METHOD FOR THE MANUFACTURE OF POLYISOCYANURATE FOAMS

Abstract: A method for the manufacture of polyisocyanurate foams which comprises blending a "B" side with an "A" side that includes an isocyanate. The "B" side comprises a diol or a polyester polyol, an amine/quaternary ammonium borate ester blend, a surfactant, a blowing agent, and a metal catalyst whose weight does not exceed 1.5% of the total weight of the "B" side. The "B" side remains a homogeneous liquid without the need for agitation for at least seven days, when use is made of a diol, and for at least one day, when use is made of a polyester polyol, and the foam formed by this method has a friability not exceeding 30%.

Description: Method for the manufacture of polyisocyanurate foams. This invention relates to the manufacture of polyisocyanurate foams, and is more particularly concerned with a method for the manufacture of foams that utilizes a very small amount of a metal catalyst and also uses an amine/quaternary ammonium borate ester blend as a polyol. Methods of manufacturing polyisocyanurate foams are well known in the art, and include the method described in United States Patent No. 4 256 802, issued to Koehler et al on March 17, 1981 (hereinafter referred to as "Koehler"). Koehler discloses polyol blends comprising from about 20% to about 85% by weight of the blend of an amine diol or mixture of amine diols selected from the formula: EMI1.1 wherein R is an aliphatic radical having from 8 to 18 carbon atoms, inclusive, each R1 is independently selected from the group consisting of hydrogen or methyl, x and y each independently have an average value from about 4 to about 15 inclusive; and from about 15 percent to about 80 percent by weight of a primary hydroxyl polyol (II) characterized by a molecular weight of from about 60 to about 1000. Koehler asserts that the polyol blends described therein are miscible with fluorocarbon blowing agents and water and other adjuvants including trimerization catalysts, and that its blends are particularly useful in a process for the preparation of polyisocyanurate foams. Those foams are said to be characterized by high reaction exotherms, making them particularly suited to the preparation of polyisocyanurate foam laminates. It is noted that the Koehler process for foam manufacture, in which the "B" side utilizes a fluorocarbon blowing agent and a polyol, and also requires a trimerization catalyst in an amount of from 2 to 20 procent by combined weight of the catalyst, fluorocarbon blowing agent, and polyol. Trimerization catalysts disclosed in Koehler include (I) a catalyst combination of alkali metal salts of an N-substituted amide, an alkali metal salt of an N(2-hydroxyphenyl)methyl glycine and optionally a tertiary amine trimerization ctalyst, and (2) the same catalyst as described hereinabove except the optional component is a hydroxyalkyltrialkylammonium carboxylate salt. Certain quaternary ammonium carboxylate salts and even quaternary borate salts have been disclosed as trimerization catalysts, but not as polyols, in several prior art references (see U.S. Patent Nos. 4,040,992, ,186,255 and 4,151,334). The aforementioned quaternary borate salts are compounds such as, for example, sodium phenyl triethanolamineborates, which all have sodium as the cationic portion of the molecule. Thus, all of these quaternary borate salts are alkali metal salts (see U.S. Patent No. 4,151,334, column 2, lines 6-7), compounds that were previously known as trimerization catalysts. The present invention is a method for the manufacture of polyisocyanurate foams, comprising blending a was side with an "A" side, the "At side comprising an isocyanate. The "B" side comprises a diol or a polyester polyol, an amine/quaternary ammonium borate ester blend, a surfactant, a blowing agent, and a metal catalyst, the weight of the metal catalyst not to exceed 1.5% of the total weight of the "B" side. The "B" side remains a homogeneous liquid without the need for agitation for at least seven days, when use is made of a diol, and for at least one