Amine Catalyst Composition for Stable HFO Polyurethane Foams
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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 inefficient polymerization kinetics.
Innovation Solution
A catalyst composition defined by specific formulae, including compounds such as N, N'-diethyl-N, N'-dimethyl-bis(aminoethyl)ether, minimizes interaction with halogen-containing blowing agents while maintaining effective polymerization activity, ensuring stable polyurethane foam production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts (ammonium salts of secondary amines or organometallic catalysts) are used to promote polyurethane foam formation, then the reaction efficiency and foam formation are improved, but the resulting foams exhibit poor long-term stability, yellowing, and loss of mechanical properties over time
Solution Approach 1:
The patent changes the chemical structure parameters of the catalyst from conventional ammonium salts or organometallic compounds to a specific tertiary amine structure with a quaternary nitrogen atom bonded to a cycloaliphatic hydrocarbon group containing a carbonyl group. This structural parameter change fundamentally alters the catalyst's chemical properties, enabling it to promote foam formation while simultaneously providing long-term stability and preventing yellowing and mechanical property loss.
2Speed
If organometallic catalysts are used to accelerate polyaddition reaction, then the reaction speed is improved, but the foams become sensitive to moisture and show reduced stability
Solution Approach 1:
The patent replaces sensitive organometallic catalysts with a stable tertiary amine catalyst that is not susceptible to moisture degradation. The specific chemical structure (quaternary nitrogen with cycloaliphatic hydrocarbon group containing carbonyl) provides inherent moisture resistance, allowing the catalyst to maintain its function without being degraded by environmental moisture, thus eliminating the stability problem associated with organometallic catalysts.
3Manufacturing precision
If catalysts with high reactivity are used to ensure complete polyaddition, then the reaction completeness is improved, but the resulting foams undergo hardening and cracking over time
Solution Approach 1:
The patent modifies the catalyst's chemical structure to achieve optimal reactivity that ensures complete polyaddition without causing excessive crosslinking. The specific structure (tertiary amine with quaternary nitrogen bonded to cycloaliphatic hydrocarbon group containing carbonyl) provides controlled catalytic activity that promotes thorough reaction while maintaining flexibility in the cured foam, preventing hardening and cracking that occur with overly reactive catalysts.
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 catalyst composition provides improved storage stability and maintains optimal polymerization kinetics, allowing for the use of low GWP agents and reduces emissions associated with the catalyst; and d) provide optimum catalytic activity and foam physical properties.
Implementation Method 1
A catalyst composition comprising at least one compound with a general formula I... promotes the polyaddition reaction between isocyanate and polyol
Data Source
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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: