2)nSiR1m—CH2CHR5—R4—CR5═CH2,
(O1/2)nSiR1m—CH2CHR5—R4—CR5═CR5—CH3,
—(R7)h—O—[C2H4O]i—[C3H6O]j—[CR82CR82O]k—R9, (2)
—Oh—R10, (3)
The foam stabilizers of formula (1c) may be used preferably in organic solvents such as dipropylene glycol, polyether alcohols or polyether diols blended in PU systems.
In the case of mixtures of stabilizers of formula (1c), it is additionally preferably possible to use a compatibilizer. This compatibilizer may be selected from the group of aliphatic or aromatic hydrocarbons, more preferably aliphatic polyethers or polyesters.
Employable silicon compounds having one or more carbon atoms preferably include the substances mentioned in the prior art. Preference is given to using those silicon compounds that are particularly suitable for the particular type of foam. Suitable siloxanes are described for example in the following documents: EP 0839852, EP 1544235, DE 102004001408, WO 2005/118668, US 2007/0072951, DE 2533074, EP 1537159, EP 533202, U.S. Pat. No. 3,933,695, EP 0780414, DE 4239054, DE 4229402, EP 867465. The silicon compounds may be produced as described in the prior art. Suitable examples are described e.g. in U.S. Pat. No. 4,147,847, EP 0493836 and U.S. Pat. No. 4,855,379.
From 0.00001 to 20 parts by mass of foam stabilizers, in particular silicon compounds, per 100 parts by mass of polyol components may preferably be used.
Optional additives used may be all substances known from the prior art that are used in the production of polyurethanes, in particular of polyurethane foams, examples being blowing agents, preferably water for formation of CO2, and, if necessary, further physical blowing agents, flame retardants, buffer substances, surfactants, biocides, dyes, pigments, fillers, antistatic additives, crosslinkers, chain extenders, cell openers, as described for example in EP 2998333A1, nucleating agents, thickeners, fragrances, cell expanders, as described for example in EP 2986661B1, plasticizers, hardening promoters, additives for preventing cold flow, as described for example in DE 2507161C3, WO 2017029054A1, aldehyde scavengers, as described for example in WO 2021/013607A1, additives for resistance of PU foams to hydrolysis, as described for example in US 2015/0148438A1, compatibilizers (emulsifiers), adhesion promoters, hydrophobization additives, flame-lamination additives, as described for example in EP 2292677B1, additives that reduce compression set, odour-reducers and/or additional catalytically active substances, in particular as defined above.
Optionally employable crosslinkers and optionally employable chain extenders are low-molecular-weight polyfunctional compounds that are reactive toward isocyanates. Examples of suitable compounds are hydroxyl- or amine-terminated substances such as glycerol, neopentyl glycol, 2-methylpropane-1,3-diol, triethanolamine (TEOA), diethanolamine (DEOA) and trimethylolpropane. The optional use concentration is preferably between 0.1 and 5 parts based on 100 parts of polyol, but can also deviate therefrom depending on the formulation. When crude MDI is used in in-situ foaming, it likewise takes on a crosslinking function. The content of low-molecular-weight crosslinkers can therefore be accordingly reduced as the amount of crude MDI increases.
Suitable optional flame retardants for the purposes of the present invention are all substances considered suitable for this purpose according to the prior art. Examples of preferred flame retardants are liquid organophosphorus compounds such as halogen-free organophosphates, for example triethyl phosphate (TEP), halogenated phosphates, e.g. tris(1-chloro-2-propyl) phosphate (TCPP), tris(1,3-dichloroisopropyl) phosphate (TDCPP) and tris(2-chloroethyl) phosphate (TCEP), and organic phosphonates, for example dimethyl methanephosphonate (DMMP), dimethyl propanephosphonate (DMPP), or oligomeric ethyl-ethylene phosphates or solids such as ammonium polyphosphate (APP) and red phosphorus. Suitable flame retardants further include halogenated compounds, for example halogenated polyols, and also solids such as expandable graphite and melamine.
The process of the invention makes it possible to produce polyurethane foams containing particularly high proportions of recycled polyols. The term polyurethane is for the purposes of the present invention to be understood in particular as a generic term for a polymer produced from di- or polyisocyanates and polyols or other isocyanate-reactive species, such as for example amines, wherein the urethane linkage is not necessarily the sole or predominating linkage type. Polyisocyanurates and polyureas are also expressly included.