day, when use is made of a polyester polyol, and the foams manufactured in the me thod of the invention have a friability not exceeding 30%. In another embodiment of the invention the diol may be selected rrom the croup consisting of diethylene glycol, dipropylene glycol, and a polyethylene glycol ether whereby the weight ratio of amine to quaternary ammonium borate ester in the amine/quaternary ammonium borate ester blend is between 1:0.15 and 1:0.90. In yet another embodiment of the invention the polyester polyol may be selected from the group consisting of Foamol 250 resin polyol, a product of Jim Walter Research Corporation, 10301 9th Street North, St. Petersburg, Florida; D-400 resin polyol available from Dixie Chemical Company, 10701 Bay Area Boulevard, Pasadena, Texas; and Terate 203 resin polyol, available from Hercules, Incorporated, Wilmington, Delaware, the weight ratio of amine to quaternary ammonium borate ester in the amine/quaternary ammonium borate esther blend being between 1:0.15 and 1:0.23. Foamol 250 is of the general formula: EMI3.1 wherein n' is either 1 or 2 and x' is an integer equal to 1 or more. Polyol D-400 is of the general formula: EMI3.2 wherein n is either 1, 2, 3, or 4, and x and y are integers having a value of 2 or more. Terate 203 is of the general formula: EMI3.3 where m is between 0 and 50, R1 is either H- or CH3- , and p and q are each integers between 1 and 10; In still another embodiment of the invention, the isocyanate is a poly meric methylene diphenyldiisocyanate. An object of the present invention is thus a method of manufacturing polyisocyanurate foams with a diol or a polyol that permits the amount of trimerization catalyst used to be significantly less than the amount of trimerization catalyst used in previous methods for the manufacture of such foams. The isocyanates used in the "A" side herein may be selected from the groups including the organic polyisocyanates which are disclosed and known in the art as useful in the production of conventionally manufactured polyisocyanurate foams. The preferred polyisocyanate is Mondur MR, a polycyclic aromatic polyisocyanate available from the Mobay Chemical Corporation, Pittsburgh, Pennsylvania. The present polyisocyanurate foams may be manufactured according to methods known in the art. These methods comprise blending two components, stirring, and allowing the component mix to rise in an open container so as to form the desired foam. The two components are known as the "A" and "B" components, with the "A" component comprising the polyisocyanate and the B" component comprising a blend of polyol, catalyst, surfactant and b'owing agent. Catalysts may be selected from those conventionally used in the art, in clouding metal salts, alkali metal salts, and tertiary amine trimerization catalysts. The preferred catalyst is potassium octanoate or potassium 2-ethylhexanoate. The present preferred catalyst is M E T - T45 cata lyst, which is 45% active potassium 2-et.vahexanoate and 55% polyethylene glyc31 having a molecular weight of 200, and which is available from M & BR< - rhemicals Inc., Rahway, New Jersey, 07065. The weight of the catalyst t De will Wt 11 be less than 1.5% of the total "B" side weight, and most pre eras ltss than 1.0% of the total "Bt side weight. The blo- ng agent nay be selected from the group including water methy- jane chloride, or any of the fluorocarbons known to those skilled in the art w -zh can be used for blowing polymer mixtures into cellular poly- mers. Generally speaking, such fluorocarbon blowing agents are fluorinated aliphatic hydrocarbons which may also be substituted by chlorine and/or bromine. A most preferred blowing agent is Freon lIA, a trifluorochloromethane produced by E. I. DuPont de Nemours & Company, Wilmington, Delaware. Surfactants may likewise be chosen from among those known to the skilled in the art; a preferred surfactant is DC-193, a surfactant having silicon glycol copolymers with a direct silicon-carbon bond, and sold by Dow Corning Corporation, Midland, Michigan. Preferred diols will be selected from the group including diethylene glycol, dipropylene glycol, and polyester and polyethylene glycols, such as PEG 200. Polyethylene glycol ethers include those compounds of the general formula: EMI5.1 Polyethylene glycols will include those compounds having longer carbon chains on either side of the oxygen atom. The general formula for the polyethylene glycols is: EMI5.2 wherein R' is either a hydrogen or methyl (CH3-) radical and wherein n may be between 0 and 10. When use is made of these diols the amine/ quaternary ammonium borate ester ratio in the amine/quaternary ammonium borate ester blend is between 1:0.15 and 1:0.90. This range of ratios is the range of ratios of amine to quaternary ammonium borate ester in the ml 200 series, that TM Armol 200 series, that is Armol 201B-125, 135, 145, 155, and 175. These compounds are available from the Armak Company, 300 S. Wacker Drive, Chicago, Illinois 60606, or can be manufactured in accordance with the procedures set forth in Examples 1 and 2 hereinbelow. Preferred polyester polyols include the D-400 polyol, the Foamol 250, and the Terate 203 polyester polyols referred to hereinabove. When use is made of these polyester polyols the amine/quaternary ammonium borate ester ratio in the amine/quaternary ammonium borate ester blend is between 1:0.15 and 1:0.23. This range of ratios is the range of ratios of amine to quaternary ammonium borate ester in the first two members of Tfl the Armol 200 series, that is, Armof 201B-125 and 13S (see above). The isocyanates may be selected from the groups including the organic polyisocyanates which are disclosed herein as useful in the production of conventionally manufactured polyisocyanurate foams. A preferred polyisocyanate is Mondure MR, a polycyclic aromatic polyisocyanate available from the Mobay Chemical Corporation, Pittsburgh, Pennsylvania. The molar ratio of isocyanate to polyol, that is, the ratio of NCO functional groups to OH functional groups, is known as the "index" or 'tNCO/OH ratio". Foams are manufactured with both isocyanates and polyols, and when the molar ratio of isocyanate to polyol is between 1.05 to 1.15, a urethane foam is formed according to the reaction: EMI6.1 The urethane product shown above is the monomeric structural unit that combines to form the polyurethane foam. At an index between 1.5 and 3.5, a urethane-modified isocyanurate foam is formed. At indices above 4.1, a isocyanurate foam is formed, having as its monomeric unit the product of the reaction: EMI6.2 which may have a minority of urethane linkages. Herein, the terms isocyanurate and polyisocyanurate and the terms urethane and polyurethane in reference to foams will be used interchangably. The present claims are directed to polyisocyanurate foams, and the NcO/OH index of the blends used to make these foams will always exceed 4.0. Typical polyisocyanurate foams manufactured in accordance with the process herein have an NCO/OH ratio of 4.4. A good foam will have as a "B" side a blend that remains homogeneous when left in a closed container for seven days, when use is made of a diol, and for one day, when use is made of a polyester polyol, and such a foam will further have a friability less than 30%. Friability will be determined in accordance with the American Society for Testing Materials (ASTM) Test C421. The amines used in the present amine/quaternary ammonium borate ester blend may include polyethoxylated or polypropoxylated amines, wherein the amines are tertiary amines having one fatty alkyl derived from various fatty sources and two or more polyoxyethylene or polyoxypropylene groups attached to the nitrogen. Typical of these polyethoxylated or polypropoxylated amines are the Ethomeen polyethoxylated amines available from the Armak Company, 300 S. Wacker Drive, Chicago, Illinois, 60606, preferably being of the general formula: EMI7.1 wherein R2 is selected from the group of alkyl radicals having between 1 and 18 carbon atoms, v and w are integers each having a value of one or more, the sum of v and w not exceeding 50; and wherein R3 and R4 may be the same or different, and may be selected from the groups consisting of H-, CH3-, C1-C10 straight- or branched-chain alkyl or alkenyl radicals, a phenyl group, a benzyl group or halogenated alkyl group. Another preferred polyalkoxylated amine includes the compound Ethomeen EA-80 polyethoxylated ether amine, which is manufactured by the combination of a C8 and C10 branched-chain alcohol and which is also available from the Armak Company, Chicago, Illinois. These preferred ether amines are selected from the group consisting of: EMI8.1 <tb> <SEP> R <tb> <SEP> j3 <tb> <SEP> t(CH2CHO) <SEP> VH <tb> <SEP> [R <SEP> - <SEP> 0 <SEP> - <SEP> R <SEP> 1 <SEP> - <SEP> N <tb> <SEP> 5 <SEP> 6 <tb> <SEP> (CH2CHO} <SEP> wH <tb> <SEP> I <tb> <SEP> R <tb> wherein <SEP> R5 <SEP> is <SEP> selected <SEP> from4 <SEP> the <tb> group of C1-C20 alkyl groups, and R6 is a C2 to C alkyl group; R3 and R4 are the same or dif 2 5 3 4 ferent and may be selected from the groups consisting of H-, CH3-, C1 to C10 straight- or branched-chain alkyl or alkenyl radicals, a phenyl group, a benzyl group, or a halogenated alkyl group; and v and w are integers each having a value of at least 1 and having. a sum not exceeding 50. The quaternary ammonium borate esters are of the general formula: EMI8.2 wherein R7 is a straight- or branched-chain alkyl or alkenyl radical having from 1 to 30 carbon atoms, inclusive, or phenyl or benzyl radical; R3 is H-, a C1 to C10 straight- or branched-chain alkyl or alkenyl radical, a phenyl group, a benzyl group, or a halogenated alkyl group; R8 and Rg are different or the same and are selected from the group incuding H-, or a C1 to C10 straight- or branchedchain alkyl or alkenyl radical, a phenyl group, or a benzyl group, and wherein m is an integer between 0 and 30, inclusive. The cationic portion of the polyalkoxylated quaternary ammonium borate ester may also be selected from the group described by the general formula: EMI8.3 wherein m and R3 are as defined hereinabove, R10 is a C1-C20 alkyl or alkoxy group, and R11 is a C2 to C5 alkyl group. Prefer ably, Rll is -C3H6- and R10 is a combination of approximately equal amounts of C12-C15 alkyl groups. In this specification, the cat ionic portion of the polyalkoxylated quaternary ammonium borate esters may be selected from either of the above two general formulae. The following Examples 1 and 2 will demonstrate the manufacture of the amine/quaternary ammonium borate ester blend used in the present invention. Examples 3-8 will demonstrate the manufacture of foams in accordance with the present process. Example 1 304 grams of 1,2-propanediol (4.0 gram moles) are added to 124 grams of boric acid (2.0 gram moles) in a one-liter, three neck flask equipped with a heating mantle, a Dean-Stark trap, and a condenser. The mixture is heated to 1280C at atmospheric pressure, and retained at that temperature and pressure for about 3 1/2 hours, during which time about 44.5 grams of water was stripped from the mixture. A water aspirator is then started to create a slight vacuum at the condenser, and another 65.0 grams of water is stripped from the mixture during the next 5 3/4 hours. The total water removed (109.5 grams) corresponds to the stoichiometric amount, but analysis of the borate ester adduct remaining in the flask showed that it contained 3.4% water. A 100 gallon Monel reactor was charged with 84 kg. (0.71 mole) of Armeen TM 97 aliphatic amine and l3.6 kg. of diethylene glycol, and the mixture was heated to 650C. Over a two hour period, 38.5 kg. (0.53 mole) of the bis propylene glycol ester described in the first paragraph of this Example was pumped into the reactor, causing the temperature to rise to 800C. After cooling to 750C, 60 kg. (3.02 mole) of ethylene oxide was added over a period of two hours and 42 minutes. During this time the total reactor pressure was not allowed to exceed 3.6 bar and the temperature was maintained at 950C. The mixture was allowed to digest for another 2 hours and 40 minutes, whereupon analysis showed 1.317 meq/g of quat and 0.307 meq/g of