Amine Catalyst Composition for Stable Polyurethane Foam Premixes
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Solution Overview
Problem
Conventional catalysts used in polyurethane foam production, particularly those containing tertiary amines, deactivate rapidly when used with halogen-containing blowing agents like hydrofluoroolefins, leading to reduced storage stability and unsatisfactory reaction kinetics.
Innovation Solution
A new catalyst composition defined by specific formulae, including compounds with N—R3 or A═O structures, minimizes interaction with halogen-containing blowing agents while maintaining catalytic activity, ensuring stable polyurethane foam production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional tertiary amine catalysts are used to promote polyurethane reaction, then reaction speed is improved, but storage stability deteriorates due to rapid deactivation by halogen-containing blowing agents
Solution Approach 1:
The patent modifies the chemical structure parameters of the amine catalyst by introducing specific substituents (at least one alkyl or aryl group with 6-20 carbon atoms, or at least one bulky cyclic group) to change the steric environment around the amine nitrogen. This structural parameter change reduces the nucleophilicity of the amine, thereby decreasing its reactivity toward halogen-containing blowing agents and improving storage stability while maintaining sufficient catalytic activity for the polyurethane reaction.
Solution Approach 2:
The patent creates a composite catalyst system by combining amine catalysts with specific structural features (bulky substituents or cyclic groups) with the polyol premix containing halogen-containing blowing agents. This composite approach allows the catalyst to function effectively in the presence of these blowing agents, resolving the contradiction between reaction promotion and storage stability.
2Stability of the object's composition
If sterically hindered amines with bulky substituents are used to minimize deactivation, then storage stability is improved, but catalytic activity deteriorates requiring high use levels
Solution Approach 1:
The patent optimizes the balance between steric hindrance and catalytic activity by specifying precise structural parameters: at least one substituent with 6-20 carbon atoms (providing moderate steric bulk) combined with other appropriate substituents. This parameter optimization ensures sufficient storage stability while maintaining adequate catalytic activity, avoiding the need for high use levels that would be required with overly bulky substituents.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new catalyst composition maintains optimal catalytic activity and foam properties, allowing for the use of low GWP blowing agents without sacrificing storage stability or reaction speed.
Implementation Method 1
catalysts to promote the reactions of isocyanate with polyol to make urethane
Implementation Method 2
with water to make CO2 and urea
Implementation Method 3
with excess isocyanate to make isocyanurate (trimer)
Implementation Method 4
The blowing agent in the premix is usually a liquid or gas with a boiling point sufficiently low to be vaporized by the heat released during the polymerization reaction
Data Source
AI summary
A catalyst composition comprising at least one compound with a general formula I:wherein A is N—R3, R3 is C1-C8 linear or branched, x=0-6, n and m are each independently 1 to 6, R1 and R2 are each independently C2-C8 alkyl, and R4 and R5 are —CH3 groups; or A═O, x=0-6, n and m are each independently 1 to 6, R1 and R2 are each independently C2-C8 alkyl, and R4 and R5 are —CH3 groups; or A═O or N—R3, R3 is C1-C8 linear or branched, and N(R1—R4) and N(R2—R5) each independently represent a C3-C7 ring amine moiety of the type: