Copper(II)-Salt Catalyst for Polyurethane Foams
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Solution Overview
Problem
The polyurethane foam industry faces challenges in achieving efficient catalysts with low emission profiles and improved physical properties such as firmness and stiffness, as existing catalysts like organotin compounds have environmental and worker exposure concerns, and reactive amines degrade fatigue properties and promote chain termination.
Innovation Solution
A composition comprising a copper(II)-salt and a compound obtained by reacting an isocyanate compound with an isocyanate-reactive compound having a tertiary amino group, which acts as a catalyst for polyurethane formation with improved curing degrees and reduced VOC emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If organotin compounds are used as catalysts, then gel reaction catalysis is efficient, but environmental and worker exposure concerns arise
Solution Approach 1:
The patent changes the chemical composition parameters by replacing organotin compounds with copper(II) salts combined with specific polydentate ligands (Schiff base derivatives containing nitrogen). This substitution maintains catalytic efficiency while eliminating the toxic environmental impact of organotin compounds, directly resolving the contradiction between productivity and harmful factors.
Solution Approach 2:
The invention uses copper(II) salts which are less persistent and less toxic than organotin compounds, effectively replacing long-lived toxic catalysts with shorter-lived, environmentally benign alternatives that can be more easily disposed of or degraded without harming the environment.
2Productivity
If reactive amines are used as catalysts, then chain termination is promoted, but fatigue properties such as humid aging compression set are degraded
Solution Approach 1:
The patent introduces polydentate ligands (Schiff base derivatives) as intermediary compounds that mediate between the copper(II) salt and the polymerization reaction. These ligands create a coordinated catalyst system that promotes gel reaction without the harmful chain termination effects of reactive amines, while preserving fatigue properties and humid aging compression set.
Solution Approach 2:
The invention creates a composite catalyst system combining copper(II) salts with polydentate ligands (Schiff base derivatives containing nitrogen). This composite catalyst achieves the desired catalytic activity for polymer growth without the detrimental side effects of reactive amines, maintaining both productivity and reliability.
3Productivity
If amine catalysts are used, then gel reaction is promoted, but volatile organic compound emissions increase
Solution Approach 1:
The patent changes the physical and chemical parameters of the catalyst system by using copper(II) salts with polydentate ligands instead of volatile amine catalysts. This substitution maintains gel reaction promotion capability while dramatically reducing VOC emissions, as the copper-based catalyst system has negligible vapor pressure compared to organic amines.
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 copper(II)-salt composition enhances catalyst performance, leading to better curing and physical properties of polyurethane foams while minimizing volatile organic compound emissions, thus addressing the industry's need for efficient and environmentally friendly catalysts.
Implementation Method 1
A composition comprising a copper(II)-salt and a compound obtained by reacting an isocyanate compound with an isocyanate-reactive compound having a tertiary amino group, which acts as a catalyst for polyurethane formation with improved curing degrees
Data Source
AI summary
The present invention relates to a composition comprising a copper(II)-salt capable of being used as a catalyst, a process for the manufacture of said composition, the use of said composition as a catalyst, in particular, as 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, polyurethane foams.