free amine and 0.38 H2O. The reactor was purged with a stream of nitrogen at 75-850C for 4 hours and an additional 6 hours at 1000C. Analysis of this adduct showed 0.11% HO 12.6 kg. of the adduct and 48.6 kg. Ethomeen T/15, also available from the Armak Company, were mixed in a 30 gallon Pfaudler reactor at 700C. Water was removed from the blend by sparging with a stream of nitrogen at 700C and 27" Hg vacuum over a 5 1/2 hour period. Analysis after this time showed; quat 0.238 meq/g, free amines 1.779 meq/g, pH (10% in H20) 10.9, H20 < 0.l% and OH value 318. This product corresponds to TM Armol 201B-125 amineXammonium borate ester blend. Example 2 17.7 kg of the adduct whose manufacture is described in the first two paragraphs of Example 1 hereinabove and 43.5 kg. of ethoxylated amine were blended at 700C in a 30 gallon Pfaudler reactor. Water was removed by sparging with a stream of nitrogen at 700C and 27" Hg vacuum over 5 hours. Analysis showed; quat 0.331 meg/g, free amine 1.650 meq/g, pH -(10% in water) 10.9, H2O < p.l%, OH value 332. This product corresponds to iM Armol 201B-135 amine/ammonium borate ester blend. tM TM TM Armol 201B-145, Armol 201B-155 and Armol 201B-175 amine/ammonium borate ester blends are manufactured in the manner described above using a ratio of the aforesaid adduct to Ethomeen T/15 of 4.8:8.2, 5.9:7.1 and 9.3:5.7, respectively. Example 3 A polyisocyanurate foam was manufactured by blending 90.4 grams of MR d my with a "B side comprising 13.4 grams of Terate 203 resin TM polyol, 13 grams of Armol 201B-135, 2.5 grams of DC-193, 0.2 grams of T-45 catalyst, and 18 grams of Freon 11A to give a blend having an NOD/OH ratio of 4.4. The resulting foam had a cream time of 6 seconds, a gel time of 8 seconds, a tack free time of 19 seconds, a density of 0.030 gram per cc., 92.21% closed cells, and a friability of 6.1%. The resulting foam was at 107.2% of its original dimensions after seven days at 700C. and 100% relative humidity, and was at 102.6% of its original dimensions after seven days at 930C and the ambient relative humidity. The rB" side, when placed in a closed container, remained a homogeneous liquid when left to stand without agitation for one day. Example 4 A polyisocyanurate foam was manufactured by blending 78.2 grams of Mondur MR with a B" side comprising 10 grams of Armol 201B-125, 13.4 grams of Terate 203 resin polyol, 2.5 grams of DC-193, 0.2 grams of T-45 catalyst, and 16 grams of Freone lIA to give a blend having an NCO/OH ratio of 4.4. The resulting foam had a cream time of 23 seconds, a gel time of 43 seconds, a tack free time of 100 seconds, a density of 0.030 gram per cc., 92.70% closed cells, and a 5.2% friability. The resulting foam also was at 109.4% of its original dimensions after seven days at 700C. and 100% relative humidity, and was at 104.9% of its original dimensions after seven days at 930C and the ambient relative humidity. The "B" side, when placed in a closed container, remained a homogeneous liquid when left to stand without agitation for one day. Example 5 A polyisocyanurate foam was manufactured by blending 89.6 grams of Mondur MR with a "B" side comprising 13.4 grams of Foamol 250, 10 grams of Armol 201B-125, 2.5 grams of DC-193, 0.2 grams of T-45 catalyst, and 17.5 grams of Freont 11A to give a blend having an NCO/OH ratio of 4.4. The resulting foam had a cream time of 11 seconds, a gel time of 21 seconds, a tack free time of 100 seconds, a density of 0.027 gram per cc., 87.71% closed cells, and a friability of 21.3%. The resulting foam was at 106.3% of its original dimensions after seven days at 700C and 100% relative humidity, and was at 103.4% of its original dimensions after seven days at 930C and the ambient relative humidity. The "B" side, when placed in a closed container, remained a homogeneous liquid when left to stand without agitation for one day. Example 6 A polyisocyanurate foam was manufactured by blending 71.6 grams of Mondur MR with a "B" side comprising 10 grams of Armol 201B-125, 13.4 grams of D-400 polyol, 2,5 grams of DC-193, 0.2 grams of