Iron Catalyst Composition for Polyurethane Resin Production
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Solution Overview
Problem
Conventional catalyst compositions for polyurethane resin production, particularly those using iron compounds, face challenges with stability in the presence of water, leading to decreased reactivity and storage issues due to hydrolysis, especially when used in water-blown foam applications.
Innovation Solution
A catalyst composition comprising a specific iron compound and a tertiary amine compound, where the iron compound is represented by the formula Fe n+ (L) n and the tertiary amine compound is represented by a specific formula, is used to enhance gelling reactivity and stability even in the presence of water, avoiding the use of harmful metal compounds like tin or lead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional iron compound catalysts are used, then gelling reaction activity is improved, but storage stability decreases due to hydrolysis in the presence of water
Solution Approach 1:
A water-soluble protective colloid is introduced as an intermediary substance that mediates between the iron compound catalyst and water. The protective colloid forms a protective environment around the catalyst, preventing direct contact between water and the iron compound, thereby maintaining catalytic activity while improving storage stability in water-containing polyol premixes.
Solution Approach 2:
The invention changes the physical-chemical parameters of the catalyst system by selecting specific iron compounds with appropriate solubility characteristics and combining them with protective colloids. This parameter optimization allows the catalyst to maintain both high reactivity and stability in aqueous environments, resolving the contradiction between activity and storage stability.
2Object-affected harmful factors
If iron compound catalysts are used in water-blown foam applications, then toxicity is reduced compared to tin or lead compounds, but reactivity decreases immediately after contact with water
Solution Approach 1:
The water-soluble protective colloid serves as a mediator that protects the iron compound catalyst from premature hydrolysis upon contact with water. This intermediary layer maintains the catalyst's reactivity while allowing the system to remain non-toxic, as the protective colloid is selected to be environmentally benign and water-soluble.
Solution Approach 2:
The protective colloid is pre-mixed with the iron compound catalyst before the catalyst contacts water during the foam expansion process. This preliminary combination creates a stable complex that prevents immediate hydrolysis, maintaining reactivity throughout the water-blown foam application while preserving the low-toxicity advantage of iron-based catalysts.
3Ease of operation
If conventional iron catalysts are stored in polyol premix containing water, then ease of use is improved, but storage stability becomes extremely difficult to maintain
Solution Approach 1:
The water-soluble protective colloid acts as a stabilizing intermediary that enables the iron compound catalyst to be stored in water-containing polyol premixes. The protective colloid forms a protective barrier that prevents hydrolysis during storage, making it easy to use the catalyst directly in the premix without requiring separate storage conditions, while maintaining long-term storage stability.
Solution Approach 2:
The protective colloid performs multiple functions simultaneously: it stabilizes the iron compound catalyst during storage, maintains catalyst reactivity, and allows the system to function in water-containing environments. This multi-functionality resolves the contradiction between ease of use (direct addition to premix) and storage stability.
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 maintains high gelling reactivity and stability over time, even in water-containing polyol premixes, enabling long-term storage and effective production of polyurethane resins without the need for toxic metal compounds.
Implementation Method 1
A catalyst for the production of a polyurethane resin, a tertiary amine compound or a metal compound is used. A tertiary amine compound has a function not only to accelerate a reaction (gelling reaction) to form an urethane bond from a polyol and an organic polyisocyanate
Implementation Method 2
a tertiary amine compound has a function not only to accelerate a reaction (gelling reaction) to form an urethane bond from a polyol and an organic polyisocyanate, but also to accelerate a reaction of water with an organic polyisocyanate to form a carbon dioxide gas (blowing reaction)
Data Source
AI summary
To provide a catalyst composition for polyurethane resin production, which has high gelling reactivity even in the coexistence of water, which is stable enough to be stored for a long period of time in a polyol premix containing water, and which does not contain a harmful metal compound such as a tin or lead compound, and a method for producing a polyurethane resin using the catalyst composition. A composition comprising an iron compound represented by the formula (1) and a tertiary amine compound represented by the formula (3) is used as a catalyst for polyurethane resin production. In the formula (1), L is a β-diketonate ligand represented by the formula (2), and n is 2 or 3. In the formula (2), each of R1 and R3 is a C1-10 alkyl group, and R2 is a hydrogen atom or a C1-7 alkyl group. In the formula (3), each of R4 to R6 is a hydrogen atom or a C1-10 alkyl group, and R7 is a C1-10 alkylene group. Fen+(L)n (1)