The production according to the invention of polyurethane foams can be carried out by any processes familiar to those skilled in the art, for example by manual mixing or preferably with the aid of high-pressure or low-pressure foaming machines. The process of the invention may be executed continuously or batchwise. Batchwise execution of the process is preferable in the production of moulded foams, refrigerators, footwear soles or panels. A continuous process is preferable for producing insulation panels, metal composite elements, slabs or in spraying methods.
The invention further provides a polyurethane foam, preferably rigid PU foam, flexible PU foam, hot-cure flexible PU foam (standard foam), viscoelastic PU foam, HR PU foam, hypersoft PU foam, semirigid PU foam, thermoformable PU foam or integral PU foam, preferably hot-cure flexible PU foam, HR PU foam, hypersoft PU foam or viscoelastic PU foam, produced by a process of the invention as described hereinabove. Hot-cure flexible PU foams are most preferred.
A very particularly preferred flexible polyurethane foam for the purposes of the present invention has in particular the following composition:
The polyurethane foams according to the invention may be used for example as refrigerator insulation, insulation panels, sandwich elements, pipe insulation, spray foam, 1- and 1.5-component can foam (a 1.5-component can foam is a foam that is produced by destroying a container in the can), imitation wood, modelling foam, packaging foam, mattresses, furniture cushioning, automotive seat cushioning, headrests, instrument panels, automotive interior trim, automotive headlining, sound absorption material, steering wheels, shoe soles, carpet backing foam, filter foam, sealing foam, sealants, adhesives, binders, lacquers or as coatings, or for producing corresponding products. This corresponds to a further subject matter of the invention.
The examples that follow describe the present invention by way of example, without any intention to limit the invention, the scope of application of which is apparent from the entirety of the description and the claims, to the embodiments specified in the examples.
The recycled polyol 1 of the invention was obtained by hydrolysis of polyurethane in the presence of a saturated K2CO3 solution and tetrabutylammonium chloride as catalyst:
A reactor from Parr (Parr Instrumental Company) equipped with a PTFE inner container and a mechanical stirrer was filled with 25 g of compressed foam pieces (approx. 1 cm×1 cm). The polyurethane foam used was produced according to formulation 1, in which the conventional polyol Arcol® 1104 had been used. To this was then added 75 g of saturated K2CO3 solution (pKb 3.67 at 25° C.). The tetrabutylammonium chloride catalyst was then added to a content of 5% by weight based on the mass of the reaction mixture. The reactor was closed and the reaction mixture was heated to an internal temperature of 150° C. for 14 hours. At the end of the 14 hours, heating was stopped and the reaction mixture was cooled to room temperature. After opening the reactor, the reaction mixture was transferred to a round-bottomed flask. The water was removed by rotary evaporation and the residual reaction mixture was extracted with cyclohexane. The cyclohexane solution was washed with 1 N aqueous HCl solution and then dried over magnesium sulfate. Removal of the cyclohexane by rotary evaporation afforded the recycled polyol 1 in the form of a liquid. The hydrolysis process was repeated so as to provide a sufficiently large amount of recycled polyol for the foaming experiments.
The total antioxidant concentration of the recycled polyol 1 was 0.18% by weight, determined from the sum total of the individual components 4,4′-dioctyldiphenylamine, 4,4′-dibutyldiphenylamine and 4-butyl-4′-octyldiphenylamine.
The recycled polyol 2 of the invention was obtained by hydrolysis of polyurethane in the presence of a 30% sodium silicate solution and tributylmethylammonium chloride as catalyst:
A reactor from Parr (Parr Instrumental Company) equipped with a PTFE inner container and a mechanical stirrer was filled with 25 g of compressed foam pieces (approx. 1 cm×1 cm). The polyurethane foam used was produced according to formulation 1, in which the conventional polyol Arcol® 1104 had been used. To this was then added 75 g of sodium silicate solution (30% by weight solution in water).
The tributylmethylammonium chloride catalyst was then added to a content of 2.5% by weight based on the mass of the reaction mixture. The reactor was closed and the reaction mixture was heated to an internal temperature of 150° C. for 10 hours. At the end of the 10 hours, heating was stopped and the reaction mixture was cooled to room temperature. After opening the reactor, the reaction mixture was transferred to a round-bottomed flask. The water was removed by rotary evaporation and the residual reaction mixture was extracted with cyclohexane. The cyclohexane phase was washed with 1 N aqueous HCl solution and then dried over magnesium sulfate. Removal of the cyclohexane by rotary evaporation afforded the recycled polyol 2 in the form of a liquid. The hydrolysis process was repeated so as to provide a sufficiently large amount of recycled polyol for the foaming experiments.
The total antioxidant concentration of the recycled polyol 2 was 0.20% by weight, determined from the sum total of the individual components 4,4′-dioctyldiphenylamine, 4,4′-dibutyldiphenylamine and 4-butyl-4′-octyldiphenylamine.
A 3 L autoclave was charged with 500.0 g of glycerol and 102.0 g of aqueous potassium hydroxide solution (45%) was added. The mixture was heated to 95° C. and stirred at this temperature for 45 minutes. The mixture was then heated to 120° C. and the pressure was reduced to 30 mbar. Volatiles were removed by distillation over a period of 80 minutes. The reaction mixture was then cooled to room temperature.
A 1 L autoclave was charged with 360.0 g of the product obtained in the previous step. The reactor contents were inertized by evacuating and releasing the vacuum with nitrogen several times. The reactor was then heated to 115° C. with stirring and evacuated to an internal pressure of 30 mbar. A total of 624 g of propylene oxide was metered in over a period of 70 minutes at a pressure of max. 1.2 bar. At the end of the propylene oxide addition, stirring was continued for a further hour at 115° C. to allow further reaction, after which volatiles were distilled off at 95° C. under reduced pressure for 15 minutes. The mixture was cooled to room temperature.
A 3 L autoclave was charged with 155.9 g of the product obtained in the previous step. The reactor contents were inertized by evacuating and releasing the vacuum with nitrogen several times. The reactor was then heated to 115° C. and evacuated to an internal pressure of 30 mbar. Over a period of 13 hours, a total of 1771 g of propylene oxide was metered in within a pressure range of max. 2.5 bar reactor internal pressure. At the end of the propylene oxide addition, stirring was continued for a further 6 hours at 115° C. At the end of the further reaction period, volatiles were removed by distillation at 95° C. over a period of 30 minutes. The reaction mixture was neutralized with 100 g of 25% phosphoric acid. Water was removed by distillation under reduced pressure and precipitated salts were filtered off.
A total of 1900 g of the glycerol polyether polyol 1 was obtained. The polyether obtained has an OH value of 59 mg KOH/g and does not contain any antioxidants.
The proportion by mass of the antioxidant of the invention according to the criteria of claim 1, for example the proportion by mass of (C7-C9 alkyl) 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate and/or (C13-C15 alkyl) 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate and/or octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate and/or pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate) and/or 4,4′-dioctyldiphenylamine, 4,4′-dibutyldiphenylamine and/or 4-butyl-4′-octyldiphenylamine, is determined in the context of the present invention by HPLC. Unless otherwise indicated, all stated percentages (%) are percentages by weight.
For this, 500 mg of the polyol of the invention is dissolved in 10 ml of ethanol. An aliquot of the solution is analysed by HPLC. The analysis is carried out using an HPLC system equipped as follows:
The one or more respective antioxidants are separated from the matrix and from one another on the basis of differences in polarity.
For the evaluation, an external calibration with standard solutions is carried out with the respective antioxidants, for example (C7-C9 alkyl) 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate and/or (C13-C15 alkyl) 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate and/or octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate and/or pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propanoate) and/or 4,4′-dioctyldiphenylamine, 4,4′-dibutyldiphenylamine and/or 4-butyl-4′-octyldiphenylamine, and a calibration curve is generated. Through evaluation of the peak areas, it is established which antioxidants are present in the respective sample and then the concentration of the analytes in the sample is determined.
The thermogravimetric analyses were carried out on a Discovery TGA from TA Instruments. The weight of sample is within a range from 15 to 25 mg in a platinum crucible. The measurements were unless otherwise described carried out for 4 h at 180° C. (temperature program T1) under an air flow of 30 ml/min.
