Glycinate Salt Catalysts for PIR/PUR Foam Rise Control
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Solution Overview
Problem
Current catalysts for PIR/PUR foam production face challenges in achieving a smooth rise profile while maintaining thermal stability and avoiding the release of malodorous low molecular weight amines, which affects processing efficiency and product quality.
Innovation Solution
The development of N,N-disubstituted glycinate salts, such as potassium N,N-bis(2-hydroxyethyl)glycinate, as catalysts for PIR/PUR foam production, which are synthesized through a two-step process involving a reaction between a secondary amine and a dicarbonyl compound, followed by neutralization with an alkali or tetraalkylammonium hydroxide, to control the foam rise profile and ensure thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If alkylammonium carboxylate salts are used as catalysts, then a smoother rate of rise profile is achieved, but thermal stability deteriorates above 100°C causing release of volatile amines
Solution Approach 1:
The patent changes the chemical structure parameters of the catalyst by using N,N-disubstituted glycinate salts with specific substituent groups (hydroxyalkyl, alkyl, cycloalkyl) instead of alkylammonium carboxylates. This structural modification maintains the smooth rise profile catalytic activity while improving thermal stability to prevent amine release above 100°C.
Solution Approach 2:
The patent employs composite catalyst systems combining N,N-disubstituted glycinate salts with specific substituent patterns that integrate both the smooth rise profile capability and thermal stability. The molecular structure combines stable salt frameworks with controlled substituent groups that prevent degradation at elevated temperatures.
2Ease of operation
If sterically hindered alkali metal carboxylate salts are used, then a controlled rise profile is achieved, but processing speed deteriorates becoming undesirably slow
Solution Approach 1:
The patent modifies the catalyst structure by using N,N-disubstituted glycinate salts with optimized substituent groups that balance steric hindrance for controlled rise profiles with sufficient catalytic activity for acceptable processing speeds. The glycinate core provides controlled reaction kinetics while the substituent groups prevent excessive slowing.
3Productivity
If alkali metal carboxylate salts are used, then catalytic activity is maintained, but control of rise speed profile deteriorates leading to processing problems
Solution Approach 1:
The patent changes from simple alkali metal carboxylate structures to N,N-disubstituted glycinate salt structures with specific substituent patterns. This structural evolution maintains high catalytic activity through the glycinate core while the substituent groups (hydroxyalkyl, alkyl, cycloalkyl) provide steric control for smooth rise profiles, eliminating foam overpacking and backflowing issues.
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
These glycinate salts provide a controlled rise profile and thermal stability, preventing the release of volatile amines, thereby improving the processing efficiency and quality of PIR/PUR foams.
Implementation Method 1
reacting a secondary amine having the general formula R1-NH-R2 and a dicarbonyl compound of the general formula R3-CO-CO-R4 under appropriate reaction conditions to form a N,N-disubstituted glycine compound
Implementation Method 2
neutralizing the reaction product of step (i) by adding a solution of an alkali or tetraalkylammonium hydroxide having the general formula MOH to form a compound according to general formula (I)
Implementation Method 3
A compound of general formula (I) as defined in the claim 1 as catalyst or co-catalyst in a rigid, semi-rigid or flexible PIR/PUR foam production
Data Source
AI summary
The present disclosure is related to a catalyst for PIR/PUR foam production comprising a compound having the general formula (I) wherein R1 and R2 are independently selected from a C1–C18 straight-chain or branched alkyl group, unsubstituted or substituted with one or more hydroxyl, amino or aminoalkyl groups, or R1 and R2, taken together, form a 5- or 6-membered ring or 7-membered bicyclic structure, one of the members of the ring or bicyclic structure being X, wherein X is selected from CH2, O, S, NCH3 or NCH2COOM, wherein R3 and R4 are independently selected from hydrogen or a C1-C4 straight-chain or branched alkyl group and wherein M is an alkali metal ion or a quaternary ammonium ion, as well as to a process for production of said compound and uses thereof and to a process for the production of PIR/PUR foam or flexible foam in the presence of the catalyst of the present disclosure.