T-45 catalyst, and 15 grams of Freone llA to give a blend having an NCO/OH ratio of 4.4 The resulting foam had a cream time of 12 seconds, a gel time of 18 seconds, a rise time of 65 seconds, a density of 0.027 gram per cc., 89.2% closed cells, and 8.5% friability. The resulting foam also was at 104.1% of its original dimensions after seven days at 700C and 100% relative humidity, and was at 105.4% of its original dimensions after seven days at 930C and the ambient relative humidity. The wBW side, when placed in a closed container, remained a homogeneous liquid when left to stand without agitation for one day. Example 7 A polyisocyanurate foam was manufactured by blending 194.7 grams of Mondur MR with a "B" side comprising 13.4 grams of diethylene glycol, Th 13 grams of Armol 20lB-125, 2.5 grams of nC-193, 0.2 grams of T-45 catalyst, and 34 grams of Freon llA to give a blend having an NCO/OH ratio of 4.4. The resulting foam had a cream time of 23 seconds, a gel time of 34 seconds, a tack free time of 48 seconds, a density of 0.030 gram per cc., 97.25% closed cells, and a friability of 5.9%. The resulting foam was at 104.2% of its original dimensions after seven days at 700C and 100% relative humidity, and was at 102.4% of its original dimensions after seven days at 930C and the ambient relative humidity. The B" side, when placed in a closed container, remained a homogeneous liquid when left to stand without agitation for seven days. Example 8 A polyisocyanurate foam was manufactured by blending 196.6 grams of TM Mondur MR with a "B" side comprising 13 grams of Armol 201B-135, 13.4 grams of diethylene glycol, 2.5 grams of DC-193, 0.2 grams of T-45 catalyst, and 34 grams of Freon llA to give a blend having an NOD/OH ratio of 4.4. The resulting foam had a cream time of 23 seconds, a gel time of 34 seconds, a rise time of 46 seconds, a density of 0.032 gram per cc., 98.62% closed cells, and a 10.28% friability. The resulting foam also was at 104.0% of its original dimensions after seven days at 700C and 100% relative humidity, and was at 101.6% of its original dimensions after seven days at 930C and the ambient relative humidity. The aBN side, when placed in a closed container, remained a homogeneous liquid when left to stand without agitation for seven days.

Claims: Claims 1. A method for the manufacture of polyisocyanurate foams, comprising blending a "B" with an "A" side, said "A" side comprising an isocyan ate and said "B" side comprising a diol or a polyester polyol, an amine/quaternary ammonium borate ester blend, a surfactant, a blowing agent, and a metal catalyst, the weight of said metal catalyst not to exceed 1.5% of the total weight of said "B" side. 2 The method as set forth in claim 1 wherein use is made of a diol and the weight ratio of amine to quaternary ammonium borate ester is between 1:0.15 and 1:0.90. 3 The method as set forth in claim 1 or 2, wherein said diol may be selected from the group consisting of diethylene glycol, dipropylene glycol, and a polyethylene glycol ether. 4. The method as set forth in claim 1 wherein use is made of a,ocryester polyol and the weight ratio of amine to quaternary aamor borate ester is between 1:0.15 and 1:0.23. 5. The method as set forth in claim 1 or 4, wherein said -*s yester polyol is of the general formula: EMI13.1 wherein m is between 0 and 50, R1 is either H- or CH3-, and p and q are integers each having a value of between 1 and 10. 6. The method as set forth in claim 1 or 4, wherein said polyester polyol is of the general formula: EMI14.1 wherein n is either 1, 2, 3, or 4, and x and y are integers having a value of 2 or more. 7. The method as set forth in claim 1 or 4, wherein said polyester polyol is of the general formula EMI14.2 where n' is either 1 or 2 and x' is an integer equal to 1 or more. 8. The method as set forth in any of the foregoing claims, wherein the isocyanate is a polymeric methylene diphenyldiisocyanate.

Inventors: LARGENT, WILLIAM JAY, WHITE, KENNETH B.
Applicants: AKZO N.V.
Application year: 1984
Main classification: C08G18
IPC codes: C08G18