The conventional polyol Arcol® 1104 is stable in air at a temperature of 180° C. for one hour. At approximately the time at which a 5% loss of mass is exceeded after 69.6 min, a pronounced loss of mass over a period of a few minutes commences. In the analogously performed measurement under a nitrogen atmosphere, the loss of mass in Arcol® 1104 over the entire measurement time of 4 hours is only 0.7%, the explanation for which being that the mass loss occurs only through a degradation reaction that takes place with oxygen. In polyol 1 produced in conventional manner by alkoxylation but not stabilized by antioxidants, the degradation process commences immediately at the start of the measurement time, with the result that a 5% loss of mass occurs after just 8.3 minutes and a 20% loss of mass after just 22.5 minutes. The recycled polyol 1 of the invention already has a content of 0.178% by weight of antioxidant 1 on being obtained from the recycling process. The loss of mass (5% after 55.6 min) commences a little earlier than with Arcol® 1104, which indicates a slightly reduced thermal durability compared to its original polyol Arcol® 1104. Addition of 0.05% by weight of antioxidant 2 brings a clear improvement in the thermal durability of recycled polyol 1, with the result that the loss of mass now commences later than in the case of Arcol® 1104. Surprisingly, the thermal durability is particularly high in the case of recycled polyol 2, which under the measurement conditions (180° C., air) does not show a 5% loss of mass until after 88.2 minutes Recycled polyol 2 thus exceeds the thermal durability of the corresponding original polyol Arcol® 1104 considerably.
The polyurethane foams were produced in the laboratory in the form of what are called handmade foams. The production of the foams was carried out at 22° C. and air pressure of 762 mmHg according to the details below. The polyurethane foams according to formulation 1 were in each case produced using 300 g of polyol. The other formulation constituents were adjusted accordingly. This meant, for example, that 1.0 part (1.0 pphp) of a component refers to 1 g of said substance per 100 g of polyol.
1)Polyol: Standard polyether polyol Arcol ® 1104 obtainable from Covestro. This is a glycerol-based polyether polyol having an OH value of 56 mg KOH/g and a number-average molar mass of 3000 g/mol and a content of 0.18% of antioxidant (mixture of 4,4′-dioctyldiphenylamine, 4,4′-dibutyldiphenylamine and 4-butyl-4-octyldiphenylamine) or recycled polyols of the invention or non-inventive recycled polyol. The recycled polyols are produced from hot-cure flexible PU foams via a chemical recycling process. The recycling processes respectively used for production of the recycled polyol of the invention and of the non-inventive recycled polyol have already previously been described.
2)Kosmos ® T9, obtainable from Evonik Industries: tin(II) salt of 2-ethylhexanoic acid.
3)Dabco ® DMEA: dimethylethanolamine, available from Evonik Industries. Amine catalyst for production of polyurethane foams
4)Polyether-modified polysiloxane, available from Evonik Industries.
5)Toluene diisocyanate T 80 (80% 2,4-isomer, 20% 2,6-isomer) from Covestro, 3 mPa · s, 48% NCO, functionality 2.
For the foams according to formulation 1, a paper cup was initially charged with the tin catalyst tin(II) 2-ethylhexanoate, polyol, the water, the amine catalysts and the respective foam stabilizer, and the contents were mixed with a disc stirrer at 1000 rpm for 60 s. After the first stirring, the isocyanate was added and incorporated with the same stirrer at 2500 rpm for 7 s and the reaction then immediately transferred to a paper-lined box (30 cm×30 cm base area and 30 cm height). After the foam had been poured in, it rose up in the foaming box. In the ideal case, the foam blew off on reaching the maximum rise height and then receded slightly. This opens the cell membranes of the foam bubbles to afford an open-pore cell structure in the foam.
To assess the properties, the following characteristic parameters were in the following section determined.
The foams produced were assessed on the basis of the following physical properties
The results in Table 3 compare the foamings of recycled polyols 1 and 2 of the invention with those of the conventional polyol Arcol® 1104, which represents the original polyol of recycled polyols 1 and 2, since this had been used for the production of the foams from which recycled polyols 1 and 2 had been obtained. The comparison of the properties of foams #1 and #2 shows that recycled polyol 1 of the invention affords a foam comparable to that of reference foam #1 obtained from Arcol® 1104. The use of 70 pphp of recycled polyol 2 together with 30 pphp of reference polyol Arcol® 1104 permits the production of foam #3, the properties of which correspond essentially to those of foams #1 and #2.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21183451.0 | Jul 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/067697 | 6/28/2022 | WO |
