Polyurethane Catalyst Composition for Reactivity Control
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Solution Overview
Problem
Current catalysts for producing polyurethane resins for shoe soles fail to balance initial reactivity suppression with curability and moldability, often resulting in poor curing properties and inadequate productivity.
Innovation Solution
A catalyst composition comprising triethylenediamine, a polyisocyanurating catalyst, and/or a highly temperature-sensitive amine, specifically selected compounds and their blends, to control reactivity and enhance curability while maintaining moldability and flowability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a tertiary amine catalyst is used to accelerate the gelling reaction and blowing reaction, then the curing rate is improved, but the initial reactivity cannot be suppressed and the curing time is delayed
Solution Approach 1:
The catalyst system is segmented into two distinct components: a tertiary amine catalyst (for accelerating gelling and blowing reactions) and a polyisocyanurating catalyst (for controlling initial reactivity). Each catalyst performs its specific function independently, allowing the curing rate and initial reactivity to be optimized separately without interfering with each other.
Solution Approach 2:
The invention uses a composite catalyst system combining two different types of catalysts (tertiary amine and polyisocyanurating catalyst) in specific proportions. This composite approach allows the system to simultaneously achieve high curing rate from the tertiary amine and suppressed initial reactivity from the polyisocyanurating catalyst, resolving the time conflict.
2Ease of operation
If the initial reactivity is suppressed to extend mold lidding time, then the moldability is improved, but the curing rate decreases and productivity is reduced
Solution Approach 1:
The catalyst functions are segmented such that the polyisocyanurating catalyst specifically controls initial reactivity to improve moldability, while the tertiary amine catalyst specifically accelerates the gelling and blowing reactions to maintain curing rate and productivity. This segmentation allows both requirements to be met simultaneously.
Solution Approach 2:
The invention changes the catalyst composition parameters by introducing a polyisocyanurating catalyst in addition to the tertiary amine catalyst. By adjusting the types and proportions of catalysts, the system achieves both suppressed initial reactivity (for moldability) and maintained curing rate (for productivity).
3Loss of time
If a quaternary ammonium salt type catalyst is used to delay curing action, then the cream time is extended, but the curing property deteriorates and final curing decreases
Solution Approach 1:
The polyisocyanurating catalyst acts as an intermediary that modifies the action of the tertiary amine catalyst. It delays the initial reactivity to extend cream time while the tertiary amine catalyst ensures proper curing property is achieved later. The polyisocyanurating catalyst mediates between the conflicting requirements of extended cream time and maintained curing property.
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 solution enables the production of polyurethane resins with improved curability, moldability, and productivity, maintaining physical properties and storage stability, suitable for shoe soles with extended cream time and reduced reactivity.
Implementation Method 1
The catalyst gives substantial influences not only on these reaction rates but also on the curing rate, flowability, moldability, dimensional stability and physical properties of the polyurethane resin, etc.
Implementation Method 2
a metal salt, a particularly an alkali metal carboxylate, is well known as a catalyst to accelerate particularly a polyisocyanurating reaction (trimerization of a polyisocyanate)
Implementation Method 3
a urea group-forming reaction (blowing reaction) by a reaction of an isocyanate and/or an isocyanate prepolymer with water
Data Source
AI summary
To provide a catalyst composition which is a catalyst composition not impairing the physical properties of a polyurethane resin and the storage stability of the starting material blend liquid and which is capable of producing a polyurethane resin excellent in curability and also excellent in moldability by suppressing the initial reactivity, with good productivity.A catalyst composition for production of a polyurethane resin, which comprises (A) triethylenediamine, and (B) a polyisocyanurating catalyst and/or (C) a highly temperature sensitive catalyst, wherein the polyisocyanurating catalyst (B) is one or more compounds selected from the group consisting of an alkali metal salt of a carboxylic acid, a quaternary ammonium salt compound of the following formula (1):wherein each of R1 to R3 is a C1-12 linear or branched, saturated or unsaturated hydrocarbon group, provided that any two among R1 to R3 may form a hetero ring via an oxygen atom or a nitrogen atom, R4 is a C1-18 alkyl group or an aromatic hydrocarbon group, and X is an organic acid group having an acid dissociation constant (pKa) of at most 4.8, N,N,N′-trimethylaminoethylethanolamine and 2,4,6-tris(dimethylaminomethyl)phenol; the highly temperature sensitive catalyst (C) is one or more compounds selected from the group consisting of a triazole salt of 1,8-diazabicyclo[5.4.0]undecene-7, a benzotriazole salt of 1,8-diazabicyclo[5.4.0]undecene-7, a triazole salt of 1,5-diazabicyclo[4.3.0]nonene-5, a benzotriazole salt of 1,5-diazabicyclo[4.3.0]nonene-5, a triazole salt of 1,8-diazabicyclo[5.3.0]decene-7 and a benzotriazole salt of 1,8-diazabicyclo[5.3.0]decene-7; and the blend ratio of the polyisocyanurating catalyst (B) and/or the highly temperature sensitive catalyst (C) to the triethylenediamine (A) is from 2 wt % to 60 wt %.